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warning - Classic Air Conditioning

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2. SEE NOTES 1 2 4 7 8 9 on the page following these figures A03213 Fig 39 Horizontal Left Application Vent Elbow Left all SEE NOTES 1 2 4 5 7 8 9 on the page following these figures 03214 Fig 40 Horizontal Left Application Vent Elbow Right then Up MUUTT SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03215 Fig 41 Horizontal Left Application Vent Elbow Up 5 EE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 42 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03218 Fig 43 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219 Fig 44 Horizontal Right Application Vent Elbow Left then Up SEE NOTES 1 2 4 5 7 8 9 02068 Fig 45 Horizontal Right Application Vent Elbow Left 1 For common vent vent connector sizing and vent material United St
3. E BOTTOM INLET 24 CASING 610mm NOTES MA 2 7 16 AIRFLOW 33mm 19 13 16 13 16 483 21mm 21mm ig OUTLET 122mm 1 2 DIA K O THERMOSTAT WIRE ENTRY 13mm 9 11 16 7 3 4 Aa 1 3 4 DIA RIGHT HAND 17mm 197mm 244mm GAS ENTRY 44mm ig 11 1 2 292mm 7 8 DIA K O WIRE ENTRY ALTERNATE 22mm JUNCTION BOX v LOCATIONS TYP VENT OUTLET h 5 PLACES i 14 7 8 378 7 8 DIA ACCESSORY 22 i 5 1 2 140mm 11 16 3 3 4 1 1 2 38mm 1 4 4 17mm 95mm 560mm 32mm 22 1 16 Ar SIDE INLET 25mm A04037 1 Two additional 7 8 in 22 mm diameter holes are located in the top plate 2 Minimum return air openings at 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 406 mm round or 14 1 2 x 12 in 368 x 305 mm rectangle b For 1200 CFM 20 in 508 mm round or 14 1 2 x 19 1 2 in 368 x 495 mm rectangle c For 1600 CFM 22 in 559 mm round 14 1 2 x 22 1 16 in 368 x 560mm 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 r
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5. 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 2006 NFPA 54 2006 9 3 2 2 1 For other than fan assisted appliances such as a draft hood equipped water heater Volume 2113 other ACH 11000 Btu hr A04002 2 For fan assisted appliances such as this furnace Volume _ 151 tn _ Fan ACH 11000 Btu hr A04003 If CIRCULATING AIR DUCTS es VENT THROUGH ROOF 12 MAX 305mm 1 SA IN PER 1000 BTUH IN DOOR ORWALL UNCONFINED INTERIOR SPACE HEATED SPACE 6 MIN 152mm FRONT U 1 SA IN PER 1000 BTUH IN DOOR ORWALL OPENINGS SHALL BE AT LEASTS IN CLEARANCE IN FRONT OF COMBUSTION AIR L 12 MAX 305mm CIRCULATING AIR DUCTS Minimum opening size is 100 sq in 64516 sq mm with minimum dimensions of 3 in 76 mm t Minimum of 3 in 76 mm when type B1 vent is used A03175 Fig 8 Air for Combu
6. TWINNING AND OR BLOWER OFF DELAY COMPONENT TEST TERMINAL J2 JUMPER BLOWER OFF DELAY c n HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX 24 V THERMOSTAT TERMINALS TRANSFORMER 24 VAC CONNECTIONS 3 FUSE LED OPERATION amp DIAGNOSTIC LIGHT PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR 115 VAC L2 NEUTRAL CONNECTIONS 115 VAC L1 LINE PL2 HOT SURFACE VOLTAGE CONNECTION IGNITER amp INDUCER BLOWER SPEED MOTOR CONNECTOR SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02100 Fig 25 Furnace Control FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE w 0 TERMINALS FIELD SUPPLIED THREE WIRE DISCONNECT HEATING ONLY e e e ere BLOWER DOOR SWITCH N e4 e 460 V e THREE WA UA PHASE LI le t 8 PE ee eee ae N e e 4e 208 230 V t GND T T lon SINGLE R I GHE E Eri ae 7 PHASE 115 V FIELD AUXILIARY pec basen G SUPPLIED _ J BOX L oH GND DISCONNECT CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as sh
7. 14 Table 5 Air Delivery CFM with Filter FURNACE RETURN AIR SPEED EXTERNAL STATIC PRESSURE IN WC SIZE INLET 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 High 1085 1035 975 915 845 770 675 565 390 195 045 08 Bottom or 2 024045 Side s Med High 920 875 830 770 710 640 555 440 250 Med Low 820 775 730 680 620 555 470 360 190 High 1440 1375 1305 1240 1160 1070 975 870 730 560 pd Med High 1360 1300 1240 1175 1115 1040 950 850 725 575 ide s Med Low 1250 1210 1160 1100 1040 965 885 790 670 520 High 1030 1010 980 945 900 845 775 680 490 335 pud Med High 835 815 790 760 720 675 610 490 375 265 ide s Med Low 725 700 675 645 600 555 475 390 300 nexum DM High 1425 1375 1820 1265 1200 1125 1035 940 830 655 036070 S di 3 Med High 1320 1280 1240 1205 1140 1075 995 905 790 620 ide s Med Low 1200 1175 1145 1105 1050 990 920 840 725 555 mox E High 1805 1740 1670 1600 1530 1445 1360 1280 1180 1075 048070 i d Med High 1630 1585 1530 1470 1405 1330 1255 1170 1080 990 ide s Med Low 1460 1420 1385 1325 1280 1220 1155 1080 995 910 So FUN High 1650 1600 1535 1465 1385 1285 1175 1055 895 645 342090 i ae i Med High 1515 1485 1440 1380 1300
8. delay type is recommended t Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Fig 26 Use best practices NEC in U S and CSA C22 1 in Canada for wire bush ings strain relief etc 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 requirements listed in Table 7 Refer to power cord manufacturer s listings 1 2 Remove cover from J Box Route listed power cord through 7 8 in 22 mm diameter hole in J Box Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used Secure field ground wire to green ground screw on J Box bracket 23 5 Connect line voltage leads as shown in Fig 26 6 Reinstall cover to J Box Do not pinch wires between cover and bracket BX CABLE INSTALLATION IN FURNACE J BOX 1 2 Remove cover from J Box Route BX cable into 7 8 inch 22 mm diameter hole in J Box Secure BX cable to J Box bracket with connectors ap proved for the type of cable used Secure field ground wire to green ground screw on J Box bracket Connect line voltage leads as shown in Fig 26 Reinstall cover to J Box Do not pinch wires between cover and bracket
9. tre utilis e avec un For Type 1 vent type This furnace is approved for UPFLOW DOWNFLOW and TS TOP PLENUM Vent Clearance to combustibles For Single Wall vents 6 inches 6 po COMBUSTIBLES Cette fournaise est approuv e pour installation HORIZONTALE et la circulation d air VERS LE HAUT et VERS LE BAS T Les fl ches de d gagement eam ne change pas avec l orientation de la fournaise 3 5 s D gagement po 1 inch 1 D gagement de l vent avec combustibles Pour conduit d vacuation paroi simple 6 po 6 inches Pour conduit d vacuation de Type B 1 1 po 1 inch Clearance in inches MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS T Installation on non combustible floors only For Installation on combustible flooring only when installed on special base Part No KGASB0201ALL or NAHA01101SB Coil Assembly Part No CAR CAP CNPV WENC or WTNC 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 DEGAGEMENT MINIMUM EN POUCES AVEC ELEMENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pour l installation sur plancher non combustible seulement
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12. 5 16 8mm 5 16 44mm 1 3 4 44mm 1 LN A89014 Fig 10 Leveling Legs Leveling Legs If Desired To install leveling legs 1 5 Position furnace on its back Locate and drill a hole in each bottom corner of furnace See Fig 10 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired Install another nut on other side of furnace base Install flat washer if desired Adjust outside nut to provide desired height and tighten inside nut to secure arrangement Reinstall bottom closure panel if removed DOWNELOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used 11 Special Base KGASB Cased Coil Assembly Part No CNPV CNRV CAR or CAP Coil Box Part No KCAKC Determine application being installed from Table 4 Construct hole in floor per Table 4 and Fig 11 Construct plenum to dimensions specified in Table 4 and Fig 11 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part No CNPV CNRV CAR or CAP or Coil Box Part No KCAKC is used install as shown in Fig 13 PLENUM OPENING D FLOOR OPENING A96283 Fig 11 Floor and Plenum Opening Dimensions NOTE It is recommended that the perforated supply air duct flanges be com
13. CONDITIONED AIR IS AND CONDITIONED AIR IS DISCHARGED DOWNWARD DISCHARGED TO THE RIGHT A02097 Fig 4 Multipoise Orientations 5 Use this procedure for installed and uninstalled ungroun notbe installed directly on any combustible material ded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to pro other than wood flooring refer to SAFETY CONSIDERATIONS be located as close to the chimney or vent and attached tect the control from damage If the control is to be in stalled in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the fur nace Put all used and new controls into containers before touching ungrounded objects to an air distribution system Refer to Air Ducts section e be provided ample space for servicing and cleaning Always comply with minimum fire protection clear ances shown on the furnace clearance to combustible label The following types of furnace installations may re quire OUTDOOR AIR for combustion due to chemical exposures 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage bd LOCATION 4 WARNING Buildings with indoor pools CARBON MONOXIDE POISONING AND UNIT DAMAGE HAZARD Commercial buildings Laundry rooms e Hobby or craft rooms and Failure to follow this warning could result in pers
14. Horizontal Left 40 132 000 5 127 7 65 Horizontal Left ee ee 154 000 5 127 7 65 Vent elbow up then 110 000 Downflow left Fig 34 036 12 only 5 127 10 3 0 Vent elbow up then 110 000 Downflow right Fig 37 036 12 only 5 127 10 3 0 4 in 102 mm inside casing or vent guard ncluding 4 in 102 mm vent section s NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 8 Secure vent connector to furnace elbow with 2 corrosion res istant sheet metal screws spaced approximately 180 apart 4 WARNING FIRE HAZARD Failure to follow this warning could result in injury death 9 Secure all other single wall vent connector joints with 3 corro sion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s re commendations and or property damage 10 The total height of the vent and connector shall be at least seven ft 2 1 M for the 154 000 Btuh gas input rate model when in stalled in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing point ing upward See Fig 36 Step 3 Adjustments 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 Table 8 Altitude Derate Multipl
15. Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale pi ce n KGASBO201ALL ou NAHA01101SB l ensemble serpentin pi ce n CAR CAP CNPV CNRV WENC ou WTNC ou le carter de serpentin COR Dans une alc ve on doit maintenir un d gagement l avant de 18 po 450mm overheat conditions that can result from inadequate La poistion indiqu e conceme le c t d entr e ou de retour quand la foumaise est dans la combustion air supply or blocked vent conditions position horizontale ji 1 Do not bypass limit switches Le contact n est permis qu entre les lignes form es par les intersections du dessus et des 2 If a limit opens call a quallified serviceman to correct deux c t s de la cherrise de la foumaise et les solives montant sous cadre de charpente the condition and reset limit switch JN 335137 101 REV A Fig 2 Clearances to Combustibles TAST FRONT o VERSER RETURN AIR Fig 3 Return Air Temperature For accessory installation details instruction literature refer to the MAX80 F 27 C MIN60 F 16 C applicable 08471 NOTE Remove all shipping brackets and materials before operating the furnace CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must
16. tre install conform ment aux instructions du fabricant et aux codes locaux En intitul e National Fuel Gas Code ou les code d installation CSAB149 1 combustion and ventilation air See manufacturer s installation information provided with this appliance Ce foumaise air chaud doit tre install de mani re ce qurilyait ait suffisamment d air de ventilation et combustion Consulter les instructions d installation du fabricant foumies avec cet appareil OPERATION INSTALLATION manufacturer s instructions and local codes In the absence 2223 1 or CSA B 149 1 Gas Installation Code l absence de ces demiers la norme ANSI Z223 1 NFPA54 2 This fumace must be installed so there are provisions for pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000 pi le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel install e dans un b timent construit sur place un plancher combustible dans une alc ve ou dans un garde robe en respectant le minimum di qu indiqu sur le diagramme conduit d vacuation de Type B 1 ou connect e au conduit ommun d autres appareils gaz Cette foumaise air puls est quip e Utiliser une trousse de conversion fournie par Cette fournaise est pr vue pour tre Cette fournaise peut tre install e sur espace libre des mat riaux combustibles tel Cette fournaise peut
17. 000 ft 610 M to 4 500 ft 1372 M 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 34 EXAMPLE 1 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT X Derate Multiplier Furnace Input Furnace Input Rate at Sea Level Factor Rate at Installa tion Altitude 88 000 X 0 90 E 79 200 2 Determine the correct orifice and manifold pressure adjust ment There are two different orifice and manifold adjust ment 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 alti tude 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 orifi
18. 036070 14 3 16 360 12 9 16 319 12 11 16 322 9 5 16 237 4 102 115 52 070 16 048070 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 126 57 090 14 042090 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 127 58 090 16 048090 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 140 64 090 20 060090 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 146 66 110 12 036110 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 135 61 110 16 048110 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 146 66 110 22 066110 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 152 69 135 16 048135 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 149 68 135 22 066135 24 1 2 622 22 7 8 581 23 584 15 1 16 383 4 102 163 74 155 20 060155 24 1 2 622 22 7 8 581 23 584 15 1 16 383 4 102 170 77 5 in or 6 in 127 or 152 mm vent connector may be required in some cases Improper adjustment alteration service maintenance or installation can cause serious injury or death Read and follow instructions and precautions in User s Information Manual provided with this by a qualified service agency or the gas supplier furnace Installation and service must be performed b Une r glage une modification un reparation un des blessures graves ou la mort dans la notice d
19. 1345 1225 A filter is required for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained in factory authorized ac cessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions UPFLOW Fig 14 Duct Flanges 16 HORIZONTAL DOWNFLOW KC UN MEG YES YES YES NOT NOT RECOMMENDED RECOMMENDED YES YES NOT RECOMMENDED A02329 1 emm THREADED ROD 4 REQ OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 8 x 4 19mm SCREWS TYPICAL FOR 2 SUPPORTS 8 203mm MIN FOR DOOR REMOVAL 1 25mm SQUARE 1 1 4 x1 1 4 x1 8 32x32x3mm ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD 05027 Fig 15 Horizontal Unit Suspension 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS AIR OPENING OUTER DOOR ASSEMBLY X USE 2 8 x 3 4 SHEET METAL SCREWS TYPICAL FOR ALL STRAPS BACK OF FURNACE FOLD ALL STRAPS UNDER FURNACE AND SECURE W 2 8 x 3 4 SHEET METAL SCREWS AIR OPENING 02014 Fig 16 Horizontal Suspension with Straps 17 LINE CONTACT ONLY PERMISSIBLE BETWEE
20. 1590 Bottom Only Med High 2230 2205 2165 2110 2035 1950 1855 1740 1615 1485 Med Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340 110 22 Bottom Sides High 2415 2350 2250 2145 2015 1875 1715 1560 066110 or 1 Side amp Bot Med High 2235 220 2155 2100 2040 1955 1850 1740 1595 1470 tom Med Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340 High 2540 2495 2430 2355 2265 2175 2065 1935 1785 1650 1Side Only Med High 2125 2120 2105 2060 2010 1940 1840 1730 1615 1485 Med Low 1795 1790 1765 1720 1650 1585 1500 1390 1280 A filter is required for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained in factory authorized ac cessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions 15 Table 5 Air Delivery with Filter Continued FURNACE RETURN AIR EXTERNAL STATIC PRESSURE IN WC SIZE INLET SPEED 0 1 02 03 05 06 07 08 09 10 EE High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835 048135 Me Med High 1790 1755 1705 1640 1550 1465 1360 1210 945 785 Med Low 1545 1525 1500 1450 1880 1315 1215 1005 855 670 High 2485 24
21. 3 827 0 m 6 300 8 400 10 500 6 600 9 900 13 200 16 500 19 800 23 100 178 3 237 8 297 3 186 8 280 3 873 7 467 2 560 6 654 1 0 00 Not Permitted 1SQIN PER 4000 2a BTUH OUTDOORS A iA 1 i 1 1 yi 305mm 12 12 a05mm 1SQIN VENT PER 2000 B amp 5 THROUGH FE i BTUH _ 45 ROOF 5 1SQIN oa PER o lt 4000 BTUH o 8 DUCTS E TO 258 a OUTDOORS gt gt 5 Loge 1SQIN w2P lt R Saoge 4000 BTUH _ lt 8 1SQIN lt PER 2000 EL BTUH o 12 305mm 12 MAX c 805mm A 12 305mm CIRCULATING AIR DUCTS DUCT 1SQIN TO PER 4000 OUTDOORS BTUH Minimum dimensions of 3 in 76 mm NOTE Use any of the following combinations of openings A amp BC amp DD amp EF 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 cu ft 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 be
22. RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS RETURN AIR SUPPLY AIR E SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS al NOTE RESTRICTION SAME FOR RETURN HORIZONAL LEFT AIR FLOW MODELS 066 060 22 AND 20 MODELS ALL OTHER MODELS HORIZONAL RETURN AIR RESTRICTIONS RETURN AIR CONNECTION 1 ONLY YES HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS A02163 RETURN AIR RETURN AIR RETURN AIR CONNECTION2 CONNECTION 3 COMBINATIONS ONLY ONLY OF 1 2 AND 3 02162 Fig 20 Horizontal Return Air Configurations and Restrictions Upflow and Horizontal Furnaces Connect supply air duct to flanges 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 to duct external to furnace main casing NOTE For horizontal applications the top most flange may be bent past 90 to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed Downflow Furnaces Connect supply air duct to supp
23. TONINO 82d IN3AdInO3 18945 e euunj paj euuoo M SIU 93119905 Q3TIVISNI 0138 uonounf e euunj eui pue uas 12euuoosip y eJiw Jaddoo juo 2 14844 DI Vg 11930 3504 end 2801 20 pared aun osn si m quawdinbe jo Aue J 1 e G3TIVISNI AHOIOV3 3dAL 3ALLOWOIR V INV 3503 Lnd E ET AS TD ee NOINIWWOO NOILO3NNOO 33NY319 OINOHIO313 SE ALON XVIN dY O L SLL NOUO3NNOO YINVITO 2INOHIOT3 L ov3 Ltd 99 NOIO3NNOO ISH VA Ave O N 154 1353 HOLIMS Qa V9 3395 HV ssa eld Qo SOLUANNOG UNOD z aid 53 N LL SOIO3NNOO 82d LINDYIO LE NOlIOVdvo dva 3 TONINOO 899 O N 154 19599 1 HOLMS HOLNHS INIA Q332018 sai o HOLMS 38nivi3diat YOLIOWdVO LIIdS LNINVINYAd YOLOW 3 MOT8 QVOTH3AO YOLOW TVN H3INI 14548 1 O N 1SdS HOIOIW yana 3 01545 13S38 O1n V HOIIMS LIWA 27151 1085 WWT 03395 9OLOW 33MO 18 W10 1H8 1 a 54 lt 4 ALON a g o A9 NI
24. careful when discon necting wires from switches because damage may occur Draft safeguard switch Inducer motor Pressure switch es Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode wm oan Flame rollout switches i Remove NOx baffles on low NOx models 6 Remove screws that fasten the collector box assembly to the cell panel Be careful not to damage the collector box Inducer assembly and elbow need not be removed from collector box 7 Disconnect gas line from gas manifold 8 Remove the 5 screws that attach the burner assembly to the 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 51 and 52 for correct igniter location 9 Using field provided 25 caliber rifle cleaning brush 36 in 914 mm long 1 4 in 6 mm 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
25. elbow Reinstall casing door Turn on gas supply and cycle furnace through one com plete heating and cooling cycle Verify the furnace temper ature rise as shown in Adjustments Section Adjust tem perature rise as shown in Adjustments Section If outdoor temperature is below 70 F 21 C 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 heavy 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 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
26. ft m Pressure No Pressure No Pressure U S A 2001 611 to 3000 914 Canada 2001 611 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A08484 41 Table 12 Orifice size and Manifold Pressure In wc for Gas Input Rate Continued Tabulated data based on 22 000 Btuh per burner derated 4 percent for each 1000 ft 305 M above sea level ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS Manifold Orifice Manifold Orifice Manifold Orifice Manifold ft m Pressure No Pressure No Pressure No Pressure 2134 to 8000 2438 8001 2439 Orifice numbers shown in BOLD are factory installed A08484a 42 Table 13 Orifice Size and Manifold Pressure In wc for Gas Input Rate Tabulated data based on 22 000 Btuh High Heat 14 5000 BTUH Low Heat per burner derated 4 percent for each 1000 ft 305 M above sea level ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m U S A and Canada U S A 2001 611 to 3000 914 Canada 2001 611 U S A and Canada 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133
27. in b above The min imum dimension of air openings shall be not less than 3 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 BOTTOM CLOSURE BOTTOM FILLER PANEL PANEL A02098 Fig 9 Removing Bottom Closure Panel 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 NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration 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 8 x 38 mm 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
28. less than 1 4 in 6 mm per linear ft 21 mm m from the furnace to the vent and shall be rigidly supported every 5 ft 1 5 M 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 12 4 3 1 of the NFPA 54 ANSI Z223 1 2006 any listed mechanical venter may be used when approved by the authority having jurisdiction In Canada Per section 8 24 2 of the CAN CSA B149 1 05 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 requirements for venting and termination included with the listed mechanical venter 30 Fig 30 Knockout Pulled Loose A04129 A04130 Fig 31 Hammer and Screwdriver Used for Knockout Fig 32 Remove Knockout with Hammer A04131 START UP ADJUSTMENT AND SAFETY CHECK Step 1 General 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 c
29. of spring cable end opposite brush 2 Insert brush end of cable into the outlet opening of cell and slowly rotate with drill DO NOT force cable Gradually insert cable into upper pass of cell See Fig 53 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 9 32 m 7 1 mm 5 16 7 9 mm 05025 Fig 51 Igniter Position Side View A05026 Fig 52 Igniter Position Top View A01050 Fig 53 Cleaning Heat Exchanger Cell 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 has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor with fine steel wool 9 Install NOx baffles if removed 10 Reinstall burner assembly Center burners in cell openings 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 hydroc
30. to follow this caution may result in unit component damage Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft 1 8 M of furnace A 1 8 in 3 mm NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve NOTE The furnace 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 47 20 TOP VIEW OF BURNER MANIFOLD ASSEMBLY 90 Elbow ur o o U To Gas T 5 Supply 2 51mm Nipple 1 Street Elbow Gas Valve 08551 Fig 21 Burner and Manifold Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21 Install a sediment trap in riser leading to furnace as shown in Fig 22 Connect a capped nipple 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 3 mm NPT plugge
31. type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 M 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
32. venting instructions for application suitability Not Suitable Is chimney i i Line chimney with property with properly sized listed flexible metal sized listed liner or liner or Type B vent per Type B vent NFGC or NSCNGPIC Vent Sizing Tables and liner or pr MEL vent manufacturer s Installation instructions Condensate drainage at bottom of chimney Not Suitable Consult Chimney Part C of s chimney an vo exposed to to be dedicated to outdoors below a single instructions for roof line furnace application suitability Install chimney adapter per instructions Chimney is acceptable for use A03206 Fig 27 Chimney Inspection Chart 27 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 Conditioning Contractor
33. 0 base required 284 483 841 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or Coil Assembly or KCAKC coil box E ud i 163 Mene au KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 16 21 5 8 16 5 8 22 1 4 ing KGASB subbase not required 406 549 422 565 Downflow Applications on Noncombustible Flooring KGASB 15 7 8 19 16 1 2 19 5 8 17 42 subbase not required 403 483 419 498 445 Downflow applications on combustible flooring KGASB sub 15 1 8 19 16 3 4 20 5 8 base required 384 483 425 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or Coil Assembly or KCAKC coil box ee 19 16 1 2 20 i 394 483 419 508 KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 19 1 2 21 5 8 20 1 8 22 1 4 ing KGASB subbase not required 495 549 511 565 Downflow Applications on Noncombustible Flooring KGASB 19 3 8 19 20 19 5 8 21 subbase not required 492 483 508 498 533 Downflow applications on combustible flooring KGASB sub 18 5 8 19 20 1 4 20 5 8 base required 473 483 514 600 Downflow Applications on Combustible Flooring with CNPV 19 19 20 20 CNRV CAR or CAP Coil Assembly or KCAKC coil box 483 483 508 508 KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 23 21 1 8 23 5 8 22 1 4 ing KGASB subba
34. 00 2310 2215 2110 2000 1880 1725 1535 1355 Bottom Only Med High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255 Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Bottom Sides High 79385 2305 2195 2085 1960 1825 1670 1465 066135 oriSide amp Bot Med High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325 tom Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 High 3245 2155 2055 1940 1825 1605 1555 1385 iSideOnly 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 2875 2305 2230 2110 2000 1865 1725 1545 Bottom Only Med High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 Med Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 Ea High 79375 2285 2200 2105 1995 1870 1730 1570 155 9095011 Med High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400 Med Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 High 2260 2180 2085 1975 1865 1740 1605 1455 iSide Only Med High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325 Med Low 1800 1790 1770 1735 1695 1640 1570 1465
35. 1220 1115 990 830 600 ide s Med Low 1385 1360 1320 1260 1195 1120 1025 915 710 565 mom High 2060 1985 1915 1820 1720 1610 1490 1340 1185 925 Eyed Eds Med High 1790 1765 1715 1645 1560 1470 1345 1195 1010 820 Med Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740 High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350 Bottom Only Med High 2225 2155 2080 1995 1895 1785 1675 1565 1420 1260 Med Low 2020 1955 1880 1805 1730 1630 1535 1420 1275 1135 High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505 Med High 2285 2215 2150 2075 1985 1890 1780 1660 1525 1360 Med Low 1995 1945 1900 1840 1770 1685 1600 1480 1350 1180 High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425 1Side Only Med High 2260 2190 2110 2035 1940 1845 1735 1620 1475 1325 Med Low 1950 1910 1855 1795 1730 1650 1555 1445 1310 1150 090 20 Both Sides or 1 060090 Side amp Bottom High 1625 1575 1515 1445 1355 1260 1165 990 785 d Med High 1510 1470 1415 1355 1285 1185 1070 890 725 ide s Med Low 1360 1335 1295 1250 1180 1100 985 810 mu m High 2035 1965 1880 1790 1680 1495 1365 1215 1075 875 x oomo Med High 1745 1710 1650 1560 1450 1340 1205 1090 955 750 048110 Side s Med Low 1530 1515 1470 1400 1310 1215 1095 990 830 670 2530 2470 2400 2320 2220 2115 2000 1865 1730
36. 310 SINGLE STAGE DELUXE INDUCED COMBUSTION 4 WAY MULTIPOISE GAS FURNACE Installation Start up Operating and Service and Maintenance Instructions Series 130 D SAFETY CONSIDERATIONS 2 ERE INTRODUCTION sssesese Ie 3 CERTIFIED CODES AND STANDARDS 4 ama Safety Arm 4 General Installation 5 ISO 9001 2000 Combustion and Ventilation Air 5 DuctSystems cece cee ter RR EH 5 uidi Acoustical Lining and Fibrous Glass Duct 5 Gas Piping and Gas Pipe Pressure Testing 5 REGISTERED Electrical Connections cee eee eee 5 VENI Me ne Re eRe Hote 5 LOCATION pee ped bee tid Cus 6 AIR FOR COMBUSTION AND VENTILATION 8 INSTALLATION 11 Read the entire instruction manual before starting the installation Bottom Return Air Inlet H Portions of the text and tables are reprinted from 54 ANSI side Return Aur Inlet eR RE 11 Z223 1 2006 with permission of Nation Fire Protection Leveling Legs If Desired 11 Pi p od uices Bottom Return Air Inlet 12 complete and official position of the NFPA or ANSI on the Suspended Furnace Support 12 referenced subject which is re
37. 4 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Proper vent sizing Defective inducer motor Low inducer voltage 115VAC Defective pressure switch Inadequate combustion air supply Disconnected or obstructed pressure tubing Low inlet gas pressure if LGPS used Restricted vent If it opens during blower on delay period blower will come on for the selected blower off delay LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame rollout or blocked vent switch if used is open Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rollout switch and BVSS require manual reset Check for Restricted vent Proper vent sizing Loose blower wheel Excessive wind Dirty filter or restricted duct system Defective blower motor or capacitor Defective switch or connections Inadequate combustion air supply Flame Roll out Switch open IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Flame sensor must not be grounded Oxide buildup on flame sensor clean with fine steel wool
38. 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 15 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 21 88 176 439 102 35 7 178 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 38 65 164 46 78 157 391 112 32 64 161 47 76 158 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 Table 11 Filter Size Information In mm FILTER SIZE FURNACE CASING WIDTH SIDE BOTTOM FILTER TYPE RETURN RETURN 16x25 3 4 14 x25 x3 4 14 1 2 368 406 635 19 356 635 19 Washable 16 x25 x3 4 16 x25 x3 4 17 1 2 445 406 x635 x19 406 x635 x19 Washable 16 x25 x3 4 20 x25 x3 4 7 21 533 406 x635 x19 508 x635 x19 Washable 16 x25 x3 4 24 x25 x3 4 A 24 610 406 x635 x19 610 x635 x19 Washable Recommended Some furnaces may have 2 filters 40 U S A and Canada U S A and Canada Table 12 Orifice Size and Manifold Pressure In wc for Gas Input Rate Tabulated data based on 22 000 Btuh per burner derated 4 percent for each 1000 ft 305 M above sea level ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE Manifold Orifice Manifold Orifice Manifold Orifice Manifold
39. 9 229 36 7 23677 7 178 27 5 17742 6 152 132 000 6 42580 10 254 44 28387 8 203 33 21290 7 178 154 000 49677 10 254 51 3 33096 9 229 38 5 24839 8 203 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 S BTUH GAS INPUT RATE 1 000 S BTUH GAS INPUT RATE 30 40 50 44 66 88 110 132 154 ACH Space Volume Ft3 M3 5160 1 050 1 400 1 750 1 100 1 650 2 200 2 750 3 300 3 850 29 7 39 6 49 5 31 1 46 7 62 2 77 8 93 4 109 0 0 50 1 260 1 680 2 100 1 320 1 980 2 640 3 300 3 960 4 620 35 6 47 5 59 4 87 3 56 0 74 7 93 4 112 1 130 8 1 575 2 100 2 625 1 650 2 475 3 300 4 125 4 950 5 775 44 5 89 4 74 3 46 7 70 0 93 4 116 8 140 1 163 5 EN 2 100 2 800 3 500 2 200 3 300 4 400 5 500 6 600 7 700 59 4 79 2 99 1 62 2 93 4 124 5 155 7 186 8 218 0 3 150 4 200 3 300 4 950 6 600 8 250 9 900 11 550 0 20 89 1 118 9 5 250 148 6 93 4 140 1 186 8 233 6 280
40. A08485 43 Table 13 Orifice Size and Manifold Pressure In wc for Gas Input Rate Continued Tabulated data based on 22 000 Btuh High Heat 14 500 Btuh Low Heat per burner derated 4 percent for each 1000 ft 305 M above sea level ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m 7001 2134 to 8000 2438 8001 2439 Orifice numbers shown inBOLD are factory installed A08485a ya EE Status code recall is completed component test will occur ED CODE 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 CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions EACH OF THE FOLLOWING STATUS CODES 15 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 PREVIOUS CODE Stored status code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to control is interrupted 12 BLOWER ON AFTER POWER UP 115 VAC or 24 Blower runs for 90 seconds if unit is
41. AN CSA B149 1 05 Section 8 and Appendix C in Canada the local building codes and furnace and vent manufacturers instructions 4 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 CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance b
42. Bulyeay yno 5 uny si JO ASLL 1 snes sinou ZZ 5 3009 SNOIAAYd ON Catalog 0 45 10 Edition Date 10 08 Printed in U S A Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 Il310A 45 9 Replaces reserves the rig 52
43. C and the CAN CSA B149 1 05 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Do not bypass the draft safeguard switch as an unsafe condition could exist which must be corrected 25 1 If a vent common or dedicated becomes blocked the fur nace 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 venter 6 Do not vent this appliance into an unlined masonry chim ney Refer to Chimney Inspection Chart Fig 27 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 f
44. ED AS SHIPPED White Common BLW Black High COOL Yellow Med High SPARE 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 f Repeat steps a through e g When correct input rate and temperature rise is achieved turn gas valve ON OFF switch to OFF h Remove manometer or similar device from gas valve i Reinstall manifold pressure tap plug in gas valve 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 4 CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace life Recheck temperature rise It must be within limits specified on the rating plate Recommended operation is at the midpoint of rise range or slightly above 6 Set thermostat heat anticipator a Mechanical thermostat Set thermostat heat anticipat or to match the amp draw of the electrical components in the R W circuit Accurate amp draw readings can be obtained at the wires normally connected to ther mostat subbase terminals R and W The thermostat anticipator should NOT be in the circuit while measur ing current 1 Remove thermostat from subbase or fr
45. ETHOD Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combus tion ventilation and dilution of flue gases using perman ent horizontal or vertical duct s or opening s directly communicating with the outdoors or spaces that freely communicate with the outdoors 2 Fig 7 illustrates how to provide TWO OUTDOOR OPENINGS one inlet and one outlet combustion and ventilation air opening to the outdoors a One opening MUST commence within 12 in 300 mm of the ceiling and the second opening MUST commence within 12 in 300 mm of the floor b Size openings and ducts per Fig 7 and Table 2 c TWO HORIZONTAL DUCTS require 1 sq in of free area per 2 000 Btuh 1 100 mm2 kW of combined input for all gas appliances in the space per Fig 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 sq in 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 mm2 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 connect ors in the space The opening shall commence within 12 in 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 150 mm from the front The opening shall directly communicate with the outdo
46. HIMNEY VENT HEIGHT SQ IN 50 MM FT M 12 19 28 38 7741 12258 18064 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 8 0 84 138 207 299 15 4 5 NR 152 233 334 20 6 0 NR NR 250 368 30 9 1 NR NR NR 404 Table B Minimum Allowable Input Rating of Space Heating Appliance in Thousands of Btuh per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ IN SQ MM FT M 12 19 28 38 7741 12258 18064 24516 Local 9996 Winter Design Temperature 17 to 26 degrees F 6 0 55 99 141 8 52 74 111 154 10 NR 90 125 169 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 10 111 149 198 15 193 247 20 293 30 377 Local 9996 Winter Design Temperature 10 to 4 degrees F 6 NR NR 145 196 8 NR NR 159 213 10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333 30 NR NR NR NR Local 99 Winter Design Temperature 11 F 16 C lower Not recommended for any vent configuration 28 The 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chapter Table 1A United States and 2A Canada or the 2005 ASHRAE Fundamentals handbook Climatic Design Information chapter and the CD ROM in cluded with the 2005 ASHRAE Funda
47. MUIS3L amp aasn NJHW Sud 991 4 4 LL ILON zd gasn Qn 251 151 OL 31ON feud m L 035 ssa 1584 SS g _ OWASLL Lad WaLNaN 21 YISH Lova T M 10 1H8 71009 SL ILON ANNONS INAWdINOA LH wanan a AA 63570 INYdONd 8 INVIO 2L VIN3HOS HOLIMS LOANNOOSIC 91315 OVASLL OL r 09 _ 1m WaLAAN L o 2 31ON a033 N3HM HOLIMS 193NNOOSIG 9 3339 LINDH ISNA TJ3A NSIO IH ma Lva lt 38vVdS WAH 7002 AA LL SLON 19 sd LLOLESLOSHVECSL Los 2 035 1HM la 3l 9 31ON aig e 5 a3sn NaH S 280 240 999 amp i Sa 1554 9 gaon Tol dz 1 OL ILON THANHS a Tels amp N3HM ozi ce amp 06 N 12913 3 251 151 ZS 19 V 99 440 INVSHOVIO NOLLOANNOO 08411 Fig 46 Wiring Diagram 37 D BURNER i ORIFICE A06666 Fig 47 Ga
48. N LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING 17 3 4 IN 451 mm OVER ALL 4 3 4 IN 121 mm UNDER DOOR 1 IN 25 mm UNDER FURNACE EXTEND OUT 12 IN 305 mm OUT FROM FACE OF DOOR Td EM WHEN USED WITH SINGLE WALL VENT CONNECTIONS Sy MANUAL SHUTOFF SS GAS VALVE SEDIMENT TRAP A02164 Fig 17 Typical Attic Installation SUPPLY AIR UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURNAIR RETURN AIR RETURN AIR RETURN AIR cru cux CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS Se TS ONLY ONLY ONLY OF 1 2 AND 066 060 22 AND YES YES YES YES 20 MODELS ALL OTHER MODELS YES YES YES Moy RETURN RETURN AIR AIR RETURN UPFLOW AIR RESTRICTIONS 02075 Fig 18 Upflow Return Air Configurations and Restrictions 18 RETURN AIR RETURN AIR SIDE RETURN NOT PERMITTED FOR ANY MODEL SUPPLY AIR SIDE RETURN NOT PERMITTED FOR ANY MODEL 066 060 22 AND 20 MODELS ALL OTHER MODELS DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR COMBINATIONS OF 1 2 AND3 CONNECTION 1 CONNECTION2 CONNECTION ONLY ONLY ONLY YES Fig 19 Downflow Return Air Configurations and Restrictions
49. Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Gas valve defective or gas valve turned off Manual valve shut off Defective Hot Surface Ignitor Control ground continuity Low inlet gas pressure Inadequate flame carryover or rough ignition Green Yellow wire MUST be connected to furnace sheet metal CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats P A04223 Fig 50 Service Label 44 SERVICE AND MAINTENANCE PROCEDURES 4 WARNING FIRE EXPLOSION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment 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 4 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before servicing disconnect all electrical power to furnace Verify proper operation after servicing 4 CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operatio
50. S close 24 VAC power is supplied for a field in stalled humidifier at the HUM terminal and the control begins a 15 sec prepurge period b Igniter Warm Up At the end of the prepurge period the Hot Surface igniter HSI is energized for a 17 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve re lay 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 prov ing period begins The HSI igniter will remain ener gized 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 automatically after three hours or 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 Heatin
51. Step 4 11 Secure field ground wire to J Box green ground screw 22 Table 7 Electrical Data VOLTS OPERATING VOLTAGE MAXIMUM UNIT RE poner MINIMUM FURNACE SIZE HERTZ RANGE UNIT AMPAC LENGTH CKT BKR WIRE PHASE 5 ITY GAUGE Maximum Minimum FT AMPSt 045 08 024045 115 60 1 127 104 5 4 7 54 49 15 15 14 045 12 036045 115 60 1 127 104 7 0 9 50 39 12 15 14 070 08 024070 115 60 1 127 104 5 0 7 06 52 16 15 14 070 12 036070 115 60 1 127 104 6 8 9 22 40 12 15 14 070 16 048070 115 60 1 127 104 9 5 12 60 29 9 15 14 090 14 042090 115 60 1 127 104 8 2 10 83 34 10 15 14 090 16 048090 115 60 1 127 104 10 0 13 13 28 9 15 14 090 20 060090 115 60 1 127 104 13 6 17 61 32 8 20 12 110 12 036110 115 60 1 127 104 8 2 10 75 34 10 15 14 110 16 048110 115 60 1 127 104 10 1 13 12 28 9 15 14 110 22 066110 115 60 1 127 104 14 8 18 99 30 9 20 12 135 16 048135 115 60 1 127 104 10 2 13 27 27 8 15 14 135 22 066135 115 60 1 127 104 14 4 18 55 30 9 20 12 155 20 060155 115 60 1 127 104 15 0 19 33 29 9 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps T Time
52. TE On 14 in 356 mm 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 holding J Box See Fig 23 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 2 Cut wire tie on loop in furnace wires attached to J box 3 Move J Box to desired location 4 Fasten J Box to casing with two screws removed in Step 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX Field Supplied Electrical Box on Furnace J Box Bracket See Fig 24 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 4 Route and secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads
53. arbons or inadequate seal may occur and RTV sealant 48 G E 162 6702 Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 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 con nection diagram on wiring label if wires were not marked for reconnection locations Draft safeguard switch Inducer motor Pressure switch es Limit over temperature switch Gas valve Hot surface igniter Flame sensing electrode 0 0 Flame rollout switches i Install NOx baffles if removed 14 Reinstall internal vent pipe if applicable 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 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never use a match or other open flame to check for gas leaks Use a soap and water solut
54. as shown in Fig 26 6 Reinstall cover to J Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 24 4 WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components 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 2 Remove the desired electrical box hole knockout and posi tion the hole in the electrical box over the hole in the fur nace casing 3 Fasten the electrical box to casing by driving two field supplied screws from inside electrical box into casing steel 4 Remove and save two screws holding J Box See Fig 23 5 Pull furnace power wires out of 1 2 inch diameter hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electrical box and into electrical box 7 Pull field power wires into electrical box 8 Remove cover from furnace J Box 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 moved in
55. ates Use the NFGC Canada use the CAN CSA B149 1 05 2 Immediately increase to 5 in 127 mm or 6 in 152 mm vent connector outside furnace casing when 5 in 127 mm 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 KGAVG0101DFG Downflow Vent Guard Kit is used in the downflow position 4 Type B vent where required refer to the Note 1 above 5 A 4 in 102 mm single wall 26 ga minimum vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace Accessory Downflow Vent Guard Kit KGAVG0101DFG re quired in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACAO02014FC or KGACA02015FC for sizing and complete application details 33 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 FURNACE VENT FURNACE MEER VENT ORIENTATION ORIENTATION INPUT BTUH HR IN mm M 154 000 Downtlow p 132 000 5 127 12 3 6 pg 110 000 036 12 only Vent elbow right 154 000 Horizontal Left then up Fig 39 132 000 5 127 7 65 5 Vent Elbow up Fig 154 000
56. b Remove outer access door c Look into blower access door sight glass for current LED status Do not remove blower access door or ter minate 115 v power to control or status code will be lost d BRIEFLY remove insulated terminal wire from the draft safeguard DSS switch until LED goes out 1 to 2 sec then reconnect it 2 When above items have been completed the LED flashes status code 4 times Record this status code for further troubleshooting 3 Component self test will begin Refer to component TEST section for complete test sequence 4 Check LED status 5 Refer to SERVICE label on front of the blower access door for more information 6 Check LED status If no previous faults in history control will flash status code 11 7 If LED status indicates proper operation RELEASE BLOWER ACCESS DOOR SWITCH reattach wire to R 45 terminal on furnace control board replace blower access door and replace burner access door Step 2 Care and Maintenance 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other vo
57. bered drill bit of 35 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 heating operation c Measure time in sec for gas meter to complete 1 re volution 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 temperature rise range specified on unit rating plate Determine the temperature rise as fol lows NOTE Blower access door must be installed when taking temperature 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 th
58. ces See EXAMPLE 2 EXAMPLE 2 0 2000 ft 0 610 M altitude For 22 000 Btuh per burner application use Table 12 Heating value 1000 Btuh 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 47 c Connect a water column manometer or similar device to manifold pressure tap Turn gas valve ON OFF switch to ON Manually close blower door switch Set thermostat to call for heat Jumper 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 ee Install regulator seal cap Leave manometer or similar device connected and proceed to Step 4 c NOTE DO NOT set manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas at sea level If manifold pressure is outside this range change main burner orifices or refer Table 12 or 13 NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a num
59. ciation ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refriger ation 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 e US and CANADA current edition of SMACNA and 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 6 Gas Piping and Gas Pipe Pressure Testing e US NFGC NFPA 54 ANSI Z223 1 2006 chapters 5 6 7 and 8 and National Plumbing Codes CAN CSA B149 1 05 Parts 4 5 and 6 and Appendices A B E and H Step 7 Electrical Connections US National Electrical Code NEC ANSI NFPA 70 2008 CANADA Canadian Electrical Code CSA C22 1 Step 8 Venting e US NFGC NFPA 54 ANSI Z223 1 2006 chapters 12 and 13 CAN CSA B149 1 05 Part 8 and Ap pendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 4 CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in furnace component damage Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during
60. 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 the United States and Canada follow all codes and standards for the following Step 1 Safety US National Fuel Gas Code NFGC 54 2006 ANSI Z223 1 2006 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CSA B149 1 05 National Standard of Canada Natural Gas and Propane Installation Codes A06745 CAN CSA B149 1 05 Step 2 General Installation 4 e US Current edition of the NFGC and the 90B For copies contact the National Fire Protection Associ ation Inc Batterymarch Park Quincy MA 02269 www NFPA org or for only the NFGC contact the American Gas Association 400 N Capitol Street N W Washington DC 20001 www AGA org e CAN CSA B149 1 05 For a copy con tact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario MOW 1R3 Canada Step 3 Combustion and Ventilation Air e US Section 9 3 of the NFGC NFPA 54 ANSI Z223 1 2006 Air for Combustion and Ventilation Part 8 of CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances Step 4 Duct Systems e US and CANADA Air Conditioning Contractors As so
61. d Ventilation section 4 Combustion products must be discharged outdoors Con nect this furnace to an approved vent system only as spe cified in the Venting section of these instructions 5 Never test for gas leaks with an open flame Use a com mercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s in tended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate 7 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con taining the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating out side the space containing the furnace See Air Ducts sec tion 8 A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these in Structions 10 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
62. d tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve Aa GAS SUPPLY MANUAL SHUTOFF VALVE oxi REQUIRED e SEDIMENT gt TRAP UNION A02035 Fig 22 Typical Gas Pipe Arrangement Piping should be pressure and leak tested in accordance with NFGC in the United States or CAN CSA B149 1 05 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 wo 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 FACTORY INSTALLED LOCATION HE TWO CN ALTERNATE 22 FIELD d n Aj LOCATIONS A02099 Fig 23 Relocating J Box A03221 Fig 24 Field Supplied Electrical Box on Furnace Casing The gas supply pressure shall be
63. de return air inlet s is used without a bottom return air inlet Not all horizontal furnaces are approved for side return air connections See Fig 20 FILTER ARRANGEMENT 4 WARNING CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 Refer to the instructions supplied with Media Cabinet for assembly and installation options A field supplied accessory external filter rack is required This furnace requires KGAFRO30ALL 1 in 25 mm 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 13 Table 4 Opening Dimensions In mm FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B c D Upflow Applications on Combustible or Noncombustible Floor 12 11 16 21 5 8 13 5 16 22 1 4 ing KGASB subbase not required 322 549 338 565 Downflow Applications on Flooring KGASB 12 9 16 19 13 3 16 19 5 8 14 3 16 subbase not required 319 483 335 498 Downflow applications on combustible flooring KGASB sub 11 13 16 19 13 7 16 20 5 8 36
64. e 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 1 8 M Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas Table 6 Maximum Capacity of Pipe NOMINAL INTERNA LENGTH OF PIPE M IRON L PIPE SIZE DIA 10 20 30 40 50 IN MM IN 3 0 6 0 9 12 1 15 2 1 2 12 7 175 120 97 82 73 3 4 19 0 00 9 360 250 200 170 151 1 25 4 36 6 680 465 375 320 285 1 1 4 1 380 1 5 GED 1400 950 770 660 580 1 1 2 1 610 at 40 9 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 6 2 ANSI Z223 2006 NFPA 54 2006 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death 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 51 mm outside the furnace 4 CAUTION FURNACE OVERHEAT HAZARD Failure
65. ec See Fig 25 Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed same as HEAT speed Terminal EAC 1 is ener gized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 sec ignition and blower ON delay 25 sec 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 addi tional 90 sec 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 sec if no other function requires blower motor BLWM opera tion 4 Heat Pump When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off times during demand defrost cycles When the R to Wand 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 sec then come back on at HEAT speed When the W input signal disappears the fu
66. ed 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 similar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING 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 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 Vent system or vent connectors may need to be resized Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC or CAN CSA B149 1 05 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 2006 NFPA 54 2006 NFGC Parts 12 and 13 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 05 C
67. eing inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47 2006 CSA 2 3 2006 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 NFGC or the CAN CSA B149 1 05 the local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the requirements defined in the NFG
68. ermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is par ticularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determ ine air temperature rise NOTE Blower access door must be installed for proper temperature rise measurement NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in wc 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 Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise d Turn thermostat down below room temperature and remove blower access door To change motor speed selection for heating remove blower motor lead from control HEAT terminal See Fig 25 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 Table 9 Speed Selection COLOR SPE
69. eturn air openings for airflow requirements above 1800 CFM Fig 1 Dimensional Drawing INTRODUCTION Series 130 D 4 way multipoise Category I fan assisted furnace is CSA design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger The furnace is factory shipped for use with natural gas 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 16 db or intermittent operation down to 55 F 13 C db such as when used with a night setback thermostat Return air temperature must not exceed 85 F 29 C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 3 Table 1 Dimensions In mm FURNACE SIZE A D E F FLUE SHIP WT CABINET WIDTH SUPPLY AIR RETURN AIR C L TOP AND COLLAR LB KG IN mm WIDTH WIDTH BOTTOM FLUE IN mm IN mm IN mm COLLAR IN mm 045 08 024045 14 3 16 360 12 9 16 819 12 11 16 322 9 5 16 237 4 102 104 47 045 12 036045 14 3 16 360 12 9 16 819 12 11 16 322 9 5 16 237 4 102 107 48 070 08 024070 14 3 16 360 12 9 16 319 12 11 16 322 9 5 16 237 4 102 111 50 070 12
70. 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 e Furnace should cycle off within 2 minutes If gas does not shut 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 hrs To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF then back ON Check Pressure Switch This control proves operation of the draft inducer blower Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire har ness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot sur face igniter should NOT glow and control diagnostic light flashes a status code 32 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer moto
71. from water Antistatic fabric softeners for clothes dryers Masonry acid washing materials 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 4 WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 accordance with the CAN CSA B149 1 05 See Fig 5 A CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Failure to follow this caution may result in furnace component damage 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 fur
72. furnace rating plate and for install ation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA A G A and C G A lis ted accessory gas conversion kit is required to convert fur nace for use with propane gas 11 See Fig 1 for required clearances to combustible construc tion 12 Maintain a 1 in 25 mm clearance from combustible ma terials to supply air ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or loc al code for further requirements 13 These furnaces SHALL NOT be installed directly on car peting tile or any other combustible material other than wood flooring In downflow installations factory access ory floor base MUST be used when installed on combust ible materials and wood flooring Special base is not re quired when this furnace is installed on manufacturer s Coil Assembly Part No CNPV CNRV CAR or CAP or when Coil Box Part No KCAKC is used See Fig 1 for clearance to combustible construction information 733mm 664mm 28 7 8 26 1 8 FLUE COLLAR 641mm 25 1 4 22 9 16 573mm JUNCTION BOX LOCATION 5 15 16 T 22mm 7 8 DIA ACCESSORY 172 DIA THERMOSTAT WIRE ENTRY 3 15 16 LEFT HAND GAS ENTRY Sue pee s 846mm 632mm 7 8 DIA ACCESSORY 2 11 16 E 549mm 140mm Mmm 215 9
73. g mode and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT speed 25 sec 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 depending on the blower OFF delay selection The furnace control CPU is fact ory set for a 120 second blower OFF delay 2 Cooling Mode See Fig 26 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 Y circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y cir cuits are opened The outdoor unit will stop and the fur nace blower motor BLWM will continue operating on the COOL speed for an additional 90 sec Cut jumper J2 to reduce the cooling off delay to 5 s
74. ier for U S A Failure to follow this caution may result in reduced furnace ALTITUDE PERCENT DERATE MULTIPLIER 0 2000 0 1 00 DO NOT redrill orifices Improper drilling burrs out of 0 610 round holes etc can cause excessive burner noise and 2001 3000 8 12 0 90 misdirection of burner flames This can result in flame 610 914 impingement of heat exchangers causing failures See Fig 3001 4000 48 914 1219 12216 oa 4001 5000 Furnace gas input rate on rating plate is for installations at 1219 1524 16 20 0 82 altitudes up to 2000 ft 610 M Furnace input rate must be 5001 6000 within 4 2 percent of furnace rating plate input 20 24 0 78 3 1524 1829 1 Determine the correct gas input rate 6001 7000 24 28 0 74 In the U S A 1829 2134 The input rating for altitudes above 2 000 ft 610 M must 7001 8000 28 32 0 70 be reduced by 4 percent for each 1 000 ft 305 M above 2134 2438 sea level For installations below 2000 ft refer to the unit 8001 9000 32 36 0 66 rating plate For installations above 2000 ft 610 M mul tiply the input on the rating plate by the derate multiplier T 36 40 0 62 in Table 8 for the correct input rate 2743 3048 In Canada Derate multiplier factors are based on midpoint altitude for altitude range The input rating must be derated by 10 percent for alti tudes of 2
75. ion 19 Check for gas leaks 20 Replace outer access door Step 3 Sequence of Operation 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 46 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 sec 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 sec period after which the LED will be ON continuous as long as no faults are detected After the 90 sec 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 26 for thermostat connections The wall thermo stat calls for heat closing the R to W circuit The fur nace control performs a self check verifies the pressure 49 switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch contacts PR
76. ize in the tables the chimney should be rebuilt or relined to conform to the requirements of the equip ment being installed and the authority having jurisdic tion A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt to conform to ANSI NFPA 211 or be lined with a UL listed ULC listed in Canada metal liner or UL listed Type B vent Relining with a listed metal liner or Type B vent is considered to be a vent in a chase 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 26 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian installation Code CSA B149 1 in Canada Crown condition Missing mortar or brick Rebuild crown Is chimney property lined with clay tile liner Is Repair liner and top liner or top seal Reline seal in good or reline chimney as condition necessary Debris in cleanout Mortar Mortar tile metal vent or tile Remove mortar fuel oil residue debris and tile debris No Remove metal vent or liner Clay tile misalignment missing sections gaps Consult Part B of chimney adapter
77. l authorities having jurisdiction 4 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 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST be provided for the ventilation devices in addition to that required by the furnace Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make up air is available 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 cu ft per 1 000 Btuh input rating for all gas appliances installed in the space e Spaces having less than 50 cu ft per 1 000 Btuh re quire the OUTDOOR COMBUSTION AIR METHOD e Spaces having at least 50 cu ft per 1 000 Btuh may use the INDOOR COMBUSTION AIR STANDARD or KNOWN AIR INFILTRATION M
78. l furnaces are approved for side return air connections See Fig 20 GAS PIPING 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Use proper length of pipe to avoid stress on gas control manifold and a gas leak Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the CAN CSA B149 1 05 in Canada 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 li censed 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 b
79. latile fluids 3 Paint thinners and other painting compounds paper bags or other paper products For continuing high performance and to minimize possible equipment failure periodic maintenance must be performed on this equipment Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace 4 WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate unit without a filter or with filter access door removed P 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 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean as necessary 3 Check electrical connections for tightness and contro
80. low room temperature 6 Verify furnace restarts by raising thermostat setting above room temperature 31 SEE NOTES 1 2 4 7 8 9 on the page following these figures 03208 Fig 33 Upflow Application Vent Elbow Up SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures A03209 Fig 34 Upflow Application Vent Elbow Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures 03210 Fig 35 Downflow Application Vent Elbow Up then Left a SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 36 Downflow Application Vent Elbow Up n 1 AA EM SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures A03207 Fig 37 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures 03212 Fig 38 Downflow Application Vent Elbow Up then Right 32
81. ls for proper operation each heating season Service as necessary 4 Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have furnace and burner serviced by a qualified service agency 5 Inspect the vent pipe vent system before each heating season for rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the accessory 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 NOTE If the filter has an airflow direction arrow the arrow must point towards the blower 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 Media cabinet filter procedures NOTE Media cabinet or 3 4 in 19 mm filter rack are accessories and are not included from the factory with standard furnace model 1 Turn off electrical supply to furnace before removing filter access door 2 Remove filter cabinet door 3 Slide filter out
82. ly 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 supplyoutlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASBO2O1ALL or a factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or 19 other accessories accessories MUST be connected to duct external to furnace casing A WARNING FIRE HAZARD A failure to follow this warning could result in personal injury or death and or property damage Never connect return air ducts to the back of the furnace Follow instructions below Return Air Connections 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 horizontal furnaces See Fig 19 Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace Upflow and Horizontal Furnaces The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 18 and 20 Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 18 and 20 Not all horizonta
83. mentals Handbook A04127 Fig 28 Using Tin Snips to Cut Tie Points Air for combustion must not be contaminated by halogen compounds which include chlorides fluorides bromides and iodides These compounds are found in many common home products such as detergent paint glue aerosol spray bleach cleaning solvent salt and air freshener and can cause corrosion of furnaces and vents Avoid using such products in the combustion air supply Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting system due to corrosion 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 in 102 mm round vent elbow is supplied with the furnace A 5 in 127 mm or 6 in 152 mm vent connector may be required for some model furnaces A field supplied 4 in 102 mm to 5 in 127 mm or 4 in 102 mm to 6 in 152 mm sheet metal increaser fitting is required when 5 in 127 mm or 6 in 152 mm vent connector is used See Fig 33 45 Venting Orientation for approved vent configurations NOTE Vent connector length for connector sizing starts at furnace vent elbow The 4 in 102 mm vent elbow is shipped for upflow configuration and may be rotated for other positio
84. n Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation P CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental pollution Remove and recycle all components or materials i e oil refrigerant et before unit final disposal Step 1 Introduction GENERAL These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 4 you must revise your orientation to component location accordingly ELECTRICAL CONTROLS AND WIRING 4 WARNING 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 26 for field wiring information and to Fig 46 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 prope
85. nace 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 the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained 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 intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the gas input 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 ignition gas input rate air temperature rise and venting according t
86. nace 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 28 through 32 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 28 A sharp blow to the rounded end of the knockout See Fig 29 will separate more tie points and allow the knockout to be pulled loose See Fig 30 Remove all burrs and sharp edges 29 A04128 Fig 29 Rounded End of Knockout 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 31 directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout See Fig 32 Remove all burrs and sharp edges A CAUTION BURN HAZARD Failure to follow this caution may cause personal injury Hot vent pipe is within reach of small children when installed in downflow position See the following instruction An accessory Vent Guard 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
87. ns Remove the 3 screws that secure vent elbow to furnace rotate furnace vent elbow to position desired reinstall 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 sheet metal screws located 180 apart NOTE An accessory flue extension KGAFEO112UPH is available 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 33 45 4 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 fur
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89. o these installation instructions 18 IN 457 2 mm MINIMUM TO BURNERS A93044 Fig 5 Installation in a Garage 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace See Fig 6 02054 Fig 6 Prohibit Installation on Back LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the 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 AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with e 0 5 installations Section 9 3 of the 54 ANSI Z223 1 2006 Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian installations Part 8 of CAN CSA B149 1 05 Venting Systems and Air Supply for Ap pliances and al
90. of cabinet 4 If equipped with permanent washable 3 4 in 19 mm 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 5 If equipped with factory specified disposable media filter replace only with media filter having the same part number and size For expandable replacement media refer to the instructions included with the replacement media If equipped with accessory KGAFRO0301ALL external filter rack See Table 11 6 Slide filter into cabinet 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 NOTE The blower wheel should not be dropped or bent as balance will be affected The following steps should be performed by a qualified service agency To ensure long life and high efficiency clean accumulated dirt and grease from blower wheel and motor annually 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 mot
91. om wall 2 Connect an amp meter as shown in Fig 49 across the R and W subbase 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 anticipator 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 ad justable settings from 90 sec to 180 sec The blower off delay jumpers are located on the furnace control board See Fig 25 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 8 Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow See Table 5 De livery CFM With Filter See Table 9 for lead color iden tification 36 Kjuo Jojow paeds uo paads s no SI Zf UBYM spuooes Jo spuooes 06 3 ond nw N dund eu Jo spuo es 081 20 OSL OZL 06 aie suomojos Buneay seb Aejap vi 3 sonas aiia am SO NAA MOT a spuooes z 1eau 10 spuo es Buneay seb Aejap L ar a SINOY Jaye 1959 ANNOYS ad AVTAG 330
92. ombustion air supply problem before resetting 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 furnace control Failure to make proper con nections will result in improper operation See Fig 26 3 Gas supply pressure to the furnace must be greater than 4 5 in wc 0 16 psig but not exceed 14 in wc 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Replace outer door Step 2 Start Up Procedures 4 WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch
93. onal injury or death and unit component damage Chemical storage areas If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space 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 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 Permanent wave solutions e Chlorinated waxes and cleaners Chlorine based swimming pool chemicals e Water softening chemicals De icing salts or chemicals Carbon tetrachloride GENERAL This multipoise furnace is shipped in packaged configuration E Some assembly and modifications are required when used in any of the four applications shown in Fig 4 Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc This furnace must e Hydrochloric acid beinstalled so the electrical components are protected e Cements and glues
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95. 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 the 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 25 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 50 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 Blower motor operates on HEAT speed for 10 sec Blower motor operates on COOL speed for 10 sec Inducer motor stops c C Reconnect lead to furnace control board release blower door switch and re install blower door 4 Operate furnace per instruction on door 5 Verify furnace shut down by lowering thermostat setting be
96. or Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 46 10 11 Loosen the thumbscrew on outer door and remove outer door 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 vent elbow b Disconnect and remove short piece of vent pipe from within furnace Remove 2 screws from blower access door and remove blower access door Disconnect blower leads from furnace control Record wire color and location for reassembly other factory wires can be left connected but field thermostat connec tions may need to be disconnected depending on their length and routing Remove 2 screws holding control box to blower shelf Hang control box from front of furnace casing and away from blower compartment Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace 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 Vacuum any loose dust from blower housing wheel and motor If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appro priate degreaser To remove wheel NOTE Before disassembly mark blower m
97. or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation 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 screws from pulling out use 2 8 x 3 4 in 19 mm screws into the side and 2 8 x 3 4 in 19 mm screws in the bottom of the furnace casing for each strap See Fig 15 and 16 12 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 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 25 mm clearance requirement on side
98. ors 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 amp 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 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning 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 Table 2 Minimum Free Area Required for Each Combustion Air Opening of 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 50 MM KW 1 SQ IN 4 000 BTUH 550 50 MM KW INPUT Free Area of Opening Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct BTUH and Duct Dia and Duct Dia and Duct Dia Sq In Sq mm In mm Sq In Sq mm In mm Sq In Sq mm In mm 44 000 2 14194 6 152 14 7 9484 5 127 1 7096 4 102 66 000 3 21290 7 178 22 14193 6 152 16 5 10645 5 127 88 000 44 28387 8 203 29 3 18903 7 178 22 14193 6 152 110 000 55 35484
99. otor and blower housing so motor and each arm is positioned at the same location during reassembly 12 13 14 15 16 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 10 in Ib when reas sembling e Remove blower wheel from housing f Clean wheel and housing Reassemble motor and blower by reversing steps 11f through 11a finishing with 11a Be sure to reattach ground wire to the blower housing 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 neces sary Spin the blower wheel by hand to verify that the wheel does not rub on the housing Reinstall blower assembly in furnace Reinstall control box assembly in furnace NOTE Refer to Table 9 for motor speed lead relocation if leads 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger life Heating fan speed s MUST be adjusted to provide proper air temperature rise as specified on the rating plate Recommended operation is at the midpoint of the rise range or slightly above Refer to SET TEMPERATURE RISE unde
100. own 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 99440 Fig 26 Heating and Cooling Application Wiring Diagram with Single Stage Thermostat 24 24 WIRING Make field 24 v connections at the 24 v terminal strip See Fig 25 Connect terminal Y as shown in Fig 26 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 us ing 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 hu midifier 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 gas valve relay GVR is energized See Fig 24 NOTE A field supplied 115 v controlled relay connect
101. pletely 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 eo FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING INC DOWNFLOW PA SUBBASE s SHEET METAL PLENUM FLOOR OPENING A96285 Fig 12 Furnace Plenum and Subbase Installed on a Combustible Floor a M LE QN ae FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM 420 PAD OPENING 08556 Fig 13 Furnace Plenum Coil Assembly or Coil Box Installed on a Combustible Floor 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 HORIZONTAL INSTALLATION 4 WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death
102. powered up during a call for heat R W closed or R W opens during blower on delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit draft safeguard flame rollout or blocked vent switch if used is open longer than 3 minutes Control will auto reset after three hours Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas Stuck open gas valve 23 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed 24 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 C 327596 101 REV B 31 33 3
103. presented only by the standard in Platform Furnace Support 13 Roll Out Protection 13 Bottom Return Air Inlet 13 Side Return Air 13 General Reguirements 14 Ductwork Acoustical Treatment 14 Supply Air Connections 14 Return Air Connections 20 START UP ADJUSTMENT AND SAFETY 31 General ads E a gee e dee 31 Start Up Procedures cece eee eee 31 Adjustments 252 6 r6 ER ees 34 Check Safety Controls 37 Checklist cert RERO eer RENE ERE EUR 38 SERVICE AND MAINTENANCE PROCEDURES 46 Introduction e 46 Care and Maintenance 46 Sequence of Operation 2 2 50 Wiring Diagrams 0 51 Troubleshooting tes esas 51 SAFETY CONSIDERATIONS 4 WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Improper installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal inju
104. r 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 25 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced 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 50 and the troubleshooting guide which can be obtained from your distributor The furnace control will store 1 status code for 72 hrs See Fig 54 a brief Troubleshooting Guide For Controls With a RED LED The stored status code will be erased from the control memory if 115 or 24 v power is interrupted 1 To retrieve status code proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 v power to furnace turned on
105. r START UP ADJUSTMENT and SAFETY CHECK were not identified before disconnection 17 Reconnect blower leads to furnace control Refer to fur nace wiring diagram and connect thermostat leads if pre viously disconnected 18 To check blower for proper rotation a Turn on electrical supply 4 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 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 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 47 19 20 21 22 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 ACCESS DOOR SWITCH Remove any jumpers or re connect any disconnected thermostat leads Replace blower access door Downflow or horizontal furnaces with vent pipe through furnace only Install and connect short piece of vent pipe inside fur nace to existing vent b Connect vent connector to vent
106. r wires replace outer door and turn on 115 v power h Blower will run for 90 sec before beginning the call for heat again 1 Furnace should ignite normally Step 5 Checklist 39 1 2 Put away tools and instruments Clean up debris Verify that blower OFF DELAY time is selected as de sired Verify that blower and burner access doors are properly in stalled Cycle test furnace with room thermostat Check operation of accessories per manufacturer s instruc tions Review User s Guide with owner Attach literature packet to furnace Table 10 Gas Rate cu ft hr SECONDS FOR 1 SIZE OF TEST DIAL SECONDS FOR 1 SIZE OF TEST DIAL REVOLUTION 1CuFt 2CuFt 5Cuft REVOLUTION iCuFt 2CuFt 5604 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
107. rnace control begins a normal in ducer post purge period and the blower switches to COOL speed after a 3 sec 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 at HEAT speed after the selected blower OFF delay period is completed Step 4 Wiring Diagrams Refer to Fig 24 and 45 for wiring diagrams Step 5 Troubleshooting Refer to the service label See Fig 50 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 50 2901 207 JEISOWWJ9U eui 10 0 A PZWOD eui 12euuoo 10 S S91 jse eq e 149443 eoeuunj y Jou s ye soway SUL 1eduunf e Buisn 1eedai ue qoud y seoq Jo uoo eoeuunj y Salim OU 3oeuuoosiq y uo 5 9 10 ZA X Queseud ji LA MI asad SI
108. rough 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 rating plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or Table 7 for equipment electrical specifications USS installations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2008 and any local codes or ordinances that might apply Canadian installations Make all electrical connections in accordance with Canadian Electrical Code CSA 22 1 authorities having jurisdiction 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal 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 NO
109. ry 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 4 CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component damage 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 4 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 Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these in
110. s Control Valve Fig 48 Orifice Hole A93059 THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 2 9 AMPS ON AMMETER _ 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING 96316 Fig 49 Amp Draw Check With Ammeter 38 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 1 Check Main Limit Switch es This control shuts off combustion control system and en ergizes air circulating blower motor if furnace overheats By using this method to check limit control it can be es tablished that limit is functioning properly and will operate if there is a restricted duct system or motor failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of card board or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace cools down 2 Check draft safeguard switch 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 con nector
111. s appliances in the space 3 In spaces that use the Indoor Combustion Air Method in filtration should be adequate to provide air for combus tion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods de scribed in the Outdoor Combustion Air Method section 10 Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a con tinuous 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 Combus tion Air Method below and 2 Outdoor openings shall be located as required in the Out door 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
112. s of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the furnace could cause the furnace and or vent to fail prematurely When a metal vent or metal liner is used the vent must be in good condition and be installed in accordance with the vent manufacturer 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 16 C db except for brief periods of time during warm up from setback at no lower than 55 F 13 C 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 caus ing condensation and corrosion in the furnace and or vent ing system Derating is permitted only for altitudes above 2000 ft 610 M 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 4 Set thermostat heat anticipator or cycle rate to reduce short cycling 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 Btuh per Hour INTERNAL AREA OF C
113. se not required 584 537 600 565 Downflow Applications on Noncombustible Flooring KGASB 22 718 19 23 1 2 19 5 8 24 1 2 subbase not required 581 483 597 498 622 Downflow applications on Combustible flooring KGASB sub 22 1 8 19 23 3 4 20 5 8 base required 562 483 603 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or Coil Assembly or KCAKC coil box yu i 155 on 506 KGASB subbase not required AIR DUCTS Ductwork Acoustical Treatment General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guidelines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design external static pressure 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 duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for
114. seb 55002 Jejeuujo JOBUUOD JEY JO 0 12 5 195 pue pea jejsouueu H eui jpeuuooeH ponad puooes 61 104 juesaid SEM 1 eui Z1 1VH LO3N ueewjeq AS 20 yo y9 eouenbes 159 jueuoduuoo 19ujoue eyeniui pue Bnjdun Je1depy euuilu ui pesn yoyms yjoinus pexoolg x ponad puooes c jo pue q seoq eouenbes 1591 jueuoduuoo y pue eui ejsoway H 1514 eui oi 1521 jueuoduioo eui eq 5 10 sayub y ui si eui OL eq jou Josues 4 Tew jeeus eoeuunj pejoeuuoo eq Jo jnus YO pauan seo deis xeu eu Buipeeooud 18114 y Y09049 SU JO uo ponad Aejap uo eut 1801 si eufis J sind00 pL e eouenboes uoniuBi y eui polled ay pesues jou s j
115. set furnace on non combustible blocks bricks or angle iron For crawl space installations if the furnace is not suspended from the floor joists the ground underneath furnace must be level and the furnace set on blocks or bricks Roll Out Protection Provide a minimum 17 3 4 in x 22 in 451 x 559 mm piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 inches 305 mm above the combustible deck or suspended furnaces closer than 12 inches 305 mm to joists The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed The bottom closure panel on furnaces of widths 17 1 2 in 445 mm 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 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 si
116. stion Ventilation and Dilution from Indoors lother combined input of all other than fan assisted appliances in Btuh hr Ifan combined input of all fan assisted appliances in Btuh 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 closeable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 8 c 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 permanent openings in doors or floors having free area of at least 2 in 2 1 000 Btuh 4 400 mm2 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 out doors having free area of at least 1 in 2 4 000 Btuh of total input rating for all ga
117. structions thoroughly and follow all warnings or cautions include in literature and attached to the unit Consult local building codes the current editions of the National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the National Standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation Codes and Canadian Electrical Code CSA C22 1 Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 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 spe cified in the Location section of these instructions 3 Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion an
118. 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 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the fur nace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily dis charged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity for example DO NOT move or shuffle your feet do not touch un grounded objects etc 4 If you touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control Or wires AIRFLOW THE BLOWER IS LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER IS LOCATED UPFLOW TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT LEN lt HORIZONTAL LEFT p AIRFLOW AIRFLOW DOWNFLOW THE BLOWER IS THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION AND OF THE BURNER SECTION
119. urnaces having a Chimney Adapter Kit numbers marked on the furnace rating plate If a clay tile lined masonry chimney is being used and it is exposed to the outdoors below the roof line relining might be required Chimneys shall conform to the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 2006 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 8 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 NFPA 54 ANSI Z223 1 2006 13 1 8 and 13 2 20 regarding alternative venting design and the Exception which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACAO02015FC 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 inp
120. ut rating is less than the max imum 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 Winter Design Temperature Chimneys having internal areas greater than 38 in 24516 mm require fur nace 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 which are 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 the Fig 27 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 con densation If a condensate drain is required by local code refer to the 54 ANSI Z223 1 2006 Sec tion 12 10 for additional information on condensate drains b Indicates the chimney exceeds the maximum permiss ible s
121. utilisation qui accompagne ce doivent tre effectur s par un r parateur qualifi ou par le fournisseur de gaz this appliance V rifier tous les l ments gaz pour rechercher les fuites apr s avoir allum cet appareil enretien ou une installation incorrect puet entrainer Suivre les instructions et les consignes qui figurent g n rateur d air chaud L installation et l entretien Check entire gas assembly for leaks after lighting natural gas at altitudes 0 10 000 ft 0 3 050m manufacturer shall be used to convert to propane gas use or may be required for some natural gas flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material fired appliances INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS This forced air fumace is equipped for use with HORIZONTAL installations An accessory kit supplied by the Clearance arrows do not change with furnace orientation pplications This furnace is for indoor installation in a uilding constructed on site This fumace may be installed on combustible This fumace may be used with a B 1 Vent ind may be vented in common with other gas 1 This fumace must be installed in accordance with the of local codes follow the National Fuel Gas Code ANSI Ce fournaise air chaud doit
122. within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF ELECTRICAL CONNECTIONS 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access panel door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 26 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness 4 WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2008 and Canadian Electrical 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 4 CAUTION FURNACE MAY NOT OPERATE Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else control will lock out Control must remain grounded th

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