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1. AVG GAS he HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 725 43 3 1 43 3 2 43 3 3 43 3 4 x 750 43 2 9 43 3 0 43 31 43 3 2 5 5001 775 43 27 43 2 8 43 2 9 43 3 0 0 800 43 2 5 43 2 6 43 27 43 2 8 a 6000 825 43 2 4 43 2 5 43 2 5 43 2 6 5 850 43 2 2 43 2 3 43 2 4 43 2 5 875 43 2 1 43 2 2 43 2 3 43 2 3 900 43 2 0 43 2 1 43 2 1 43 2 2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS EE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 675 43 3 1 43 3 2 43 3 3 43 3 4 700 43 2 9 43 3 0 43 3 1 43 3 2 6001 725 43 2 7 43 2 8 43 2 9 43 2 9 i6 750 43 2 5 43 2 6 43 27 43 2 8 s 7000 775 43 2 3 43 2 4 43 2 5 43 2 6 5 800 43 2 2 43 2 3 43 2 3 43 2 4 825 43 2 1 43 2 1 43 2 2 43 2 3 850 48 3 7 43 2 0 43 2 1 43 2 1 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS T RANGES HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 650 43 2 9 43 3 0 43 3 1 43 3 2 675 43 2 7 43 2 7 43 2 8 43 2 9 5 7001 700 43 2 5 43 2 6 43 2 6 43 2 7 2 to 725 43 2 3 43 2 4 43
2. FER CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause prema ture furnace component failure Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will pre vent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential RETURN AIR MIN60 F 02055 Fig 3 Return Air Temperature In the United States and Canada follow all codes and standards for 1 Disconnect all power to the furnace Multiple disconnects may the following be required DO NOT TOUCH THE CONTROL OR ANY Step 1 Safety WIRE CONNECTED TO THE CONTROL PRIOR TO DIS e US National Fuel Gas Code NFGC NFPA 54 2002 ANSI CHARGING YOUR BODY S ELECTROSTATIC CHARGE Z223 1 2002 and the Installation Standards Warm Air Heating TO GROUND and Air Conditioning Systems ANSI NFPA 90B 2 Firmly touch the clean unpainted metal surface of the furnace gt CANADA CSA B149 1 00 National Standard of Canada chassis which is close to the control Tools held in a person s Natural Gas and Propane Installation Codes NSCNGPIC hand during grounding will be satisfac
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4. AdAL 30V18 SALLOWOLNY dW ISNA 300819313 9NIAOud 3lNV 14 O N 1SdS 13539 MS LNOTION 314 NOLLO3NNOO HIV DINOH1O3T3 0 OWA S LL NOLLO3NNOO H3NV319 9INOH10313 O N 1585 13S34 OLNV HOLIMS 33VS 14 XAYLINOYID ONY HOSSI90H dOHOIN WHO LIOVavo ON 1595 13539 HOLIMS 44 1 0342018 uOLIOvdvO LI1dS LN3NVINH3d HOLON H3MO 18 O N LSdS HOLOW H3MO18 1895 Av T3H 39NVHO 43385 HOLON H3MO18 end 554 2 LSud cova ssa dvo 55 8 uva YT0 LHE aucouza 31ON 034 N3HW HOLIMS LO3NNOOSIG 8 HO ISNA aan ma eduvds amad ui duvds PRINTED CIRCIUT BOARB Lt ILON a Tu o 5991 aasn N3HW E B 5 HM EHE E aad e 5 ma aasn HO puo NIMU LSAL i ssa ssa 1564 PH Oli ALON THANHO N3HM e 659 69 HO 199135 HAN 251 151 EST id C Od AVTA0 340 J2 INVHOVIG NOLLO3NNOO 32 Table 8 Altitude Derate Multipler for U S A ALTITU
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7. NO H3MO 8 Ulejs s 0 10 e 15 uny s 10 ASLL osje UD sepoo sniejs 5 ZZ Jaye Sepoo 3800 SfIOIA3Hd ON 47 Copyright 2005 Carrier Corporation 58511351 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations rook x PC 101 Catalog No See Cover Printed in U S A Form 585 1351 Pg 48 5 05 Replaces 5857 1251 ab 8a
8. 5 Location Relative to Cooling 7 AIR FOR COMBUSTION AND VENTILATION 7 INSTALLATION 5 0 BBs bitin i hess es Rice eas 10 Upflow Installation 10 Bottom Return Air Inlet 10 Side Return Air Inlet 10 Leveling Legs If Desired 10 Downtlow Installation rer treinta 10 Bottom Return Air 11 Horizontal Installation ai coser rests 11 Suspended Furnace Support 11 Platform Furnace Support sees 11 Roll Out Protection Lil Bottom Return Air Inlet 5 cereos 11 Side AIT Inlef cni t is Se NAN et 11 Filter Arrangement 5er 11 Ait DUCES et converte eia e ad b e i er tres 11 General Requirements rre 11 Ductwork Acoustical Treatment 12 Supply Air Connections 12 Return Air Connections 14 Gas 15 Electrical Connections 19 115 V Wiring 19 J Box Relocation 20 Electrical Connection to J Box 21 Power Cord Installation in Furnace J Box 21 BX Cable Installation in Furnace 22 EFFICIENCY RATING CERTIFIED ISO 9001 2000 CERTIFIED REGISTERED p BD 22 ANCCeSSOLI S
9. 58STA 58STX Induced Combustion 4 Way Multipoise Furnace Installation Start up Operating and Service and Maintenance Instructions Series 120 The 58STA STX 4 way Multipoise Gas Furnaces feature Carrier s QuieTech noise reduction system for incredibly quiet induced draft operation Applications are easy with 4 way multipoise design through the furnace downflow venting 13 different venting options and a door designed for easy service access An inner blower door is provided for tighter sealing in sensitive applications The 58STA STX furnaces are approved for use with natural or propane gas and the 58STX is also approved for use in Low NOx Air Quality Management Districts STANDARD FEATURES QuieTech noise reduction system Microprocessor based control center Adjustable heating air temperature rise Adjustable cooling airflow LED diagnostics and self test feature 4 way Multipoise furnace 13 vent applications Inner blower door Hot surface ignition HSI Draft safeguard switch to ensure proper furnace venting All models are Chimney Friendly when used with accessory vent kit Heat pump compatible Residential installations eligible for consumer financing through the Retail Credit Program Twinning in Upflow Downflow and Horizontal LIMITED WARRANTY Catalog No 535 80149 Form No 20 year warranty on Super S heat exchanger 5 year parts warranty on all other components 5857 13
10. 7 Pull field power wires into electrical box 8 Remove cover from furnace J Box 21 1 NOTE 2 FIVE WIRE THREE WIRE HEATING ONLY FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING THERMOSTAT TERMINALS FIELD SUPPLIED DISCONNECT e e e e BLOWER DOOR SWITCH 8 rd OR x ED i _______ PHASE g1 1 T 208 230 ee le De e gt AUXILIARY 115 V FIELD Le e 4 SUPPLIED J BOX L CANNES GND DISCONNECT pL CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A99440 Fig 25 Heating and Cooling Application Wiring Diagram with 1 Stage Thermostat BX CABLE INSTALLATION IN FURNACE J BOX Remove cover from J Box 2 Route BX cable into 7 8 inch diameter hole in J Box 3 Secure BX cable to J Box bracket with connectors approved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads
11. WVHOVIG OLLVIN3HOS HOLIMS LOANNOOSIG 91915 OVASE I OL 3419143934 89185 01915 01315 WNIWYSL MAYOS ONIHIM 07314 999 1OH1NO9 NO HOLONGNOD OvAv2 ONIHIM 07313 OVASLI ONIHIM 47219 ONIHIM 4 OVASLI ONIHIM AHOLOVA TWNIWHYAL TOH LNOO 89d TIVNIIAH3 L G3HEVINNN NOILONAL OVAVS OVASLE HANHOASNVEL WNINHAL NIML 9 1531 IN3NOdWOO O N LSdS HOLIMS SYNSSAYd ISH LINOHI9 Z YOLOSNNOD LINDHIO 2 YOLOSNNOO 89d LINDUID FE OH1NOO HOLIMS SYNLWHAdWAL IVOTH3AO HOLON 13S34 OLNY O N LSdS 13S34 OLNV HOLIMS lt Y E NvaL NIML 1S31 Sud ld eld 99 10 2151 O N LSdS HOLIMS SYNSSAYd SVO MOT 3009 SNLYLS HOS 30010 ONLLLIIW3 LHOIT XO8 NOILONNP AVIAG 340 H3MO 18 SNILV3H HO19313S HAdWN AVIA 440 H3MO 18 O N LSdS HOLIMS 490 1H31NI 55300 O N LSdS HOLON 1 3109 5 HOLON 14 dY 970 NOLLO3NNOO H3IAIGIANH CO N LSdS Av 13H HALINOI 3OVIYNS LOH OVA SLL HALINOI 3OVIHNS LOH O N LSdS AVISY SVD ALNVONNGSY SATWA SVD LNAWdINOA 5 GATIVISNI 07915 391430 LdQHH3 INI LNAYYND H33IV3H8 HO ISNA GATIVLSNI
12. inducer Proper Low inducer voltage 115VAC Inadeqi Low inlet gas pressure if LGPS used If it opens during blower on delay period blower will come on for the selected blower off dela LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame rollout or blocked vent switch if whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rol Proper vent sizing Dirty filter or restricted duct system Defective blower motor or capacitor Inadequate combustion air supply Flame Roll out Switch open IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs selected Oxide bi Proper Gas valve defective or gas valve turned off Defective Hot Surface Ignitor Low inlet gas pressure Green Yellow wire MUST be connected to furnace sheet metal CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to shuts off for 15 minutes before retry Check for Excessive wind Defective inducer motor Defective pressure switch Disconnected or obstructed pressure tubing Restricted vent vent sizing uate combustion air supply used is open Blower will run for 4 minutes or until open switch remakes Restricted vent Excessive wind lout switch and BVSS require manual reset Check for Loose blower wheel Defective switch
13. 10 Secure all other single wall vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations The total height of the vent and connector shall be at least seven feet for the 154 000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward See Fig 36 Caution For the following applications use the minimum vertical vent heights as specified below For all other applications follow exclusively the National Fuel Gas Code MINIMUM FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT BTU HR VENT DIAMETER IN MINIMUM VERTICAL VENT HEIGHT FT 154 000 Downflow e 132 000 5 12 9 110 000 036 12 only Vent elbow right Horizontal Left then up 5 7 Fig 39 4 i Vent Elbow up 154 000 Horizontal Left Fig 40 132 000 5 7 Horizontal Left Ment E DOW rigot 154 000 5 7 Fig 41 Vent elbow up then left 110 000 Downflow Fig 34 036 12 only 5 10 Vent elbow up then right 110 000 Fig 37 036 12 only 10 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in inside casing or vent guard Including 4 in vent section s 30 A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrica
14. 18 and 20 Bypass humidifier may be injury or death attached to unused side return air side of the furnace casing See Never connect return air ducts to the back of the furnace Fig 18 and 20 Follow instructions below Not all horizontal furnaces are approved for side return air connections See Fig 20 Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 19 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most 14 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS AIR EH S eee OUTER DOOR ASSEMBLY N USE 2 8 x 3 4 SHEET METAL SCREWS TYPICAL FOR ALL STRAPS Pd BACK OF a FURNACE Pd P Pa FOLD ALL STRAPS UNDER FURNACE AND SECURE W 2 8 x 3 4 L ir SHEET METAL SCREWS AIR OPENING Fig 16 Horizontal Suspension with Straps LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING 17 3 4 OVER ALL 4 3 4 UNDER DOOR 1 UNDER FURNACE EXTEND OUT 12 OUT FROM FACE OF DOOR 30 IN MIN WORK AREA WHEN USED WITH SINGLE WALL VENT CONNECTIONS A Y gt Se MANUAL SHUTOFF Sy GAS VALVE SEDIMENT TRAP Fig 17 Typical Attic Installation GAS PIPING A WARNING FIRE OR EXP
15. 2 5 43 2 5 o 8000 750 43 2 1 43 2 2 43 2 3 43 2 4 775 43 2 0 43 2 1 43 2 2 43 2 2 800 48 3 6 48 3 7 43 2 0 43 2 1 825 48 3 3 48 3 5 48 3 6 48 3 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 625 43 27 43 27 43 2 8 43 2 9 650 43 2 5 43 2 5 43 2 6 43 2 7 6 8001 675 43 2 3 43 2 4 43 2 4 43 2 5 lt to 700 43 2 1 43 2 2 43 2 3 43 2 3 2 9009 725 48 3 7 43 2 0 43 2 1 43 2 2 750 48 3 5 48 3 6 48 3 7 43 2 0 775 49 3 8 48 3 4 48 3 5 48 3 6 Orifice numbers 43 are factory installed b Inducer motor 6 Remove screws that fasten the collector box assembly to the c Pressure switch es cell panel Be careful not to damage the collector box Inducer Se assembly and elbow need not be removed from collector box d Limit overtemperature switch 7 Disconnect gas line from gas manifold Gas valve 8 Remove the 5 screws that attach the burner assembly to the gt 0 en Hot surface igniter Flame sensing electrode Flame rollout switches Remove NOx baffles on low NOx models 42 cell panel The gas valve and individual burners need not be removed from support assembly NOTE Be very careful when removing burner assembly to avoid breaking igniter See Fig 50 and 51 for correct igniter location Table 13 Orifice Size And Manifold Pres
16. 2 5 43 2 6 43 2 7 43 2 7 950 43 2 4 43 2 4 43 2 5 43 2 6 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE O __060_ __ 062 _ EN FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure U S A Only 4001 to 5000 750 43 3 3 43 3 4 43 3 5 43 3 6 775 43 3 1 43 3 2 43 3 3 43 3 4 800 43 2 9 43 3 0 43 3 1 43 3 2 825 43 2 7 43 2 8 43 2 9 43 3 0 850 43 2 6 43 2 7 43 2 8 43 2 8 875 43 2 4 43 2 5 43 2 6 43 2 7 900 43 2 3 43 2 4 43 2 5 43 2 5 925 43 2 2 43 2 2 43 2 3 43 2 4 Orifice numbers 43 are factory installed If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when disconnecting wires from switches because damage may occur a Draft safeguard switch Table 13 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS
17. 2 6 43 27 43 28 43 29 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE a __060_ ___062 _ __ 064 _ BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 775 42 3 2 42 3 3 42 3 4 42 3 5 800 43 3 6 43 3 8 42 3 2 42 3 3 3001 825 43 3 4 43 3 5 43 3 7 43 3 8 U S A Only to 850 43 3 2 43 3 3 43 3 4 43 3 6 4000 875 43 3 0 43 3 1 43 3 3 43 3 4 900 43 2 9 43 3 0 43 3 1 43 3 2 925 43 2 7 43 2 8 43 2 9 43 3 0 950 43 2 6 43 2 7 43 2 8 43 2 8 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE Es 0 60 ___062 _ 0 64 FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 750 43 3 6 43 3 8 42 3 2 42 3 3 E 775 43 3 4 43 3 5 43 3 6 43 3 8 5 4001 800 43 3 2 43 3 3 43 3 4 43 3 5 4 to 825 43 3 0 43 3 1 43 3 2 43 3 3 oO 5000 850 43 2 8 43 2 9 43 3 0 43 3 1 2 875 43 2 7 43 2 8 43 2 9 43 2 9 900 43 2 5 43 2 6 43 2 7 43 2 8 925 43 24 43 2 5 43 2 6 43 2 6 Orifice numbers 43 are factory installed The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door a Disconnect vent connector from furnace v
18. 675 645 600 555 475 390 Bottom High 1425 1375 1320 1265 1200 1125 1035 940 036070 oF Med High 1320 1280 1240 1205 1140 1075 995 905 Side s Med Low 1200 1175 1145 1105 1050 990 920 840 Bottom High 1805 1740 1670 1600 1580 1445 1360 1280 048070 B Med High 1630 1585 1530 1470 1405 1330 1255 1170 Side s Med Low 1460 1420 1385 1325 1280 1220 1155 1080 Bottom High 1650 1600 1535 1465 1385 1285 1175 1055 042090 er Med High 1515 1485 1440 1380 1300 1220 1115 990 Side s Med Low 1385 1360 1320 1260 1195 1120 1025 915 Bottom High 2060 1985 1915 1820 1720 1610 1490 1340 048090 Med High 1790 1765 1715 1645 1560 1470 1345 1195 Side s Med Low 1505 1505 1480 1440 1375 1300 1190 1045 Bottom High 2405 2310 2220 2130 2025 1920 1790 1660 oak Med High 2225 2155 2080 1995 1895 1785 1675 1565 Med Low 2020 1955 1880 1805 1730 1630 1535 1420 High 2530 2450 2365 2270 2165 2065 1940 1805 Both Sides or 060090 Med High 2285 2215 2150 2075 1985 1890 1780 1660 1 Side amp Bottom Med Low 1995 1945 1900 1840 1770 1685 1600 1480 High 2475 2395 2300 2200 2090 1985 1865 1730 1 Side Only Med High 2260 2190 2110 2035 1940 1845 1735 1620 Med Low 1950 1910 1855 1795 1730 1650 1555 1445 Bottom
19. High 1625 1575 1515 1445 1355 1260 1165 990 036110 Med High 1510 1470 1415 1355 1285 1185 1070 890 Side s Med Low 1360 1335 1295 1250 1180 1100 985 810 Bottom High 2035 1965 1880 1790 1680 1495 1365 1215 048110 or Med High 1745 1710 1650 1560 1450 1340 1205 1090 Side s Med Low 1530 1515 1470 1400 1310 1215 1095 990 High 2530 2470 2400 2320 2220 2115 2000 1865 ou Med High 2230 2205 2165 2110 2035 1950 1855 1740 Med Low 1920 1900 1880 1845 1795 1730 1650 1555 Bottom Sides or High 2415 2350 2250 2145 2015 1875 066110 1 Side amp Bottom Med High 2235 2200 2155 2100 2040 1955 1850 1740 Med Low 1920 1900 1880 1845 1795 1730 1650 1555 High 2540 2495 2430 2355 2265 2175 2065 1935 1 Side Only Med High 2125 2120 2105 2060 2010 1940 1840 1730 Med Low 1795 1790 1765 1720 1650 1585 1500 A filter is required for each return air inlet Airflow performance included 1 in washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions 16 Table 5 Air Delivery CFM With Filter Continued FURNACE RETURN AIR BEEN EXTERNAL STATIC PRESSURE IN WC SIZE IN
20. NOTE Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw Using the schematic diagram in Fig 45 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W the control will start a 90 second blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The red LED light will flash code 12 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normally The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU transformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV 1 Heating See Fig 25 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS is open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch contacts PRS close 24 vac power is supplied for a field installed humidifier at the HUM terminal and the control begin
21. RTV sealant 162 P771 9003 is available through RCD in 3 oz tubes 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connection diagram on wiring label if wires were not marked for reconnection locations a b Pressure switch es a a gt moa en Draft safeguard switch Inducer motor Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode Flame rollout switches Install NOx baffles if removed 14 Reinstall internal vent pipe if applicable 91252 Fig 52 Cleaning Heat Exchanger Cell 15 Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 180 apart 16 Replace blower access door only if it was removed 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in fire personal injury or death Never use a match or other open flame to check for gas leaks Use a soap and water solution 19 Check for gas leaks 20 Replace outer access door Step 3 Sequence of Operation
22. approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements including local building codes the National Fuel Gas Code ANSI Z223 1 2002 NFPA 54 2002 NFGC Parts 10 and 13 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 00 NSCNGPIC Section 7 Appendix C in Canada the local building codes and furnace and vent manufacturers instructions gt These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47 2003 CSA 2 3 2003 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSCNGPIC the local building codes and furnace and vent manufacturers instructions 23 The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in a build up of carbon monoxide and lead to personal injury or death Do not bypass th
23. cannot damage electrical or gas components 13 Reinstall cover to J Box Do not pinch wires between cover and bracket POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electrical require ments listed in Table 5 Refer to power cord manufacturer s 2 Remove the desired electrical box hole knockout and position listings the hole in the electrical box over the hole in the furnace gt 1 casing 2 1 Select and remove a hole knockout in the casing where the electrical box is to be installed NOTE Check that duct on side of furnace will not interfere with installed electrical box Remove cover from J Box Route listed power cord through 7 8 inch diameter hole in J Box Secure power cord to J Box bracket with a strain relief 3 Fasten the electrical box to casing by driving two field supplied screws from inside electrical box into casing steel 3 4 Remove and save two screws holding J Box See Fig 22 bushing or a connector approved for the type of cord used 5 Pull furnace power wires out of 1 2 inch diameter hole in 4 Secure field ground wire to green ground screw on J Box J Box Do not loosen wires from strain relief wire tie on bracket outside of J Box 5 Connect line voltage leads as shown in Fig 25 6 Route furnace power wires through holes in casing and 6 Reinstall cover to J Box Do not pinch wires between cover electrical box and into electrical box and bracket
24. ciale pi ce n KGASBO 201ALL l ensemble serpentin pi ce n CD5 ou ou le carter de serpentin pi ce KCAKC Dans une alc ve on doit maintenir un d gagement l avant de 18 450mm Lapoistion indiqu e concerne le c t d entr e ou de retour quand la fournaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la cherrise de la fournaise et les solives montant sous cadre de charpente 327590 101 REV C Clearance in inches D gagement po Fig 2 Clearances to Combustibles A04123 Table 1 Dimensions IN F D E FURNACE A SUPPLY AIR RETURN AIR CULTO OND COLLAR SHIP WT um SIZE CABINET WIDTH WIDTH WIDTH FLUE COLLAR IN IN IN IN 045 08 024045 14 3 16 12 9 16 12 11 16 9 5 16 4 104 045 12 036045 14 3 16 12 9 16 12 11 16 9 5 16 4 107 070 08 024070 14 3 16 12 9 16 12 11 16 9 5 16 4 111 070 12 036070 14 3 16 12 9 16 12 11 16 9 5 16 4 115 070 16 048070 17 1 2 15 7 8 16 11 9 16 4 126 090 14 042090 17 1 2 15 7 8 16 11 9 16 4 127 090 16 048090 21 19 3 8 19 1 2 13 5 16 4 140 090 20 060090 21 19 3 8 19 1 2 13 5 16 4 146 110 12 036110 17 1 2 15 7 8 16 11 9 16 4 135 110 16 048110 21 19 3 8 19 1 2 13 5 16 4 146 110 22 066110 21 19 3 8 19 1 2 13 5 16 4 152 135 16 048135 21 19 3 8 19 1 2 13 5 16 4 149 135 22 066135 24 1 2 22 7 8 23 15 1
25. holding J box See Fig 22 NOTE The J Box cover need not be removed from the J Box in order to move the J Box Do NOT remove green ground screw inside J Box The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J Box outboard of the casing Table 7 Electrical Data VOLTS OPERATING MAXIMUM MAXIMUM UNIT MAXIMUM MINIMUM FURNACE SIZE Bree oe RANGE UNIT AMPS AMPACITY WIRE LENGTH FUSE rong BKR WIRE GAUGE 045 08 024045 115 60 1 127 104 54 754 49 15 14 045 12 036045 115 60 1 127 104 7 0 9 50 39 15 14 070 08 024070 115 60 1 127 104 5 0 7 06 52 15 14 070 12 036070 115 60 1 127 104 6 8 9 22 40 15 14 070 16 048070 115 60 1 ___127 104 95 12 60 29 15 14 090 14 042090 115 60 1 127 104 82 10 83 34 15 14 090 16 048090 115 60 1 127 104 10 0 13 13 28 15 14 090 20 060090 115 60 1 127 104 13 6 17 61 32 20 12 110 12 036110 115 60 1 127 104 8 2 10 75 34 15 14 110 16 048110 115 60 1 127 104 10 1 13 12 28 15 14 110 22 066110 115 60 1 127 104 14 8 18 99 30 20 12 135 16 048135 115 60 1 127 104 10 2 13 27 27 15 14 135 22 066135 115 60 1 127 104 144 18 55 30 20 12 155 20 060155 115 601 127 104 15 0 19 33 29 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily 3t Unit ampacity 125 percent of largest operatin
26. installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning explo sion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or accessories when modifying this product A CAUTION FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may re quire excessive servicing or cause premature component failure Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these ins
27. joints Pipe dope must be resistant to the action of propane gas A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in death personal injury and or property damage If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in outside the furnace A CAUTION FURNACE OVERHEAT HAZARD Failure to follow this caution may result in property damage Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gauge connection MUST be 17 available external static pressure installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve NOTE The gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas control valve See Fig 46 Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21a Install a sediment trap in riser leading to furnace as shown in Fig 21b Connect a capped nippl
28. objects CANADA Part 7 of NSCNGPIC Venting Systems and Air Supply for Appliances Step 4 Duct Systems gt US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Con tractors National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16 Step 5 Acoustical Lining and Fibrous Glass Duct US and CANADA current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 6 Gas Piping and Gas Pipe Pressure Testing US NFGC chapters 5 6 7 and 12 and National Plumbi Codes SE i MM e not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage LOCATION GENERAL Some assembly and modifications are required when used in any of the four applications shown in Fig 4 This furnace must be installed so the electrical components are protected from water CANADA NSCNGPIC Parts 3 4 and 5 and Appendices A B E and H be located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section Step 7 Electrical Connections be provided ampl
29. off within 2 minutes determine reason draft safeguard switch did not function properly and correct condition f Remove blockage from furnace vent elbow g Switch will auto reset when it cools h Re install vent connector NOTE Should switch remain open longer than 3 minutes furnace control board will lockout the furnace for 3 hours To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF then back ON 3 Check Pressure Switch This control proves operation of the draft inducer blower a Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace Qa Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control diagnostic light flashes a 35 status code 32 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace Reconnect inducer motor wires replace outer door and turn on 115 v power Blower will run for 90 sec before beginning the call for heat again i Furnace should ignite normally Step 5 Checklist 1 Put away tools and instruments Clean up debris 2 Check that blower OFF DELAY time is selected as desir
30. on their length and routing 6 Remove 2 screws holding control box to blower shelf 7 Hang control box from front of furnace casing and away from blower compartment 39 8 Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace 9 Clean blower wheel and motor using a vacuum with soft brush attachment Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blades 10 Vacuum any loose dust from blower housing wheel and motor Table 12 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based On 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS PESE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 600 43 2 7 43 2 8 43 2 9 43 3 0 5 625 43 25 43 2 6 43 2 6 43 27 4 to 650 43 2 3 43 2 4 43 2 4 43 2 5 10 000 675 43 2 1 43 25 43 2 3 43 2 3 3 700 48 3 7 43 2 0 43 2 1 43 2 2 725 48 8 5 48 3 6 48 3 7 43 2 0 Orifice numbers 43 are factory installed 11 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel NOTE Before d
31. or connections flame signal lost during blower on delay period blower will come on for the blower off delay Check for Flame sensor must not be grounded uildup on flame sensor clean with fine steel wool lame sense microamps 5 microamps D C min 4 0 6 0 nominal Manual valve shut off Control ground continuity Inadequate flame carryover or rough ignition Gas val Reset power to clear lockout Replace control if status code repeats Software check error J ve relay stuck open Flame sense circuit failure A04223 Fig 49 Service Label ELECTRICAL CONTROLS AND WIRING A CAUTION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Fig 25 for field wiring information and to Fig 45 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 24 Any shorts of the 24 v wi
32. return air to cause normal circulation NOT be in the circuit while measuring current d Burners will re light when furnace cools down 1 Remove thermostat from subbase or from wall 2 Check draft safeguard switch 2 Connect an amp meter as shown in Fig 48 across the R and W terminals or R and W wires at wall 3 Record amp draw across terminals when furnace is in heating and after blower starts 4 Set heat anticapator on thermostat per thermostat instructions and install on subbase or wall b Electronic thermostat Set cycle rate for 4 cycles per hr 7 Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec The blower off delay jumpers are located on the 34 The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal Table 10 GAS RATE FT HR SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 4 2 5 FOR 1 1 2 5
33. such as those published by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guide lines reference tables available from your local distributor The duct system should be sized to handle the required system design Table 4 Opening Dimensions In FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B C D Upflow Applications on Combustible or Noncombustible E Flooring KGASB subbase not required 121116 2198 13 976 Downflow Applications on Noncombustible Flooring KGASB subbase not required Toute i 1973 16 1938 14 3 16 Downflow applications on combustible flooring KGASB subbase required 11 13 16 19 13 7 16 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 12 5 16 19 13 5 16 20 not required Upflow Applications on Combustible or Noncombustible E 7 Flooring KGASB subbase not required 18 AlS 1655 itid Downflow Applications on Noncombustible Flooring T KGASB subbase not required buds 1802 1996 17 1 2 Downflow applications on combustible flooring KGASB subbase required 15 1 8 19 16 3 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 1
34. these instructions INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW DOWNFLOW and natural gas at altitudes 0 10 000 ft 0 3 050m HORIZONTAL installations An accessory kit supplied the Cette fournaise est approuv e pour installation HORIZONTALE manufacturer shall be used to convert to propane et la circulation d air VERS LE HAUT et VERS LE BAS gas use or may be required for some natural gas applications Clearance arrows This furnace is for indoor installation in a do not change with building constructed on site furnace orientation This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combusitble material This fumace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Les fl ches de d gagement ne change pas avec l orientation de la fournaise TOP PLENUM DESSUS CHAMBRED AIR Cette fournaise air puls est quip e pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000 pi Utiliser une trousse de conversion fournie par le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel Cette fournaise est pr vue pour tre install e dans un b timent construit sur p
35. to 4 500 ft above sea level by an authorized Gas Conversion Station or Dealer To determine correct input rate for altitude see example 1 and use 0 90 as derate multiplier factor EXAMPLE 1 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT Derate Furnace Input Rate Furnace Input Rate X Multiplier at Installation at Sea Level Factor Altitude 88 000 X 0 90 79 200 2 Determine the correct orifice and manifold pressure adjust ment There are two different orifice and manifold adjustment tables All models in all positions except Low NOx models in downflow or horizontal positions use Table 12 22 000 BTUH Burner Low NOx models in the downflow or horizontal positions must use Table 13 21 000 BTUH Burner See input listed on rating plate a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain average yearly gas specific gravity from local gas supplier c Find installation altitude in Table 12 or 13 d Find closest natural gas heat value and specific gravity in Table 12 or 13 e Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation f Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY g Replace orifice with correct size if required by Table 12 or 13 Use only factory supplied orifices See EXAMPLE 2 For 22 000 BTUH burner applicat
36. ventilation air opening to the outdoors a One opening MUST commence within 12 300 mm of the ceiling and the second opening MUST commence within 12 300 mm of the floor Size openings and ducts per Fig 7 and Table 2 TWO HORIZONTAL DUCTS require 1 square inch of free area per 2 000 Btuh 1 100 mm kW of combined input for all gas appliances in the space per Fig 7 and Table 2 TWO OPENINGS OR VERTICAL DUCTS require 1 square inch of free area per 4 000 Btuh 550 mm kW for combined input of all gas appliances in the space per Fig 7 and Table 2 3 ONE OUTDOOR OPENING requires a 1 square inch of free area per 3 000 Btuh 734 mm kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connectors in the space The opening shall commence within 12 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 25 mm from the sides and back and 6 150 mm from the front The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors Indoor Combustion Air NFPA amp AGA Standard and Known Air Infiltration Rate Methods Indoor air is permitted for combustion ventilation and dilution if the Standard or Known Air Infiltration Method is used A WARN
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38. 16 4 163 155 20 060155 24 1 2 22 7 8 23 15 1 16 4 170 5 or 6 vent connector may be required in some cases 3 Provide adequate combustion and ventilation air to the furnace 13 These furnaces SHALL NOT be installed directly on carpet space as specified in Air for Combustion and Ventilation ing tile or any other combustible material other than wood section flooring In downflow installations factory accessory floor 4 Combustion products must be discharged outdoors Connect base MUST be used when installed on combustible materials this furnace to an approved vent system only as specified in and wood flooring Special base is not required when this the Venting section of these instructions furnace is installed on manufacturer s Coil Assembly Part No CDS or 5 or when Coil Box Part is used See 5 Never test for gas leaks with an open flame Use a commer M Hin Fig 2 for clearance to combustible construction information cially available soap solution made specifically for the detec tion of leaks to check all connections as specified in the Gas INTRODUCTION Piping section This Series 120 C 4 way multipoise Category I fan assisted gt 9 10 11 12 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as speci fied in the Start Up Adjustm
39. 1640 1570 1465 1345 1225 High m m 2260 2180 2085 1975 1865 1740 1605 1455 1 Side Only Med High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325 Med Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 A filter is required for each return air inlet Airflow performance included 1 in washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in Indicates unstable operating conditions Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts Refer to Table 6 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of
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41. 2 6 43 2 7 43 2 7 43 2 8 3 800 43 2 4 43 2 5 43 2 6 43 2 7 825 43 2 3 43 2 8 43 24 43 25 850 43 24 43 2 2 43 23 43 2 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ARANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 650 43 3 1 43 3 2 43 3 4 43 3 5 675 43 2 9 43 3 0 43 3 1 43 3 2 5 g i 700 43 2 7 43 2 8 43 29 43 3 0 6 725 43 2 5 43 2 6 43 2 7 43 2 8 5 8000 750 43 2 4 43 2 4 43 25 43 2 6 5 775 43 2 2 43 2 3 43 2 4 43 2 4 800 43 2 1 43 2 1 43 2 2 43 2 3 825 48 37 43 2 0 43 24 43 2 2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 625 43 29 43 3 0 43 3 1 43 3 2 650 43 27 43 2 8 43 2 9 43 3 0 5 8001 675 43 2 5 43 2 6 43 2 7 43 2 8 4 to 700 43 2 3 43 24 43 2 5 43 2 6 e 9000 725 43 2 2 43 2 2 43 2 3 43 24 750 43 2 0 43 24 43 2 2 43 2 2 775 48 3 6 48 3 7 43 2 0 43 24 Orifice numbers 43 are factory installed 4 Remove 2 screws from blower access door and remove blower access door 5 Disconnect blower leads from furnace control Record wire color and location for reassembly All other factory wires can be left connected but field thermostat connections may need to be disconnected depending
42. 4 5 7 8 9 on th Fig 42 Horizontal Right Application following these fgures 9 A03219 Vent Elbow Right Fig 43 Horizontal Right Application Vent Elbow Left then Up 29 lan KL SEE NOTES 1 2 4 5 7 8 9 A02068 Fig 44 Horizontal Right Application Vent Elbow Left Venting Notes for Figures 32 44 For common vent vent connector sizing and vent material United States use the NFGC Canada use the NSCNGPIC Immediately increase to 5 inch or 6 inch vent connector outside furnace casing when 5 inch vent connector is required refer to Note 1 above 3 Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when KGAVGO010IDFG Downflow Vent Guard Kit is used in the downflow position Type B vent where required refer to Note 1 above 5 Four inch single wall 26 ga min vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace 6 Accessory Downflow Vent Guard KGAVGOIOIDFG required in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACAO02015FC for sizing and complete application details 8 Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart
43. 44 8 33 7 154 000 77 10 51 3 9 38 5 8 EXAMPLES Determining Free Area FURNACE WATER HEATER TOTAL INPUT 110 000 30 000 140 000 divided by 4 000 35 0 Sq In for each two Vertical Ducts or Openings 66 000 40 000 106 000 divided by 3 000 35 3 Sq In for a Single Duct or Opening 88 000 30 000 118 000 divided by 2 000 59 0 Sq In for each of two Horizontal Ducts Table 3 Minimum Space Volumes for 100 Combustion Ventilation and Dilution from Indoors OTHER THAN FAN ASSISTED TOTAL FAN ASSISTED TOTAL 1 000 5 BTUH GAS INPUT RATE 1 000 5 BTUH GAS INPUT RATE ACH 30 40 50 44 66 88 110 132 154 Space Volume ft 0 60 1 050 1 400 1 750 1 100 1 650 2 200 2 750 3 300 3 850 0 50 1 260 1 680 2 100 1 320 1 980 2 640 3 300 3 960 4 620 0 40 1 575 2 100 2 625 1 650 2 475 3 300 4 125 4 950 5 775 0 30 2 100 2 800 3 500 2 200 3 300 4 400 5 500 6 600 7 700 0 20 3 150 4 200 5 250 3 300 4 950 6 600 8 250 9 900 11 550 0 10 6 300 8 400 10 500 6 600 9 900 13 200 16 500 19 800 23 100 0 00 NP NP NP NP NP NP NP NP NP NP Not Permitted Outdoor Combustion Air Method Provide the space with sufficient air for proper combustion ventilation and dilution of flue gases using permanent hori zontal or vertical duct s or opening s directly communicat ing with the outdoors or spaces that freely communicate with the outdoors 2 Fig 7 illustrates how to provide TWO OUTDOOR OPEN INGS one inlet and one outlet combustion and
44. 5 Verify furnace shut down by lowering thermostat setting below room temperature 6 Verify furnace restarts by raising thermostat setting above room temperature Step 3 Adjustments A WARNING FIRE HAZARD Failure to follow this warning could result in reduced furnace life property damage injury and death DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures A CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Fig 47 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft Furnace input rate must be within 2 percent of furnace rating plate input 31 Determine the correct gas input rate In the U S A The input rating for altitudes above 2 000 ft must be reduced by 4 percent for each 1 000 ft above sea level For installa tions below 2000 ft refer to the unit rating plate For installations above 2000 ft multiply the input on the rating plate by the de rate multiplier in Table 8 for the correct input rate In Canada The input rating must be derated by 10 percent for altitudes of 2 000 ft
45. 5 1 2 19 16 1 2 20 not required Upflow Applications on Combustible or Noncombustible X _ Flooring KGASB subbase not required ave aloe 20 1 8 Downflow Applications on Flooring _ _ KGASB subbase not required pes 13 o 1555 21 Downflow applications on combustible flooring KGASB subbase required 18 5 8 19 20 1 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 19 19 20 20 not required Upflow Applications on Combustible or Noncombustible g i Flooring KGASB subbase not required eis bad SEM Downflow Applications on Noncombustible Flooring X KGASB subbase not required eee 19 ane 11 24 1 2 Downflow applications on Combustible flooring KGASB subbase required 22 1 8 19 23 3 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 22 1 2 19 23 1 2 20 not required CFM at the design external static pressure The furnace airflow rates are provided in Table 5 AIR DELIVERY CFM With Filter When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnac
46. 51 5 05 4 Way Multi Single Stage Induced Combustion ise Furn Cancels 310A 45 4 IM PG8J 04 1131 0A 45 5 IM PG8J 0 Installation Start up Operating an Service and Maintenance Instructions Series 120 C NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2002 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety TABLE OF CONTENTS SAFETY CONSIDERATIONS ss 2 INTRODUCTION 5 rne ri Cr EE EUR eee e ter Reads 4 CODES AND STANDARDS netter indie 4 Spi E 5 General icc a eytete Roesch 5 Combustion and Ventilation Air 5 Duct SYSTEMS decetero te EURO ee XR o PRESE eroe repe 5 Acoustical Lining and Fibrous Glass 5 Gas Piping and Gas Pipe Pressure 5 Electrical Connections aurrrera irni eene 5 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE ee ca tees tesis res eve taedas 5 LOCATION 5 General bees
47. AZARD Failure to follow this warning could result in fire personal injury or death Never operate unit without a filter or with filter access door removed 7 Replace filter cabinet door 8 Turn on electrical supply to furnace BLOWER MOTOR AND WHEEL A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces The minimum maintenance on this furnace is as follows 1 Check and clean air filter each month or more frequently if required Replace if torn NOTE The blower wheel should not be dropped or bent as balance will be affected 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean as necessary The following steps should be performed by a qualified service agency 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary To ensure long life and high efficiency clean accumulated dirt and grease from blower whe
48. DE PERCENT DERATE MULTIPLIER FT OF DERATE FACTOR 0 2000 0 1 00 2001 3000 8 12 0 90 3001 4000 12 16 0 86 4001 5000 16 20 0 82 5001 6000 20 24 0 78 6001 7000 24 28 0 74 7001 8000 28 32 0 70 8001 9000 32 36 0 66 9001 10 000 36 40 0 62 Derate multiplier factors are based on midpoint altitude for altitude range f Set thermostat to call for heat g Jumper R and W thermostat connections on furnace control board to start furnace h Remove regulator seal cap and turn regulator adjusting screw counterclockwise out to decrease input rate of clockwise in to increase input rate i Install regulator seal cap j Leave manometer or similar device connected and proceed to Step 4 NOTE DO NOT set manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas at sea level If manifold pressure is outside this range change main burner orifices or refer to Table 12 or 13 NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 4 Verify natural gas input rate by clocking meter NOTE Gas valve regulator adjustment cap must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter b Run furnace for 3 minutes in heatin
49. ING CARBON MONOXIDE POISONING HAZARD Failure to supply outdoor air via grilles or ducts could result in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual 1SQIN PER 4000 DUCTS TO BTUH OUTDOORS 1 NE EM 12 D 12 1SQIN VENT MAX PER 2000 B t THROUGH BTUH 348 ROOF On PER Tq 4000 BTUH 4 8 DUCTS TO 225 a OUTDOORS 2252 5 Ost zs 1SQIN wa 9 2 PER 200 4000 qaga BTUH TOZH 1 SQIN 2526 PER 2000 A GE aoo 197 12 a 12 MAX CIRCULATING AIR DUCTS ANO on TO PER 4000 OUTDOORS BTUH Minimum dimensions of 3 in NOTE Use any of the following combinations of openings A amp B D amp E F amp G A03174 Fig 7 Air for Combustion Ventilation and Dilution for Outdoors The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to b
50. IR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR a CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS SSS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES YES YES YES 20 MODELS ALL OTHER MODELS YES YES YES YES RETURN AIR a UPFLOW ETUR RETURN AIR RESTRICTIONS m A02075 Fig 18 Upflow Return Air Configurations and Restrictions RETURN RETURN AIR SIDE RETURN SIDE RETURN NOT PERMITTED NOT PERMITTED FOR MODEL FOR ANY MODEL DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRICTIONS FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR E CONNECTION1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 066 060 22 AND YES V M 20 MODELS ALL OTHER MODELS YES 1 SUPPLY AIR i ss A02163 Fig 19 Downflow Return Air Configurations and Restrictions RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS 2 ie icis X O Sound ron NOTE RESTRICTION SAME FOR RETURN RESTRICTIONS HORIZONAL LEFT HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTIO
51. LET 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Bottom High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835 048135 or Med High 1790 1755 1705 1640 1550 1465 1360 1210 945 785 Side s Med Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670 suitors High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355 ni Med High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255 y Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 High 2385 2305 2195 2085 1960 1825 1670 1465 066135 a Med High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325 Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 High 2245 2155 2055 1940 1825 1695 1555 1385 1 Side Only Med High 2135 2085 2035 1975 1895 1795 1685 1565 1445 1265 Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545 Sni Med High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 y Med Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 Sides r High 2375 2285 2200 2105 1995 1870 1730 1570 060155 1 Side amp Bottom Med High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400 Med Low 1800 1790 1770 1735 1695
52. LOSION HAZARD Failure to follow this warning coud result in personal injury A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage death and or property damage ee manifold and gas leak Never purge a gas line into a combustion chamber Never test s for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections PIC in Canada 15 A02014 A02164 Use proper length of pipe to avoid stress on gas control Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the NSCNG Table 5 Air Delivery CFM With Filter FURNACE RETURN AIR EXTERNAL STATIC PRESSURE IN WC SIZE INLET SPEED ya 02 04 05 06 07 08 Bottom High 1085 1035 975 915 845 770 675 565 024045 or Med High 920 875 830 770 710 640 555 440 Side s Med Low 820 775 730 680 620 555 470 360 Bottom High 1440 1375 1305 1240 1160 1070 975 870 036045 bi Med High 1360 1300 1240 1175 1115 1040 950 850 Side s Med Low 1250 1210 1160 1100 1040 965 885 790 Bottom High 1080 1010 980 945 900 845 775 680 024070 Med High 835 815 790 760 720 675 610 490 Side s Med Low 725 700
53. N 3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES 20 MODELS ALL OTHER MODELS YES A02162 Fig 20 Horizontal Return Air Configurations and Restrictions 18 Table 6 Maximum Capacity of Pipe NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE DIAMETER SIZE IN 10 20 30 40 50 IN 1 2 0 622 175 120 97 82 73 3 4 0 824 360 250 200 170 151 1 1 049 680 465 375 320 285 1 1 4 1 380 1400 950 770 660 580 1 1 2 1 610 2100 1460 1180 990 900 Cubic ft of natural gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 12 2 ANSI Z223 2002 NFPA 54 2002 TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY fi 90 Elbow To Gas 5 5 P4 5 upply U 2 Nipple 90 Elbow Close Nipple T Gas Valve A02327 Fig 21a Right Side Gas Entry Example GAS 7h SUPPLY MANUAL SHUTOFF VALVE REQUIRED SEDIMENT TRAP UNION A02035 Fig 21b Typical Gas Pipe Arrangement ELECTRICAL CONNECTIONS A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in serious personal injury or death Blower access panel door
54. OX 18Hg 19 13 16 LOCATION 5 15 16 413 16 OUTLET 4 1 2 DIA WIRE ENTRY 7 8 DIA 1 3 4 DIA RIGHT HAND 7 3 4 ACCESSORY Ta DIA THERMOSTAT GAS ENTRY 1 WIRE ENTRY 11 12 3 15 16 ALTERNATE JUNCTION BOX LOCATIONS TYP VENT OUTLET 5 PLACES TYP 33 5 16 UU 6 24 718 14 7 8 5 1 2 11 16 5 1 2 21 5 8 141 16 BOTTOM INLET 22 1 16 SIDE INLET 24 ____ CASING A04037 NOTES 1 Two additional 7 8 in diameter holes are located in the top plate 2 Minimum return air openings ar furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in round or 14 1 2 x 12 in rectangle b For 1200 CFM 20 in round or 14 1 2 x 19 1 2 in rectangle c For 1600 CFM 22 in round or 14 1 2 x 22 in rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM Fig 1 Dimensional Drawing SAFETY CONSIDERATIONS A WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation serious injury death or property damage Improper
55. REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 e Furnace should cycle off within 2 minutes If gas does not shut
56. Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws HORIZONTAL INSTALLATION A WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation serious injury death or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control opera tion will be adversely affected Never connect return air ducts to the back of the furnace The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad Suspended Furnace Support The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the furnace from each bottom corner To prevent
57. al vent or metal liner is used the vent must be in good condition and be installed in accordance with the vent manufac turer s instructions To prevent condensation in the furnace and vent system the following precautions must be observed 1 The return air temperature must be at least 60 F db except for brief periods of time during warm up from setback at no lower than 55 F db or during initial start up from a standby condition 2 Adjust the gas input rate per the installation instructions Low gas input rate causes low vent gas temperatures causing condensation and corrosion in the furnace and or venting system Derating is permitted only for altitudes above 2000 ft 3 Adjust the air temperature rise to the midpoint of the rise range or slightly above Low air temperature rise can cause low vent gas temperature and potential for condensation problems CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54 ANSI 2223 1 and ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian installation Code CSA B149 1 in Canada Crown condition Missing mortar or brick Yes Rebuild crown Is chimney property lined with clay tile liner No Yes Is Repair liner and top liner or top seal Reline seal in good or reline chimney as condition necessary Debris in cleanout Mortar ti
58. all other than fan assisted appli ances in Btu hr Ij combined input of all fan assisted appliances in Btu hr ACH air changes per hour ACH shall not exceed 0 60 The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method 1 Adjoining rooms can be considered part of a space if a There are no closable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 1 000 Btuh 2 000 mm kW of the total input rating of all gas appliances in the space but not less than 100 in 0 06 m One opening shall commence within 12 300 mm of the ceiling and the second opening shall commence within 12 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 8 Combining space on different floor levels The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more perma nent openings in doors or floors having free area of at least 2 in 7 1 000 Btuh 4 400 mm kW of total input rating of all gas appliances 2 An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1 in 4 000 Btuh of total input rating for all gas appliances in the space 3 In spaces that use the Indoor Combustio
59. allow the knockout to be pulled loose See Fig 29 Remove all burrs and sharp edges For the knockouts in the other locations on the door top and sides tin snips can also be used along the door edges however the preferred method is to use a hammer and screwdriver to strike a sharp blow See Fig 30 directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout See Fig 31 Remove all burrs and sharp edges An accessory Vent Guard Kit KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall slope upwards not less than 1 4 in per linear ft 21mm m from the furnace to the vent and shall be rigidly supported every 5 ft or less with metal hangers or straps to ensure there is no movement after installation SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting In the U S Per section 10 3 4 of the NFGC any listed mechanical venter may be used when approved by the authority having jurisdiction In Canada Per section 7 24 2 of the NSCNGPIC any listed venters may be used when approved by the authority having jurisdiction Select the listed mechanical venter to match the Btuh input of the furnace being vented Follow all manufacturer s installation re quirements f
60. anical means to either draw or force products of combustion through the combus tion chamber and or heat exchanger The furnace is factory shipped for use with natural gas A CSA A G A and C G A listed gas conversion kit is required to convert furnace for use with propane gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum continuous return air temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed 85 F db Failure to follow these return air temperature limits may affect reliability of heat exchang ers motors and controls See Fig 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before oper ating the furnace CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction NTI Step 8 MAX 85 F US NFGC chapters 10 and 13 CANADA NSCNGPIC Part 7 and Appendix ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE
61. ans clothes dryers attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST be provided for the ventilation devices in addition to that required by the furnace Refer to Carbon Monoxide Hazard warning in venting section of these instruc tions to determine if an adequate amount of make up air is available gt The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1 000 Btuh input rating for all gas appliances installed in the space e Spaces having less than 50 cubic feet per 1 000 Btuh require the OUTDOOR COMBUSTION AIR METHOD e Spaces having at least 50 cubic feet 1 000 Btuh may use the INDOOR COMBUSTION AIR STANDARD or KNOWN AIR INFILTRATION METHOD Table 2 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS FURNACE 1 SQ IN 2 000 BTUH 1 100 SQ MM KW 1 SQ IN 3 000 BTUH 734 SQ MM KW 1 SQ IN 4 000 BTUH 550 SQ MM KW INPUT Free Area of Free Area of Free Area of BTUH Opening and Duct n ee Opening and Dust s qd dnd bud b iod Sq In sq In i Sq In 44 000 22 6 14 7 5 11 4 66 000 33 7 22 6 16 5 5 88 000 44 8 29 3 7 22 6 110 000 55 9 36 7 7 27 5 6 132 000 66 10
62. as shown in Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover and bracket 24 V WIRING Make field 24 v connections at the 24 v terminal strip See Fig 24 Connect terminal Y as shown in Fig 25 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115 VAC 1 0 amps maximum and are energized during blower motor operation See Fig 24 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the 1 4 in male quick connect HUM terminal and Com 24V screw terminal on the control board thermostat strip The HUM terminal is energized when pressure switch PRS closes See Fig 24 NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or si
63. burner flame is proven the blower motor is energized on HEAT speed 25 seconds after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC 1 is energized and remains energized as long as the blower motor BLWM is energized f Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 5 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 seconds depend ing on the blower OFF delay selection The furnace control CPU 15 factory set for 120 second blower OFF delay 2 Cooling Mode See Fig 25 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds Cut jumper J2 to reduce the cooling off delay to 5 seconds See Fig 24 3 Continuous Blower Mode When the R to G circuit is closed by the thermos
64. cation is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 4 you must revise your orientation to component location accord ingly SERVICE E If status code recall is needed briefly remove then reconnect one main limit wire to display stored status code On RED LED boards do not remove power or blower door before initiating status code recall After status code recall is completed component test will occur LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115 polarity reversed If twinned refer to twinning kit instructions EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 24 to control is interrupted BLOWER ON AFTER POWER UP 115 or 24 _ Blower runs for 90 seconds if unit is powered up during a call for heat R W closed or R W opens during blower on delay LIMIT CIRCUIT LOCKOUT L
65. cation or inadequate protection could result in fire or explosion When the furnace is installed in a residential garage the burners and ignition sources must be located at least 18 inches above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the NFGC or NSCNGPIC See Fig 5 A CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause premature furnace component failure This gas furnace may be used for heating buildings under construction provided that The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents th
66. ce agency mos T lean 6 Inspect any accessories attached to the furnace such as a Recommended humidifier or electronic air cleaner Perform any service or Some furnaces may have 2 filters maintenance to the accessories as recommended in the acces sory instructions CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application The filter is exterior to the furnace casing Step 2 Care and Maintenance A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in corrosion of heat exchanger fire personal injury or death Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum NOTE If the filter has an airflow direction arrow the arrow must point towards the blower A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning com pounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids 3 Paint thinners and other painting compounds paper bags or other paper products Media cabinet filter proced
67. e 1 Less than 0 40 ACH and 2 Equal to or greater than 0 10 ACH Infiltration rates greater than 0 60 ACH shall not be used The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2 Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space Table 3 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223 1 2002 NFPA 54 2002 8 3 2 2 1 For other than fan assisted appliances such as a draft hood equipped water heater _ 21 ft3 l other Volume Other _ ACH 04002 CIRCULATING AIR DUCTS VENT THROUGH ROOF acy 12 Ez TSQN PER 1000 2 BTUH IN DOOR OR WALL e DE EL INTERIOR UNCONFINED HEATED E SPACE SPACE Ni 29 M FRONT mie OZ 1 SQIN 24 PER 1000 2 BTUH IN DOOR 40 ORWALL 4 12 MAX CIRCULATING AIR DUCTS Minimum opening size is 100 sq in with minimum dimensions of 3 in tMinimum of 3 in when type B1 vent is used A03175 Fig 8 Air for Combustion Ventilation and Dilution from Indoors 2 For fan assisted appliances such as this furnace _ 1513 tan Volume ACH os fs A04003 If Lune combined input of
68. e 9 for motor speed lead relocation if leads were not identified before disconnection 17 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected 18 To check blower for proper rotation a Turn on electrical supply A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this 40 switch for service purposes b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door d Verify blower is rotating in the correct direction If furnace is operating properly RELEASE BLOWER AC CESS DOOR SWITCH Remove any jumpers or reconnect any disconnected thermostat leads Replace blower access door 19 20 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to
69. e draft safeguard switch as an unsafe condition could exist which must be corrected 1 If a vent common or dedicated becomes blocked the furnace will be shut off by the draft safeguard switch located on the vent elbow 2 Do not connect this Category I furnace into a single wall dedicated or common vent The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors 3 Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 4 In the U S Do not vent this appliance with any solid fuel burning appliance In Canada Check with the authority having jurisdiction for approval on use with solid fuel burning appliance 5 Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed power ventor 6 Do not vent this appliance into an unlined masonry chimney Refer to Chimney Inspection Chart Fig 26 MASONRY CHIMNEY REQUIREMENTS NOTE These furnaces are CSA design certified for use in exterior clay tile lined masonry chimneys with a factory accessory Chimney Adapter Kit Refer to the furnace rating plate for correct kit usage The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate If a clay tile lined masonry chimney is being used and it is exposed to the outdoors below the roof l
70. e entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is main tained between 55 F 13 C and 80 F 27 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermit tent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the firing rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including igni tion gas input rate air temperature rise and venting according to these installation instructions A WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in unsafe furnace operation DO NOT install the furnace on its back or hang furnace with control compartment facing downward Safety control opera tion will be adversely affected Never connect return air ducts to back of furnace See Fig 6 LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on the downst
71. e into lower end of tee Capped nipple should extend below level of furnace gas controls Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve A 1 8 in NPT plugged tapping accessible for test gauge connection MUST be installed immedi ately upstream of gas supply connection to furnace and down stream of manual equipment shutoff valve Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 in we turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF SUPPLY AIR RETURN AIR UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS A
72. e space for servicing and cleaning Always US National Electrical Code NEC ANSUNFPA 70 2002 comply with minimum fire protection clearances shown on the CANADA Canadian Electrical Code CSA C22 1 furnace clearance to combustible construction label AIRFLOW THE BLOWER IS LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER 15 LOCATED UPFLOW TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT lt HORIZONTAL LEFT AIRFLOW HORIZONTAL RIGHT gt DOWNFLOW THE BLOWER IS THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION AND OF THE BURNER SECTION CONDITIONED AIR IS AND CONDITIONED AIR 15 DISCHARGED DOWNWARD A BELOW DISCHARGED TO THE RIGHT A02097 Fig 4 Multipoise Orientations fuel burning equipment must be supplied with air for fuel combustion Sufficient air must be provided to avoid negative pressure in the equipment room or space positive seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and from draft safeguard opening A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air
73. e with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork pass ing through unconditioned space should be insulated and sealed to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts Supply Air Connections For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks Upflow and Horizontal Furnaces Connect suppl
74. ead color identification Step 4 Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation A CAUTION FURNACE OVERHEATING HAZARD 5 1 Check Main Limit Switch es Failure to properly set temperature rise may cause excessive This control shuts off combustion control system and ener furnace temperatures and shorten furnace life DRE T gizes air circulating blower motor if furnace overheats By Recheck temperature rise It must be within limits specified A p n using this method to check limit control it can be established on the rating plate Recommended operation is at the mid NC that limit is functioning properly and will operate if there is a point of rise range or slightly above m restricted duct system or motor failure If limit control does 6 Set thermostat heat anticipator not function during this test cause must be determined and a Mechanical thermostat Set thermostat heat anticipator to Corrected match the amp draw of the electrical components in the a Run furnace for at least 5 minutes R W circuit Accurate amp draw readings can be obtained b Gradually block off return air with a piece of cardboard or at the wires normally connected to thermostat subbase sheet metal until the limit trips terminals R and W The thermostat anticipator should c Unblock
75. ed 3 Verify that blower and burner access doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Guide with owner 7 Attach literature packet to furnace SERVICE AND MAINTENANCE PROCEDURES A WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in possible damage to this equipment serious personal injury or death The ability to properly perform maintenance on this equip ment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death or property damage Before servicing disconnect all electrical power to furnace Verify proper operation after servicing A CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operation or failure of furnace Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation Step 1 Introduction GENERAL These instructions are written as if the furnace is installed in an upflow application An upflow furnace appli
76. ee Fig 25 3 Gas supply pressure to the furnace must be greater than 4 5 in we 0 16 psig but not exceed 14 in we 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Replace outer door Step 2 Start Up Procedures A WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause property damage personal injury or death Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks 5 1 2 4 7 8 9 on the page following these figures A03208 Fig 32 Upflow Application Vent Elbow Up Fig SEE NOTES 1 2 3 4 7 8 9 on the pages following hese figures A03209 33 Upflow Application Vent Elbow Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures Fig 34 Downflow Application Vent Elbow Up then Left A03210 28 SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 35 Downfl
77. el and motor annually 37 TABLE 12 Orifice Size and Manifold Pressure For Gas Input Rate Tabulated Data Based On 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE NES _ 060 ___062 _ __ 064 _ Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 900 42 3 5 42 3 6 42 3 7 41 3 5 5 925 42 3 3 42 3 4 42 3 5 42 3 7 950 43 3 8 42 3 3 42 3 4 42 3 5 gt 0 975 43 3 6 43 3 8 42 3 2 42 3 3 S 2000 1000 43 3 5 43 3 6 43 3 7 43 3 8 4 1025 43 3 3 43 3 4 43 3 5 43 3 6 0 1050 44 3 6 43 3 2 43 3 4 43 3 5 gt 1075 44 3 4 44 3 5 43 3 2 43 3 3 1100 44 3 3 44 3 4 44 3 5 43 3 2 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE a __060_ ___062 _ __ 064 _ BTU CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure U S A 800 42 3 4 42 3 5 42 3 6 42 3 7 5 m 825 42 32 42 33 42 34 42 35 S to 850 43 3 7 43 3 8 42 3 2 42 3 3 3000 875 43 3 5 43 3 6 43 3 7 43 3 8 ar 900 43 3 3 43 3 4 43 3 5 43 3 6 Canada lt Altitudes 925 43 31 43 3 2 43 3 3 43 3 4 2000 950 43 2 9 43 3 0 43 31 43 3 2 2 to 975 43 2 8 43 2 9 43 3 0 43 3 1 4500 1000 43
78. ent elbow Clean blower motor and wheel as follows Turn off electrical supply to furnace 2 Loosen the thumbscrew on outer door and remove outer door 38 b Disconnect and remove short piece of vent pipe from within furnace Table 12 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based On 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS gera HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 725 43 3 4 43 3 5 43 3 6 43 3 7 750 43 3 2 43 3 3 43 3 4 43 3 5 5 5001 775 43 3 0 43 3 1 43 3 2 43 3 3 4 to 800 43 2 8 43 2 9 43 3 0 43 3 1 6000 825 43 2 6 43 2 7 43 2 8 43 2 9 3 850 43 2 5 43 2 5 43 2 6 43 2 7 875 43 2 3 43 24 43 2 5 43 2 6 900 43 2 2 43 2 3 43 2 3 43 2 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 675 43 3 4 43 3 5 43 3 6 43 3 7 700 43 3 1 43 3 8 43 3 4 43 3 5 5 725 43 2 9 43 3 0 43 3 1 43 3 2 4 750 43 27 43 28 43 29 43 3 0 ui 7000 775 43
79. ents and Safety Check section See furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section The furnace is not to be used for temporary heating of buildings or structures under construction See page 7 caution box regarding the heating of buildings under construction These Multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA listed gas conversion kit is required to convert furnace for use with propane gas See Fig 2 for required clearances to combustible construction Maintain a 1 clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace See NFPA 90B or local code for further requirements furnace is CSA design certified A Category I fan assisted furnace is an appliance equipped with an integral mech
80. eoo e oT REDE EIER 22 VENNE 2 202 General Venting Requirements 23 Masonry Chimney Requirements 23 Appliance Application Requirements 24 Additional Venting Requirements 26 Sidewall Venting 26 START UP ADJUSTMENT AND SAFETY CHECK 27 M de 27 Start Up Procedures eerte esos etn 56 55 27 Adqustments rete rrt cere rrr n eere enne enean 31 Check Safety Controls coercet ee tee rino 34 C 35 SERVICE AND MAINTENANCE PROCEDURES 20 99 tient 222 General scenes etos 2 85 Electrical Controls and Wiring 36 Care and Maintenance 37 Cleaning and or Replacing Air Filter 5 37 Blower Motor and Wheel ee 37 Cleaning Heat Exchanger eene 40 S quence of ODeratlol o oaa cede ni tiet 44 Witing Diagrattis x aseeecenosososa casae eiecti ce eie Perder 45 Troubleshooting Jide 45 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No See Cover Tab 8 Printed in U S A Form 58ST 13SI Pg 1 5 05 Replaces 5857 1251 28 7 8 26 1 8 FLUE COLLAR 25 1 4 2716 A 22 9 16 isie AIRFLOW JUNCTION B
81. er to control or status code will be lost BRIEFLY remove insulated terminal wire from the draft safeguard switch DSS until LED goes out 1 to 2 sec then reconnect it When above items have been completed the LED flashes status code 4 times Record this status code for further troubleshooting Component self test will begin Refer to COMPONENT TEST section for complete test sequence Check LED status Refer to the SERVICE label on the front of the blower access door for more information Check LED status If no previous fault is in history control will flash status code 11 If LED status indicates proper operation RELEASE BLOWER ACCESS DOOR SWITCH reattach wire to R terminal on furnace control board replace blower access door and replace burner access door Table 11 FILTER SIZE INFORMATION IN Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have FURNACE FILTER QUANTITY AND SIZE FILTER furnace and burner serviced by a qualified service agency CASING WIDTH Side Return Bottom Return 5 Inspect the vent pipe vent system before each heating season 14 1 2 1 16 X 25 X 1 1 14 X 25 X 1 Cleanable for rust corrosion water leakage sagging pipes or broken 17 2 1 16 X 25 X 1 1 16 X 25 X 1 Cleanable fittings Have vent pipes vent system serviced by a qualified 21 1 16 X 25 X 1 1 20 X 25 X 1 Cleanable servi
82. es to COOL speed after a 3 second delay If the R to W and Y and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W and Y signals disap pear leaving the G signal the blower motor BLWM will continue running the blower motor BLWM at HEAT speed after the selected blower OFF delay period is completed Step 4 Wiring Diagrams Refer to Fig 25 and 45 for wiring diagrams Step 5 Troubleshooting Refer to the service label See Fig 49 Service Label The Troubleshooting Guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After replacing any component verify correct operation sequence 901 207 eu 10 eui 0 jeuiuuJe JEISOWJAY APZWOD SU 1 9 0 jojsise jse eq e sul Jeur3 1 eoeuunj eu jou Si eu am Jeduinf e yeeda y eoeuunj y seJIM jejsouueu y JOOUUODSIG 101 U09 SY uo 20 ZA A Queseud LA M 1e Juasaid Ave SI ejqeo Bunoeuuoouejul JO jejsoul18uj WOO 49949 LHVLS 01 X9eq pue 18 291q 25
83. fold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 900 42 3 2 42 3 3 42 3 4 42 3 5 3 925 43 3 7 43 3 8 42 3 2 42 3 3 S 950 43 3 5 43 3 6 43 3 7 43 3 8 Z 0 975 43 3 3 43 3 4 43 3 5 43 3 7 UN 1000 44 3 6 43 3 3 43 3 4 43 3 5 d 1025 44 3 4 44 3 6 43 3 2 43 3 3 7 1050 44 3 8 44 3 4 44 3 5 43 3 2 1075 45 3 8 44 3 2 44 3 3 44 3 4 1100 46 3 8 45 3 7 44 3 2 44 3 3 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE EE 2 _ 060 __ 0862 _ __ 064 _ BTU CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure aes 800 43 3 8 42 3 2 42 3 3 42 3 4 E 2001 825 43 3 5 43 3 7 43 3 8 42 3 2 S to 850 43 3 3 43 3 5 43 3 6 43 3 7 3000 875 43 3 2 43 3 3 43 3 4 43 3 5 c or 900 43 3 0 43 3 1 43 3 2 43 3 3 925 43 2 8 43 29 43 3 0 43 3 4 Altitudes ui 2000 950 43 2 7 43 2 8 43 2 9 43 2 9 to 975 43 2 5 43 2 6 43 2 7 43 2 8 4500 1000 43 2 4 43 25 43 2 6 43 27 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE __058__ __060_ ___062 __ 064 _ BTU CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 775 43 3 5 43 3 7 43 3 8 42 3 2 800 43 3 3 43 3 4 43 3 5 43 3 7 3001 825 43 31 43 3 2 43 3 3 43 3 4 U S A Only to 850 43 2 9 43 3 0 43 3 1 43 3 2 4000 875 43 2 8 43 2 9 43 3 0 43 3 1 900 43 2 6 43 2 7 43 2 8 43 2 9 925 43
84. for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products Do not install furnace in a corrosive or contaminated atmosphere Make sure all combustion and circulating air requirements are met in addition to all local codes and ordinances gt The following types of furnace installations may require OUT DOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms and Chemical storage areas 18 IN MINIMUM If air is exposed to the following substances it should not be used TO BURNERS A93044 for combustion air and outdoor air may be required for combus tion Fig 5 Installation in a Garage Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals A WARNING e De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials FIRE INJURY OR DEATH HAZARD Improper lo
85. g component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps T Time delay type is recommended Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop FACTORY INSTALLED LOCATION TWO ALTERNATE FIELD LOCATION A02099 Fig 22 Relocating J Box Cut wire tie on loop in furnace wires attached to J Box Move box to desired location Fasten J Box to casing with two screws removed in Step 1 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX gt Field Supplied Electrical Box on Furnace J Box Bracket See Fig 23 1 Remove cover from furnace J Box 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will not pierce wire insulation 3 Route furnace power wires through holes in electrical box and J Box bracket and make field wire connections in electrical box Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 20 A03221 Fig 23 Field Supplied Electrical Box on J Box bracket and bracket Furnace Casing 4 Route and secure field ground wire to green ground screw on 5 Connect line voltage leads as shown i
86. g operation c Measure time in sec for gas meter to complete 1 revolu tion and note reading The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow d Refer to Table 10 for cubic ft of gas per hr e Multiply gas rate cu ft hr by heating value Btu cu ft to obtain input If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct input is achieved Reinstall regulator seal cap on gas valve 5 Set temperature rise The furnace must operate within the temperature rise ranges specified on the furnace rating plate Do not exceed tempera ture rise range specified on unit rating plate Determine the temperature rise as follows NOTE Blower access door must be installed when taking tem perature rise reading Leaving blower access door off will result in incorrect temperature measurements a Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see 33 REGULATOR SEAL CAP CR REGULATOR ADJUSTMENT 2 SCREW ON OFF SWITCH S OFF REGULATOR SPRING 1 2 NPT INLET gt GAS PRESSURE REGULATOR INLET ADJUSTMENT PRESSURE TAP we MANIFOLD PRESSURE TAP 1 2 NPT omer A 04166 Fig 46 Gas Control Valve radiant heat from heat exchangers Radiant heat affec
87. h cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly A05025 5 8 Clean flame sensor with fine steel wool Fig 50 1 Position Side View g g gt 9 Install NOx baffles if removed 10 Reinstall burner assembly Center burners in cell openings 1 7 8 10 Remove old sealant from cell panel and collector box flange 11 Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant 05026 G E 162 6702 Dow Corning 738 are needed before starting Fig 51 Igniter Position Top View 9 Using field provided 25 caliber rifle cleaning brush 36 in long 1 4 diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows a Remove metal screw fitting from wire brush to allow insertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush 43 installation DO NOT substitute any other type of
88. in 80 mm INSTALLATION UPFLOW INSTALLATION Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used 10 don or BOTTOM CLOSURE BOTTOM FILLER PANEL PANEL A02098 Fig 9 Removing Bottom Closure Panel NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 10 Install field supplied 5 16 X 1 1 2 in max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see Item 1 in Bottom Return Air Inlet section To install leveling legs 1 Posit
89. ine relining might be required Chimneys shall conform to the Standard for Chimneys Fireplaces Vents and Soild Fuel Burning Appliances ANSI NFPA 211 2003 in the United States and to a Provincial or Territorial Building Code in Canada in its absence the National Building Code of Canada and must be in good condition U S A Refer to Sections 13 1 9 and 13 2 20 of the NFGC or the authority having jurisdiction to determine whether relining is required If relining is required use a properly sized listed metal liner Type B vent or a listed alternative venting design NOTE See the NFGC 13 1 9 and 13 2 20 regarding alternative venting design and the exception which cover installations such as the Chimney Adapter Kits KGACAOQ2014FC KGACAO020ISFC which are listed for use with these furnaces The Chimney Adapter Kit is listed alternative venting system for these furnaces See the kit instructions for complete details Canada and U S A This furnace is permitted to be vented into a clay tile lined masonry chimney that is exposed to the outdoors below the roof line provided 1 Vent connector is Type B double wall and 2 This furnace is common vented with at least 1 draft hood equipped appliance and 3 The combined appliance input rating is less than the maximum capacity given in Table A and 4 The input rating of each space heating appliance is greater than the minimum input rating given in Table B for the local 99 Winte
90. ion furnace on its back Locate and drill a hole in each bottom corner of furnace See Fig 10 2 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement 5 Reinstall bottom closure panel if removed DOWNFLOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used Special Base KGASB e Cased Coil Assembly Part No CDS or 5 Coil Box Part No KCAKC 1 Determine application being installed from Table 3 2 Construct hole in floor per Table 3 and Fig 11 3 Construct plenum to dimensions specified in Table 3 and Fig 11 4 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part CD5 or 5 or Coil Box Part No KCAKC is used install as shown in Fig 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14 02071 Fig 10 Leveling Legs Bottom
91. ions use Table 12 EXAMPLE 2 0 2000 ft altitude Heating value 1000 Btu cu ft Specific gravity 0 62 Therefore Orifice No 43 Manifold pressure 3 7 in wc Furnace is shipped with No 43 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate 3 Adjust manifold pressure to obtain correct input rate a Turn gas valve ON OFF switch to OFF b Remove manifold pressure tap plug from gas valve See Fig 46 c Connect a water column manometer or similar device to manifold pressure tap d Turn gas valve ON OFF switch to ON e Manually close blower door switch 8 060 weibeig 614 lt NO SI Zf spuooes 10 spuooes 06 yeay 10 spuooes 08 10 06 OL 06 Bureau pL spuooes 2 yeay spuooes EL y aay Jaye 5 031002 njsseoonsun Jaye 4n290 3noxoop uoniu6 ZL g pesn jou si Sd 1 USM fuojoe4 L 4 jou s Aiosseooy 1e1depy Aauwiyo SSAg ue
92. isassembly mark blower motor and blower housing so motor and each arm is positioned at the same location during reassembly a Disconnect capacitor wires and ground wire attached to blower housing b Remove screws securing cutoff plate and remove cutoff plate from housing c Loosen set screw holding blower wheel on motor shaft 160 20 in Ib when reassembling d Remove bolts holding motor to blower housing and slide motor out of wheel 40 20 in Ib when reassembling e Remove blower wheel from housing f Clean wheel and housing 12 Reassemble motor and blower by reversing steps 11f through finishing with 11 Be sure to reattach ground wire to the blower housing 13 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 16 Reinstall blower assembly in furnace Reinstall control box assembly in furnace A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may shorten heat exchanger life Heating fan speed s MUST be adjusted to provide proper air temperature rise as specified on the rating plate Recom mended operation is at the midpoint of the rise range or slightly above Refer to SET TEMPERATURE RISE under START UP ADJUSTMENT and SAFETY CHECK NOTE Refer to Tabl
93. jnuiui g uey uedo jj q3N3dO3H HO 35010 LON HOLIMS 3HflSS3Hd Jour 11045 eJe OSI 0 spee 12euuoosIq spee Buum Atz repuooes uous 110 Y90949 NadO SI 3SN4 SDVLIOA 0 35 HONJS einsseJgd eqn ensseJd 10 YOOUD N3dO LON GIG HOLIMS SYNSS3Yd seb Ayea 10 uado yong SI UNL jim 526 jym po oJd si 4 TVNOIS ONAO d 3NV TH TVNEHONEY M 526 11045 JO 10 u09 uo se pasop xong 110 40049 181 G pue amod WNL 10104901 ONILV3H SVO YE 5 ees SInOU JOYE 19S9 O s dwaye y ul eurej avoid pue seb ejui payrey 5 5 10104901 NOILINOI EE ees 5 e J9ye 1959 IIM ouo sanu e uey uedo SI JI YOHMS JUBA JO noJ oJ eue yep eui JI 51000 1042071 10103901 LINDYID poued suedo M H 10 y 10 dn pejewod SI JI SPUO98S 06 10 suni uone1edo H3MOd
94. l shock personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 3 To Begin Component Self Test Remove blower access door Disconnect the thermostat R lead from furnace control board Manually close the blower door switch Short jumper the Com 24V terminal on control to the TEST TWIN 3 16 inch quick connect terminal on control until LED goes out approximately 2 sec Gas valve and humidifier will not be turned on See Fig 24 NOTE The furnace control allows all components except the gas valve to be run for short period of time This feature helps diagnose a system problem in case of a component failure Component test feature will not operate if any thermostat signal is present at the control Component test sequence is as follows Refer to service label attached to furnace or see Fig 49 a LED will display previous status code 4 times b Inducer motor starts and continues to run until Step f of component test sequence Hot surface igniter is energized for 15 sec then off a Blower motor operates on HEAT speed for 10 sec e Blower motor operates on COOL speed for 10 sec f Inducer motor stops g Reconnect R lead to furnace control board release blower door switch and re install blower door 4 Operate furnace per instruction on door
95. lace Cette fournaise peut tre install e sur un plancher combustible dans une alc ve ou dans un garde robe en respectant le minimum d espace libre des mat riaux combustibles tel Vent Clearance to combustibles qu indiqu sur le diagramme For Single Wall vents 6 inches 6 po Cette fournaise peut tre utilis e avec un For Type B 1 vent type 1 inch 1 po dne 2 D gagement de l vent avec combustibles conduit d vacuation de Type B 1 ou connect e Pour conduit d vacuation paroi simple 6 po 6 inches au conduit ommun d autres appareils gaz Pour conduit d vacuation de Type B 1 1 po 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS Installation on non combusibible floors only For Installation on combustible flooring only when installed on special base Part No KGASB0201ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC 18 inches front clearance required for alcove Indicates supply or retum sides when furnace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket and building joists studs or framing D GAGEMENT MINIMUM EN POUCES AVEC L MENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pour l installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp
96. le metal vent fuel oil residue No Remove metal vent No or liner Yes Mortar or tile debris Yes Yes Remove mortar and tile debris Clay tile misalignment missing sections gaps Consult Part B of chimney adapter venting instructions for application suitability Not Suitable No 15 chimney lined with properly sized listed liner or Type B vent Line chimney with property sized listed flexible metal liner or Type B vent per NFGC or NSCNGPIC Vent Condensate drainage at bottom of chimney Sizing Tables and liner or vent manufacturer s Installation instructions Install chimney adapter per instructions Not Suitable Consult Chimney s chimne exposed to to be dd to Chimney adapter venting Suitable outdoors below asingle instructions for roof line Yes application suitability furnace No Install chimney adapter per instructions Chimney is acceptable for use Fig 26 Chimney Inspection Chart ia 25 4 Set the thermostat heat anticipator or cycle rate to reduce short cycling Air for combustion must not be contaminated by halogen com pounds which include chlorides fluorides bromides and iodides These compounds are found in many common home products such as detergent paint glue aerosol spray bleach cleaning solvent salt and air freshener and can cause corrosion of fur
97. mi lar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING gt The furnace shall be connected to a listed factory built chimney or vent or a clay tile lined masonry or concrete chimney Venting into an unlined masonry chimney or concrete chimney is prohibited When an existing Category I furnace is removed or replaced the 22 original venting system may no longer be sized to properly vent the attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of condensate and combustion products and spillage of combustion products into the living space A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas Propane Installation Code and these instructions Deter mine that there is no blockage or res
98. n Air Method infiltration should be adequate to provide air for combustion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a continu ous sealed vapor barrier Openings are gasketed or sealed and b Doors and openable windows are weatherstripped and c Other openings are caulked or sealed These include joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines etc Combination of Indoor and Outdoor Air 1 Indoor openings shall comply with the Indoor Combustion Air Method below and 2 Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below b Outdoor opening size reduction Factor is 1 minus the Ratio in a above c Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor in b above The minimum dimension of air openings shall be not less than 3
99. n Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover TWINNING AND OR COMPONENT TEST TERMINAL BLOWER OFF DELAY J2 JUMPER BLOWER OFF DELAY HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX 24 V THERMOSTAT 5 2g TRANSFORMER 24 CONNECTIONS 3 AMP FUSE LED OPERATION amp 718 DIAGNOSTIC LIGHT 5 PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR 115 VAC L2 NEUTRAL CONNECTIONS AUT SPARE 2 SPARE 1 SPARE 2 PL2 HOT SURFACE IGNITER amp INDUCER MOTOR CONNECTOR 115 VAC L1 LINE BLOWER SPEED VOLTAGE CONNECTION SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02100 Fig 24 Furnace Control Electrical Box on Furnace Casing Side See Fig 23 9 Route field ground wire through holes in electrical box and casing and into furnace J Box 10 Reattach furnace J Box to furnace casing with screws re A WARNING moved in Step 4 FIRE OR ELECTRICAL SHOCK HAZARD 11 Secure field ground wire to J Box green ground screw Failure to follow this warning could result in personal injury 12 Complete electrical box wiring and installation Connect line death or property damage voltage leads as shown in Fig 25 Use best practices NEC in If field supplied manual disconnect switch is to be mounted U S and CSA C22 1 in Canada for wire bushings strain on furnace casing side select a location where a drill or relief etc fastener
100. naces and vents Avoid using such products in the combustion air supply Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting system due to corrosion Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with this furnace ADDITIONAL VENTING REQUIREMENTS A 4 round vent elbow is supplied with the furnace A 5 inch or 6 inch vent connector may be required for some model furnaces A field supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal increaser fitting is required when 5 inch or 6 inch vent connector is used See Fig 32 44 Venting Orientation for approved vent configurations NOTE Vent connector length for connector sizing starts at furnace vent elbow The 4 inch vent elbow is shipped for upflow configuration and may be rotated for other positions Remove the 3 screws that secure vent elbow to furnace rotate furnace vent elbow to position desired re install screws The factory supplied vent elbow does NOT count as part of the number of vent connector elbows The vent connector can exit the door through one of 5 locations on the door 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant
101. ockout occurs if the limit draft safeguard flame rollout or blocked vent switch if used is open longer than 3 minutes Control will auto reset after three hours Refer to 33 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED will flash code and then turn ON the inducer motor The inducer motor will run for the entire component test The hot surface ignitor blower motor fan speed on AMBER LED boards only blower motor heat speed and blower motor cool speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on 9 12 13 14 21 22 23 24 327596 101 REV 31 33 34 45 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes
102. or venting and termination included with the listed mechanical venter A04127 Fig 27 Using Tin Snips to Cut Tie Points 04128 Fig 28 Rounded End of Knockout A04129 Fig 29 Knockout Pulled Loose A04130 Fig 30 Hammer and Screwdriver Used for Knockout 27 A04131 Fig 31 Remove Knockout with Hammer START UP ADJUSTMENT AND SAFETY CHECK Step 1 General A WARNING FIRE HAZARD Failure to follow this warning could result in a fire and lead to property damage personal injury or death This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switches Correct inadequate combustion air supply problem and reset the switches A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 1 Maintain 115 v wiring and ground Improper polarity will result in rapid flashing LED and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the furance control Failure to make proper connections will result in improper operation S
103. ow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures Fig 36 Downflow Application Vent Elbow Left then Up 03207 SEE NOTES 1 2 3 4 5 7 8 9 on the page following hese fi these figures A03212 Fig 37 Downflow Application Vent Elbow Up then Right t SEE NOTES 1 2 4 7 8 9 on the page following these figures SEE NOTES 1 2 4 5 7 8 9 on the page A03213 following these figures Fig 38 Horizontal Left Application Vent Elbow Left A03215 Fig 40 Horizontal Left Application Vent Elbow Up if gt E EE SEE NOTES 1 2 4 5 7 8 9 on the page SEE NOTES 1 2 4 5 7 8 9 on the page 03214 following these figures A03216 following these figures Fig 39 Horizontal Left Application Fig 41 Horizontal Left Application Vent Elbow Right Vent Elbow Right then Up E N p IE Ml SEE NOTES 1 2 4 7 8 9 on the page A03218 following these figures i SEE NOTES 1 2
104. r Design Temperature Chimneys having internal areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces See footnote at bottom of Table B and 5 The authority having jurisdiction approves If all of these conditions cannot be met an alternative venting design shall be used such as the listed chimney adapter kit with these furnaces listed for use with the kit a listed chimney lining system or a Type B common vent Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and or re lining Refer to Fig 26 to perform a chimney inspection If the inspection of a previously used tile lined chimney a Shows signs of vent gas condensation the chimney should be relined in accordance with local codes and the authority having jurisdiction The chimney should be relined with a listed metal liner Type B vent or a listed chimney adapter kit shall be used to reduce condensation If a condensate drain is required by local code refer to the NFGC Section 10 9 for additional information on condensate drains b Indicates the chimney exceeds the maximum permissible size in the tables the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt
105. re move blower access door e To change motor speed selection for heating remove blower motor lead from control HEAT terminal See Fig 24 Select desired blower motor speed lead from one of the other terminals and relocate it to the HEAT terminal See Table 9 for lead color identification Reconnect original lead to SPARE terminal f Repeat steps a through e 10 d A FROM UNIT 24 V CONTROL TERMINALS _ 0 5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING EXAMPLE 5 0 AMPS ON AMMETER g When correct input rate and temperature rise is achieved 10 TURNS AROUND JAWS turn gas valve ON OFF switch to OFF h Remove manometer or similar device from gas valve 96316 Fig 48 Amp Draw Check With Ammeter i Reinstall manifold pressure tap plug in gas valve A WARNING furnace control board See Fig 24 FIRE HAZARD Leaking gas could be ignited and cause fire explosion personal injury property damage or death Reinstall manifold pressure tap plug in gas valve to prevent gas leak j Reinstall blower access door if removed k Turn gas valve ON OFF switch to ON 8 To change the blower off delay setting move the jumper from one set of pins on the control to the pins used for the selected blower off delay Factory off delay setting is 120 sec Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow See Table 5 Air Delivery CFM With Filter See Table 9 for l
106. ream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position A02054 Fig 6 Prohibit Installation on Back AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with US installations Section 8 3 of the NFGC Air for Combus tion and Ventilation and applicable provisions of the local building codes Canadian installations Part 7 of the NSCNGPIC Venting Systems and Air Supply for Appliances and all authorities having jurisdiction A CAUTION FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation f
107. ring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced Proper instrumentation is required to service electrical controls The control in this furnace is equipped with a Status Code LED Light Emitting Diode to aid in installation servicing and troubleshooting It can be viewed through the sight glass in blower access door The furnace control LED is either ON continuously rapid flashing or a code composed of 2 digits The first digit is the number of short flashes the second digit is the number of long flashes For an explanation of status codes refer to service label located on blower access door or Fig 49 and the troubleshooting guide which can be obtained from your distributor The furnace control will store 1 status code for 72 hours See Fig 53 a brief Troubleshooting Guide 36 For Controls With a Red LED The stored status codes WILL be erased from the control memory if 115 24 v power is interrupted 1 To retrieve the status code proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 power to furnace turned on Remove outer access door Look into blower access door sight glass for current LED status DO NOT remove blower access door or terminate 115 v pow
108. s a 15 second prepurge period 44 b Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second igniter warm up period Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens The gas valve GV permits gas flow to the burners where it is ignited by the HSI Five seconds after the GVR closes a 2 second flame proving period begins The HSI igniter will remain energized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ignition Lockout Lockout will be reset auto matically after three hours by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W G etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the
109. s are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s is used without a bottom return air linlet Not all horizontal furnaces are approved for side return air connections See Fig 20 FILTER ARRANGEMENT A WARNING FIRE CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in fire personal injury or death Never operate a furnace without a filter or with filter access door removed There are no provisions for an internal filter rack in these furnaces A field supplied accessory external filter rack is required This furnace requires KGAFRO301ALL 1 external filter rack or a suitable field supplied substitute such as the Media Cabinet Refer to the instructions supplied with external filter rack for assembly and installation options AIR DUCTS General Requirements The duct system should be designed and sized according to accepted national standards
110. screws from pulling out use 2 8 x 34 in screws into the side and 2 8 x 4 in screws in the bottom of the furnace casing for each strap See Fig 15 and 16 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment screws are not in tension are loaded in shear for reliable support 11 Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Fig 2 and 17 For furnaces with 1 in clearance requirement on side set furnace on non combustible blocks bricks or angle iron For crawlspace installations if the furnace is not suspended from the floor joists the ground under neath furnace must be level and the furnace set on blocks or bricks Roll Out Protection Provide a minimum 17 3 4 X 22 piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 in to joists The sheet metal MUST extend underneath the furnace casing by 1 in with the door removed The bottom closure panel on furnaces of widths 17 1 2 in and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 17 for proper orientation of roll out shield Bottom Return Air Inlet These furnace
111. sheet metal screws located 180 apart NOTE An accessory flue extension KGAFE0112UPH is avail able to extend from the furnace elbow to outside the furnace casing If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 32 44 A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 3 Orient the door to determine the correct location of the door cutout to be removed 4 Use aviation type tin snips to remove the correct U shaped cut out in door NOTE If this furnace is equipped with knockouts in the door for the vent a number of techniques can be used to remove these knockouts as seen in Fig 27 through 31 The knockout in the bottom of the door is unique due to its flanging and is not easily removed by first cutting the two tie points at the edge of the door using aviation type tin snips See Fig 27 A sharp blow to the rounded end of the knockout See Fig 28 will separate more tie points and
112. sure For Gas Input Rate Continued Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 2 600 43 2 4 43 2 5 43 2 6 43 2 7 625 43 2 3 43 2 3 43 2 4 43 2 5 9001 to 650 43 2 1 43 2 2 43 2 2 43 2 3 o 10 000 675 48 3 6 48 3 8 43 2 1 43 2 1 2 700 48 3 4 48 3 5 48 3 6 48 3 7 725 49 3 7 49 3 8 48 3 4 48 3 5 Orifice numbers 43 are factory installed 9 327 2 Insert brush end of cable into the outlet opening of cell and slowly rotate with drill DO NOT force cable Gradually insert cable into upper pass of cell See Fig 5 16 52 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great A force Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of cell and proceed to clean 2 lower passes of cell in same manner as upper pass 5 Repeat foregoing procedures until each cell in furnace 1 has been cleaned 6 Using vacuum cleaner remove residue from eac
113. switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 25 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 33 C rise A WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in serious injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2002 and Canadian Elec trical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground A CAUTION FURNACE MAY NOT OPERATE Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw 115 V Wiring Verify that the voltage frequency and phase correspond to that specified on unit ra
114. tat the blower motor BLWM will operate on continuous blower speed same as HEAT speed Terminal EAC 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 seconds ignition and blower ON delay 25 seconds allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at HEAT speed When the thermostat calls for cooling the blower motor BLWM will operate at COOL speed When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous blower speed When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Heat Pump When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off times during demand defrost cycles When the R to W and Y or R to W and Y and G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge period and 45 the blower switch
115. ting of Space Heating Appliance in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY SQ IN 12 19 28 38 Local 99 Winter Design Temperature 17 to 26 degrees F VENT HEIGHT FT 6 0 55 99 141 M 8 52 74 111 154 10 NR 90 125 169 2 15 NR NR 167 212 20 NR NR 212 258 30 NR NR NR 362 Local 99 Winter Design Temperature 5 to 16 degrees F 6 NR 78 121 166 8 NR 94 135 182 10 NR 111 149 198 2 15 NR NR 193 247 20 NR 293 30 NR NR NR 377 Local 99 Winter Design Temperature 10 to 4 degrees F 6 NR NR 145 196 8 159 213 5 10 175 231 15 NR 283 T 20 NR NR NR 333 30 NR NR NR NR Local 99 Winter Design Temperature 11 degrees F or lower Not recommended for any vent 5 configuration 2 5 os The 99 Winter Design Dry Bulb db temperatures are found in the 1993 ASHRAE Fundamentals Handbook Chapter 24 Table 1 United States and 2 Canada or use the 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chap ter Table 1A United States and 2A Canada tioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the fur nace could cause the furnace and or vent to fail prematurely When a met
116. ting plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or Table 7 for equipment electrical specifications U S installations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2002 and any local codes or ordinances that might apply Canadian installations Make all electrical connections in accor dance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction A WARNING FIRE HAZARD Failure to follow this warning could result in serious injury death or property damage Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Use a separate fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 7 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace will NOT operate J BOX RELOCATION NOTE If factory location of J Box is acceptable go to next section Electrical Connection to J Box NOTE On 14 wide casing models the J Box shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing 1 Remove and save two screws
117. to conform to ANSI NFPA 211 or be lined with a UL listed ULC listed in Canada metal liner or UL listed Type B vent Relining with a listed metal liner or Type B vent is considered to be a vent in a chase If a metal liner or Type B vent is used to line a chimney no other appliance shall be vented into the annular space between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors amp AGA Table A Combined Appliance Maximum Input Rating in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT FT SQ IN 12 19 28 38 6 74 119 178 257 8 80 130 193 279 10 84 138 207 299 15 NR 152 233 334 20 NR NR 250 368 30 NR NR NR 404 APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable listings standards and codes The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Condi 24 Table B Minimum Alowable Input Ra
118. torily discharged Step 2 General Installation 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing to US Current edition of the NFGC and the NFPA 90B For recharge your body with static electricity for example DO copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 www NFPA org pus move or shuffle your feet do not touch ungrounded for only the NFGC contact the American Gas Association 400 objects etc N Capitol Street N W Washington DC 20001 4 If you touch ungrounded objects and recharge your body with www AGA org static electricity firmly touch a clean unpainted metal CANADA NSCNGPIC For a copy contact Standard Sales surface of the furnace again before touching control or wires CSA International 178 Rexdale Boulevard Etobicoke Tor 5 Use this procedure for installed and uninstalled ungrounded onto Ontario MOW 1R3 Canada furnaces Step 3 Combustion and Ventilation Air 6 Before removing a new control from its container discharge gt US Section 8 3 of the NFGC Air for Combustion and your body s electrostatic charge to ground to protect the Ventilation control from damage If the control is to be installed in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the furnace Put all used and new controls into containers before touching ungrounded
119. triction leakage corrosion and other deficiencies which could cause an unsafe condition As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Close fireplace dampers Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appli ance is operating continuously Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appli ance to their previous conditions of use Vent system or vent connectors may need to be resized Vent systems or vent connectors must be sized to
120. tructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify hazards which may result in minor personal injury or product and property damage NOTE is used to highlight sugges tions which will result in enhanced installation reliability or operation 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a location and position as specified in the Location section of
121. ts temperature rise readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Blower access door must be installed for proper tempera ture rise measurement NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in we 4 Dirty filter A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power before changing speed tap c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise D BURNER _ N N Fig 47 Orifice Hole A93059 THERMOSTAT SUBBASE Table 9 Speed Selection TERMINALS WITH THERMOSTAT REMOVED COLOR SPEED AS SHIPPED ANITICIPATOR CLOCK ETC White Common BLW MUST BE OUT OF CIRCUIT Black High COOL Yellowt Med High SPARE ONE Blue Med Low SPARE Red Low HEAT 1 5 HP motor models BLUE to HEAT RED to SPARE T Not available on 1 5 HP motors NOTE Continuous blower is the HEAT speed d Turn thermostat down below room temperature and
122. umidifier or other accesso ries All accessories MUST be connected external to furnace casing Connect supply air duct to supply air outlet on furnace Bend flange inward past 90 with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASBO201ALL or factory ap 13 UPFLOW DOWNFLOW HORIZONTAL PREFERRED PREFERRED PREFERRED PREFERRED EY PREFERRED MIN PERMITTED PERMITTED PERMITTED A02329 Fig 14 Duct Flanges 14 THREADED ROD 4 REQ OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 x 3 4 SCREWS TYPICAL FOR 2 SUPPORTS 8 MIN FOR DOOR REMOVAL 1 SQUARE 11 4 11 4 1 8 ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD A05027 Fig 15 Horizontal Unit Suspension Return Air Connections horizontal furnaces Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace Upflow and Horizontal Furnaces WARNING The return air duct must be connected to bottom sides left or FIRE HAZARD right or a combination of bottom and side s of main furnace Failure to follow this warning could cause a fire personal casing as shown in Fig
123. ures NOTE Media cabinet or 1 Filter Rack are accessories and are For continuing high performance and to minimize possible equip not included from the factory with the standard furnace model ment failure periodic maintenance must be performed on this 1 equipment Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract Turn off electrical supply to furnace before removing filter access door 2 Remove filter cabinet door 3 Slide filter out of cabinet A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or product damage Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating 5 instructions on the label attached to the furnace 4 If equipped with permanent washable 1 inch filter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended See Table 11 for size information If equipped with factory specified disposable media filter replace only with media filter having the same part number and size For expandable replacement media refer to the instructions included with the replacement media If equipped with KGAFRO301ALL external filter rack See Table 11 6 Slide filter into cabinet A WARNING CARBON MONOXIDE POISONING AND FIRE H
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125. vent elbow 21 22 Reinstall casing door Turn on gas supply and cycle furnace through one complete heating and cooling cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70 F turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service agency NOTE If the heat exchangers get a heavy accumulation of soot and carbon they should be replaced rather than trying to clean them thoroughly A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem TABLE 13 Orifice Size and Manifold Pressure For Gas Input Rate Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS RANGE HEAT VALUE ___9 60 ___062 _ 064 FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Mani
126. y air duct to flange on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected external to furnace main casing NOTE For horizontal applications the top most flange may be 12 bent past 90 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed MP CNN FLOOR OPENING FURNACE OR COIL CASING WHEN USED VALLES A PLENUM COMBUSTIBLE FLOORING B D FLOOR we zug DOWNFLOW OPENING SHEET METAL PLENUM A96283 Fig 11 Floor and Plenum Opening Dimensions A96285 Fig 12 Furnace Plenum and Subbase Installed on a Combustible Floor CN 5 FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM a OPENING A04140 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor Downflow Furnaces proved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct h

Series 120 - HVACpartners

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