Goodman Mfg Gas Heater CVM96 User Manual

INSTALLATION INSTRUCTIONS FOR *MVM96 & *CVM96  
MODULATING GAS FURNACE  
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)  
Installer: Affix all manuals adjacent to the unit.  
These furnaces comply with requirements em-  
bodied in theAmerican National Standard / Na-  
®
tional Standard of CanadaANSI 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.  
5151 San Felipe Suite 500  
Houston, TX 77056  
www.goodmanmfg.com • www.amana-hac.com  
IO-406  
6/11  
© 2011 Goodman Manufacturing Company, L.P.  
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GAS SUPPLY AND PIPING .............................................................................................................................. 29  
HIGH ALTITUDE DERATE .................................................................................................................................. 29  
PROPANE GAS CONVERSION ........................................................................................................................... 29  
GAS PIPING CONNECTIONS ............................................................................................................................. 30  
PROPANE GAS TANKS AND PIPING ................................................................................................................... 32  
CIRCULATING AIR & FILTERS........................................................................................................................ 33  
DUCT WORK -AIR FLOW ................................................................................................................................. 33  
CHECKING DUCT STATIC .................................................................................................................................. 33  
BOTTOM RETURN AIR OPENING [UPFLOW MODELS]............................................................................................ 34  
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK ................................................... 34  
UPRIGHT INSTALLATIONS .................................................................................................................................. 35  
HORIZONTAL INSTALLATIONS ............................................................................................................................. 35  
STARTUP PROCEDURE & ADJUSTMENT ................................................................................................... 35  
HEATING OPERATION WITH CTK01AATHERMOSTAT (COMMUNICATING) .................................................................. 36  
HEATING OPERATION WITH CTK02AATHERMOSTAT (MODULATING COMMUNICATING) ................................................ 37  
HEAT ANTICIPATOR SETTING ............................................................................................................................. 37  
DRAIN TRAP PRIMING .................................................................................................................................... 37  
FURNACE OPERATION ..................................................................................................................................... 37  
GAS SUPPLY PRESSURE MEASUREMENT ........................................................................................................... 37  
GAS MANIFOLD PRESSURE MEASUREMENT ....................................................................................................... 38  
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ...................................................................................... 39  
TEMPERATURE RISE ...................................................................................................................................... 39  
CIRCULATOR BLOWER SPEEDS ........................................................................................................................ 40  
BLOWER HEAT OFF DELAY TIMINGS ................................................................................................................ 42  
COMFORTNET™ SYSTEM ............................................................................................................................ 42  
OVERVIEW ................................................................................................................................................... 42  
AIRFLOW CONSIDERATION ................................................................................................................................ 42  
DIP SWITCHES................................................................................................................................................. 44  
FOSSIL FUEL APPLICATIONS ............................................................................................................................ 45  
CTK0*AA WIRING ....................................................................................................................................... 45  
COMFORTNET™ SYSTEM ADVANCED FEATURES .................................................................................................. 45  
FURNACE ADVANCED FEATURES MENU .............................................................................................................. 46  
NETWORK TROUBLESHOOTING ........................................................................................................................... 47  
SYSTEM TROUBLESHOOTING ............................................................................................................................ 47  
FAULT RECALL SEQUENCE .............................................................................................................................. 47  
FAULT CLEAR SEQUENCE: .............................................................................................................................. 48  
NORMAL SEQUENCE OF OPERATION......................................................................................................... 48  
POWER UP .................................................................................................................................................. 48  
HEATING MODE ............................................................................................................................................ 48  
COOLING MODE ........................................................................................................................................... 49  
FAN ONLY MODE .......................................................................................................................................... 49  
OPERATIONAL CHECKS ................................................................................................................................ 49  
SAFETY CIRCUIT DESCRIPTION .................................................................................................................. 49  
INTEGRATED FURNACE CONTROL (IFC) ............................................................................................................. 49  
PRIMARY LIMIT ............................................................................................................................................. 49  
AUXILIARY LIMIT ............................................................................................................................................ 49  
ROLLOUT LIMIT ............................................................................................................................................. 49  
PRESSURE SWITCHES..................................................................................................................................... 50  
FLAME SENSOR ............................................................................................................................................ 50  
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TROUBLESHOOTING ..................................................................................................................................... 50  
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .............................................................................................. 50  
DIAGNOSTIC CHART ....................................................................................................................................... 50  
RESETTING FROM LOCKOUT ............................................................................................................................ 50  
MAINTENANCE ................................................................................................................................................ 50  
ANNUAL INSPECTION ....................................................................................................................................... 51  
FILTERS ....................................................................................................................................................... 51  
BURNERS ..................................................................................................................................................... 51  
INDUCED DRAFT AND CIRCULATOR BLOWERS ...................................................................................................... 51  
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)................................................................... 51  
FLAME SENSOR (QUALIFIED SERVICER ONLY) ................................................................................................... 51  
BEFORE LEAVING AN INSTALLATION .......................................................................................................... 52  
REPAIR AND REPLACEMENT PARTS ........................................................................................................... 52  
TROUBLESHOOTING CODES....................................................................................................................... 53  
STATUS CODES............................................................................................................................................... 58  
WIRING DIAGRAM............................................................................................................................................ 59  
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.  
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Adhere to the following warnings and cautions when installing, 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  
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.  
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.  
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.  
WHAT TO DO IF YOU SMELL GAS:  
DO NOT TRY TO LIGHT ANY APPLIANCE.  
CARBON MONOXIDE POISONING HAZARD  
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE  
IN YOUR BUILDING.  
Special Warning for Installation of Furnace or Air Handling Units in  
Enclosed Areas such as Garages, Utility Rooms or Parking Areas  
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBORS  
PHONE. FOLLOW THE GAS SUPPLIERS INSTRUCTIONS.  
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE  
DEPARTMENT.  
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED  
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.  
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.  
WARNING  
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.  
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.  
CO can cause serious illness including permanent brain damage or death.  
-
B10259-216  
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 WATERBEARING 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  
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.  
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.  
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS  
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT  
SOURCES SHOULD BE UTILIZED.  
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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  
controlstotheircontainersbeforetouchinganyungrounded  
object.  
SHIPPINGINSPECTION  
All units are securely packed in shipping containers tested ac-  
cording to International SafeTransitAssociation specifications.  
Thecartonmustbecheckeduponarrivalforexternaldamage. If  
damage is found, a request for inspection by carrier’s agent  
must be made in writing immediately.  
TOTHEINSTALLER  
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. Makeanotationondeliveryreceiptofanyvisibledamage  
to shipment or container.  
2. Notify carrier promptly and request an inspection.  
3. Withconcealeddamage, carriermustbenotifiedassoon  
as possible - preferably within five days.  
4. Filetheclaimwiththefollowingsupportdocumentswithin  
a nine month statute of limitations.  
Before installing this unit, please read this manual thoroughly to  
familiarize yourself with specific items which must be adhered to,  
including but not limited to: unit maximum external static pres-  
sure, gas pressures, BTU input rating, proper electrical connec-  
tions, circulating air temperature rise, minimum or maximum CFM,  
and motor speed connections.  
IMPORTANTNOTETOTHEOWNERREGARDINGPRODUCTWAR-  
RANTY  
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 con-  
tractor or contact customer service (877-254-4729) to obtain a  
copy.  
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.  
Copy of the inspection report issued by carrier’s  
representativeatthetimedamageisreportedtocarrier.  
ToreceivetheLifetimeHeatExchangerLimitedWarranty(goodfor  
as long as you own your home) and the 10-year Parts Limited  
Warranty, online registration must be completed within 60 days of  
installation. Online registration is not required in California or Que-  
bec. Complete warranty details are available from your local  
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.  
ELECTROSTATICDISCHARGE(ESD)PRECAUTIONS  
ToregisteryourGoodmanbrandunit, gotowww.goodmanmfg.com.  
Click on the word “Warranty” located 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 damage.  
By putting the furnace, the control, and the person at the same  
electrostatic potential, these steps will help avoid exposing the  
integrated control module to electrostatic discharge. This pro-  
cedure is applicable to both installed and non-installed (un-  
grounded)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.). Ifyoucomeincontactwithanungrounded  
object, repeat step 2 before touching control or wires.  
To register yourAmana® brand unit, go to www.amana-hac.com.  
Click on the word “Warranty” located on the top right 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.  
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 contractor or  
contact customer service at (877-254-4729) to obtain a copy of  
your warranty certificate.  
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 navigation panel on  
the home page of each website. The Online Product Registration  
pages are located in this same section.  
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In such applications, the furnace must be installed with the follow-  
ing stipulations:  
WARNING  
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.  
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  
It must not be used as a “make-up” air unit.  
Itmustbeinstalledwithtwo-pipesystemsforcombustion  
air, especially if VOC’s or other contaminants are present  
in the conditioned space.  
All other warranty exclusions and restrictions apply This  
furnace is an ETL dual-certified appliance and is  
appropriateforusewithnaturalorpropanegas(NOTE: If  
using propane, a propane conversion kit is required).  
FEATURES  
This furnace is a part of the ComfortNet™ family of products. The  
CTK0*AA thermostat kit allows this furnace to be installed as part  
of a digitally communicating system. The ComfortNet system pro-  
vides automatic airflow configuration, enhanced setup features,  
and enhanced diagnostics. It also reduces the number of thermo-  
stat wires to a maximum of four. It may be also installed as part of  
anon-communicating system using a standard 24 VAC thermo-  
stat.  
Dual certification means that the combustion air inlet pipe is op-  
tional and the furnace can be vented as a:  
This product may be installed with the ComfortNet thermostat and  
a non-ComfortNet compatible single stage air conditioning unit.  
However, this reduces the benefits of the ComfortNet system as  
the enhancements will only apply to the furnace.  
Non-direct vent (single pipe) central forced air furnace in  
which combustion air is taken from the installation area  
or from air ducted from the outside or,  
Direct vent (dual pipe) central forced air furnace in which  
all combustion air supplied directly to the furnace burners  
through a special air intake system outlined in these  
instructions.  
The modulating furnace operation is based off of negative pres-  
sure created by the the draft inducer. The Integrated Furnace  
Control (IFC) receives commands from the room thermostat.  
The IFC then controls the RPM of the (3 phase) inducer by  
varying the frequency and voltage to the inducer. This is known  
as variable frequency drive (VFD). The inducer, pressure  
switches, and gas valve are linked by pneumatic tubing. The  
gas valve modulates based on this negative pressure.  
This furnace may be used as a construction site heater ONLY if  
all of the following conditions are met:  
The vent system is permanently installed per these  
installation instructions.  
A room thermostat is used to control the furnace. Fixed  
jumpers that provide continuous heating CANNOT be  
used and can cause long term equipment damage.  
Return air ducts are provided and sealed to the furnace.  
A return air temperature range between 60ºF (16ºC) and  
80ºF (27ºC) is maintained.  
Airfiltersareinstalledinthesystemandmaintainedduring  
constructionreplacedasappropriateduringconstruction,  
and upon completion of construction.  
PRODUCT APPLICATION  
This furnace is primarily designed for residential home-heating ap-  
plications. 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 installed 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 commer-  
cial applications:  
Theinputrateandtemperaturerisearesetperthefurnace  
rating plate.  
100% outside air is provided for combustion air  
requirementsduringconstruction.Temporaryductingcan  
be used.  
Schools,Officebuildings,Churches,Retailstores,  
Nursinghomes,Hotels/motels,Commonorofficeareas  
NOTE: Do not connect the temporary duct directly to the  
furnace. Theductmustbesizedforadequatecombustion  
and ventilation in accordance with the latest edition of  
the National Fuel Gas Code NFPA 54/ANSI Z223.1 or  
CAN/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.  
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All furnace operating conditions (including ignition, input  
rate, temperature rise and venting) are verified according  
to these installation instructions.  
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.  
NOTE: The Commonwealth of Massachusetts requires that the  
following additional requirements must also be met:  
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.  
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.  
To ensure proper furnace operation, install, operate and  
maintain the furnace in accordance with these installation  
and operation instructions, all local building codes and or-  
dinances. In their absence, follow the latest edition of the Na-  
tional Fuel Gas Code (NFPA54/ANSI Z223.1), and/or CAN/CSA  
B149 Installation Codes, local plumbing or waste water codes,  
and other applicable codes.  
Provide provisions for venting combustion products  
outdoors through a proper venting system. Special  
consideration should be given to vent/flue pipe routing  
and combustion air intake pipe when applicable. Refer  
to Vent/Flue Pipe and CombustionAir Pipe -Termination  
Locations for appropriate termination locations and to  
determineifthepipingsystemfromfurnacetotermination  
canbeaccomplishedwithintheguidelinesgiven. NOTE:  
The length of flue and/or combustion air piping can be a  
limiting factor in the location of the furnace.  
Acopy of the National Fuel Gas Code (NFPA54/ANSI Z223.1)  
can be obtained from any of the following:  
American National Standards Institute  
1430Broadway  
Locate the furnace so condensate flows downwards to  
the drain. Do not locate the furnace or its condensate  
drainage system in any area subject to below freezing  
temperatures without proper freeze protection. Refer to  
Condensate Drain Lines and Trap for further details.  
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.  
Set the furnace on a level floor to enable proper  
condensate drainage. If the floor becomes wet or damp  
at times, place the furnace above the floor on a concrete  
base sized approximately 1-1/2" larger than the base of  
the furnace. Refer to the Horizontal Applications and  
Considerations for leveling of horizontal furnaces.  
Ensure upflow or horizontal furnaces are not installed  
directly on carpeting, or any other combustible material.  
The only combustible material allowed is wood.  
A special accessory subbase must be used for upright  
counterflow unit installations over any combustible  
material (including wood). Refer to subbase instructions  
for installation details. (NOTE: A subbase will not be  
required if an air conditioning coil is located beneath the  
furnace between the supply air opening and the  
combustible floor.  
New York, NY 10018  
National Fire Protection Association  
1 Batterymarch Park  
Quincy, MA 02269  
CSA International  
8501 East Pleasant Valley  
Cleveland, OH44131  
Theratedheatingcapacityofthefurnaceshouldbegreaterthanor  
equal to the total heat loss of the area to be heated. The total heat  
loss should be calculated by an approved method or in accor-  
dancewithASHRAEGuideorManualJ-LoadCalculationspub-  
lished by theAir Conditioning Contractors ofAmerica.  
A copy of the CAN/CSA B149 Installation Codes can also be  
obtainedfrom:  
CSA International  
178RexdaleBoulevard  
Etobicoke, Ontario, Canada M9W 1R3  
LOCATION REQUIREMENTS &CONSIDERATIONS  
Follow the instructions listed below and the guidelines provided in  
the Combustion and Ventilation Air Requirements section when  
selecting a furnace location.  
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:  
WARNING  
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,  
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE  
OBSERVED WHEN INSTALLING THIS UNIT.  
permanentwavesolutions  
chlorinated waxes or cleaners  
chlorine-based swimming pool chemicals  
water softening chemicals  
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deicing salts or chemicals  
carbon tetrachloride  
halogen type refrigerants  
cleaning solutions (such as perchloroethylene)  
printing inks  
paintremovers  
varnishes  
hydrochloric acid  
cements and glues  
CLEARANCESANDACCESSIBILITY  
Installations must adhere to the clearances to combustible mate-  
rials to which this furnace has been design certified. The minimum  
clearanceinformationforthisfurnaceisprovidedontheunit’sclear-  
ance label. These clearances must be permanently maintained.  
Clearances must also accommodate an installation’s gas, electri-  
cal, and drain trap and drain line connections. If the alternate  
combustion air intake or vent/flue connections are used additional  
clearance must be provided to accommodate these connections.  
RefertoVent/FluePipeandCombustionAirPipefordetails. NOTE:  
In addition to the required clearances to combustible materials, a  
minimum of 24 inches service clearance must be available in front  
of the unit.  
antistatic fabric softeners for clothes dryers  
and masonry acid washing materials  
Seal off a non-direct vent furnace if it is installed near an  
area frequently contaminated by any of the above  
substances. This protects the non-direct vent furnace  
from airborne contaminants. To ensure that the  
enclosednon-directvent furnacehasanadequatesupply  
of combustion air, vent from a nearby uncontaminated  
room or from outdoors. Refer to the Combustion and  
Ventilation Air Requirements for details.  
If the furnace is used in connection with a cooling coil  
unit, install the furnace upstream or in parallel with the  
cooling coil unit. Premature heat exchanger failure will  
result if the cooling unit is placed ahead of the furnace.  
If the furnace is installed in a residential garage, position  
the furnace so that the burners and ignition source are  
located not less than 18 inches (457 mm) above the  
floor. Protect the furnace from physical damage by  
vehicles.  
TOP  
TOP  
SIDE  
SIDE  
SIDE  
BOTTOM  
Horizontal  
BOTTO M  
Upflow  
Counterflow  
A furnace installed in a confined space (i.e., a closet or utility  
room) must have two ventilation openings with a total minimum  
free area of 0.25 square inches per 1,000 BTU/hr of furnace input  
rating. Refer to Specification Sheet applicable to your model for  
minimum clearances to combustible surfaces. One of the ventila-  
tion openings must be within 12 inches of the top; the other open-  
ing must be within 12 inches of the bottom of the confined space.  
In a typical construction, the clearance between the door and door  
frame is usually adequate to satisfy this ventilation requirement.  
If the furnace is installed horizontally, ensure the access  
doorsarenotontheup/topordown/bottomsideofthe  
furnace.  
Do not connect this furnace to a chimney flue that serves  
a separate appliance designed to burn solid fuel.  
OnCounterflowInstallations, theairconditioningcoilmust  
bedownstreamonthesupply(positive)sideofthefurnace  
heat exchanger.  
EXISTINGFURNACEREMOVAL  
NOTE: When an existing furnace is removed from a venting sys-  
tem serving other appliances, the venting system may be too large  
to properly vent the remaining attached appliances.  
Counterflow Installation over a noncombustible floor.  
Beforesettingthefurnaceovertheplenumopening,ensure  
the surface around the opening is smooth and level. A  
tight seal should be made between the furnace base and  
floor by using a silicone rubber caulking compound or  
cement grout.  
Counterflow Installation over a combustible floor. If  
installation over a combustible floor becomes necessary,  
use an accessory subbase (see Specification Sheet  
applicableforyourmodelfordetails.) Aspecialaccessory  
subbase must be used for upright counterflow unit  
installationsoveranycombustiblematerialincludingwood.  
Refertosubbaseinstructionsforinstallationdetails. Follow  
the instructions with the subbase for proper installation.  
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.)  
ThefollowingventtestingprocedureisreproducedfromtheAmeri-  
can National Standard/National Standard of Canada for Gas-  
Fired Central Furnaces ANSI Z21.4, CSA-2.3 latest edition  
Section 1.23.1.  
The following steps shall be followed with each appliance con-  
nected to the venting system placed in operation, while any  
other appliances connected to the venting system are not in  
operation:  
1. Seal any unused openings in the venting system;  
2. Inspect the venting system for proper size and horizon-  
tal pitch, as required by the National Fuel Gas Code,  
ANSI Z223.1 or the Natural Gas and Propane Installa-  
tion Code, CSA B149.1-05 and these instructions. De-  
termine that there is no blockage or restriction, leak-  
age, corrosion and other deficiencies which could cause  
an unsafe condition.  
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3. As far as practical, close all building doors and win-  
dows and all doors between the space in which the  
appliance(s) connected to the venting system are lo-  
cated and other spaces of the building.  
COMBUSTION & VENTILATION AIR REQUIREMENTS  
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.  
4. Close fireplace dampers.  
5. Turn on clothes dryers and any appliance not connected  
to the venting system. Turn on any exhaust fans, such  
as range hoods and bathroom exhausts, so they shall  
operate at maximum speed. Do not operate a summer  
exhaust fan.  
Improved construction and additional insulation in buildings have  
reduced heat loss by reducing air infiltration and escape around  
doors and windows. These changes have helped in reducing  
heating/cooling costs but have created a problem supplying com-  
bustion and ventilation air for gas fired and other fuel burning  
appliances. Appliances that pull air out of the house (clothes  
dryers, exhaust fans, fireplaces, etc.) increase the problem by  
starving appliances for air.  
6. Follow the lighting instructions. Place the appliance being  
inspected in operation. Adjust thermostat so appliance  
shall operate continuously.  
7. Test for spillage from draft hood appliances at the draft  
hood relief opening after 5 minutes of main burner op-  
eration. Use the flame of a match or candle.  
Housedepressurizationcancausebackdraftingorimpropercom-  
bustion of gas-fired appliances, thereby exposing building occu-  
pants to gas combustion products that could include carbon mon-  
oxide.  
8. If improper venting is observed during any of the above  
tests, the venting system must be corrected in accor-  
dance with the National Fuel Gas Code ANSI Z223.1/  
NFPA54 and/or National Gas and Propane Installation  
Code CSA B149.1-05.  
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 appli-  
cable provisions of the local building codes for determining the  
combustion air requirements for the appliances.  
9. After it has been determined that each appliance con-  
nected 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.  
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.  
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 CSA B149.1-05  
Installation Codes.  
INSTALLATION POSITIONS  
This furnace may be installed in an upright position or horizontal  
on either the left or right side panel. Do not install this furnace on  
its back. For upright upflow furnaces, return air ductwork may be  
attached to the side panel(s) and/or basepan. For horizontal  
upflow furnaces, return air ductwork must be attached to the  
basepan. For both upright or horizontal counterflow furnaces,  
return ductwork must be attached to the basepan (top end of the  
blower compartment). NOTE: Ductwork must never be attached  
to the back of the furnace. Contact your distributor for proper  
airflow requirements and number of required ductwork connec-  
tions. Refer to “Recommended Installation Positions” figure for  
appropriate installation positions, ductwork connections, and re-  
sulting airflow arrangements.  
THERMOSTATLOCATION  
The thermostat should be placed approximately five feet from the  
floor on a vibration-free, inside wall in an area having good air  
circulation. Do not install the thermostat where it may be influ-  
enced by any of the following:  
Drafts, or dead spots behind doors, in corners, or under  
cabinets.  
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.  
HORIZONTAL APPLICATIONS & CONSIDERATIONS  
Horizontal applications, in particular, may dictate many of the  
installation’s specifics such as airflow direction, ductwork connec-  
tions, flue and combustion air pipe connections, etc. The basic  
applicationofthisfurnaceasahorizontalfurnacediffersonlyslightly  
from an upright installation. When installing a furnace horizontally,  
additional consideration must be given to the following:  
Consult the instructions packaged with the thermostat for  
mounting instructions and further precautions.  
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LEVELING  
Leveling ensures proper condensate drainage from the heat ex-  
changer and induced draft blower. For proper flue pipe drainage,  
the furnacemust belevellengthwisefrom end toend. Thefurnace  
should also be level from back to front or have a slight tilt with the  
access doors downhill (approximately 3/4 inches) from the back  
panel. The slight tilt allows the heat exchanger condensate, gen-  
erated in the recuperator coil, to flow forward to the recuperator coil  
frontcover.  
ALTERNATEVENT/FLUEANDCOMBUSTIONAIRCONNECTIONS  
In horizontal installations provisions for alternate flue and combus-  
tion air piping are available for upflow furnaces with left discharge  
and counterflow furnaces with right air discharge. This configura-  
tion allows the flue and combustion air piping to be run vertically  
through the side of the furnace. Refer to the “Recommended In-  
stallation Positions” figure for further detail. The standard piping  
connections may also be used in these positions. Refer to Vent/  
Flue Pipe and Combustion Air Pipe for details concerning the  
conversion to the alternate vent/flue and combustion air connec-  
tions.  
HorizontalFurnace  
FURNACESUSPENSION  
If suspending the furnace from rafters or joists, use 3/8" threaded  
rod and 2”x2”x1/8” angle iron as shown in the following diagram.  
Thelengthofrodwilldependontheapplicationandtheclearances  
necessary.  
If the furnace is installed in a crawl space it must be suspended  
from the floor joist or supported by a concrete pad. Never install  
the furnace on the ground or allow it to be exposed to water.  
When using the horizontal alternate vent configuration, you must  
use the RF000142 vent drain kit. See following illustration.  
VENT-DRAIN  
“FIELD-SUPPLIED DRAIN  
HOSE” FROM VENT-  
DRAIN CONNECTED TO  
CONDENSATE DRAIN  
LINE WITH “FIELD-  
SUPPLIED CONNECTOR”  
NOTE: MAKE SMALL  
LOOP IN HOSE TO  
SERVE AS “P-TRAP”  
2"X2"X3/8" ANGLE IRON  
(3 PLACES)  
AlternateVent/FlueLocation  
DRAINTRAPANDLINES  
In horizontal applications the condensate drain trap is secured to  
the furnace side panel, suspending it below the furnace. A mini-  
mum clearance of 4 3/4 inches below the furnace must be pro-  
vided for the drain trap. Additionally, the appropriate downward  
piping slope must be maintained from the drain trap to the drain  
location. Refer to Condensate Drain Trap and Lines for further de-  
tails. If the drain trap and drain line will be exposed to temperatures  
near or below freezing, adequate measures must be taken to pre-  
vent condensate from freezing.  
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Pr essure  
Switch  
Manifo ld Pressure  
High Stage Low Stage  
3.5" w.c. 1" w.c.  
Gas  
Altitude  
Kit  
Orifice  
Change  
#451  
Natural  
None  
None  
None  
0-7000  
1.25MM2  
Propane  
LPKMOD*****  
10.0" w.c.  
2.6" w.c.  
NOTE: In Canada, gas furnaces are only certified to 4500 feet.  
1 Except 115,000 BTU: #43  
2 Except 115,000 BTU: #55  
Furnace Model  
A/GMVM960603BX  
A/GMVM960805CX  
A/GMVM961005DX  
A/GMVM961155DX  
A/GCVM960604CX  
A/GCVM960805DX  
GCVM961005DX  
LP Kit  
LPKMOD060UF  
LPKMOD080UF  
LPKMOD100UF  
LPKMOD115UF  
LPKMOD060CF  
LPKMOD080CF  
LPKMOD100CF  
RecommendedInstallationPositions  
NOTE: Alternate “vertical” piping connections can not be used  
when an upflow furnace is installed with supply air discharging to  
the right, or when a counterflow furnace is installed with supply air  
discharging to the left. In either case, use the standard flue and  
combustion air piping connections.  
The indicated kits must be used to insure safe and proper furnace  
operation. All conversions must be performed by a qualified in-  
staller, or service agency.  
VENT/FLUE PIPE & COMBUSTION AIR PIPE  
ALTERNATEELECTRICALANDGASLINECONNECTIONS  
WARNING  
Thisfurnacehasprovisionsallowingforelectricalandgaslinecon-  
nections through either side panel. In horizontal applications the  
connections can be made either through the “top” or “bottom” of  
the furnace.  
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY  
INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS  
GIVEN IN THIS SECTION.  
DRAINPAN  
WARNING  
A drain pan must be provided if the furnace is installed above a  
conditioned area. The drain pan must cover the entire area under  
the furnace (and air conditioning coil if applicable).  
UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY  
INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE  
FURNACE TO ASSURE IT IS PROPERLY SEALED. LEAKS IN THE FLUE  
SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO  
EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.  
FREEZEPROTECTION  
Refer to HorizontalApplications and Conditions - Drain Trap and  
Lines.  
A condensing gas furnace achieves its high level of efficiency by  
extracting almost all of the heat from the products of combustion  
and cooling them to the point where condensation takes place.  
Because of the relatively low flue gas temperature and water con-  
densation requirements, PVC pipe is used as venting material.  
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS  
WARNING  
This furnace must not be connected to Type B, BW, or L vent or  
vent connector, and must not be vented into any portion of a fac-  
tory built or masonry chimney except when used as a pathway for  
PVC as described later in this section. Never common vent this  
appliance with another appliance or use a vent which is used by a  
solid fuel appliance. Do not use commercially available “no hub  
connectors” other than those shipped with this product.  
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.  
This furnace is shipped from the factory configured for natural gas  
up to 10,000 ft. altitude. Propane conversions require the proper  
LP kit to compensate for the energy content difference be-  
tween natural and propane gas.  
LP kits include a manifold assembly, including an LP gas  
valve, orifices and LP burners.  
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It is the responsibility of the installer to follow the manufacturers’  
recommendationsandtoverifythatallvent/fluepipingandconnec-  
tors are compatible with furnace flue products. Additionally, it is  
the responsibility of the installer to ensure that all piping and con-  
nections possess adequate structural integrity and support to pre-  
ventfluepipeseparation, shifting, orsaggingduringfurnaceopera-  
tion.  
PROPERVENT/FLUEANDCOMBUSTIONAIRPIPINGPRACTICES  
Adhere to these instructions to ensure safe and proper furnace  
performance. The length, diameter, and number of elbows of the  
vent/flue pipe and combustion air pipe (when applicable) affects  
the performance of the furnace and must be carefully sized. All  
piping must be installed in accordance with local codes and these  
instructions.  
DUALCERTIFICATION:NON-DIRECT/DIRECTVENT  
Piping must be adequately secured and supported to prohibit sag-  
ging, joint separation, and/or detachment from the furnace. Hori-  
zontalrunsofvent/fluepipingmustbesupportedeverythreetofive  
feet and must maintain a 1/4 inch per foot downward slope, back  
towardsthefurnace, toproperlyreturncondensatetothefurnace’s  
drain system. Allowances should be made for minor expansion  
and contraction due to temperature variations. For this reason,  
particular care must be taken to secure piping when a long run is  
followed by a short offset of less than 40 inches.  
This furnace is dual certified and may be installed as a non-direct  
vent (single pipe) or direct vent (dual pipe) appliance. Anon-direct  
vent installation requires only a vent/flue pipe, while a direct vent  
installation requires both a vent/flue pipe and a combustion air  
intake pipe. Refer to the appropriate section for details concerning  
piping size, length, number of elbows, furnace connections, and  
terminations.  
WARNING  
Precautions should be taken to prevent condensate from freezing  
inside the vent/flue pipe and/or at the vent/flue pipe termination. All  
vent/fluepipingexposedtotemperatures below 35°F forextended  
periods of time must be insulated with 1/2” thick closed cell foam.  
Also all vent/flue piping exposed outdoors in excess of the termi-  
nations shown in this manual (or in unheated areas) must be insu-  
lated with 1/2” thick closed cell foam. Inspect piping for leaks prior  
to installing insulation.  
TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS  
MUST BE KEPT AWAY FROM ALL IGNITION SOURCES  
(I.E., SPARKS, OPEN  
FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS.  
AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR  
EYES.  
Two- or three-inch nominal diameter PVC Schedule 40 pipe meet-  
ing ASTM D1785, PVC primer meeting ASTM F656, and PVC  
solventcementmeetingASTMD2564specificationsmustbeused.  
Fittings must be DWV type fittings meeting ASTM D2665 and  
ASTM D3311. Carefully follow the pipe manufacturer’s instruc-  
tions for cutting, cleaning, and solvent cementing of PVC.  
TERMINATIONLOCATIONS  
NOTE: Refer to Location Requirements and Considerations for  
combustion air contaminant restrictions.  
The following bullets and diagram describe the restrictions con-  
cerning the appropriate location of vent/flue pipe and combustion  
airintakepipe(whenapplicable)terminations. RefertoNon-Direct  
Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping lo-  
cated in this section for specific details on termination construc-  
tion.  
The use of Schedule 40 PVC or ABS cellular core (Foam Core)  
plastic pipe is also acceptable as a flue/vent and intake pipe mate-  
rial. PVC primer meeting ASTM F656 and PVC solvent cement  
meetingASTM D2564 specifications must be used. Fittings must  
be DWV type fittings meeting ASTM D2665 and ASTM D3311.  
Carefully follow the manufactures instructions for cutting, cleaning  
and solvent cementing of PVC.  
All terminations (flue and/or intake) must be located at  
least12inchesabovegroundlevelortheanticipatedsnow  
level.  
MATERIALSANDJOININGMETHODS  
Vent terminations (non-direct and direct vent) must  
terminate at least 3 feet above any forced air inlet located  
within 10 feet.  
As an alternative to PVC pipe, primer, solvent cement, and fittings,  
ABS materials which are in compliance with the following specifi-  
cations may be used. Two-or-three-inch ABS Schedule 40 pipe  
must meet ASTM D1527 and, if used in Canada, must be CSA  
listed. Solvent cement for ABS to ABS joints must meet ASTM  
D2235 and, if used in Canada, must be CSA listed. The solvent  
cementforthePVCtoABStransitionjointmustmeetASTMD3138.  
Fittings must be DWV type fittings meeting ASTM D2661 and  
ASTM D3311 and, if used in Canada, must be CSAlisted. Care-  
fully follow the manufacturers’ instructions for cutting, cleaning,  
and solvent cementing PVC and/orABS.  
NOTE: This provision does not apply to the combustion  
air intake termination of a direct vent application.  
Theventterminationofanon-directventapplicationmust  
terminate at least 4 feet below, 4 feet horizontally from,  
or 1 foot above any door, window, or gravity air inlet into  
any building.  
The vent termination of a direct vent application must  
terminate at least 12 inches from any opening through  
which flue gases may enter a building (door, window, or  
gravity air inlet).  
The vent termination of vent pipe run vertically through a  
roof must terminate at least 12 inches above the roof line  
(or the anticipated snow level) and be at least 12 inches  
from any vertical wall (including any anticipated snow  
buildup).  
All 90° elbows must be medium radius (1/4 bend DWV) or long  
radius (Long sweep 1/4 bend DWV) types conforming toASTM  
D3311. Amedium radius (1/4 bend DWV) elbow measures 3 1/  
16” minimum from the plane of one opening to the centerline of the  
other opening for 2” diameter pipe, and 4 9/16” minimum for 3”  
pipe.  
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Aventterminationshallnotterminateoverpublicwalkways  
or over an area where condensate or vapor could create  
a nuisance or hazard or could be detrimental to the  
operation of regulators, relief valves, or other equipment.  
The combustion air intake termination of a direct vent  
application should not terminate in an area which is  
frequently dusty or dirty.  
VENT/FLUEPIPE  
Vent/flue pipe can be secured to the vent/flue coupling using the  
rubber coupling and worm gear hose clamps provided with this  
furnace (see “Standard Connections” figure). The rubber coupling  
allows separation of the vent/flue pipe from the furnace during ser-  
vicing. CombustionAir and Vent piping should be routed in a man-  
ner to avoid contact with refrigerant lines, metering devices, con-  
densate drain lines, etc. If necessary, clearances may be in-  
creased by utilizing two 45 deg. Long-Sweep Elbows and creat-  
ing an “S” joint to provide additional space at connection loca-  
tions. This joint can be rotated on the fitting to establish maxi-  
mum clearance between refrigerant lines, metering devices, and  
condensate drain lines, etc. This joint is the equivalent of one 90  
deg. elbow when considering elbow count.  
Non-Direct Vent  
&
Direct Vent  
Vent/Flue Terminations  
Non-Direct Vent  
Vent/Flue Termination  
No Terminations  
Above Walkway  
4' min.  
4'  
min.  
Grade or Highest  
Anticipated  
12" min.  
Snow Level  
V
E
N
T
Non-Direct Vent  
Vent/Flue Termination  
12" min.  
Forced Air  
Inlet  
Direct Vent  
Vent/Flue Termination  
45 DEGREE  
LONG-SWEEP  
ELBOWS  
Vent Termination Clearances  
NOTE: InCanada,theCanadianFuelGasCodetakesprecedence  
over the preceding termination restrictions.  
CANADIANVENTINGREQUIREMENTS  
In Canada, venting must conform to the requirements of the cur-  
rent CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed,  
ULC-S636complianttwo-orthree-inchdiameterPVCorABSpipe,  
solventcement, andfittingsthroughout. Thecertifiedpipingshould  
be clearly marked with the ULC Std “S636” on the pipe and fittings.  
Carefully follow the pipe manufacturers’ instructions for cutting,  
cleaning, and solvent cementing PVC and/orABS.  
IncreasedClearanceConfiguration  
NOTE: Do not use other commercially available “no hub connec-  
tors” due to possible material conflicts. The vent/flue pipe can also  
be secured using a PVC or ABS elbow or coupling using the  
appropriate glue (see Materials and Joining Methods).  
The vent can be run through an existing unused chimney provided  
the space between the vent pipe and the chimney is insulated and  
closed with a weather-tight, corrosion-resistant flashing.  
NOTE: For non-direct vent installations, a minimum of one 90°  
elbow should be installed on the combustion air intake coupling to  
guard against inadvertent blockage.  
STANDARDFURNACECONNECTIONS  
COMBUSTION AIR PIPE  
It is the responsibility of the installer to ensure that the piping  
connections to the furnace are secure, airtight, and adequately  
supported.  
DIRECTVENT INSTALLATIONS  
On upflow units secure the combustion air intake pipe directly to  
the air intake coupling. On counterflow units secure the combus-  
tion air intake pipe to the air intake coupling using the rubber cou-  
plingandwormgearhoseclampsprovidedwiththeunit. Thecoun-  
terflow rubber coupling allows service removal of air intake piping  
internal to the furnace blower compartment. NOTE: Because of  
probable material conflicts, do not use other commercially avail-  
able “no hub connectors”. The combustion air intake pipe can  
also be secured directly to the counterflow unit air intake pipe  
coupling.  
As shipped, attachment “couplings” for vent/flue and combustion  
air intake pipe connections are provided on the furnace’s top cover  
(upflow) or basepan (counterflow). To use the standard connec-  
tions, field supplied vent/flue pipe and combustion air intake pipe  
(when applicable) should be secured directly to the furnace at  
these locations.  
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3. Upflow andCounterflow units.  
NON-DIRECTVENT INSTALLATIONS  
Remove the vent/flue pipe from the furnace.  
4. Cut the vent/flue pipe 3.75 inches from the flanged end of  
the pipe (see “Vent/Flue Pipe Cuts” figure).The section of  
pipe attached to the coupling will reach through the side  
panel to the induced draft blower. Discard remaining pipe  
and elbows.  
A minimum of one 90° elbow should be installed on the combus-  
tion air intake “coupling” to guard against inadvertent blockage.  
COMBUSTION  
VENT/FLUE  
PIPE  
COMBUSTION  
AIR PIPE  
(DIRECT VENT ONLY)  
AIR PIPE  
VENT/FLUE  
PIPE  
(DIRECT VENT ONLY)  
90 PVC  
RUBBER  
90 PVC  
ELBOW  
(NON-DIRECT VENT)  
RUBBER  
ELBOW  
COUPLING  
WITH WORM  
GEAR CLAMPS  
COUPLINGS  
WITH WORM  
GEAR CLAMPS  
(NON-DIRECT VENT)  
Counterflowunits.  
OR  
OR  
Cut the vent/flue pipe 3.75 inches from the blower deck  
coupling (see “Vent/Flue Pipe Cuts” figure).Save vent/flue  
pipeattachedtoblowerdeckcouplingforuseinthealternate  
location. Discard remaining pipe and elbows.  
FLANGE  
3.75"  
UPFLOW  
COUNTERFLOW  
CUT HERE  
Standard Connections  
ALTERNATEFURNACECONNECTIONS  
If the standard locations are undesirable for a specific installation,  
alternate side panel locations are available for both combustion air  
inlet and vent/flue pipe connections. These locations may be of  
particular benefit to upright upflow installations requiring additional  
access to an Acoil, or to upright counterflow installations requiring  
additional access to a filter or electronic air cleaner, or to horizontal  
installations desiring vent/flue (and combustion air intake) piping  
run vertically from the side of the cabinet.  
Vent/FluePipeCuts  
5. Remove plastic plug from alternate vent/flue location.  
Relocate and install plug in standard vent/flue location (top  
cover).  
Counterflow units.  
NOTE: Standard and alternate locations can be combined (i.e.,  
an installation may use the standard combustion air intake loca-  
tionbutusethealternatevent/fluelocationorviceversa), ifneeded.  
Remove plastic plug from alternate vent/flue location.  
Relocate and install plug in standard vent/flue location  
(basepan). Plug remaining hole in blower deck with plastic  
plug included in the drain kit bag.  
WARNING  
6. Upflow andCounterflow units.  
Insertcutsectionofvent/fluepipeandcouplingintoalternate  
vent/flue location. Using a rubber coupling and worm gear  
hose clamps from the drain kit bag, attach the vent/flue  
pipe and coupling to the induced draft blower. Secure the  
coupling to the cabinet using the screws removed in step 1  
or with field-supplied 3/8” #8 self drilling screws.  
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A  
PRECAUTION WHEN REMOVING HOLE PLUGS.  
ALTERNATEVENT/FLUELOCATION  
The alternate vent/flue location is the large hole directly in line with  
the induced draft blower outlet. To use the alternate vent/flue loca-  
tion refer to the following steps and the “Alternate Vent/Flue Loca-  
tionfigure.  
WARNING  
THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN THE  
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,  
EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD‐  
SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS  
CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES,  
INCLUDING CARBON MONOXIDE  
NOTE: Counterflow instructions follow the upflow instructions.  
1. Remove and save the four screws securing the vent/flue  
coupling to the furnace top panel.  
Counterflow units.  
Remove and save the four screws securing the vent/flue  
coupling to the furnace basepan. Also remove the three  
screws securing the furnace’s internal vent/flue piping to  
the blower deck.  
7. Upflow andCounterflow units.  
For upright installations, externally mount the rubber  
elbow to the vent/flue coupling using a worm gear hose  
clamp. Secure field supplied vent/flue piping to the rubber  
elbow using a worm gear hose clamp. NOTE: Use of the  
alternate vent/flue location for upright installations, requires  
the drain trap be installed on the same side of the unit as  
the flue pipe.  
2. Upflow andCounterflow units.  
Loosen the worm gear hose clamps on the rubber elbow  
and detach it from both the induced draft blower and the  
vent/fluepipe.  
15  
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8. Upflowand Counterflowunits.  
3. Remove plastic plug from alternate combustion air intake  
location. Relocate and install plug in standard air intake  
location (basepan). Plug the remaining hole in the blower  
deck with the plastic plug included in the drain kit bag.  
4. With the gasket facing the cabinet side panel, and the  
flange’s flat spot facing forward, secure the combustion air  
intake coupling to the cabinet using the screws removed in  
step 1 or with field-supplied 3/8” #8 self -drilling screws.  
For horizontal installations, externally secure the field-  
suppliedvent/fluepipedirectlytothevent/fluecouplingusing  
a PVC orABS coupling or elbow.  
ALTERNATECOMBUSTIONAIRINTAKELOCATION  
The alternate combustion air intake location consists of a large,  
unobstructed hole (alternate vent connection is aligned with the  
Induced Draft Blower). To use the alternate combustion air intake  
location, refer to the following steps, and the “Alternate Combus-  
tionAir Intake Location” figure.  
CAUTION  
BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS  
WHEN REINSTALLING COUPLING AND SCREWS.  
1. Removeandsavethefourscrewssecuringthecombustion  
air intake coupling to the basepan. Remove an additional  
three screws securing the furnace’s internal combustion  
air intake pipe to the blower deck.  
2. Remove the combustion air intake pipe from the furnace  
andcutthepipeatthebasepancoupling. Savethebasepan  
coupling and gasket from the blower deck coupling for use  
in the alternate location. Discard the remaining pipe.  
5. For non-direct vent installations installed horizontally, a  
minimum of one 90° elbow should be installed on the  
combustionairintake couplingtoguardagainst inadvertent  
blockage. Noelbowisrequiredonthealternatecombustion  
air intake of upright installations, however, a minimum  
clearanceof2inchesisrequiredtoassureproperairsupply.  
3
3
REMOVE  
PIPE  
REMOVE  
PIPE  
1
REMOVE  
3 SCREWS  
5
5
REMOVE  
REMOVE  
AND RELOCATE  
AND RELOCATE  
2
2
DETACH RUBBER  
ELBOW FROM  
ID BLOWER AND  
VENT/FLUE  
PIPE  
DETATCH RUBBER  
ELBOW FROM  
ID BLOWER AND  
VENT/FLUE  
PIPE  
5
ADDITIONAL PLUG  
FROM DRAIN KIT  
6
SECURE TO  
ID BLOWER WITH  
6
RUBBER COUPLING  
SECURE TO  
AND HOSE  
CABINET WITH  
CLAMPS  
7
EXTERNALLY  
MOUNT  
SCREWS  
RUBBER ELBOW  
6
SECURE TO  
ID BLOWER WITH  
RUBBER COUPLING  
AND HOSE  
CLAMPS  
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6. For direct vent installations, secure field-supplied  
combustionairintakepipedirectlytotheairintakecoupling.  
NOTE: APVCcouplingorelbowisrequiredoncounterflow  
units.  
COUNTERFLOW  
Non-Direct Vent (Single Pipe)  
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)  
Pipe (4)  
(Inch)  
Number of Elbows (3)(5)  
Unit  
Input  
1
2
3
4
5
6
7
8
NON-DIRECTVENT(SINGLEPIPE)PIPING  
2 or 2 1/2 61  
71  
2 or 2 1/2 61  
58  
55 52  
65 62  
55 52  
65 62  
49  
46  
43  
40  
60,000  
Non-direct ventinstallations require only a vent/flue pipe. The vent  
pipe can be run horizontally with an exit through the side of the  
building or run vertically with an exit through the roof of the building.  
The vent can also be run through an existing unused chimney;  
however, it must extend a minimum of 12 inches above the top of  
the chimney. The space between the vent pipe and the chimney  
must be closed with a weather-tight, corrosion-resistant flashing.  
For details concerning connection of the vent/flue pipe to the fur-  
nace, refer to Vent/Flue Pipe and Combustion Air - Standard Fur-  
nace Connections or Alternate Furnace Connections for specific  
details. Refer to the followingNon-Direct Vent (Single Pipe) Piping  
- Vent/Flue Pipe Terminations for specific details on termination  
construction.  
3
68  
58  
68  
59  
49  
59  
56  
46  
56  
53  
43  
53  
50  
40  
50  
80,000  
3
3
71  
71  
100,000  
68  
65 62  
59  
56  
53  
50  
*Maximum allowable limits listed are individual lengths for inlet & flue  
and NOT a combination.  
1) One 90° elbow should be secured to the combustion air intake connection.  
2) Minimum requirement for each vent pipe is five (5) feet in length and one  
elbow/tee.  
3) Tee used in the vent/flue termination must be included when determining the  
number of elbows in the piping system.  
Although non-direct vent installations do not require a combustion  
air intake pipe, a minimum of one 90° elbow should be attached to  
the furnace’s combustion air intake if: an upright installation uses  
the standard intake location, or a horizontal installation uses the  
alternateairintakelocation. Thiselbowwillguardagainstinadvert-  
ent blockage of the air intake.  
4) 2-1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.  
5) Increased Clearance Configurations using (2) 45 deg. Long Sweep el-  
bows should be considered equivalent to one 90 deg. elbow.  
VENT/FLUEPIPE TERMINATIONS  
VENT/FLUE PIPE LENGTHS AND DIAMETERS  
NOTE: If either a 90 degree or 45 degree elbow is used for  
terminiation, it must be pointed downward.  
Refer to the following table for applicable length, elbows, and pipe  
diameter for construction of the vent/flue pipe system of a non-  
direct vent installation. In addition to the vent/flue pipe, a single 90°  
elbow should be secured to the combustion air intake to prevent  
inadvertent blockage. The tee used in the vent/flue termination  
must be included when determining the number of elbows in the  
piping system.  
The vent/flue pipe may terminate vertically, as through a roof, or  
horizontally, as through an outside wall.  
Vertical vent/flue pipe terminations should be as shown in the fol-  
lowing figure. Refer to Vent/Flue Pipe and Combustion Air Pipe -  
Termination Locations for details concerning location restrictions.  
The penetration of the vent through the roof must be sealed tight  
with proper flashing such as is used with a plastic plumbing vent.  
UPFLOW  
Non-Direct Vent (Single Pipe)  
Horizontal vent/flue pipe terminations should be as shown in the  
following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe  
- Termination Locations for details concerning location restrictions.  
A 2 3/8” diameter wall penetration is required for 2” diameter pipe.  
A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diam-  
eter hole is required for 3” diameter pipe. To secure the pipe pass-  
ing through the wall and prohibit damage to piping connections, a  
coupling should be installed on either side of the wall and solvent  
cemented to a length of pipe connecting the two couplings. The  
length of pipe should be the wall thickness plus the depth of the  
socket fittings to be installed on the inside and outside of the wall.  
The wall penetration should be sealed with silicone caulking  
material.  
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)  
Pipe (4)  
(Inch)  
Number of Elbows (3)(5)  
Unit  
Input  
1
2
3
4
5
6
7
8
2or 21/2 49 46 43 40 37 34 31 28  
60,000  
3
3
71 68 65 62 59 56 53 50  
71 68 65 62 59 56 53 50  
80,000  
100,000  
115,000  
3
49 46 43 40 37 34 31 28  
*Maximum allowable limits listed are individual lengths for inlet & flue  
and NOT a combination.  
17  
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In a basement installation, the vent/flue pipe can be run between  
joist spaces. If the vent pipe must go below a joist and then up into  
the last joist space to penetrate the header, two 45° elbows should  
be used to reach the header rather than two 90° elbows.  
DIRECTVENT(DUALPIPE)PIPING  
The inlet air screens provided in the installation instruction packet  
are available for the installer to use in the inlet of the combustion air  
pipe to prevent animals from building nests in the combustion air  
pipe. Installation of screens, while strongly recommended, is not  
required and will not affect performance of the unit.  
12 " Min To Roof  
Or Highest Anticipated  
Snow Level  
Direct vent installations require both a combustion air intake and a  
vent/flue pipe. The pipes may be run horizontally and exit through  
the side of the building or run vertically and exit through the roof of  
the building. The pipes may be run through an existing unused  
chimney; however, they must extend a minimum of 12 inches  
above the top of the chimney. The space between the pipes and  
the chimney must be closed with a weather tight, corrosion resis-  
tant flashing. Both the combustion air intake and a vent/flue pipe  
terminations must be in the same atmospheric pressure zone.  
Refer to Vent/Flue and Combustion Air Pipe - Termination Loca-  
tions or Concentric Vent Termination for specific details on termi-  
nation construction. For details concerning connection of pipes to  
the furnace, refer to the Vent/Flue Pipe and Combustion Pipe -  
StandardFurnaceConnectionsorAlternateFurnaceConnections.  
Vertical Termination (Single Pipe)  
_____________________________________  
TEE (OPTIONAL)  
90º or 45°  
MEDIUM RADIUS ELBOWS  
12 " Min To Roof  
Or Highest Anticipated  
Snow Level  
12" MIN. TO ROOF  
OR HIGHEST ANTICIPATED  
SNOW LEVEL  
VENT/FLUE & COMBUSTION AIR PIPE LENGTHS &DIAMETERS  
Refer to the following table for applicable length, elbows, and pipe  
diameterforconstructionofthevent/flueandcombustionairintake  
pipe systems of a direct vent (dual pipe) installation. The number  
of elbows tabulated represents the number of elbows and/or tees  
in each (Vent/Flue & Combustion Air Intake) pipe. If there is a  
difference between the two pipes, count the pipe with the most  
fittings. Elbows and/or tees used in the terminations must be  
included when determining the number of elbows in the piping  
systems.  
NOTE: Care should be taken to prevent condensate  
accumulationsonroofingmaterial.  
Alternate Vertical Termination (Single Pipe)  
_____________________________________  
If the combustion air intake pipe is to be installed above a finished  
ceiling or other area where dripping of condensate will be objec-  
tionable, insulation of the combustion air pipe may be required.  
Use 1/2” thick closed cell foam insulation such as Armaflex™ or  
Insultubewhererequired.  
12" TO GROUND OR  
HIGHEST ANTICIPATED  
SNOW LEVEL  
MIN.  
12"  
FROM  
WALL  
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS  
Thevent/flueandcombustionairpipesmayterminatevertically, as  
through a roof, or horizontally, as through an outside wall.  
HorizontalTermination(SinglePipe)  
_____________________________________  
12" MIN.  
UPFLOW  
Direct Vent (Dual Pipe) Maximum Allowable Length*  
of Vent/Flue & Combustion Air Intake Pipe (ft)  
VENT/FLUE TEE (OPTIONAL)  
or  
45° ELBOW  
Number of Elbows (1)(2)(3)(5)  
Pipe(4)  
TURNED DOWN or  
90° ELBOW TURNED  
DOWN  
Unit Input Termination  
(Btu)  
Style  
(inch)  
2 or 2 1/2 49 46  
71 68  
2 or 2 1/2 36 33  
1
2
3
4
5
6
7
8
43  
65  
30  
51  
65  
51  
43  
29  
40  
62  
27  
48  
62  
48  
40  
26  
37  
59  
24  
45  
59  
45  
37  
23  
34 31  
56 53  
21 18  
42 39  
56 53  
42 39  
34 31  
20 17  
28  
50  
15  
36  
50  
36  
28  
14  
Standard  
3
12" MIN. ABOVE  
HIGHEST ANTICIPATED  
SNOW LEVEL  
60,000  
Alternate  
3
3
3
3
3
57 54  
71 68  
57 54  
49 46  
35 32  
Standard  
Alternate  
Standard  
Alternate  
80,000  
100,000  
115,000  
HorizontalTermination(SinglePipe)  
AboveHighestAnticipatedSnowLevel  
*Maximum allowable limits listed are individual lengths for inlet & flue and NOT a combination.  
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COUNTERFLOW  
Direct Vent (Dual Pipe) Maximum Allowable Length*  
of Vent/Flue & Combustion Air Intake Pipe (ft)  
Horizontal terminations should be as shown in the following figure.  
Refer to Vent/Flue Pipe and Combustion Pipe - Termination Loca-  
tion for location restrictions. A2 3/8” diameter wall penetration is  
required for 2” diameter pipe. A3” diameter hole is required for a 2  
1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter  
pipe. To secure the pipe passing through the wall and prohibit  
damage to piping connections, a coupling should be installed on  
either side of the wall and solvent cemented to a pipe connecting  
the two couplings. The pipe length should be the wall thickness  
plus the depth of the socket fittings to be installed on the inside  
and outside of the wall. The wall penetration should be sealed with  
silicone caulking material.  
Number of Elbows (1)(2)(3)(5)  
Pipe(4)  
(inch)  
Unit Input Termination  
(Btu)  
Style  
1
2
3
4
5
6
7
8
2 or 2 1/2 49 46  
71 68  
2 or 2 1/2 36 33  
57 54  
2 or 2 1/2 61 58  
71 68  
2 or 2 1/2 48 45  
43  
65  
30  
51  
55  
65  
42  
51  
65  
51  
40  
62  
27  
48  
52  
62  
39  
48  
62  
48  
37  
59  
24  
45  
49  
59  
36  
45  
59  
45  
34 31  
56 53  
21 18  
42 39  
46 43  
56 53  
33 30  
42 39  
56 53  
42 39  
28  
50  
15  
36  
40  
50  
27  
36  
50  
36  
Standard  
3
60,000  
Alternate  
Standard  
Alternate  
3
3
80,000  
3
3
3
57 54  
71 68  
57 54  
Standard  
Alternate  
12" MIN  
100,000  
*Maximum allowable limits listed are individual lengths for inlet & flue and NOT a combination.  
3" MIN  
24" MAX  
1) Elbows and/or tees used in terminations must be included when determin-  
ing quantity of allowable elbows in the system.  
2) Number of elbows tabulated are for each (Vent/Flue & Combustion Air  
Intake) pipe.  
3" MIN  
24" MAX  
3) Minimum requirements for each Vent/Flue & Combustion Air Intake pipe is  
five (5) feet in length and one elbow/tee.  
90º OR 45°  
MEDIUM RADIUS  
ELBOW  
12" MIN. TO ROOF OR  
HIGHEST ANTICIPATED  
SNOW LEVEL  
SCREEN  
(OPTIONAL)  
4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.  
5) Increased Clearance Configurations using (2) 45 deg. Long Sweep el-  
bows should be considered equivalent to one 90 deg. elbow.  
12" MIN. TO ROOF OR  
HIGHEST ANTICIPATED  
SNOW LEVEL  
Vertical pipe terminations should be as shown in the following  
figure. Refer to Vent/Flue Pipe and Combustion Pipe - Termina-  
tion Locations for details concerning location restrictions. The  
penetrations through the roof must be sealed tight with proper  
flashing such as is used with a plastic plumbing vent.  
Standard Horizontal Terminations (Dual Pipe)  
_____________________________________  
90°  
MEDIUM  
RADIUS  
ELBOW  
VENT/FLUE  
12" MIN.  
24" MAX  
3" MIN  
24" MAX  
SCREEN  
(OPTIONAL)  
AIR  
INTAKE  
SCREEN  
(OPTIONAL)  
12" MIN. TO ROOF  
OR HIGHEST ANTICIPATED  
SNOW LEVEL  
12" MIN. ABOVE  
HIGHEST ANTICIPATED  
SNOW LEVEL  
_____________________________________  
TEE (OPTIONAL)  
AlternateHorizontalVentTermination(DualPipe)  
VENT/FLUE  
COMBUSTION  
AIR INTAKE  
12" MIN.  
SCREEN  
(OPTIONAL)  
12" MIN. TO ROOF  
OR HIGHEST ANTICIPATED  
SNOW LEVEL  
Vertical Terminations (Dual Pipe)  
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SIDE WALL VENT KIT  
This kit is to be used with 2” or 3” direct vent systems. The vent kit  
must terminate outside the structure and may be installed with the  
intake and exhaust pipes located side-by-side or with one pipe  
above the other. This kit is NOT intended for use with single pipe  
(indirect vent) installations.  
Refer to the directions furnished with the Side Wall Vent Kit  
(p/n0170K00000S) forinstallationspecifications.  
CONDENSATE DRAIN LINES & DRAIN TRAP  
A condensing gas furnace achieves its high level of efficiency by  
extracting almost all of the heat from the products of combustion  
and cooling them to the point where condensation takes place.  
The condensate which is generated must be piped to an appropri-  
ate drain location.  
AlternateVentTerminationAboveAnticipatedSnowLevel  
(DualPipe)  
In a basement installation, the pipes may be run between the joist  
spaces. If the pipes must go below the joist and then up into the  
last joist space to penetrate the header, two 45° elbows should be  
used to reach the header rather than two 90° elbows.  
In upright installations, the furnace’s drain hoses may exit either  
the right or left side of the furnace. NOTE: If the alternate vent/flue  
outlet is utilized in an upright installation, the drain trap and drain  
connections must be located on the same side as the alternate  
vent/flue outlet.  
VENT/INTAKETERMINATIONSFORINSTALLATIONOFMULTIPLE  
DIRECTVENTFURNACES  
In horizontal installations, the drain hoses will exit through the  
bottom (down side) of the unit with the drain trap suspended be-  
neath the furnace. The field-supplied drain system must be in  
accordance with all local codes and the instructions in the follow-  
ing sections.  
If more than one direct vent furnace is to be installed vertically  
through a common roof top, maintain the same minimum clear-  
ances between the exhaust vent and air intake terminations of  
adjacent units as with the exhaust vent and air intake terminations  
of a single unit.  
Follow the bullets listed below when installing the drain system.  
Refer to the following sections for specific details concerning fur-  
nace drain trap installation and drain hose hook ups.  
If more than one direct vent furnace is to be installed horizontally  
through a common side wall, maintain the clearances as in the  
following figure. Always terminate all exhaust vent outlets at the  
same elevation and always terminate all air intakes at the same  
elevation.  
The drain trap supplied with the furnace must be used.  
The drain line between furnace and drain location must  
be constructed of 3/4” PVC.  
The drain line between furnace and drain location must  
maintain a 1/4 inch per foot downward slope toward the  
drain.  
Do not trap the drain line in any other location than at  
the drain trap supplied with the furnace.  
Vents  
90°  
Medium  
Radius  
Elbows  
Do not route the drain line outside where it may freeze.  
If the drain line is routed through an area which may  
see temperatures near or below freezing, precautions  
must be taken to prevent condensate from freezing  
within the drain line.  
If an air conditioning coil is installed with the furnace, a  
common drain may be used. An open tee must be  
installed in the drain line, near the cooling coil, to  
relieve positive air pressure from the coil’s plenum.  
This is necessary to prohibit any interference with the  
function of the furnace’s drain trap.  
3" Min.  
24" Max.  
3" Min.  
24" Max.  
3" Min.  
24" Max.  
Air  
Intakes  
Screen  
(Optional)  
12" Min.  
12" MIN. ABOVE  
HIGHEST ANTICIPATED  
SNOW LEVEL  
HorizontalVentingOfMultipleUnits  
CONCENTRICVENTTERMINATION  
NOTE: In vertical installations, air conditioning coil condensate  
may drain into the furnace trap as long as there is a trap  
between the coil and the furnace trap and the drain pipe is not  
terminating below the water level of the furnace trap.  
RefertothedirectionsprovidedwiththeConcentricVentKit(DCVK)  
for installation specifications.  
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STANDARDRIGHTORLEFTSIDEDRAINHOSECONNECTIONS  
UPRIGHTINSTALLATIONS-TRAPONRIGHTSIDE  
All installations positions require the use of the drain trap, hoses,  
tubes, and clamps. The following quantity of hoses, tubes, and  
hose clamps are provided with the unit.  
In a upright installation drain hoses are connected to drain ports on  
the rubber elbow and the recuperator coil front cover. The drain  
lines are then routed through the right side panel and into the drain  
trap secured to the outside of the cabinet.  
HOSE A  
QTY: 1  
NOTE: Refer to Alternate Vent/Flue Hose Connections for up-  
right installations using an alternate vent/flue outlet.  
1. Removetherubberplugfromtherightsideofthefrontcover  
drain port.  
HOSE B  
QTY: 1  
DRAIN TRAP  
TUBE 1  
2. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear side panel grommet hole.  
QTY: 1  
QTY: 1  
GREEN  
TUBE 2  
3. Cut and remove 1/4 inch from the end of the drain port on  
the rubber elbow.  
4. Insert Tube 1 into rubber elbow drain port and secure with  
silverhoseclamp. Angletubeoutwardtowardfrontoffurnace.  
5. Cut 17 3/4 inches from the long end of Hose B and discard.  
Secure the remaining hose to Tube 1 with a green hose  
clamp. Route the other end of Hose B to front right side  
panel grommet hole.  
HOSE CLAMPS  
QTY: 3  
QTY: 2  
SILVER  
HOSE CLAMP  
QTY: 1  
RED  
HOSE CLAMP  
QTY: 1  
Hose and Tube Identification  
For details concerning mounting of the drain trap, refer toHorizon-  
tal Drain Trap Mounting.  
6. Insert short end of each of tube 2 through side panel  
grommet holes. Secure tubes to hosesAand B with green  
hoseclamps. Ensurehosesandtubesmaintainadownward  
slope for proper drainage and that they are not kinked or  
binding.  
RIGHT SIDE  
PANEL  
RUBBER  
ELBOW  
RUBBER ELBOW  
DRAIN PORT  
SILVER HOSE CLAMP  
TUBE 1  
HOSE  
SIDE PANEL  
B
GROMMET  
HOLES  
TUBE(S) 2  
DRAIN  
TRAP  
HOSE  
A
RED HOSE  
CLAMP  
FRONT  
COVER  
DRAIN PORT  
GREEN  
HOSE  
CLAMPS  
(3 PLACES)  
UprightStandardConnections-RightSide  
(UpflowShown,CounterflowSimilar)  
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4. Cut 1/4 inch from the end of the drain port on the externally  
mounted rubber elbow. Discard cut portion.  
ALTERNATEVENT/FLUEDRAINHOSECONNECTIONS  
Upright installations using the alternate vent/flue outlet will require  
“right-side only” drain hoses to be connected as follows. Refer to  
Vent/Flue Pipe and Combustion Air Pipe for details on alternate  
vent/flue pipe connection.  
1. Removetherubberplug/capfromtheright-sidedrainporton  
the front cover . Save for use in step 3.  
5. Insert Tube 1 into rubber elbow drain port and secure with a  
silver hose clamp. Angle tube toward trap.  
6. Cut 17 3/4 inches from the long end of Hose B and discard.  
7. Secure straight end of Hose B to exposed end of Tube 1  
with a green hose clamp. Route hose toward right side  
panel grommet holes.  
2. SecureHoseAtofrontcoverdrainportwitharedhoseclamp.  
Route hose to rear right side panel grommet hole.  
3. Removegrommetfromfrontright-sidepaneldrainhole. Seal  
hole in grommet with large end of plug. Reinstall grommet  
and plug into side panel drain hole.  
8. Insert short end of one Tube 2 through rear right side panel  
grommet drain hole. Secure tube to Hose A with a green  
hose clamp.  
9. InsertshortendofremainingTube2intoHoseBfromrubber  
elbow and secure with green hose clamp. Ensure hoses  
and tubes maintain a downward slope for proper drainage  
and are not kinked or binding.  
RUBBER ELBOW  
(EXTERNALLY  
MOUNTED)  
RUBBER  
ELBOW  
FRONT  
COVER  
DRAIN  
PORT  
DRAIN PORT  
HOSE B  
SILVER HOSE CLAMP  
TUBE 1  
GREEN HOSE  
CLAMPS  
(3 PLACES)  
HOSE A  
TUBE(S) 2  
RED HOSE  
CLAMP  
DRAIN TRAP  
UprightAlternateConnections-RightSideOnly  
(UpflowShown, CounterflowSimilar)  
22  
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5. Cut “X” inches from the long end of Hose B and discard.  
Refer to table for appropriate length to cut. Secure  
remaining hose to Tube 1 with a green hose clamp. Route  
other end of Hose B to front left side panel grommet hole.  
UPRIGHTINSTALLATIONS-TRAPONLEFTSIDE  
NOTE: For left side trap installation, grommets must be moved  
to the left side of the furnace and the plugs installed on the right  
side of the furnace.  
1. Remove the rubber plug/cap from the left side drain port  
on the front cover.  
NOTE: Long hose “B” must always be connected to Tube 1 and  
the elbow and not on the front cover.  
6. InsertshortendofeachTube2throughsidepanelgrommet  
holes. Secure tubes to Hose A and Hose B with green  
hose clamps. Ensure hoses and tubes maintain a  
downward slope for proper drainage and that they are not  
kinked or binding.  
2. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear side panel grommet hole.  
3. Cut and remove 1/4 inch from the end of the drain port on  
the rubber elbow.  
4. Insert Tube 1 into rubber elbow drain port and secure with  
silver hose clamp. Angle tube outward toward front of  
furnace.  
LEFT  
SIDE PANEL  
FRONT COVER  
DRAIN PORT  
RUBBER  
ELBOW  
RED HOSE  
CLAMP  
RUBBER  
ELBOW  
DRAIN PORT  
HOSE A  
SILVER HOSE  
CLAMP  
SIDE PANEL  
DRAIN  
HOLES  
TUBE 1  
TUBE(S) 2  
GREEN HOSE  
CLAMP  
DRAIN  
TRAP  
HOSE B  
GREEN  
HOSE CLAMP  
Upright “Standard” Connections - Left Side  
(UpflowShown,CounterflowSimilar)  
"X" Length to Cut From Long  
Cabinet Width  
(inches)  
Models  
(kBTU_Tons)  
End of Hose B  
(inches)  
17 1/2  
21  
60_3  
60_4  
80 5  
80_5  
100_5  
115_5  
7
3 1/2  
24 1/2  
None  
2. Secure drain trap to side panel at the mounting holes  
(dimples or crosshairs on counterflow models) located  
below the grommet drain holes.  
3. Attach PVC drain line to drain trap outlet with either a 90°  
elbow or coupling.  
UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)  
1. Insert drain tubes into drain trap and position the drain  
trap against the side panel. NOTE: Drain tubes must  
reach the bottom of the drain trap.  
23  
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2. Secure Hose A to front cover drain tap with a red hose  
clamp. Route hose to rear right (down) side panel grommet  
holes.  
HORIZONTALINSTALLATIONS  
RIGHT SIDE DOWN  
3. Cut 1/4 inch from the end of the drain port on the rubber  
elbow and discard.  
4. Insert Tube 1 into rubber elbow drain port and secure with  
a silver hose clamp. Angle tube outward toward front of  
furnace.  
Horizontal installations with the right side down require that the  
drain hoses be connected to the right side front cover drain port  
and the rubber elbow drain port.  
NOTE: On counterflow models, relocation of the front cover  
pressure switch hose is required.  
5. Cut 17 3/4 inches from the long end of Hose B and discard.  
6. Secure remaining end of Hose B to exposed end of Tube  
1 with a green hose clamp. Route hose to front right  
down side panel grommet holes.  
Make connections as follows:  
1. Remove the rubber plug/cap from right side of the front  
cover drain port.  
7. Cut 5 1/2 inches straight length from the long end of each  
Tube 2 and discard the radius pieces.  
Counterflow furnaces  
Relocate the front cover pressure switch hose connection  
from the left side pressure tap to the right (down) side tap.  
The pressure switch hose must be connected to the down  
side to guard against blocked drain conditions. Cut hose  
to appropriate length to minimize sagging. Plug left  
(unused) pressure tap with plug removed from right side.  
8. Insert approximately one inch of each Tube 2 through the  
right down side panel grommet holes. Secure tubes to  
Hose A and Hose B using green hose clamps. Ensure  
hoses and tubes maintain a downward slope for proper  
drainage and are not kinked or bound.  
For details concerning mounting of the drain trap, refer to Con-  
densateDrainLinesandDrainTrap-Horizontal DrainTrapMount-  
ing.  
FRONT COVER  
DRAIN PORT  
RED HOSE  
CLAMP  
HOSE A  
HOSE B  
FRONT  
COVER  
PRESSURE  
TAP  
RUBBER  
ELBOW  
“FIELD-SUPPLIED  
DRAIN HOSE”  
FROM VENT-DRAIN  
CONNECTED TO  
CONDENSATE  
VENT-DRAIN  
DRAIN LINE WITH  
“FIELD-SUPPLIED  
CONNECTOR”  
RIGHT  
NOTE: MAKE  
SIDE  
SMALL  
TUBES 2  
LOOP IN HOSE  
PANEL  
TO SERVE  
AS “P-TRAP”  
RUBBER ELBOW  
DRAIN TRAP  
Allow 4-3/4”  
minimum  
GREEN  
HOSE  
DRAIN PORT  
TUBE 1  
CLAMP  
SILVER HOSE  
CLAMP  
for trap  
(3 PLACES)  
Horizontal Connections - Right Side Down  
(UpflowShown, CounterflowSimilar)  
When using the horizontal alternate  
vent configuration, you must use the  
RF000142 vent drain kit.  
24  
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Horizontal installations with the left side panel down will require  
drain hoses to be connected to the left side front cover drain port  
and the side drain port on the rubber elbow.  
7. Insert approximately one inch of each Tube 2 through left  
side panel grommet hole. Secure tubes to Hose A and  
Hose B with a green hose clamps. NOTE: Tube must  
reach bottom of trap. Ensure hoses and tubes maintain a  
downward slope for proper drainage and that they are not  
kinked or binding.  
1. Removetherubberplug/capfromthefrontcoverleft(down)  
side drain port.  
2. Relocate the front cover pressure switch hose connection  
from the right side (as shipped) pressure tap to the left  
(down) side tap. The pressure switch hose must be  
connected to the down side to guard against blocked drain  
conditions. Cut hose to appropriate length to minimize  
sagging. Plug right (unused) pressure tap with plug  
removed from left side.  
For details concerning mounting of the drain trap, refer to Con-  
densateDrainLinesandDrainTrap-HorizontalDrainTrapMount-  
ing.  
HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE  
PANEL)  
1. Position the drain trap against side panel with drain tubes  
inserted into trap. Note that the trap may be orientated  
with the outlet facing either the furnace’s top cover or base  
pan.  
3. Secure Hose A to front cover drain port with a red hose  
clamp. Route hose to rear left (down) side panel grommet  
holes. NOTE: For left side drainage, grommets must be  
relocated to left side panel.  
2. Secure drain trap to side panel at the dimples or crosshairs  
located on either side of the grommet drain holes.  
3. Confirm that tubes reach bottom of drain trap and that all  
hoses maintain a downward slope and are not kinked or  
binding.  
4. Remove the rubber cap from the side drain port on the  
rubber elbow.  
5. Secure the short end of Hose B to rubber elbow side drain  
port using a green hose clamp. NOTE: For left side  
drainage, route hose to far left (down) side panel grommet  
holes. NOTE: Horizontal left side connections (when using  
new side port drain elbow) does not require connecting a  
hose to the induced draft blower housing.  
4. Attach PVC drain line to drain trap outlet with either a 90°  
elbow or coupling.  
6. Cut 5 1/2 inches straight length from the long end of each  
Tube 2 and discard radius ends.  
GREEN HOSE  
CLAMP  
HOSE B  
HOSE A  
FRONT  
COVER  
PRESSURE  
TAP  
GREEN HOSE  
CLAMP  
TUBE(S) 2  
LEFT SIDE  
FRONT COVER  
DRAIN PORT  
PANEL  
DRAIN TRAP  
Allow  
RED HOSE CLAMP  
4-3/4” minimum  
SIDE PANEL  
GROMMET  
HOLES  
for trap  
Horizontal Connections - Left Side Down  
(UpflowShown, CounterflowSimilar)  
25  
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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  
(left side for counterflows) electrical connection with the junction  
box located inside the burner compartment. To make electrical  
connections through the opposite side of the furnace, the junc-  
tion box must be relocated to the other side of the burner com-  
partment prior to making electrical connections. To relocate the  
junction box, follow the steps shown below.  
ELECTRICAL CONNECTIONS  
WARNING  
HIGH VOLTAGE !  
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO  
THE UNIT MUST BE POLARIZED AND GROUNDED.  
WARNING  
NOTE: Wire routing must not to interfere with circulator blower  
operation, filter removal, or routine maintenance.  
HIGH VOLTAGE !  
TO AVOID PERSONAL INJURY OR DEATH DUE TO  
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER  
BEFORE SERVICING OR CHANGING ANY ELECTRICAL  
WIRING.  
JUNCTIONBOXRELOCATION  
WARNING  
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A  
PRECAUTION WHEN REMOVING HOLE PLUGS.  
CAUTION  
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING  
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS  
OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.  
WARNING  
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,  
DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS  
UNIT.  
WIRINGHARNESS  
The wiring harness is an integral part of this furnace. Field alter-  
ation to comply with electrical codes should not be required.  
Wires are color coded for identification purposes. Refer to the  
wiring diagram for wire routings. If any of the original wire as  
supplied with the furnace must be replaced, it must be replaced  
with wiring material having a temperature rating of at least 105°  
C. Any replacement wiring must be a copper conductor.  
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.  
115VOLTLINECONNECTIONS  
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 ofThe National  
Electric Code,ANSI NFPA70 and/orThe Canadian Electric Code  
CSA C22.1.  
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 relo-  
cated to the left side prior to making electrical connections. To  
relocate the junction box, perform the following steps.  
1. Remove the burner compartment door.  
2. Remove and save the two screws securing the junction  
box to the side panel.  
3. Relocate junction box and associated plugs and grommets  
to opposite side panel. Secure with screws removed in  
step 2.  
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  
overcurrent protection specified on the unit rating plate. An elec-  
trical disconnect must be provided at the furnace location.  
WARNING  
Connect hot, neutral, and ground wires as shown in the wiring  
diagram located on the unit’s blower door. For direct vent appli-  
cations, the cabinet opening to the junction box must be sealed  
air tight using either an UL approved bushing such as Heyco  
Liquid Tight or by applying non-reactive UL approved sealant to  
bushing.  
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 ELECTRICAL CODE.  
26  
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To ensure proper unit grounding, the ground wire should run from  
the furnace ground screw located inside the furnace junction box  
all the way back to the electrical panel. NOTE: Do not use gas  
piping as an electrical ground. To confirm proper unit grounding,  
turn off the electrical power and perform the following check.  
1. Measureresistancebetweentheneutral(white)connection  
and one of the burners.  
IMPORTANT NOTE  
THERMOSTAT “R” REQUIRED IF OUTDOOR UNIT IS EQUIPPED WITH A  
COMFORT ALERTMODULE OR IF THE OUTDOOR UNIT IS A PART OF  
THE CONFORTNETFAMILY OF EQUIPMENT.  
2. Resistance should measure 10 ohms or less.  
This furnace is equipped with a blower door interlock switch which  
interruptsunitvoltagewhentheblowerdoorisopenedforservicing.  
Do not defeat this switch.  
24 V THERMOSTAT CONNECTIONS  
AUX  
24VOLTTHERMOSTATWIRING  
IMPORTANT NOTE  
Low Voltage Connections with Auxiliary Terminals  
The auxiliary contacts are shipped with a factory installed  
jumper. As an option, the auxiliary contacts may be wired to  
a normally closed float switch. In the event of open contacts,  
the furnace will be disabled until the condition is corrected.  
These are 24 volt terminals fed internally, do not apply another  
voltage source to these terminals.  
WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER  
OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE.  
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.  
R
Furnace Integrated  
Control Module  
R
IMPORTANT NOTE  
NEU  
Y
C
DIP SWITCH #13 MUST BE SET TO MATCH THERMOSTAT TYPE. TO USE  
THE CTK01AA COMMUNICATING THERMOSTAT, DIP SWITCH #13  
MUST BE SET TO ON POSITION. THIS IS ALSO THE CORRECT SETTING  
FOR A NONCOMMUNICATING 2STAGE THERMOSTAT. TO USE  
CTK02AA MODULATING THERMOSTAT, CHECK TO MAKE SURE DIP  
SWITCH #13 IS IN THE OFF POSITION (FACTORY POSITION). THIS IS  
ALSO THE CORRECT POSITION WHEN USING A NONCOMMUNICATING  
SINGLESTAGE THERMOSTAT.  
Dehumidistat  
[Optional]  
Remote  
Condensing Unit  
(Single-Stage Cooling)  
Thermostat - Single-Stage Heating with Single-Stage Cooling  
IMPORTANT NOTE  
TO APPLY A SINGLESTAGE HEATING THERMOSTAT, THE THERMOSTAT  
SELECTOR SWITCH ON THE INTEGRATED CONTROL MODULE MUST BE  
SET ON SINGLESTAGE.  
Asatwo-stagenon-communicatingfurnace, thefurnaceintegrated  
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 Cooling’, and ‘Two-  
Stage Heating withTwo-Stage Cooling’. Refer to the following fig-  
ures for proper connections to the integrated control module.  
_____________________________________  
R
Furnace Integrated  
Control Module  
R
Low voltage connections can be made through either the right or  
left side panel. Thermostat wiring entrance holes are located in the  
blowercompartment. Thefollowingfigureshowsconnectionsfora  
“heat/cool system”.  
NEU  
Y
C
Dehumidistat  
[Optional]  
Remote  
Condensing Unit  
(Single-Stage Cooling)  
Thermostat - Two-Stage Heating with Single-Stage Cooling  
This furnace is equipped with a 40 VAtransformer 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.  
NOTE: Use of ramping profiles requires a jumper between Y1  
and O.  
27  
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Once the switch is set, the dehumidify function is enabled during a  
combinationcallforcooling(T-Stat)anddehumidification(DEHUM-  
Stat). Refer to the dip switch chart in the back section of this  
manual.  
Y2  
W1 W2  
Furnace Integrated  
Control Module  
Y2  
Y2  
W1 W2  
FOSSILFUELAPPLICATIONS  
NEU  
Dehumidistat  
[Optional]  
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).  
Remote  
Condensing Unit  
(Two-Stage Cooling)  
Thermostat - Two-Stage Heating with Two-Stage Cooling  
IMPORTANT NOTE  
A heat pump thermostat with three stages of heat is required to  
properly use a two-stage furnace in conjunction with a heat pump.  
Refer to the fossil fuel kit installation instructions for additional  
thermostat requirements.  
SET DIP SWITCH #14 TO ON POSITION WHEN USING A 2STAGE  
COOLING THERMOSTAT.  
Thermostat Wiring Diagrams  
Strictly follow the wiring guidelines in the fossil fuel kit installation  
instructions. All furnace connections must be made to the furnace  
two-stageintegratedcontrolmoduleandtheFURNACEterminal  
strip on the fossil fuel control board.  
SINGLE-STAGE HEATINGTHERMOSTATAPPLICATION  
A single-stage thermostat with only one heating stage may be  
used to control this furnace.  
115VOLTLINECONNECTIONOFACCESSORIES (HUMIDIFIERAND  
ELECTRONICAIRCLEANER)  
To use a single-stage thermostat, turn off power to the furnace,  
move the thermostat selection DIP switch to the OFF position.  
Turnpowerbackon. Referto the dip switch chart in this manual.  
WARNING  
HIGH VOLTAGE !  
24VOLTDEHUMIDISTATWIRING  
TO AVOID PERSONAL INJURY OR DEATH DUE TO  
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER  
BEFORE SERVICING OR CHANGING ANY ELECTRICAL  
WIRING.  
The optional usage of a dehumidistat allows the furnace’s circula-  
tor blower to operate at a slightly lower speed (85% of desired  
speed) during a combined thermostat call for cooling and dehumi-  
distat call for dehumidification. This can be done through an inde-  
pendent dehumidistat or through a thermostat’s DEHUM terminal  
(if available). This lower blower speed enhances dehumidification  
of the conditioned air as it passes through theAC coil. For proper  
function, a dehumidistat 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.  
Thefurnaceintegratedcontrolmoduleisequippedwithlinevoltage  
accessoryterminalsforcontrollingpowertoanelectronicaircleaner.  
The accessory load specifications are as follows. (The furnace  
control board also has a set of dry contacts for humidifier  
connection.)  
Humidifier  
Electronic Air Cleaner  
1.0 Amp maximum at 120 VAC  
1.0 Amp maximum at 120 VAC  
To install/connect a dehumidistat:  
1. Turn OFF power to furnace.  
Turn OFF power to the furnace before installing any accessories.  
Follow the humidifier or air cleaner manufacturers’ instructions 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 Electronic air cleaner hot terminal is identified as  
EAC. The EAC neutral terminal is identified as NEUTRAL. A  
line voltage humidifier may be connected between one of the  
HUM contacts and NEUTRAL. The other HUM contact must  
be fed from the L1 terminal.  
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.  
5. Turn ON power to furnace.  
All field wiring must conform to applicable codes. Connections  
should be made as shown in the following figure.  
To enable the dehumidify function on the integrated control mod-  
ule, set the dehumidification ENABLE dipswitch from OFF to ON.  
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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.  
NEUTRAL  
L1  
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.  
AUX OUT  
AUX IN  
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.  
HIGHALTITUDEDERATE  
Accessories Wiring  
High altitude kits are purchased according to the installation alti-  
tude and usage of either natural or propane gas. Consult the  
furnace Specification Sheet for appropriate kits.  
If it is necessary for the installer to supply additional line voltage  
wiring to the inside of the furnace, the wiring must conform to all  
local codes, and have a minimum temperature rating of 105°C. All  
line voltage wire splices must be made inside the furnace junction  
box.  
Do not derate the furnace by adjusting the manifold pressure to a  
lower pressure than specified on the furnace rating plate. The  
combination of the lower air density and a lower manifold pressure  
willprohibittheburnerorificefromdrawingtheproperamountofair  
into the burner. This may cause incomplete combustion, flash-  
back, and possible yellow tipping.  
The integrated furnace control HUM (dry contacts) are closed  
whenever the inducer is energized in a non-communicating  
installation. When used with a CTK02AA communicating ther-  
mostat, the HUM terminals are closed whenever there is a  
call for humidity. The integrated control module electronic air  
cleanerterminals(EAC)areenergizedwith115voltswheneverthe  
circulator blower is energized.  
In some areas the gas supplier may artificially derate the gas in an  
effort to compensate for the effects of altitude. If the gas is artifi-  
cially derated, the appropriate orifice size must be determined  
based upon the BTU/ft3 content of the derated gas and the alti-  
tude. RefertotheNationalFuelGasCode, NFPA54/ANSIZ223.1,  
andinformationprovidedbythegassuppliertodeterminetheproper  
orifice size.  
24VOLTHUMIDIFIER  
A 5" long brown wire in the wire harness at the low fire pressure  
switch provides 24 VAC humidifier control. This wire is powered  
any time the pressure switch is closed. To connect 24 VAC HUM,  
connect the 24 VAC line of the humidifier to the 5” brown wire. The  
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.  
Adifferentpressureswitchmayberequiredathighaltituderegard-  
less of the BTU/ft3 content of the fuel used. Consult the furnace  
Specification Sheet for pressure switch.  
PROPANEGASCONVERSION  
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.  
GAS SUPPLY AND PIPING  
The furnace rating plate includes the approved furnace gas input  
rating and gas types. The furnace must be equipped to operate on  
the type of gas applied. This includes any conversion kits required  
for alternate fuels and/or high altitude.  
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 for details.  
Consult the furnace Specification Sheet for a listing of appro-  
priate kits. 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.  
29  
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The following stipulations apply when connecting gas piping. Re-  
fer to Gas Piping Connections figure for typical gas line connec-  
tions to the furnace.  
GAS VALVE  
This unit is equipped with a 24 volt gas valvewhich modulates by  
pneumatic linkage to the combustion air blower Tapsfor mea-  
suringthegassupplypressureandmanifoldpressureareprovided  
on the valve. This is a non-convertible gas valve equipped for  
natural gas.  
Gas piping must be supported external to the furnace  
cabinet so that the weight of the gas line does not distort  
the burner rakc, manifold or gas valve.  
Use black iron or steel pipe and fittings for building piping.  
Where possible, use new pipe that is properly chamfered,  
reamed, and free of burrs and chips. If old pipe is used, be  
sure it is clean and free of rust, scale, burrs, chips, and old  
pipe joint compound.  
The gas valve has a manual ON/OFF control located on the valve  
itself. This control may be set only to the “ON” or “OFF” position.  
Refer to the lighting instructions label or Startup Procedure &  
Adjustment for use of this control during start up and shut down  
periods.  
Use pipe joint compound on male threads ONLY. Always  
use pipe joint compound (pipe dope) that is APPROVED  
FORALLGASSES. DO NOTapply compound to the first  
two threads.  
GASPIPINGCONNECTIONS  
WARNING  
Use ground joint unions.  
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.  
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.  
When sizing a trunk line, be sure to include all appliances which  
will operate simultaneously when sizing a trunk line.  
Alwaysuseaback-upwrenchwhenmakingtheconnection  
to the gas valve to keep it from turning. The orientation of  
thegasvalveonthemanifoldmustbemaintainedasshipped  
from the factory. Maximum torque for the gas valve  
connection is 375 in-lbs; excessive over-tightening may  
damagethegasvalve.  
Thegaspipingsupplyingthefurnacemustbeproperlysizedbased  
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.  
Natural Gas Capacity of Pipe  
In Cubic Feet of Gas Per Hour (CFH)  
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.  
Length of  
Nominal Black Pipe Size  
Pipe in Feet  
1/2"  
132  
92  
73  
63  
56  
50  
46  
43  
40  
38  
3/4"  
1"  
1 1/4"  
1 1/2"  
1600  
1100  
980  
10  
20  
30  
40  
50  
60  
70  
80  
90  
100  
278  
190  
152  
130  
115  
105  
96  
520  
350  
285  
245  
215  
195  
180  
170  
160  
150  
1050  
730  
590  
500  
440  
400  
370  
350  
320  
305  
Tighten all joints securely.  
760  
670  
610  
Connect the furnace to the building piping by one of the  
followingmethods:  
560  
530  
90  
Rigid metallic pipe and fittings.  
84  
79  
490  
460  
Semi-rigid metallic tubing and metallic fittings.  
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on  
0.60 Specific Gravity Gas)  
Aluminum alloy tubing must not be used in exterior  
locations. In order to seal the grommet cabinet  
penetration,rigidpipemustbeusedtoreachtheoutside  
ofthecabinet. Asemi-rigidconnectortothegaspiping  
may be used from there.  
BTUH Furnace Input  
CFH =  
Heating Value of Gas (BTU/Cubic Foot)  
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.  
Use listed gas appliance connectors in accordance with  
their instructions. Connectors must be fully in the same  
room as the furnace.  
Protect connectors and semirigid tubing against physical  
and thermal damage when installed. Ensure aluminum-  
alloy tubing and connectors are coated to protect against  
external corrosion when in contact with masonry, plaster,  
or insulation, or subjected to repeated wetting by liquids  
such as water (except rain water), detergents, or sewage.  
30  
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GAS VALVE  
MANUAL  
SHUT OFF VALVE  
(UPSTREAM FROM  
MANIFOLD  
BURNERS  
GAS LINE  
PLUG IN  
PIPE UNION)  
PLUG IN  
ALTERNATE  
GAS LINE  
HOLE  
GAS LINE  
HOLE  
HEIGHT REQUIRED  
BY LOCAL CODE  
GROMMET  
IN STANDARD  
GAS LINE HOLE  
GAS VALVE  
PIPE UNION  
DRIP LEG  
DRIP LEG  
BURNERS  
MANUAL SHUT-OFF VALVE  
(UPSTREAM FROM GROUND  
JOINT PIPE UNION)  
GROUND JOINT  
PIPE UNION  
DRIP LEG  
GROMMET IN STANDARD  
GAS LINE HOLE  
GAS VALVE  
GAS VALVE  
BURNERS  
BURNERS  
DRAIN TRAP  
DRAIN TRAP  
MANIFOLD  
PLUG IN ALTERNATE  
GAS LINE HOLE  
ALTERNATE GAS  
LINE LOCATION  
PLUG IN ALTERNATE  
GAS LINE HOLE  
MANIFOLD  
ALTERNATE GAS  
LINE LOCATION  
HORIZONTAL[COUNTERFLOW]  
HORIZONTAL [UPFLOW MODEL]  
GasPipingConnections  
31  
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DIRECT/STANDARDINLETPIPING  
PROPANEGASTANKSAND PIPING  
WARNING  
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.  
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A  
PRECAUTION WHEN REMOVING HOLE PLUGS.  
When gas piping enters directly to the gas valve through the stan-  
dard inlet hole, the installer must supply straight pipe with a ground  
joint union to reach the exterior of the furnace. The rigid pipe must  
be long enough to reach the outside of the cabinet to seal the  
grommet cabinet penetration. A semi-rigid connector to the gas  
piping can be used outside the cabinet per local codes.  
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.  
A gas detecting warning system is the only reliable way to detect  
a propane gas leak. Rust can reduce the level of odorant in pro-  
pane gas. Do not rely on your sense of smell. Contact a local  
propane gas supplier about installing a gas detecting warning sys-  
tem. If the presence of gas is suspected, follow the instructions  
listed in the Safety Precautions section of this manual.  
INDIRECT/ALTERNATEINLETPIPING  
When gas piping enters indirectly to the gas valve through the  
alternate gas inlet hole the following fittings (starting from the gas  
valve) to reach the outside of the cabinet must be supplied:  
Close nipple.  
All propane gas equipment must conform to the safety standards  
of the National Board of Fire Underwriters, NBFU Manual 58.  
90degreeelbow.  
2½ inch nipple.  
90degreeelbow.  
For satisfactory operation, propane gas pressure must be 10” WC  
+ .5” WCatthe furnace manifold with all gas appliances in opera-  
tion. Maintaining proper gas pressure depends on three main fac-  
tors:  
1. Vaporization rate, depending on temperature of the liquid,  
and “wetted surface” area of the container or containers.  
2. Proper pressure regulation. (Two-stage regulation is  
recommended for both cost and efficiency).  
Straight pipe, with a ground joint union, to reach the exterior  
of the furnace. The rigid pipe must be long enough to reach  
theoutsideofthecabinetsoastosealthegrommetcabinet  
penetration. Asemi-rigid connector to the gas piping can  
be used outside the cabinet per local codes.  
GAS PIPING CHECKS  
3. Pressure drop in lines between regulators, and between  
second stage regulator and the appliance. Pipe size will  
dependonlengthofpiperunandtotalloadofallappliances.  
Before placing unit in operation, leak test the unit and gas connec-  
tions.  
Complete information regarding tank sizing for vaporization, rec-  
ommended regulator settings, and pipe sizing is available from  
most regulator manufacturers and propane gas suppliers.  
WARNING  
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH  
OR OPEN FLAME TO TEST FOR LEAKS.  
Since propane gas will quickly dissolve white lead and most stan-  
dard commercial compounds, special pipe dope must be used.  
Shellac-based compounds resistant to the actions of liquefied pe-  
troleum gases such as Gasolac®, Stalactic®, Clyde’s® or John  
Crane® are satisfactory.  
Check for leaks using an approved chloride-free soap and water  
solution, anelectroniccombustiblegasdetector, orotherapproved  
testing methods.  
NOTE: Never exceed specified pressures for testing. Higher  
pressure may damage the gas valve and cause subsequent  
overfiring, resulting in heat exchanger failure.  
Refer to the following illustration for typical propane gas installa-  
tions and piping.  
Disconnect this unit and shutoff valve from the gas supply piping  
system before pressure testing the supply piping system with  
pressures in excess of 1/2 psig (3.48 kPa).  
5 to 15 PSIG  
First Stage  
(20 PSIG Max.)  
Regulator  
Continuous  
11" W.C.  
Isolate this unit from the gas supply piping system by closing its  
external manual gas shutoff valve before pressure testing supply  
piping system with test pressures equal to or less than 1/2 psig  
(3.48 kPA).  
200 PSIG  
Maximum  
Second Stage  
Regulator  
PropaneGasInstallation(Typ.)  
32  
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A closed return duct system must be used, with the return duct  
connected to the furnace. NOTE: Ductwork must never be at-  
tached to the back of the furnace. For upflow installations requir-  
ing 1800 CFM or more, use either two side returns or bottom  
return or a combination of side /bottom. Flexible joints may be  
used for supply and return connections to reduce noise transmis-  
sion.To prevent the blower from interfering with combustion air or  
draft when a central return is used, a connecting duct must be  
installed between the unit and the utility room wall. Never use a  
room, closet, or alcove as a return air chamber.  
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.  
Pipe or  
Nominal Pipe Size  
Schedule 40  
Tubing Size, O.D. Type L  
Tubing  
Length  
Feet  
10  
3/8"  
730  
500  
400  
370  
330  
300  
260  
220  
200  
190  
170  
160  
1/2"  
1,700  
1,100  
920  
5/8"  
3,200  
220  
3/4"  
7/8"  
1/2"  
3/4"  
5,300  
3,700  
2,900  
2,700  
2,400  
2,200  
1,900  
1,700  
1,400  
1,300  
1,200  
1,100  
8,300  
5,800  
4,700  
4,100  
3,700  
3,300  
2,900  
2,600  
2,300  
2,100  
1,900  
1,800  
3,200  
2,200  
1,800  
1,600  
1,500  
1,300  
1,200  
1,000  
900  
7,500  
4,200  
4,000  
3,700  
3,400  
3,100  
2,600  
2,300  
2,100  
1,900  
1,700  
1,500  
20  
30  
2,000  
1,700  
1,500  
1,300  
1,200  
1,000  
900  
40  
850  
50  
770  
60  
700  
80  
610  
100  
125  
150  
175  
200  
540  
CHECKING DUCT STATIC  
490  
430  
830  
830  
Refer to your furnace rating plate for the maximum ESP (ex-  
ternal duct static) rating.  
400  
780  
770  
380  
730  
720  
To convert to capacities at 15 psig settings - multiply by 1.130  
To convert to capacities at 5 psig settings - multiply by 0.879  
Total external static refers to everything external to the fur-  
nace cabinet. Cooling coils, filters, ducts, grilles, registers  
must all be considered when reading your total external static  
pressure. The supply duct pressure must be read between  
the furnace 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.  
Propane Gas Piping Chart I  
Sizing Between Second or Second Stage Regulator & Appliance*  
Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting.  
Capacities in 1,000 BTU/hour.  
Pipe or  
Nominal Pipe Size  
Tubing Size, O.D. Type L  
Tubing  
Length  
Feet  
10  
Schedule 40  
3/8"  
39  
26  
21  
19  
18  
16  
13  
11  
10  
9
1/2"  
92  
62  
50  
41  
37  
35  
29  
26  
24  
21  
19  
17  
5/8"  
199  
131  
107  
90  
3/4"  
329  
216  
181  
145  
131  
7/8"  
501  
346  
277  
233  
198  
1/2"  
275  
189  
152  
129  
114  
103  
89  
3/4"  
1"  
1-1/4" 1-1/2"  
567 1,071 2,205 3,307  
20  
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  
30  
40  
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.  
50  
79  
448  
409  
346  
307  
275  
252  
209  
185  
913  
834  
724  
630  
567  
511  
439  
390  
1,417  
1,275  
1,066  
976  
60  
72  
1,211 187  
80  
62  
104  
90  
81  
72  
66  
60  
155  
138  
122  
109  
100  
93  
100  
125  
150  
200  
250  
55  
78  
48  
69  
866  
To determine total external duct static pressure, proceed as  
follows;  
43  
63  
787  
8
39  
54  
665  
8
36  
48  
590  
1. With clean filters in the furnace, use a draft gauge (in-  
clined manometer) to measure the static pressure of the  
return duct at the inlet of the furnace. (Negative Pressure)  
*Data in accordance with NFPA pamphlet No. 54  
Propane Gas Piping Chart II  
2. Measure the static pressure of the supply duct. (Positive  
Pressure)  
CIRCULATING AIR & FILTERS  
DUCTWORK-AIR FLOW  
3. The difference between the two numbers is .4” w.c.  
Example:  
WARNING  
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON  
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR  
SUPPLY.  
static reading from return duct = -.1" w.c.  
static reading from supply duct = .3" w.c.  
total external static pressure on this system = .4" w.c.  
Duct systems and register sizes must be properly designed for  
the CFM and external static pressure rating of the furnace. Design  
the ductwork in accordance with the recommended methods of  
“Air Conditioning Contractors ofAmerica” Manual D.  
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.  
Install the duct system in accordance with Standards of the Na-  
tionalBoardofFireUnderwritersfortheInstallationofAirCondition-  
ing, Warm Air Heating and Ventilating Systems. Pamphlets No.  
90A and 90B.  
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,  
registers, undersized and/or oversized poorly laid out duct work.  
33  
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When the furnace is used in connection with a cooling unit, the  
furnace should be installed in parallel with or on the upstream side  
of the cooling unit to avoid condensation in the heating element.  
With a parallel flow arrangement, the dampers or other means  
used to control the flow of air must be adequate to prevent chilled  
air from entering the furnace and, if manually operated, must be  
equipped with means to prevent operation of either unit unless the  
damper is in the full heat or cool position.  
When the furnace is installed without a cooling coil, it is recom-  
mended that a removable access panel be provided in the outlet  
air duct. This opening shall be accessible when the furnace is  
installed and shall be of such a size that the heat exchanger can  
be viewed for visual light inspection or such that a sampling probe  
can be inserted into the airstream. The access panel must be  
made to prevent air leaks when the furnace is in operation.  
When the furnace is heating, the temperature of the return air  
entering the furnace must be between 55°F and 100°F.  
FILTERS-READTHISSECTIONBEFOREINSTALLINGTHERETURN  
AIRDUCTWORK  
Checking Static Pressure  
(80% Furnace Shown, 90% Similar)  
Filters must be used with this furnace. Discuss filter maintenance  
with the building owner. Filters do not ship with this furnace, but  
must be provided, sized and installed externally by the installer.  
Filters must comply with UL900 or CAN/ULCS111 standards. If  
the furnace is installed without filters, the warranty will be voided.  
BOTTOMRETURNAIROPENING[UPFLOWMODELS]  
The bottom return air opening on upflow models utilizes a “lance  
and cut” method to remove sheet metal from the duct opening in  
the base pan. To remove, simply press out the lanced sections by  
hand to expose the metal strips retaining the sheet metal over the  
duct opening. Using tin snips, cut the metal strips and remove the  
sheet metal covering the duct opening. In the corners of the open-  
ing, cut the sheet metal along the scribe lines to free the duct  
flanges. Using the scribe line along the duct flange as a guide,  
unfoldtheductflangesaroundtheperimeteroftheopeningusinga  
pair of seamer pliers or seamer tongs. NOTE:Airflow area will be  
reduced by approximately 18% if duct flanges are not unfolded.  
This could cause performance issues and noise issues.  
On upflow units, guide dimples locate the side return cutout loca-  
tions. Use a straight edge to scribe lines connecting the dimples.  
Cut out the opening on these lines. NOTE:An undersized open-  
ing will cause reduced airflow.  
RefertoMinimumFilterAreatablestodeterminefilterarearequire-  
ments.  
UPFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
600  
---  
800  
---  
1000 1200  
1400  
672  
1600 2000  
WARNING  
0603__XA  
0805__XA  
627*  
---  
627*  
836*  
768  
---  
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A  
PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR  
OPENINGS.  
---  
---  
836*  
836*  
960  
1005__XA  
1155__XA  
---  
---  
---  
940*  
940*  
940*  
960  
COUNTERFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
CUT USING TIN SNIPS  
600  
800  
1000 1200  
1400  
1600 2000  
PRESS OUT BY HAND  
0604__XA  
---  
---  
320*  
---  
320*  
427*  
336  
384  
---  
0805__XA  
1005__XA  
---  
---  
427*  
427*  
480  
*Minimum filter area dictated by heating airflow requirement.  
Permanent Minimum Filter Area (sq. in)  
CUT FOUR CORNERS  
AFTER REMOVING SHEET  
METAL  
[Based on a 600 ft/min filter face velocity]  
SCRIBE LINES OUTLINING  
DUCT FLANGES  
DuctFlangeCutOuts  
34  
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FILTER  
ACCESS  
DOOR  
UPFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
600  
800  
1000 1200  
1400  
1600 2000  
0603__XA  
0805__XA  
---  
---  
564*  
---  
564*  
752*  
672  
768  
RETURN  
DUCT  
---  
---  
---  
---  
752*  
940*  
768  
960  
960  
CENTRAL  
RETURN  
GRILLE  
1005__XA  
1155__XA  
---  
940*  
940*  
FILTER  
SUPPORT  
BRACKET  
(Field Supplied)  
COUNTERFLOW  
COOLING AIRFLOW REQUIREMENT (CFM)  
600  
800  
1000 1200  
1400  
1600 2000  
0604__XA  
---  
---  
641*  
---  
641*  
854*  
672  
768  
---  
0805__XA  
1005__XA  
---  
---  
854*  
854*  
960  
*Minimum filter area dictated by heating airflow requirement.  
Disposable Minimum Filter area (sq. in)  
[Based on 300 ft/min filter face velocity]  
AIR FLOW  
PossibleUprightCounterflow  
FilterLocations  
UPRIGHT INSTALLATIONS  
Depending on the installation and/or customer preference, differ-  
ing filter arrangements can be applied. Filters can be installed in  
the central return register or a side panel external filter rack kit  
(upflows). Asanalternativeamediaairfilterorelectronicaircleaner  
can be used as the requested filter.  
HORIZONTALINSTALLATIONS  
Filters must be installed in either the central return register or in  
the return air duct work.  
STARTUP PROCEDURE &ADJUSTMENT  
The following figure shows possible filter locations.  
AIR FLOW  
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 section.  
CENTRAL  
RETURN  
GRILLE  
SIDE RETURN  
EXTERNAL FILTER  
RACK KIT  
UNIT CALL FOR HEAT ENDS  
(EITHER SIDE)  
100%  
IGNITION(80%)  
10 MINS.  
78%  
8 MINS.  
57%  
2 MINS.  
PossibleUprightUpflow  
MIN.  
Operation with Conventional 1-Stage Thermostat  
(DIP switch selections 1-Stage heat)  
Call for heat, thermostat energizes W1 on IFC (W2 input is  
ignored).  
After a successful Light Off Sequence and expiration of the  
Ignition Stabilization Period:  
35  
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After 2 minutes, the IFC increases to 57% at a rate  
of 1% per second  
After 10 total minutes, the IFC increases to 78% at a  
rate of 1% per second.  
After 20 total minutes, the IFC increases to 100% at  
a rate of 1% per second for the remainder of the call  
for heat.  
The circulator is adjusted to the appropriate CFM,  
corresponding to the current firing rate.  
Call for 2nd-Stage Heat - Thermostat contacts close R to W1  
and W2.  
After a successful Light Off Sequence and expiration of the  
Ignition Stabilization Period:  
The IFC adjusts to the low firing rate.  
After 2 minutes, the IFC increases to 80%.  
Thereafter, the IFC will increase 10%, at a rate of 1%  
per second, every 10 minutes for the remainder of  
the call for heat.  
The circulator is adjusted to the appropriate CFM,  
corresponding to the current firing rate.  
IGNITION(80%)  
UNIT CALL FOR HEAT ENDS  
100%  
70%  
IGNITION(80%)  
10 MINS.  
60%  
8 MINS.  
78%  
50%  
2 MINS.  
MIN.  
50%  
MIN.  
CALL FOR  
2ND STAGE HEAT  
2 MINS.  
Operation with Conventional 2-Stage Thermostat  
(DIP switch selects 2-stage heat)  
Call for 1st-Stage Heat - Thermostat contacts close R to W1.  
Call for 2nd-Stage Heat with 1st-Stage call for heat call in  
progress, with conventional 2-Stage Thermostat.  
After a successful Light Off Sequence and expiration of the  
Ignition Stabilization Period:  
The IFC increases the firing rate to 100% at a rate of  
1% per second for the remainder of the W2 call.  
The circulator is adjusted to the appropriate CFM,  
corresponding to the current firing rate.  
The IFC adjusts to the low firing rate.  
After 2 minutes, the IFC increases to 50% fort he  
next 8 minutes.  
Thereafter, the IFC will increase 10%, at a rate of 1%  
per second, every 10 minutes for the remainder of  
the call for heat (See above figure).  
The circulator is adjusted to the appropriate CFM,  
corresponding to the current firing rate.  
Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat re-  
mains.  
The IFC remains at the current firing rate until the  
1st-Stage call for heat is satisfied.  
HEATING OPERATION WITH CTK01AATHERMOSTAT  
(COMMUNICATING)  
10 MINS.  
When the Thermostat Heat Setup DIP switch is set  
to 2-Stage heat, the IFC operation will be compatible  
with a CTK01AA communicating thermostat.  
When a call for heat is sent, the furnace will go through  
the Light Off Sequence, at which time the Heat Current  
Demand Status will still show 0%. After the successful  
Light Off Sequence and expiration of the Ignition  
Stabilization Period:  
90%  
8 MINS.  
IGNITION (80%)  
70%  
60%  
50%  
The IFC adjusts to the low firing rate.  
After 2 minutes, the IFC accepts the specific Heat  
Requested Demand.  
2 MINS.  
MIN.  
Operation with Conventional 2-Stage Thermostat  
(DIP switch selects 2-stage heat)  
36  
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If the differential is equal to or less than 2 degrees,  
the IFC will follow the conventional 2-Stage algorithm,  
equivalent to a W1 request and be reflected in the  
Heat Current Demand Status %.  
If the heat differential is greater than 2 degrees, the  
IFC will follow the conventional 2-Stage algorithm,  
equivalent to a W2 request and be reflected in the  
Heat Current Demand Status %.  
FURNACESTARTUP  
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.  
NOTE: This furnace is equipped with an ignition device which  
automatically lights the burner. Do not try to light the burner by  
hand.  
The circulator will operate per the heat airflow profile.  
5. Move the furnace gas valve manual control to the OFF  
position.  
HEATING OPERATION WITH CTK02AATHERMOSTAT  
(MODULATING COMMUNICATING)  
6. Wait five minutes then smell for gas. Be sure check near  
the floor as some types of gas are heavier than air.  
7. If you smell gas after five minutes, immediately follow the  
Safety Instructions on page 5 of this manual. If you do not  
smell gas after five minutes, move the furnace gas valve  
manual control to the ON position.  
When the Thermostat Heat Setup DIP switch is set  
to 1-Stage heat, the IFC operation will be compatible  
with a modulating communicating thermostat  
(CTK02AA).  
When a call for heat is sent, the furnace will go through  
the Light Off Sequence, at which time the Heat Current  
Demand Status will still show 0%. After the successful  
Light Off Sequence and expiration of the Ignition  
Stabilization Period:  
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.  
• The IFC adjusts to the low firing rate.  
12. After the burners are lit, set the thermostat to desired  
temperature.  
• After 2 minutes, the IFC accepts the specific Heat  
Requested Demand.  
• If the differential is 2 degrees or less, the Heat  
Current Demand Status will show 50%.  
• If the specific Heat Requested Demand is above 2  
degrees, the Heat Current Demand Status will track  
the specific Heat Requested Demand.  
FURNACESHUTDOWN  
1. Set the thermostat to the lowest setting.  
Theintegratedcontrolwillclosethegasvalveandextinguish  
flame. Followinga15seconddelay, theinduceddraftblower  
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.  
The circulator will operate per the heat airflow profile.  
HEATANTICIPATORSETTING  
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 set-  
ting to 0.7 amps. Follow the thermostat manufacturer’s instruc-  
tions on how to adjust the heat anticipator setting.  
2. Removetheburnercompartmentdoorandmovethefurnace  
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.  
DRAINTRAPPRIMING  
GASSUPPLYPRESSUREMEASUREMENT  
The drain trap must be primed prior to furnace startup. To prime, fill  
the drain trap with water. This ensures proper furnace drainage  
upon startup and prohibits the possibility of flue gases escaping  
through the drain system. Air conditioning condensate may be  
drained into the furnace trap. Please see requirements in Con-  
densate Drain Lines & Drain Trap section.  
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.  
FURNACEOPERATION  
Purge gas lines of air prior to startup. Be sure not to purge lines  
into an enclosed burner compartment.  
The line pressure supplied to the gas valve must be within the  
range specified below. The supply pressure can be measured at  
the gas valve inlet pressure boss or at a hose fitting installed in the  
gas piping drip leg. The supply pressure must be measured with  
the burners operating. To measure the gas supply pressure, use  
thefollowingprocedure.  
Check for leaks using an approved chloride-free soap and water  
solution, anelectroniccombustiblegasdetector, orotherapproved  
method. Verify that all required kits (propane gas, etc.) have been  
appropriately installed.  
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the normal firing rate sequence at a rate of 100% for 5  
minutes or until the end of the call for heat. The display  
will show the normal “Hi” while the control is firing at  
100%. If the Fault Recall Push-Button has not been  
pressed within 5 seconds of displaying “Ft” the display  
will revert back to normal.  
PS  
ATMOSPHERE  
PORT  
CONNECTION  
FLOW  
DIRECTION  
4. Measure furnace gas supply pressure with burners firing.  
Supply pressure must be within the range specified in the  
Inlet Gas Supply Pressure table.  
HoneywellModelVR9205R  
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.  
2-PIN  
POWER  
CONNECTOR  
ometer  
Man  
pen to  
O
Atm  
osphere  
Hose  
If supply pressure differs from table, make the necessary adjust-  
ments to pressure regulator, gas piping size, etc., and/or consult  
with local gas utility.  
5. Turn OFF gas to furnace at the manual shutoff valve and  
disconnect manometer. Reinstall plug before turning on  
gas to furnace.  
i
Inlet  
Pressure  
Tap  
6. Turn OFF any unnecessary gas appliances stated in step  
3.  
1/8 NPT  
Gas Line  
anometer  
M
Gas  
Shutoff  
Valve  
Outlet  
Pressure  
Tap  
1/8 NPT  
Gas Line  
To Furnace  
Open To  
Atmosphere  
Drip Leg Cap  
With Fitting  
Honeywell Model VR9205R Connected to Manometer  
Manometer Hose  
1. Turn OFF gas to furnace at the manual gas shutoff valve  
external to the furnace.  
2. Connect a calibrated water manometer (or appropriate gas  
pressure gauge) at either the gas valve inlet pressure boss  
or the gas piping drip leg. See Honeywell VR9205R gas  
valve figure for location of inlet pressure boss.  
Manometer  
Measuring Inlet Gas Pressure (Alt. Method)  
GASMANIFOLDPRESSUREMEASUREMENT  
NOTE: If measuring gas pressure at the drip leg or Honeywell  
VR9205R gas valve, a field-supplied hose barb fitting must be  
installed prior to making the hose connection.  
CAUTION  
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE  
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING  
PLATE. GAS VALVE IS FACTORY SET AND DOES NOT REQUIRE ANY  
FIELD ADJUSTMENT. DO NOT ATTEMPT TO ADJUST VALVE.  
3. Turn ON the gas supply and operate the furnace and all  
other gas consuming appliances on the same gas  
supply line.  
Field Test Mode is intended to help a service person  
troubleshoot and check out an installed appliance.  
Themanifoldpressuremustbemeasuredwiththeburnersoperat-  
ing. To measure the manifold pressure, use the following proce-  
dure.  
1. Turn OFF gas to furnace at the manual gas shutoff valve  
external to the furnace.  
To enter Field Test Mode the Fault Recall Push-Button  
must be pressed twice within a 5 second period at any  
time during a heating cycle, at which time the display  
will show “Ft”. While the display is showing “Ft”,  
pressing and holding the Fault Recall Push-Button for  
3 seconds will enable the field test mode and override  
2. Turn off all electrical power to the system.  
38  
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3. Outlet pressure tap connections: Remove the outlet  
pressure boss plug. Install an 1/8" NPT hose barb fitting  
into the outlet pressure tap.  
4. Attach a hose and manometer to the outlet pressure barb  
fitting.  
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.  
GASINPUTRATEMEASUREMENT(NATURALGASONLY)  
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. TurnOFFthegassupplytoallothergas-burningappliances  
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.  
4. CalculatethefurnaceinputinBTUsperhour(BTU/hr). Input  
equals the sum of the installation’s gas heating value and a  
conversionfactor(hourstoseconds)dividedbythenumber  
of seconds per cubic foot. The measured input must not  
be greater than the input indicated on the unit rating plate.  
EXAMPLE:  
NOTE: After every time the main power is turned off  
and back on, the furnace will enter a calibration routine  
on the next call for heat The inducer will ramp up and  
down during the calibration routine. After calibration,  
the furnace will proceed to ignition cycle.  
7. Field Test Mode is intended to help a service person  
troubleshoot and check out an installed appliance.  
To enter Field Test Mode the Fault Recall Push-Button  
must be pressed twice within a 5 second period at any  
time during a heating cycle, at which time the display  
will show “Ft”. While the display is showing “Ft”,  
pressing and holding the Fault Recall Push-Button for  
3 seconds will enable the field test mode and override  
the normal firing rate sequence at a rate of 100% for 5  
minutes or until the end of the call for heat. The display  
will show the normal “Hi” while the control is firing at  
100%. If the Fault Recall Push-Button has not been  
pressed within 5 seconds of displaying “Ft” the display  
will revert back to normal.  
Installation’s gas heating (HTG) value: 1,000 BTU/ft3  
(Obtained from gas supplier)  
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  
NOTE: Gas valve is factory set and does NOT require  
any field adjustment. Do NOT attempt to adjust valve.  
NOTE: The final manifold pressure cannot vary by more than ±  
0.3” w.c. for Natural and + 0.5” for LP from the specified setting.  
Consult your local gas supplier if additional input rate adjustment  
is required.  
Measure the gas manifold pressure with burners firing.  
8. Turn off all electrical power and gas supply to the system.  
9. Remove the manometer hose from the hose barb fitting.  
10. 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.  
5. Turn ON gas to and relight all other appliances turned off in  
step1. Becertainthatallappliancesarefunctioningproperly  
and that all pilot burners are operating.  
TEMPERATURERISE  
11. Turn on electrical power and gas supply to the system.  
12. Close thermostat contacts “R” and “W1/W2” to energize  
thevalve.  
Temperature rise must be within the range specified on the unit  
rating plate.An incorrect temperature rise may result in condens-  
ing in or overheating of the heat exchanger. An airflow and tem-  
perature rise table is provided in the Specification Sheet applicable  
to your model. Determine and adjust temperature rise as follows:  
1. Operate furnace with burners firing for approximately ten  
minutes. Ensureallregistersareopenandallductdampers  
are in their final (fully or partially open) position.  
2. Placethermometersinthereturnandsupplyductsasclose  
to the furnace as possible. Thermometers must not be  
influenced by radiant heat by being able to “see” the heat  
exchanger.  
Using a leak detection solution or soap suds, check for leaks at  
outlet pressure boss plug. Bubbles forming indicate a leak. SHUT  
OFF GASAND REPAIRALLLEAKS IMMEDIATELY!  
NOTE: For natural gas to LP conversion, consult the furnace  
Specification Sheet.  
Manifold Gas Pressure  
Gas  
High Stage  
High Stage  
Range  
Nominal  
3.5" w.c.  
10.0" w.c.  
Natural  
3.2 - 3.8" w.c.  
9.5 - 10.5" w.c.  
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.  
Propane  
39  
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4. Adjust temperature rise by adjusting the circulator blower  
speed. Increase blower speed to reduce temperature rise.  
Decreaseblowerspeedtoincreasetemperaturerise. Refer  
to Startup Procedure and Adjustment -Circulator Blower  
Speeds for speed changing details.  
The cooling system manufacturer’s instructions must be checked  
for required air flow. Any electronic air cleaners or other devices  
may require specific air flows, consult installation instructions of  
those devices for requirements.  
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  
andfindtherequiredcoolingspeedandadjustmentsetting.  
Example: A *MVM960603BX furnace installed with a  
2.5 ton air conditioning system. The air flow  
HEAT EXCHANGER  
RADIATION "LINE OF SIGHT"  
SUPPLY  
AIR  
TSUPPLY  
needed is 1000 CFM. Looking at the cooling  
speed chart for *MVM960603BX, find the air  
flow closest to 1000 CFM. A cooling airflow  
of 1000 CFM can be attained by selecting  
RISE  
=
T
TRETURN  
-
SUPPLY  
the cooling speed “C” and the adjustment  
to “normal”.  
TRETURN  
4. Continuous fan speed is selectable at 25%, 50%, 75%  
or 100% ofthefurnace’smaximum airflow capability.  
RETURN  
AIR  
Example: If the furnace’s maximum airflow capability is  
2000 CFM, the continuous fan speed will be  
0.25 x 2000 or 500 CFM.  
Temperature Rise Measurement  
CIRCULATORBLOWERSPEEDS  
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 9  
and 10 appropriately. Refer to the dip switch chart for  
switch positions and their corresponding taps. Verify CFM  
by noting the number displayed on the dual 7-segment  
LED display.  
WARNING  
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,  
TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.  
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 7 and 8. 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.  
This furnace is equipped with a multi-speed circulator blower. This  
blower provides ease in adjusting blower speeds. The heating  
blower speed is shipped set at “B”, and the cooling blower speed  
is set at “D”. These blower speeds should be adjusted by the  
installer to match the installation requirements so as to provide the  
correct heating temperature rise and correct cooling CFM.  
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 nearest 100  
CFM. The display alternates airflow delivery indication and the  
operating mode indication.  
Example: The airflow being delivered is 1225 CFM. The display  
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.  
Example: Cooling Capacity of 30,000 BTU/hr.  
30,000/12,000 = 2.5Tons  
2. Determine the proper air flow for the cooling system. Most  
coolingsystemsaredesignedtoworkwithairflowsbetween  
350and450CFMperton. Mostmanufacturersrecommend  
an air flow of about 400 CFM per ton.  
Example: 2.5 tons X 400 CFM per ton = 1000 CFM  
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Profile A provides only an OFF delay of one (1) minute at  
100% of the cooling demand airflow.  
Low  
Tap Stage  
Cool  
High  
Stage  
Cool  
Low  
Stage  
Heat  
High  
Stage  
Heat  
Model  
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
370  
540  
790  
980  
530  
730  
930  
1220  
500  
740  
920  
1160  
390  
550  
680  
800  
540  
750  
980  
1210  
510  
710  
910  
1160  
510  
710  
910  
1160  
660  
860  
880  
970  
1220  
1340  
1460  
1590  
1600  
1710  
1800  
1910  
1730  
1770  
1840  
1870  
820  
100% CFM  
100% CFM  
1 min  
OFF  
OFF  
*CVM960604CX*  
1150  
1470  
900  
1040  
1120  
1110  
1200  
1270  
1330  
1220  
1250  
1300  
1310  
600  
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. Aone (1)  
minuteOFFdelayat100%ofthecoolingairflowisprovided.  
1100  
1430  
1880  
780  
*CVM960805DX*  
GCVM961005DX*  
*MVM960603BX*  
*MVM960805CX*  
*MVM961005DX*  
*MVM961155DX*  
1070  
1380  
1780  
630  
100% CFM  
100% CFM  
1 min  
50% CFM  
1/2 min  
OFF  
OFF  
800  
650  
890  
1000  
1210  
830  
690  
950  
ProfileCrampsupto85%ofthefullcoolingdemandairflow  
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.  
730  
1030  
1600  
1690  
1800  
1890  
1810  
1850  
1890  
1940  
1810  
1850  
1890  
1940  
1140  
1190  
1270  
1330  
1230  
1260  
1300  
1330  
1230  
1260  
1300  
1330  
1090  
1460  
1800  
790  
100% CFM  
OFF  
OFF  
1100  
1410  
1830  
790  
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.  
1100  
1410  
1830  
AirflowTable  
OFF  
OFF  
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)  
determineswhichsetofspeedsareavailable. Theselected  
speedmustprovideatemperaturerisewithintheriserange  
listed with the particular model.  
8. Select the desired “heating” speed tap by positioning  
switches3 and 4 appropriately. Refertofigureabove. Verify  
CFMbynotingthenumberdisplayedonthedual7-segment  
LED display.  
In general lower heating speeds will: reduce electrical consump-  
tion, lower operating sound levels of the blower, and increase the  
outlet air temperature delivered to the home. The speeds avail-  
able allow the blower performance to be optimized for the particu-  
lar homeowner’s needs.  
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Two-way digital communications is accomplished using only two  
wires. The thermostat and subsystem controls are powered with  
24 VAC. Thus, a maximum of 4 wires between the equipment and  
thermostat is all that is required to operate the system.  
BLOWERHEAT OFFDELAYTIMINGS  
The integrated control module provides a selectable heat off delay  
function. The heat off delay period may be set to 90, 120, 150, 180  
seconds using the DIP switches or jumper provided on the control  
module. The delay is factory shipped at 150 seconds but may be  
changed to suit the installation requirements and/or homeowner  
preference. Refer to the dip switch chart in the back section of  
this manual for switch positions and corresponding delay times.  
AIRFLOWCONSIDERATIONS  
Airflow demands are managed differently in a fully communi-  
cating system than they are in a non-communicating wired  
system. The system operating mode (as determined by the  
thermostat) determines which unit calculates the system air-  
flow demand. If the indoor unit is responsible for determining  
the airflow demand, it calculates the demand and sends it to  
the ECM motor. If the outdoor unit or thermostat is respon-  
sible 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  
systems, the operating mode, and airflow demand source.  
COMFORTNET™ SYSTEM  
OVERVIEW  
NOTE: Dip switch #13 MUST be set to match thermostat  
type. To use the CTK01AA communicating thermostat, dip  
switch #13 must be set to ON position. This is also the cor-  
rect setting for a non-communicating 2-stage thermostat. To  
use the CTK02AA modulating thermostat, check to make  
sure dip switch #13 is in the OFF position (factory position).  
This is also the correct position when using a non-communi-  
cating single stage thermostat.  
System Operating  
System  
Airflow Demand Source  
Air Conditioner  
Furnace  
Mode  
Cooling  
The ComfortNet system is a system that includes a ComfortNet  
compatiblefurnaceandairconditionerorheatpumpwithaCTK0*AA  
thermostat. A valid ComfortNet system could also be a compat-  
iblefurnace, CTK0*AAthermostatandnon-compatible, singlestage  
air conditioner. Any other system configurations are considered  
invalid ComfortNet systems and must be connected as a tradi-  
tional (or non-communicating) system (see Electrical Connec-  
tions for wiring connections).  
Air Conditioner +  
Furnace  
Heating  
Continuous Fan  
Thermostat  
Cooling  
Heat Pump  
Heat Pump  
Furnace  
Heat Pump Heating  
Only  
A ComfortNet heating/air conditioning system differs from a non-  
communicating/traditional system in the manner in which the in-  
door unit, outdoor unit and thermostat interact with one another. In  
a traditional system, the thermostat sends commands to the in-  
door 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.  
Heat Pump +  
Furnace  
Auxiliary Heating  
Continuous Fan  
Thermostat  
Cooling  
Heating  
Furnace  
Furnace  
The indoor unit, outdoor unit and thermostat comprising a  
ComfortNet system “communicate” digitally with one another, cre-  
ating atwo-way communications path. The thermostat still sends  
commands to the indoor and outdoor units. However, the thermo-  
stat may also request and receive information from both the indoor  
and outdoor units. This information may be displayed on the  
ComfortNet thermostat. The indoor and outdoor units also inter-  
act with one another. The outdoor unit may send commands to or  
request information from the indoor unit. This two-way digital com-  
munications between the thermostat and subsystems (indoor/out-  
door unit) and between subsystems is the key to unlocking the  
benefits and features of the ComfortNet system.  
Furnace + Non-  
Comm 1stg Air  
Conditioner  
Continuous Fan  
Thermostat  
42  
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In continuous fan mode, the CTK0*AA thermostat provides  
the airflow demand. The thermostat may be configured for  
one of threecontinuous fan speed settings allow for 25%, 50%  
or 75% airflow, based on the furnaces’ maximum airflow ca-  
pability. 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.  
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 de-  
mand 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.  
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DIP SWITCHES  
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FOSSILFUELAPPLICATIONS  
NOTE: Use of the CTK0*AA 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  
furnacetransformer.  
This furnace can be used in conjunction with a ComfortNet™  
compatible heat pump in a fossil fuel application. A fossil fuel  
application refers to a combined gas furnace and heat pump in-  
stallation which uses an outdoor temperature sensor to determine  
the most cost efficient means of heating (heat pump or gas fur-  
nace). When used with the CTK0*AA thermostat, the furnace/  
heat pump system is automatically configured as a fossil fuel  
system. The balance point temperature may be adjusted via  
the CTK0*AA thermostat advanced user menus (see CTK0*AA  
instructions for additional information).  
CTK0*AA  
Thermostat  
1
1
2
2
R
R
C
C
ComfortNet Compatible  
Furnace Integrated  
Control Module  
40VA Transformer  
(included in CTK0*AA kit)  
ComfortNet Compatible  
AC/HP Integrated  
Control Module  
R
C
1
2
CTK0*AAWIRING  
24 VAC  
208/230 VAC  
NOTE: RefertoElectricalConnectionsfor115voltlineconnections  
to the furnace.  
System Wiring using Two-Wires between Furnace and AC/HP and  
Four-Wires between Furnace and Thermostat  
NOTE: Aremovableplugconnectorisprovidedwiththecontrolto  
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.  
COMFORTNETCOMPATIBLEFURNACEWITH NON-COMFORTNET  
COMPATIBLESINGLE-STAGEAIRCONDITIONER  
Four wires are required between the furnace and thermostat. Two  
wiresarerequiredbetweenthefurnacecontrolandsinglestageair  
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 CTK0*AA kit. Remove  
the red keying tabs from the on-board connector block and posi-  
tion both 4-position connector such that “1”, “2”, “R”, “C”, and “Y1”  
positions are filled.  
Typical 18AWG thermostat wire may be used to wire the system  
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-WIREINDOOR AND OUTDOORWIRING  
Typical ComfortNet wiring will consist of four wires between the  
indoor unit and outdoor unit and between the indoor unit and ther-  
mostat. The required wires are: (a) data lines, 1 and 2; (b) thermo-  
stat “R” (24 VAC hot) and “C” (24 VAC common).  
CTK0*AA  
Thermostat  
4-Position Connectors  
from CTK0*AA  
Thermostat Kit  
1
2
R
C
CTK0*AA  
Thermostat  
1
1
2
2
R
R
C
C
ComfortNet Compatible  
Furnace Integrated  
Control Module  
W1 W2 Y1 Y2  
O
1
2
R C G  
ComfortNet Compatible Furnace  
Integrated Control Module  
Non-ComfortNet Compatible  
Single Stage AC  
C
Y
ComfortNet Compatible AC/HP  
Integrated Control Module  
1
2
R
C
SystemWiringbetweenFurnaceandNon-Communicating  
CompatibleSingleStageAirConditioner  
System Wiring using Four-Wires  
TWO-WIREOUTDOOR,FOUR-WIRE INDOOR WIRING  
COMFORTNETSYSTEMADVANCEDFEATURES  
The ComfortNet system permits access to additional system in-  
formation, advanced setup features, and advanced diagnostic/  
troubleshootingfeatures. Theseadvancedfeaturesareorganized  
into a menu structure. The menus are accessed and navigated as  
described in the instructions provided with the CTK0*AA com-  
municating control.  
Two wires can be utilized between the indoor and outdoor units.  
For this wiring scheme, only the data lines, 1 and 2, are needed  
between the indoor and outdoor units. A 40VA, 208/230 VAC to  
24VAC transformer must be installed in the outdoor unit to provide  
24VAC power to the outdoor unit’s electronic control. The trans-  
former is included with the CTK0*AA kit. See kit instructions for  
mountingandwiringinstructions. Fourwiresarerequiredbetween  
the indoor unit and thermostat.  
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FURNACEADVANCEDFEATURESMENUS  
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  
Lease 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  
Model Number (MOD NUM)  
Indication (for Display Only; not User Modifiable)  
Displays the furnace model number  
Serial Number (SER NUM)  
Software (SOFTWARE)  
Displays the furnace serial number (Optional)  
Displays the application software revision  
SET-UP  
Submenu Item  
Heat Airflow Trim (HT TRM)  
User Modifiable Options  
-15% to +15% in 3% 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  
Section XIV, Startup Procedure and  
Adjustment – Circulator Blower Speeds for  
addition information)  
STATUS  
Submenu Item  
Indication (for Display Only; not User Modifiable)  
Mode (MODE)  
Displays the current furnace operating mode  
CFM (CFM  
Displays the airflow for the current operating mode  
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NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED  
WITH A NON-COMMUNICATING 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-  
is 18  
communicating 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%  
Selects the airflow trim amount for the non-  
communicating compatible single stage AC  
unit  
Selects the airflow profile for the non-  
communicating compatible single stage AC  
unit  
Selects the indoor blower ON delay for the  
non-communicating compatible single  
stage AC unit  
A, B, C, or D, default is A  
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-communicating compatible single  
stage AC unit  
The ComfortNet™ system is a fully communicating system, and  
thus, constitutes a network. Occasionally the need to trouble-  
shoot the network may arise. The integrated furnace control has  
some on-board tools that may be used to troubleshoot the net-  
work. These tools are: red communications LED, green receive  
(Rx) LED, and learn button.  
THERMOSTAT MENU  
If this furnace is installed with a communicating compatible heat  
pump, the system is recognized as a dual fuel system. The  
balance point temperature should be set via the thermostat ad-  
vanced menu. Navigate to the THERMOSTAT menu. Press the  
INSTALLER CONFIG key. Navigate to the SETUP menu and  
press the INSTALLER CONFIG button. See communicating  
thermostat installation instructions for additional information.  
Navigate to dF BAL PNT. Adjust the dual fuel system balance  
point using the back/forward arrows.  
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.  
DIAGNOSTICS  
Learn button – Used to reset the network. Depress the  
button for approximately 2 seconds to reset the network.  
Accessing the furnace’s diagnostics menu provides ready ac-  
cess to the last ten 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: 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. Navigate to the diagnostics menu as described  
aboveinAccessingandNavigatingtheAdvancedFeaturesMenus.  
SYSTEMTROUBLESHOOTING  
NOTE: Refer to the instructions accompanying the ComfortNet  
compatible outdoorAC/HPunit for troubleshooting information.  
Refer to the Troubleshooting Codes for a listing of possible fur-  
nace error codes, possible causes and corrective actions.  
FAULTRECALL SEQUENCE  
NOTE: It is highly recommended that the fault history be cleared  
when performing maintenance or servicing the furnace.  
Only allowed in standby mode while display is  
showing ON.  
NETWORKTROUBLESHOOTING  
Hold fault recall push-button for 2-5 seconds (until  
display is blank) and then release.  
Display will then be blank for 2 seconds before  
displaying faults stored in history.  
All faults are displayed one time, from most recent to  
least recent.  
A Maximum of 3 consecutive faults of the same type  
will be logged.  
Each error is displayed for 2 seconds, with a blank  
screen for 1 second in between.  
The indoor control is equipped with a bank of three dipswitches  
that provide biasing and termination functions for the communi-  
cations transmission lines. The outdoor control in the commu-  
nicating compatible unit is equipped with a bank of two  
dipswitches that provide termination functions for the communi-  
cations transmission lines. Communications errors will result if  
these switches are not correctly set. Note that the ON position  
is the correct position for all bias and pull up/pull down  
dipswitches.  
When all errors have been displayed, the display  
returns to ON.  
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LED  
LED Status  
Indication  
Possible Causes  
Corrective Action(s)  
Notes & Cautions  
Off  
1 Flash  
Normal condition  
None  
None  
None  
• Communications Failure  
Communications Failure  
Depress Learn Button  
Verify that pull up, pull  
down and bias dip  
switches are in the  
ON position.  
Depress once quickly for a  
power-up reset  
Depress and hold for 2  
seconds for an out-of-box  
reset.  
Red  
Communications  
LED  
2 Flashes  
Out-of-box reset  
Control power up  
None  
None  
Learn button depressed  
Rapid Flashing  
On Solid  
Normal network traffic  
Control is “talking” on  
network as expected  
None  
None  
Data 1/ Data 2 miss-wire  
Data 1 and data 2 wires reversed • Check communications  
• Turn power OFF prior to  
repair.  
at furnace, thermostat or  
communicating compatible  
outdoor AC/HP  
wiring (data 1/ data 2  
wires).  
Green  
Receive  
LED  
Short between data 1 and  
data 2 wires.  
• Check wire connections at  
terminal block  
Verify wires at terminal  
blocks are securely twisted  
together prior to inserting  
into terminal block.  
Short between data 1 or  
data 2 wires and R  
(24VAC) or C (24VAC  
common).  
• Check data 1/ data 2  
voltages.  
• Verify data 1 and data  
voltages as described above  
FAULTCLEAR SEQUENCE:  
Gasvalveopensatendofigniterwarmupperiod, delivering  
gas to burners and establishing flame.  
Only allowed in standby mode, while display is  
showing ON.  
Hold fault recall push-button for 5-10 seconds (until  
display starts flashing “—”) and then release.  
All faults in the history will have been cleared, and  
display returns to ON.  
If you hold the button for longer than 10 seconds, the  
display will return to ON and the faults will not be  
cleared.  
Integrated control module monitors flame presence. Gas  
valve will remain open only if flame is detected.  
The percentage of heating demand is sent from the IFC  
to determine what RPM the draft inducer should run at.  
A higher percentage demand will drive the inducer RPM  
higher. This will cause the gas valve to modulate higher.  
The burner will modulate based on the inducer speed  
Circulator blower is energized on heat speed following a  
thirty (30) second blower on delay. The circulator blower  
CFM will increase or decrease with gas valve modulation.  
Electronic air cleaner terminal is energized with circulator  
blower.  
NORMAL SEQUENCE OF OPERATION  
POWER UP  
The normal power up sequence is as follows:  
Furnace is now operating on the specified stage called for  
by the thermostat.  
115 VAC power applied to furnace.  
Integrated control module performs internal checks.  
Furnace runs, integrated control module monitors safety  
circuits continuously.  
Integrated control module monitors safety circuits  
continuously.  
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  
Furnaceawaitscallfromthermostat. Dual7-segmentLED’s  
display O while awaiting call from thermostat.  
blower to their high stage settings.  
HEATINGMODE  
The thermostat contacts open, completing the call for heat.  
Gas valve closes, extinguishing flame.  
The normal operational sequence in heating mode is as follows:  
Thermostat contacts close, initiating a call for heat.  
Induceddraftblowerisde-energizedfollowingafifteensecond  
post purge. Humidifier contacts open.  
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  
runduringthisperioddependsonthelastheatcallprovided  
by the thermostat.  
Induced draft blower is energized on high speed for a 15-  
secondprepurge.  
Induceddraftblowerstepstolowspeedfollowingprepurge.  
Low stage pressure switch contacts are closed.  
Igniter warm up begins upon step to low speed and  
presence of closed low stage pressure switch contacts.  
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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).  
OPERATIONAL CHECKS  
The burner flames should be inspected with the burner compart-  
ment 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 burners without  
curling, floating, or lifting off. Flames must not impinge on the  
sides of the heat exchanger firing tubes.  
Circulator blower and electronic air cleaner terminal is de-  
energized.  
CirculatorblowerrampsdowntoOFFduringthe30seconds  
following the heat off delay period.  
Furnace awaits next call from thermostat.  
COOLINGMODE  
The normal operational sequence in cooling mode is as follows:  
R and Y1/G or Y2/G thermostat contacts close, initiating a  
call for cool.  
Integrated control module performs safety circuit checks.  
Burner Flame  
Outdoor fan and compressor are energized to their  
appropriatespeed.  
SAFETY CIRCUIT DESCRIPTION  
Circulatorblowerisenergizedontheappropriatecoolspeed  
at the level and time determined by the selected ramping  
profile. Electronic air cleaner terminal is energized with  
circulator blower.  
Anumberofsafetycircuitsareemployedtoensuresafeandproper  
furnace operation. These circuits serve to control any potential  
safety hazards and serve as inputs in the monitoring and diagno-  
sis of abnormal function. These circuits are continuously moni-  
tored during furnace operation by the integrated control module.  
Furnace circulator blower and outdoor cooling unit run their  
appropriate speeds, integrated control module monitors  
safety circuits continuously.  
INTEGRATED FURNACE CONTROL(IFC)  
R and Y1/G or Y2/G thermostat contacts open, completing  
the call for cool.  
The integrated control module is an electronic device which, if a  
potential safety concern is detected, will take the necessary pre-  
cautions and provide diagnostic information through an LED dis-  
play.  
Outdoor fan and compressor are de-energized.  
Circulator blower continues running during a cool off delay  
period. TheOFFdelaytimeandairflowlevelaredetermined  
by the selected ramping profile.  
Electronic air cleaner terminal and circulator blower are de-  
energized.  
PRIMARY LIMIT  
The primary limit control is located on the partition panel and moni-  
tors heat exchanger compartment temperatures. It is a normally-  
closed (electrically), automatic reset, temperature-activated sen-  
sor. The limit guards against overheating as a result of insufficient  
conditioned air passing over the heat exchanger.  
Furnace awaits next call from thermostat.  
FANONLYMODE  
AUXILIARYLIMIT  
The normal operational sequence in fan only mode is as follows:  
The auxiliary limit controls are located on or near the circulator  
blowerandmonitorsblowercompartmenttemperatures. Theyare  
a normally-closed (electrically), auto-reset sensors. These limits  
guard against overheating as a result of insufficient conditioned air  
passing over the heat exchanger.  
R and G thermostat contacts close, initiating a call for fan.  
Integrated control module performs safety circuit checks.  
Circulator blower is energized on continuous fan speed  
(25%, 50%, 75% or 100% dip switch selectable when  
using a conventional thermostat). Electronic air cleaner  
terminal is energized.  
ROLLOUT LIMIT  
The rollout limit controls are mounted on the burner/manifold as-  
sembly and monitor the burner flame. They are normally-closed  
(electrically), manual-reset sensors. These limits guard against  
burner flames not being properly drawn into the heat exchanger.  
The IFC HUM dry contacts close.  
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.  
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PRESSURESWITCHES  
DIAGNOSTICCHART  
The pressure switches are normally-open (closed during opera-  
tion) negative air pressure-activated switches. They monitor the  
airflow (combustion air and flue products) through the heat ex-  
changer via pressure taps located on the induced draft blower and  
the coil front cover. These switches guard against insufficient air-  
flow(combustionairandflueproducts)throughtheheatexchanger  
and/or blocked condensate drain conditions.  
WARNING  
HIGH VOLTAGE !  
TO AVOID PERSONAL INJURY OR DEATH DUE TO  
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER  
BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.  
Refer to the Troubleshooting Codes for assistance in determining  
the source of unit operational problems. 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.  
FLAMESENSOR  
The flame sensor is a probe mounted to the burner/manifold as-  
sembly which uses the principle of flame rectification to determine  
the presence or absence of flame.  
TROUBLESHOOTING  
RESETTINGFROMLOCKOUT  
ELECTROSTATICDISCHARGE(ESD)PRECAUTIONS  
Furnace lockout results when a furnace is unable to achieve igni-  
tion after three attempts during a single call for heat. It is charac-  
terized by a non-functioning furnace and a E0code displayed on  
the dual 7-segment display. If the furnace is in “lockout”, it will (or  
can be) reset in any of the following ways.  
NOTE: Discharge body’s static electricity before touching unit.  
An electrostatic discharge can adversely affect electrical  
components.  
Use the following precautions during furnace installation and ser-  
vicing to protect the integrated control module from damage. By  
putting the furnace, the control, and the person at the same elec-  
trostatic potential, these steps will help avoid exposing the inte-  
grated control module to electrostatic discharge. This procedure  
is applicable to both installed and uninstalled (ungrounded) fur-  
naces.  
1. Disconnect all power to the furnace. Do not touch the  
integrated control module or any wire connected to the  
controlprior todischargingyourbody’selectrostatic charge  
toground.  
1. Automatic reset. The integrated control module will  
automatically reset itself and attempt to resume normal  
operations following a one hour lockout period.  
2. Manual power interruption. Interrupt 115 volt power to the  
furnace.  
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.  
NOTE: If the condition which originally caused the lockout still  
exists, thecontrolwillreturntolockout. RefertotheTroubleshooting  
Codes for aid in determining the cause.  
2. Firmlytouchaclean, unpainted, metalsurfaceofthefurnace  
away from the control. Any tools held in a person’s hand  
during grounding will be discharged.  
MAINTENANCE  
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  
moveorshuffleyourfeet, donottouchungroundedobjects,  
etc.). If you come in contact with an ungrounded object,  
repeat step 2 before touching control or wires.  
WARNING  
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.  
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  
controlstotheircontainersbeforetouchinganyungrounded  
object.  
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HORIZONTAL UNIT FILTER REMOVAL  
ANNUALINSPECTION  
The furnace should be inspected by a qualified installer, or service  
agency at least once per year. This check should be performed at  
the beginning of the heating season. This will ensure that all fur-  
nace components are in proper working order and that the heating  
system functions appropriately. Pay particular attention to the fol-  
lowing items. Repair or service as necessary.  
Filters in horizontal installations are located in the central return  
register or the ductwork near the furnace.  
Toremove:  
1. Turn OFF electrical power to furnace.  
2. Removefilter(s)fromthecentralreturnregisterorductwork.  
3. Replace filter(s) by reversing the procedure for removal.  
4. Turn ON electrical power to furnace.  
Flue pipe system. Check for blockage and/or leakage.  
Check the outside termination and the connections at  
and internal to the furnace.  
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL  
Heatexchanger. Checkforcorrosionand/orbuildupwithin  
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.  
Follow the manufacturer’s directions for service.  
BURNERS  
Visually inspect the burner flames periodically during the heating  
season. Turn on the furnace at the thermostat and allow several  
minutes for flames to stabilize, since any dislodged dust will alter  
the flames normal appearance. Flames should be stable, quiet,  
soft, and blue (dust may cause orange tips but they must not be  
yellow). They should extend directly outward from the burners  
without curling, floating, or lifting off. Flames must not impinge on  
the sides of the heat exchanger firing tubes.  
FILTERS  
CAUTION  
INDUCEDDRAFTANDCIRCULATORBLOWERS  
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.  
The bearings in the induced draft blower and circulator blower mo-  
tors are permanently lubricated by the manufacturer. No further  
lubrication is required. Check motor windings for accumulation of  
dust which may cause overheating. Clean as necessary.  
FILTERMAINTENANCE  
CONDENSATETRAPANDDRAINSYSTEM(QUALIFIEDSERVICER  
ONLY)  
Improper filter maintenance is the most common cause of inad-  
equate heating or cooling performance. Filters should be cleaned  
(permanent) or replaced (disposable) every two months or as re-  
quired. When replacing a filter, it must be replaced with a filter of  
the same type and size.  
Annuallyinspectthedraintubes, draintrap, andfield-supplieddrain  
line for proper condensate drainage. Check drain system for hose  
connection tightness, blockage, and leaks. Clean or repair as  
necessary.  
FILTER REMOVAL  
FLAMESENSOR(QUALIFIEDSERVICERONLY)  
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). Amedia air filter or  
electronic air cleaner can be used as an alternate filter. Follow the  
filter sizes given in the Recommended Minimum Filter size table  
to ensure proper unit performance.  
Under some conditions, the fuel or air supply can create a nearly  
invisible coating on the flame sensor. This coating acts as an  
insulator causing a drop in the flame sense signal. If the flame  
sense signal drops too low the furnace will not sense flame and  
will lock out. The flame sensor should be carefully cleaned by a  
qualified servicer using emery cloth or steel wool. Following clean-  
ing, the flame sense signal should be as indicated in the Specifica-  
tions Sheet.  
To remove filters from an external filter rack in an upright upflow  
installation, follow the directions provided with external filter rack  
kit.  
51  
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Functional Parts List-  
Gas Valve  
BEFORE LEAVING AN INSTALLATION  
Blower Motor  
Blower Wheel  
Blower Mounting Bracket  
BlowerCutoff  
BlowerHousing  
Inductor  
Heat Exchanger with  
RecuperatorCoil  
CoilFrontCover  
IntegratedControlModule  
Transformer  
Cycle the furnace with the thermostat at least three times.  
Verify cooling and fan only operation.  
Gas Manifold  
Natural Gas Orifice  
Propane Gas Orifice  
Igniter  
Review the Owner’s Manual with the homeowner and  
discuss proper furnace operation and maintenance.  
Flame Sensor  
Leave literature packet near furnace.  
Rollout Limit Switch  
Primary Limit Switch  
Auxiliary Limit Switch  
Pressure Switch  
InducedDraftBlower  
Door Switch  
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.  
Although only functional parts are shown in the parts list,  
all sheet metal parts, doors, etc. may be ordered by  
description.  
Parts are available from your distributor.  
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TROUBLESHOOTING CODES  
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TROUBLESHOOTING CODES  
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TROUBLESHOOTING CODES  
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TROUBLESHOOTING CODES  
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TROUBLESHOOTING CODES  
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STATUS CODES  
INTERNAL CONTROL FAULT/NO POWER  
NORMAL OPERATION  
O
n
LOCKOUT DUE TO EXCESSIVE RETRIES  
LOW STAGE PRESSUE SWITCH STUCK CLOSED AT START OF HEATING CYCLE  
LOW STAGE PRSSURE SWITCH STUCK OPEN  
OPEN HIGH LIMIT SWITCH  
E 0  
E 1  
E 2  
E 3  
E 4  
E 5  
E 6  
E 7  
E 8  
E 9  
E A  
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 PRSSURE SWITCH STUCK OPEN  
REVERSED 115 VAC POLARITY  
ROLLOUT SWITCH OPEN  
AUXILIARY INPUT OPEN  
F
d 0  
d 4  
b 0  
b 1  
b 2  
b 3  
b 4  
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  
b 6  
b 7  
b 9  
C 1  
C 2  
LOW STAGE COOL  
HIGH STAGE COOL  
% OF HIGH HEAT  
HIGH HEAT  
CONTINUOUS FAN  
F
FIELD TEST MODE  
t
F
CFM x 100, ALTERNATES WITH THERMOSTAT CALL  
& GAS HEAT OPERATING PERCENTAGE.  
1 2  
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WIRING DIAGRAM  
*MVM96_A*, *CVM96_A*  
TO  
GND  
24V  
115 V C/1 Ø /60  
HZ  
A
HUM.  
POWER SUPPLY WITH  
OVERCURRENT  
PROTECTION  
ID BLOWER TWO-STAGE PRESSURE  
SWITCH ASSEMBLY  
HOT  
DEVICE  
L
BR  
SURFACE  
IGNITER  
WARNING:DISCONNECT  
POWER BEFORE  
SERVICING WIRING.  
TO UNIT MUST BE  
PROPERLY POLARIZED  
AND GROUNDED.  
BK  
HIGH FIRE  
PRESSURE  
SWITCH  
OR  
N
R
LOW FI  
E
WH  
C
C
PRESSURE  
SW ITCH  
DISCONNECT  
NO  
NO  
YL  
2
CIRCUIT  
2
1
CONNECTOR  
TO 115VAC/1  
Ø /60 HZ POWER SUPPLY WITH  
OVERCURRENT PROTECTION DEVICE  
OR  
GND  
L
N
MODULATING  
GAS VALVE  
(HONEY W ELL)  
WARNING:  
2
1
C
BR  
FLAME  
DISCONNECT POWER  
BEFORE SERVICING  
WIRING TO UNIT  
MUST BE PROPERLY  
POLARIZED AND  
C
SENSOR  
GY  
GY  
FRONT COVER  
PRESSURE SWITCH  
PM  
NO  
D ISCON NECT  
GROUNDED.  
MANUAL RESET ROLLOUT LIMIT CONTROLS  
(SINGLE CONTROL ON 45 kBTU)  
PU  
PK  
DOOR  
T
SWI CH  
JUNCTION BOX  
OR  
AUTO RESET PRIMARY  
LIMIT CONTROL  
INDUC TOR COIL  
70kBTU,90kBTU,  
115kBTU MODELS  
ONLY  
OR  
PU  
INDOOR  
AIR  
INDUCED  
DRAFT  
3
2
1
WH  
RD  
BK  
CIRCULATOR  
BLWR  
BLOW ER  
GND  
LINE  
EAC  
NEUTRAL  
NEUTRAL  
GND  
BURNER COMPARTMENT  
BLOWER COMPARTMENT  
ELECTRONIC  
AIR CLEANER  
PU  
AUTO RESET  
AUXILIARY  
LIMIT CONTROL  
OPTIONAL  
3
YL  
2
1
3Ø ID  
BLWR  
HUM  
IGN  
NEUTRAL  
NEUTRAL  
HUMIDIFIER  
OPTIONAL  
1
2
3
HOT SURFACE  
IGNITER  
FS  
FLAME  
SENSOR  
115  
VAC  
NEUTRAL  
LINE  
DIAGNOSTIC  
LED'S  
HSI  
EAC  
40 VA  
FUSE 3A  
TR ANSFORM ER  
TR (5)  
R
24 VAC  
AU TO RESET PRIMARY  
AUTO RESET AUXILIARY LIMIT  
CONTROLS  
LIMIT CONTROL  
TO +VDC  
(3)  
(6)  
Y1  
24  
VAC  
LOW FIRE PRESS.  
SWITCH  
C
W 1  
W2  
(12)  
115  
VAC  
NO  
NO  
(2)  
TO  
MICRO  
C
HIGH FIRE  
Y2  
G
MANUAL RESET  
R
U T  
OLLO  
PRESS. SWITCH  
(11)  
LIMIT CONTROLS  
WH  
O
FUSE  
DEHUM  
24 V THERMOSTAT CONNECTIONS  
AUX  
(8)  
NO  
24 V 3A  
PM  
C
FR ONT COVER  
PRESS. SW ITCH  
C
(7)  
C
ECM MTR  
HARNESS  
(10)  
GAS  
VALVE  
BK  
RD  
BL  
GY  
GND (4)  
TR (9)  
GND (4)  
W H  
GND  
BK  
TO  
R
5
BK  
WH  
GR  
+
VDC (1)  
4
3
2
1
INDOOR  
AIR  
C IRCULATOR  
R X (2)  
TX (3)  
GND  
PK  
TO  
MICRO  
BLOWER  
BLW R  
COMPARTMENT  
DOOR SWITCH  
(OPEN WHEN  
DOOR OPEN)  
INTEGRATED CONTR OL  
MODULE  
BLOWER  
CIRCULATOR  
INDUCTOR COIL  
70kBTU,90kBTU,  
HUMIDIFIER  
OPTIONAL  
115kBTU MOD  
ONLY  
ELS  
NOTES:  
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.  
COLOR CODES:  
EQUIPMENT GND  
LOW VOLTAGE FIELD  
PK PINK  
FIELD GND  
LOW VOLTAGE (24V)  
HI VOLTAGE (115V)  
HI VOLTAGE FIELD  
BR BROWN  
WH WHITE  
BL BLUE  
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUS BE  
T
USED WHEN SERVICING.  
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE  
FURNACE MUST BE REPLACED, IT MUST BE REPLACED W ITH  
WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT  
LEAST 105°C. USE COPPER CONDUCTORS ONLY.  
4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO  
N.E.C. AND LOCAL CODES.  
5. TO RECALL THE LAST 10 FAULTS, MOST RECENT TO LEAST  
FIELD SPLICE  
GY GRAY  
SW ITCH (TEMP)  
IGNITER  
RD RED  
JUNCTION  
YL YELLOW  
OR ORANGE  
PU PURPLE  
GR GREEN  
TERMINAL  
SWITCH PRESSURE  
INTERNAL TO  
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS W HILE  
IN STANDBY (NO THERMOSTAT INPUTS)  
N
I
TEGRATED CONTROL  
OVERCURRENT  
PROT. DEVICE  
BK BLACK  
PLUG CONNECTION  
0140F00863-B  
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.  
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5151 San Felipe Suite 500  
Houston, TX 77056  
www.goodmanmfg.com • www.amana-hac.com  
© 2011 Goodman Manufacturing Company, L.P.  
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