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INSTALLATION INSTRUCTIONS ! WARNING

1. SEE NOTES 1 2 4 7 8 9 on the page following these figures SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures A03209 A03208 441 01 1421 01 Specifications are subject to change without notice 27 Figure 30 Downflow Application Vent Elbow Up then Figure 32 Downflow Application Vent Elbow Left then Up Left SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures SEE NOTES 1 2 4 5 6 7 8 9 on the page following these figures A03207 A03210 Figure 33 Downflow Application Vent Elbow Up then Figure 31 Downflow Application Vent Elbow Up 28 o pl SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 441 01 1421 01 Specifications are subject to change without notice Figure 34 Horizontal Left Application Vent Elbow Left SEE NOTES 1 2 4 7 8 9 on the page following these figures A03213 Figure
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4. 441 01 1421 01 Specifications are subject to change without notice 33 Table 11 Gas Rate Cu Ft Hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION ER Ft 2 Cu Ft 5 Cu Ft FOR 1 REVOLUTION 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 93 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 Table 12 Filter Size Information In mm FURNACE CASING WIDTH FILTE
5. NOTE Blower access door must be installed when taking temperature rise reading Leaving blower access door off will result in incorrect temperature measurements 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power and install lockout tag before changing speed tap NOTE check 32 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly important with straight run ducts When thermometer readings stabilize subtract re turn air temperature from supply air temperature to determine air temperature rise If the temperature rise is outside this range first 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restric tions causing static pressures greater than 0 50 in w c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise 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 Figure 25 Select desired blower motor speed lead from one of the
6. 59 0 Sq In for each of two Horizontal Ducts 441 01 1421 01 Specifications are subject to change without notice 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 ACH 30 40 50 44 66 88 110 132 Space Volume ft 3 0 60 1 050 1 400 1 750 1 100 1 650 2 200 2 750 3 300 0 50 1 260 1 680 2 100 1 320 1 980 2 640 3 300 3 960 0 40 1 575 2 100 2 625 1 650 2 475 3 300 4 125 4 950 0 30 2 100 2 800 3 500 2 200 3 300 4 400 5 500 6 600 0 20 3 150 4 200 5 250 3 300 4 950 6 600 8 250 9 900 0 10 6 300 8 400 10 500 6 600 9 900 13 200 16 500 19 800 0 00 NP NP NP NP NP NP NP NP ACH Air Changes Hour NP Not Permitted 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 Figure 6 Figure 6 Prohibit Installation on Back 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 c
7. sinus S uey JeBuo uedo j Aejop jjo eui JO uo JeMo q ponad Aejap uo su do qaNado3H YO 25070 LON HOLIMS 55 pesojo xonis uoiMs eqni einsseid YOOUD N3dO LON GIG HOLIMS 55 441 01 1421 01 Specifications are subject to change without notice 46 CASING GROUP Outer door Blower door Top filler plate Bottom filler plate Bottom enclosure ELECTRICAL GROUP Control bracket Junction box Limit switch es Circuit board Door switch Transformer Wiring harness 115v Wiring harness 24v PARTS REPLACEMENT INFORMATION GUIDE BLOWER GROUP Blower housing Blower cutoff Blower motor Blower wheel Capacitor where used Capacitor strap where used Grommet Power choke where used GAS CONTROL GROUP Manifold Burner assembly Orifice Flame sensor Hot surface igniter MODEL NUMBER IDENTIFICATION GUIDE DIGIT POSITION F or G Mainline N Entry 8 80 AFUE M Multiposition EFFICIENCY POSITION V Variable Speed Blower Motor ECM X ECM Blower Motor S Single stage T Two stage N Standard L Low Nox 045 45 000 BTU hr 070 70 000 BTU hr 090 90 000 BTU hr 110 110 000 BTU hr 135 135 000 BTU hr 14 143 16 17 171 2 21221 24 241 08 800 CFM 12 1200 CFM 14 1400 CF
8. SPARE 1 SPARE 2 HEAT SPARE 3 COOLING COM BHT CLR BLWM NOTE 16 Hol lo laaj EAC 1 N XFMR 115VAC LS1 152 NOTE 10 Pme TRAN 5 2NAC WHENUSED BVSS 055 FRS1 6 24VACRED COMBLUE gt Pts PRS NOTE 11 LGPS WHEN USED Gv LINDYID Q31NItid PCB COM NOTE 5 HUM 2AVAC pi4 NOTE 3 P1 9 1 11 PTT If any of the original equipment wire is replaced use wire rated for 105 C Use only copper wire between the disconnect switch and the furnace junction box JB This wire must be connected to furnace sheet metal for control to prove flame Symbols are electrical representation only Solid lines inside PCB are printed circuit board conductors and are not included in legend Replace only with a 3 amp fuse Inducer IDM motor contains internal auto reset thermal overload switches OL Neutral connections are interchangeable within the Neutral connector block Blower motor speed selections are for average conditions see installation instructions for details on optimum speed selection Factory connected when BVSS Chimney Adapter Accessory Kit is not installed Factory connected when LGPS is not used gnition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours Blower on delay gas heating 25 seconds cooling or heat pump 2 seconds Blower off delay gas heating selections are 90 120 150 or 180 s
9. refer to the unit rating plate For installations above 2000 ft 610 M multiply the input on the rating plate by the de rate multiplier in Table 8 for the correct input rate 2 Determine the correct orifice and manifold pressure ad justment There are two different orifice and manifold adjustment tables All models in all positions except Low NOx models in downflow or horizontal positions use Table 13 22 000 Btuh Burner Low NOx models in the downflow or horizontal posi tions must use Table 14 21 000 Btuh Burner See in put 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 13 or 14 d Find closest natural gas heat value and specific grav ity in Table 13 or 14 e Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation 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 10 11 13 and 14 Use only factory supplied orifices See EXAMPLE 1 441 01 1421 01 Table 10 Altitude Derate Multiplier for U S A ALTITUDE PERCENT DERATE FT M OF MULTIPLIER DERATE FACTOR 0 2000 0 610 0 1 00 2001 3000 610 914 8 12 0 90 3001 4000 914 1
10. 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 Downflow Vent Guard Kit is used in the downflow position 4 Type B vent where required refer to Note 1 above Specifications are subject to change without notice 29 5 Four inch single wall 26 ga min vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace 6 Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit for sizing and complete application details 8 Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart 9 Secure all other single wall vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations 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
11. 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 mo tor BLWM will operate at COOL speed When the ther mostat is satisfied the blower motor BLWM will operate an additional 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 automatically changes the timing sequence to avoid long blower off times during demand defrost cycles When the R to W and Y or R to W and Y and G circuits are energized the furnace control CPU will con tinue 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 peri od then shut off for 24 sec then come back on at HEAT speed When the W input signal disappears the fur nace control begins a normal inducer post purge peri od and the blower switches to COOL speed after a 3 sec delay If the R to W and Y and G signals disap pear at the same time the blower motor BLWM will re main on for the selected blower OFF delay period If the R to W and Y signals disappear leaving the G signal the blower motor BLWM will continue r
12. 3 i945 1890 1830 1770 1715 i655 1600 1545 1480 1430 Orange 2 1420 1340 1280 1200 1140 1065 1005 925 865 790 Hed 1 1280 1205 i40 1055 990 910 840 760 695 630 Gay 5 2065 2005 i940 18 5 1810 1740 1670 1600 1530 1470 Bie 4 1825 1760 i695 1630 1560 1490 1420 1350 1275 1205 1352420 Yellow 3 1760 1690 1625 i555 1485 1415 1345 1275 1200 1130 Orange 2 1620 1550 1480 1405 1335 1260 195 1130 1065 995 NO Co gt O1 2 gt Red 1 1325 1260 1185 NOTES 1100 1025 955 885 805 735 670 1 A filter is required for each return air inlet Airflow performance includes a 3 4 in 19 mm washable filter media such as contained in factory authorized accessory filter rack See accessory list To determine airflow performance without this filter assume an additional 0 1 in W C available external static pressure 2 ADJUST THE BLOWER SPEED TAPS AS NECESSARY FOR THE PROPER AIR TEMPERATURE RISE FOR EACH INSTALLATION 3 Highlighted areas indicate airflow range is beyond the range allowed for heating THESE AIRFLOW RANGES MAY ONLY BE USED FOR COOLING Indicates unstable operating conditions Table 6 Maximum Capacity of Pipe NOMINAL IRON INTERNAL PIPE DIAMETER SIZE IN mm In mm 10 1 2 13 0 622 16 175 53 3 4 19 0 824 21 360 110 1 25 1 049 27 680 207 1 1
13. 980 945 920 890 855 815 770 735 690 645 0451412 Orange 3 770 720 685 840 800 385 Bue 2 710 660 620 580 540 490 455 415 375 335 Hed 1 600 540 S00 455 4i5 385 345 305 235 Guy 5 ne i40 i095 1055 1005 960 915 865 820 780 Yelov 4 1000 940 895 850 800 750 695 650 600 555 0701712 Bue 3 990 93s 895 845 790 740 690 640 590 535 Orange 2 85 775 720 660 605 560 495 435 385 335 Hed 1 860 68s 515 445 385 340 275 205 1215 980 0701716 Bue 3 1215 nes 1120 1075 1085 985 940 895 845 840 Orange 2 1175 130 1085 1035 990 945 900 855 805 760 Hed 1 1080 1015 955 920 875 820 780 725 670 620 B15 B15 1714 Bue 3 1220 1185 1160 1105 1065 1025 975 915 840 740 1030 985 940 900 535 Red 1 945 905 855 800 750 670 600 540 490 435 995 Bue 4 1440 1895 1350 1305 1255 1200 1145 1090 1040 950 0902116 940 1260 1210 1160 1105 1050 990 Hed 1 1095 i040 980 905 845 780 720 650 755 520 Gray 5 2255 2205 2150 2100 2040 1985 1920 1835 1735 1615 Yellow 4 1600 1525 i465 1400 1335 1275 1210 1150 1080 1015 1102120 Blue
14. U S A Refer to Sections 13 1 8 and 13 2 20 of the NFGC NFPA 54 ANSI 2223 1 2012 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 2012 13 1 8 and 19 2 20 regarding alternative venting design and the Exception which cover installations such as the Chimney Adapter Kits 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 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 double wall and 2 This furnace is common vented with at least 1 draft hood equipped appliance and 3 The combined appliance input rating is less than the maximum capacity given in Table 8 and Specifications are subject to change without notice 23 4 The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99 Winter Design Temperature Chim neys having internal areas greater than 38 square inches require furnace input ratings greater than the in put ratings of these furnaces See footnote at bottom of Table 9 and 5 The authority having jurisdiction approves If all of t
15. 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 10 Specifications are subject to change without notice 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 Outdoor Combustion Air Method mentioned previ ously 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 Meth od below Figure 9 Removing Bottom Closure Panel FILLER PANEL b Outdoor opening size reduction Factor is 1 minus the Ratio in a above c Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor in b above The minim um 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 two screws holding bottom filler panel See Figure 9 2 Rotate bottom
16. from Indoors RCULATING AIR DUCTS VENT THROUGH ROOF 12 MAX 305mm 1 SQ IN PER 1000 BTUH IN DOOR OR WALL UNCONFINED INTERIOR SPACE HEATED SPACE 6 MIN 152mm FRONT 1 SQIN 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 in 2 with minimum dimensions of 3 in 76 mm Minimum of 3 in 76 mm when type B1 vent is used A03175 2 An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1 in 2 4 000 Btuh of total input rating for all gas appliances in the space 3 In spaces that use the Indoor Combustion Air Meth od infiltration should be adequate to provide air for combustion permanent ventilation and dilution of flue gases However in buildings with unusually tight con struction additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section Unusually tight construction is defined as construction with a Walls and ceilings exposed to the outdoors have a continuous sealed vapor barrier Openings are gas keted or sealed and b Doors and openable windows are weatherstripped and
17. condition occurs in the gas control area DO NOT bypass the switches Correct inadequate combustion air supply problem before resetting the switches 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 1 Maintain 115 v wiring and ground Improper polarity will result in flashing a status code 10 and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the furnace control Failure to make proper connections will result in improper operation See Figure 26 3 Gas supply pressure to the furnace must be greater than 4 5 in w c 0 16 psig but not exceed 14 in w c 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 30 Specifications are subject to change without notice Step 2 Start Up Procedures 4 WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause 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 f
18. 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 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Figure 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 441 01 1421 01 closure panel to install leveling legs To remove bottom Figure 11 Floor and Plenum Opening Dimensions closure panel see Item 1 in Bottom Return Air Inlet section To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace See Figure 10 2 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base In stall flat washer if desired Figure 10 Leveling Legs A96283 Figure 12 Furnace Plenum and Subbase Installed on a Combustible Floor
19. furnace is approved for UPFLOW DOWNFLOW and HORIZONTAL installations Clearance arrows do not change with furnace orientation This forced air furnace is equipped for use with natural gas at altitudes O 10 000 ft 0 3 050m An accessory kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for some natural gas applications This furnace is for indoor installation in a building constructed on site This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material This furnace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Vent Clearance to combustibles For Single Wall vents 6 inches 6 po For Type B 1 vent type 1 inch 1 po 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 END4X ENWAX WENC WTNC WENW OR WTNW 18 inches front clearance required for alcove Indicates supply or return sides when furnace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket serviceman to correct the condition and reset
20. gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in w c stated on gas control valve See Figure 41 Some installations require gas entry on right side of furnace as viewed in upflow See Figure 18 Install a sediment trap in riser leading to furnace as shown in Figure 19 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 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 Figure 18 Burner and Manifold TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY 90 Elbow _ E ig Jae 5 2 51mm Nipple CER Street A t Gas Valve A08551 Figure 19 Typical Gas Pipe Arrangement GAS 7 SUPPLY pA MANUAL SHUTOFF VALVE REQUIRED wb SEDIMENT TRAP UNION A02035 441 01 1421 01 Table 5 Air Delivery CFM With Filter WIRE Test Airflow Delivery Various External Static Pressures in w c UNIT SIZE LEAD SPEED COLOR 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 1230 1190 1155 1120 1080 1045 1010 895 Yelov 4
21. is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents 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 n
22. limit switch CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction 4 Specifications are subject to change without notice 336996 101 REV In the United States follow all codes and standards for the following Safety e 5 National Fuel Gas Code NFGC NFPA 54 2012 ANSI Z223 1 2012 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B 441 01 1421 01 Figure 3 Return Air Temperature NSH MAX 80 F 27 C zc mm RETURN AIR MIN 60 F 16 C nux pin mpm A06745 General Installation e Current edition of the NFGC and the NFPA 908 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 Combustion and Ventilation Air e NFGC NFPA 54 ANSI Z223 1 2012 Section 9 3 Air for Combustion and Ventilation Duct Systems e Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Con tract
23. maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash a status code 10 and furnace will NOT operate J BOX RELOCATION NOTE If factory location of J Box is acceptable go to next section ELECTRICAL CONNECTION TO NOTE 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 Specifications are subject to change without notice 19 NOTE The 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 2 Cut wire tie on loop in furnace wires attached to J box 3 Move 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 Electrical Box on Furnace Casing Side 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
24. maximum 2 percent voltage drop ELECTRICAL CONNECTIONS A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing 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 Figure 26 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 35 C rise 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 NFPA 70 2011 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 c
25. other terminals and relocate it to the HEAT terminal See Table 5 for lead color identifica tion Reconnect original lead to SPARE terminal f Repeat steps a through e When correct input rate and temperature rise is achieved turn gas valve ON OFF switch to OFF Remove manometer or similar device from gas valve Reinstall manifold pressure tap plug in gas valve Figure 41 Gas Control Valve A06666 Figure 42 Orifice Hole N BURNER ORIFICE A93059 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 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 mid point of rise range or slightly above Specifications are subject to change without notice 441 01 1421 01 6 Set thermostat heat anticipator a Mechanical thermostat Set thermostat heat anticip ator to match the amp draw of the electrical compon ents in the R W circuit Accurate amp draw readings can be obtained at the wires normally connected to thermostat subbase terminals R and W The thermo stat anticipator should NOT be in the circuit while measuring current 1 Remove thermostat from subbase or from
26. vent elbow with at least two field supplied corrosion resistant sheet metal 441 01 1421 01 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 Figure 28 Figure 40 3 Determine the correct location of the knockout to be re moved 4 Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth until the slug breaks free 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 Specifications are subject to change without notice 25 26 Crown condition Missing mortar or brick Is chimney property lined with clay tile liner Is liner and top seal in good condition Debris in cleanout Mortar tile metal vent fuel oil residue Figure 27 Chimney Inspection Chart CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances Rebuild crown Repair liner or top seal or reline chimney as necessary Mortar or tile Remove mortar deb
27. will not interfere with installed electrical box 2 Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace 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 5 Pull furnace power wires out of 1 2 in 12 mm diamet er 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 Pull field power wires into electrical box 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 removed in Step 4 11 Secure field ground wire to J Box green ground screw 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Figure 26 Use best practices NEC in U S for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket Figure 23 Relocating J Box FACTORY INSTALLED LOCATION L gt ALTERNATE FIELD LOCATION Figure 24 Field Supplied Electrical Box on Furnace Casing A10141 20 Specifications are subject to change without notice 441 01 1421 01 POWER CORD INSTALLATION
28. 1 4 subbase not required 406 549 422 565 Downflow Applications on Noncombustible Flooring 15 7 8 19 16 1 2 19 5 8 17 1 2 subbase not required 403 483 419 498 445 Downflow Applications on Combustible Flooring subbase required ye 203 Mon po Downflow Applications on Combustible Flooring Coil with Coil 15 1 2 19 16 1 2 20 ENWAX or Coil Casing NAEA subbase not required 394 483 419 508 Upflow Applications on Combustible or Noncombustible Flooring 19 1 2 21 5 8 20 1 8 22 1 4 subbase not required 495 549 511 565 Downflow Applications on Noncombustible Flooring 19 3 8 19 20 19 5 8 21 subbase not required 492 483 508 498 533 Downflow Applications on Combustible Flooring subbase required pei 403 d e Downflow Applications on Combustible Flooring with Coil ENDAX 19 19 20 20 ENWAX or Coil Casing NAEA subbase not required 483 483 508 508 Upflow Applications on Combustible or Noncombustible Flooring 23 21 1 8 23 5 8 22 1 4 subbase not required 584 537 600 565 Downflow Applications on Noncombustible Flooring 22 7 8 19 23 1 2 19 5 8 24 1 2 subbase not required 581 483 597 498 622 Downflow Applications on Combustible Flooring subbase required cog 263 p e Downflow Applications on Combustible Flooring with Coil ENDAX 22 1 2 19 23 1 2 20 ENWAX or Coil Casing NAEA subbase not required 572 483 597 508 HORIZONTAL INSTALLATION A WARNING FIRE EXPL
29. 219 12 16 0 86 4001 5000 1219 1524 16 20 0 82 5001 6000 1524 1829 20 24 0 78 6001 7000 1829 2134 24 28 0 74 7001 8000 2134 2438 28 32 0 70 8001 9000 2438 2743 32 36 0 66 9001 10 000 2743 3048 36 40 0 62 Derate multiplier factors are based on midpoint altitude for altitude range EXAMPLE 1 0 to 2000 ft 0 to 610 M altitude For 22 000 Btuh per burner application use Table 13 Heating value 1000 Btuh cu ft Specific gravity 0 62 Therefore Orifice No 43 Manifold pressure 3 7 in w c 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 Figure 41 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 Remove regulator seal cap and turn regulator adjust ing screw counterclockwise out to decrease input rate of clockwise in to increase input rate Install regulator seal cap i Leave manometer or similar device connected and proceed to Step 4 NOTE DO NOT set manifold pressure less than 3 2 in w c or more than 3 8 in w c for natural gas at sea level If manifold pressure is outside
30. 35 Horizontal Left Application Vent Elbow Right then Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03214 Figure 36 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03214 Figure 37 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page ollowing these figures A03215 441 01 1421 01 Figure 38 Horizontal Right Application Vent Elbow Left then Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219 Figure 39 Horizontal Left Application Vent Elbow Right E SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Figure 40 Horizontal Right Application Vent Elbow Left SEE NOTES 1 2 4 5 7 8 9 A02068 Venting Notes for Figure 28 Figure 40 1 For common vent vent connector sizing and vent material United States use the NFGC 2 Immediately increase to 5 inch 127 mm or 6 inch 152 mm vent connector outside furnace casing when 5 inch
31. 4 32 1 380 35 1400 427 1 1 2 38 1 610 41 2100 640 LENGTH OF PIPE FT M 20 30 40 50 120 37 97 30 82 25 73 22 250 76 200 61 170 52 151 46 465 142 375 114 320 98 285 87 950 290 770 235 660 201 580 177 1460 445 1180 360 990 301 900 274 Cubic ft of natural gas per hr for gas pressures of 0 5 psig 14 in w c or less and a pressure drop of 0 5 in w c based on a 0 60 specific gravity gas Ref Chapter 6 ANSI Z223 2012 NFPA 54 2012 Piping should be pressure and leak tested in accordance with NFGC in the United States 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 w c 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 w c turn off electric shutoff switch 441 01 1421 01 located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF Specifications are subj
32. 5 Figure 4 Multipoise Orientations AIRFLOW gt THE BLOWER 15 LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER IS LOCATED PELO TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT lt HORIZONTAL LEFT AIRFLOW DOWNFLOW THE BLOWER IS LOCATED ABOVE THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED DOWNWARD HORIZONTAL RIGHT THE BLOWER IS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT AIRFLOW A02097 LOCATION 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be GENERAL This multipoise furnace is shipped in packaged configuration Some assembly and modifications are required when used in any of the four applications shown in Figure 4 This furnace must beinstalled so the electrical components are protec ted from water contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten i furnace life Air contaminants are found in aerosol proved floor base or coil model numbers END4X sprays detergents bleache
33. 9 Winter Design Temperature 11 F 24 C or lower Not recommended for any vent configuration The 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chapter Table 1A Un ited States or the 2005 ASHRAE Fundamentals handbook Climatic Design Information chapter and the CD ROM included with the 2005 ASHRAE Fun damentals Handbook 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 Contractors 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 T
34. A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI 2223 1 54 Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Close fireplace dampers Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner oper
35. CE OF OPERATION 42 WIRING DIAGRAM sssssseen Inh 44 TROUBLESHOOTING GUIDE 45 E A LUDI 5 man CERTIFIED a www ahridirectory org a Use of the AHRI Certified TM Mark indic ates a manufacturer s participation in the program For verification of certification for individual products go to www ahridirect ISO 9001 E QMI SAI Global 4 WARNING PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Failure to carefully read and follow this warning could result in equipment malfunction property damage personal injury and or death Installation or repairs made by unqualified persons could result in equipment malfunction property damage personal injury and or death The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments Installation must conform with local building codes and with the Natural Fuel Gas Code NFCG NFPA 54 ANSI 2223 1 INSTALLER Affix these instructions on or adjacent to the furnace CONSUMER Retain these instructions for future reference Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2012 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washing ton DC 20001 This reprinted material is not the complete and officia
36. CL MD RE FURNACE OR COIL CASING WHEN USED Iw 44mm 1 3 4 44mm Sa COMBUSTIBLE FLOORING NC DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR _____ OPENING A89014 4 Adjust outside nut to provide desired height and tight en inside nut to secure arrangement 5 Reinstall bottom closure panel if removed DOWNFLOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following two accessories are used e Downflow combustible floor subbase e Coil model numbers END4X ENW4X e Coil casing model number NAEA 1 Determine application being installed from Table 4 2 Construct hole in floor per Table 4 and Figure 11 Construct plenum to dimensions specified in Table 4 rite and Figure 11 4 If downflow subbase is used install as shown in 4 422520222 223243 Figure 12 If coil model numbers END4X ENWAX or FURNACE coil casing model number NAEA are used install as APPROVED shown in Figure 13 COIL ASSEMBLY NOTE t is required that the perforated supply air duct COIL BOX flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil MOBBING or coil casing To remove the supply air duct flange use wide zi duct pliers or hand seamers to b
37. 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 Remove cover from J Box 2 Route listed power cord through 7 8 in 22 mm dia meter hole in J Box 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Figure 26 6 Reinstall cover to J Box Do not pinch wires between cover and bracket BX CABLE INSTALLATION IN FURNACE J BOX 1 Remove cover from J Box 2 Route BX cable into 7 8 inch diameter hole in J Box 3 Secure BX cable to J Box bracket with connectors ap proved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Figure 26 6 Reinstall cover to J Box Do not pinch wires between cover and bracket 24 V WIRING Make field 24 v connections at the 24 v terminal strip See Figure 24 Connect terminal Y Y2 as shown in Figure 25 for proper cooling operation Use only AWG 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 si
38. INSTALLATION INSTRUCTIONS 80 Single Stage ECM Motor Category I Gas Furnace N8MXL These instructions must be read and understood completely before attempting installation Safety Labeling and Signal Words DANGER WARNING CAUTION and NOTE The signal words DANGER WARNING CAUTION and NOTE are used to identify levels of hazard seriousness The signal word DANGER is only used on product labels to signify an immediate hazard The signal words WARNING CAUTION and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product DANGER Immediate hazards which will result in severe person al injury or death WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION Hazards or unsafe practices which may result in minor personal injury or product or property damage NOTE Used to highlight suggestions which will result in en hanced installation reliability or operation Signal Words in Manuals The signal word WARNING is used throughout this manual in the following manner WARNING The signal word CAUTION is used throughout this manual in the following manner Signal Words on Product Labeling Signal words are used in combination with colors and or pictures or product labels N Safety alert symbol When you see this symbol on the unit and in instructions or manu als be alert to the potential for personal i
39. M 16 1600 CFM 20 2000 CFM 22 2200 CFM 1 N 8 M X L Gas valve Manual reset limit switches HEAT EXCHANGER GROUP Heat exchanger cell Cell panel Lox NOx baffle INDUCER GROUP Housing assembly Pressure switch Inducer motor Inducer wheel Vent elbow assembly 12 A 1 HEAT INPUT CABINET WIDTH COOLING AIRFLOW SALES MAJOR REVISION DIGIT ENGINEERING MINOR REVISION DIGIT TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or the classified section of your local telephone directory under the Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact International Comfort Products Consumer Relations Department P O Box 128 Lewisburg TN 37091 USA 931 270 4100 Have available the product model number and the serial number located on the unit rating plate to ensure correct replacement parts WARNING Improper installation adjustment alteration service or maintenance can cause personal injury property damage or death Consult a qualified installer service agency or your local gas supplier for information or assistance The qualified installer or service agency must use only factory authorized replacement parts kits or accessories when modifying this product 47 Specifications are subject to change without notice Copyright 2015 International Comfort Products Lewisburg TN 37091 USA 441 01 1421 01
40. ORIZONAL LEFT HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 5 TONS AND YES GREATER ALL OTHER MODELS YES 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED 18 Specifications are subject to change without notice 441 01 1421 01 Table 7 Electrical Data Operating Volts Voltage Range Minimum Maximum Maximum FURNACE Hertz Maxi Mini Maximum Unit Wire Size Wire Lengtht Fuse or CKT MODEL Phase mum mum Unit Amps Ampacity AWG ft m BKRt Amps 0451412 115 60 1 127 104 5 6 7 8 14 0 47 0 14 3 15 0 0701712 115 60 1 127 104 5 6 7 8 14 0 47 0 14 3 15 0 0701716 115 60 1 127 104 10 0 13 3 14 0 27 0 8 2 15 0 0901714 115 60 1 127 104 8 2 11 0 14 0 33 0 10 1 15 0 0902116 115 60 1 127 104 82 11 0 14 0 33 0 10 1 15 0 1102120 115 60 1 127 104 13 4 174 12 0 33 0 10 1 20 0 1352420 115 60 1 127 104 10 7 14 0 14 0 26 0 7 9 15 0 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 delay type is recommended t Length shown is as measured 1 way along wire path between unit and service panel for
41. OSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal 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 Figure 2 and Figure 17 For furnaces with 1 in 25 mm clearance requirement on side set furnace on noncombustible 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 mm 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 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 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 thread
42. OTIVE BLADE TYPE FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE FIELD INSTALLED amp SUPPLIED EQUIPMENT GROUND GAS VALVE REDUNDANT GAS VALVE RELAY DPST N O HOT SURFACE IGNITER 115VAC HOT SURFACE IGNITER RELAY SPST N O LINE VOLTAGE HUMIDIFIER CONNECTION 115V 24VAC HUMIDIFIER CONNECTION 0 5 AMP MAX INDUCED DRAFT MOTOR SHADED POLE INDUCED DRAFT MOTOR RELAY SPST N O BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O BLOWER OFF DELAY JUMPER SELECTOR COOLING OFF DELAY DEFEAT JUMPER JUNCTION BOX LIGHT EMITTING DIODE FOR STATUS CODES GREEN LOW GAS PRESSURE SWITCH SPST N O LIMIT SWITCH AUTO RESET SPST N C WHT WHT com ____ FUSE OR CIRCUIT BREAKER amp DISCONNECT SWITCH WHEN REQ D NOTE 2 PRINTED CIRCUIT BOARD CONTROL 11 CIRCUIT PCB CONNECTOR 2 CIRCUIT CONNECTOR 2 CIRCUIT HSI CONNECTOR 5 CIRCUIT BLWM SPEED TAP CONNECTOR 4 CIRCUIT BLWM POWER CONNECTOR PRESSURE SWITCH SPST N O TEST TWIN COMPONENT TEST amp TWIN TERMINAL TRAN TRANSFORMER 115VAC 24VAC JUNCTION UNMARKED TERMINAL PCB CONTROL TERMINAL FACTORY WIRING 115VAC FACTORY WIRING 24VAC FIELD WIRING 115VAC FIELD WIRING 24VAC CONDUCTOR ON CONTROL PCB FIELD WIRING SCREW TERMINAL FIELD EARTH GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE O TO 115 VAC FIELD DISCONNECT SWITCH NOTE 2 ILK NEURALI j EQUIPMENT SCHEMATIC DIAGRAM
43. R SIZE In mm In mm Side Return Bottom Return FILTER TYEE 14 1 2 868 abe x 635 x 19 856 x 638 x 19 Washable 17 1 2 445 408 x 636 x 19 406 x 635 x 19 washable 21 533 lige x pos 5 9 ee oe Washable 24 610 16 x 25 x 3 4 24 X 25 X 3 4 ES Recommended 34 406 x 635 x 19 610 x 635 x 19 Specifications are subject to change without notice 441 01 1421 01 Table 13 Orifice Size and Manifold Pressure in w c for Gas Input Rate TABULATED DATA BASED ON 22 000 BTUH PER BURNER DERATED 4 1000 FT 305M 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 2001 611 to 3000 914 3001 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A10180 441 01 1421 01 Specifications are subject to change without notice 35 Table 13 Orifice Size and Manifold Pressure in w c for Gas Input Rate CONT TABULATED DATA BASED ON 22 000 BTUH PER BURNER DERATED 4 1000 FT 305M ABOVE SEA LEVEL ALTITUDE 2134 to 8000 2438 8001 2439 to 9001 2744 to AVG GAS AT ALTITUDE Btu cu ft Manifold Pressure Orifice No Manifold Pressure Orifice numbers shown inBOLD are
44. SIZE SHIP WT FURNACE SIZE IN MM IN MM IN MM IN MM IN MM LB KG 0451412 14 3 16 360 12 9 16 319 9 5 16 237 12 11 16 322 4 102 104 47 0701712 17 1 2 445 15 7 8 403 11 9 16 294 16 406 4 102 126 57 0701716 17 1 2 445 15 7 8 403 11 9 16 294 16 406 4 102 126 57 0901714 17 1 2 445 15 7 8 403 11 9 16 294 16 406 4 102 127 58 0902116 21 533 19 3 8 492 13 5 16 838 19 1 2 495 4 102 140 64 1102120 21 533 19 3 8 492 13 5 16 838 19 1 2 495 4 102 152 69 1352420 24 1 2 622 22 7 8 581 15 1 16 383 23 584 4 102 163 74 135 size furnaces require a 5 in or 6 in 127 or 152 mm vent Use a vent adapter between furnace and vent stack 2 Specifications are subject to change without notice 441 01 1421 01 SAFETY CONSIDERATIONS 4 WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation serious injury death or property damage Improper installation adjustment alteration service 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 maintenance or use could cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury
45. ST BE OUT OF CIRCUIT HOOK AROUND AMMETER 10 ae FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 50 AMPS ON AMMETER _ _ 0 5 AMPS FOR THERMOSTAT 3 10 TURNS AROUND JAWS _ ANTICIPATOR SETTING A96316 Check Pressure Switch This control proves operation of the draft inducer blower a Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire har ness 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 flashes a status code 3 If hot surface igniter glows when inducer motor is disconnected shut down furnace immedi ately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power h Blower will run for 90 sec and flash status code 1 2 before beginning the call for heat again i Furnace should ignite normally Step 5 Checklist 1 2 3 Put away tools and instruments Clean up debris Verify that heat off delay time is selected as desired Verify that blower and burner access doors are prop erly installed Cycle test furnace with room thermostat Check operation of accessories per manufacturer s in structions Review User s Guide with owner Attach literature packet to furnace
46. 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 airstream The cover attachment shall prevent leaks 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 Figure 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 degrees 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 supply air outlet on furnace Bend flange inward past 90 with wide duct pliers See Figure 14 The supply air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connec
47. 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 type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer 441 01 1421 01 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 Ductwork Acoustical Treatment 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
48. To perform status code recall component test the control must be in idle mode no calls for heat cool or fan with the blower off displaying a Heartbeat Status code recall component test can be performed in one of two ways 1 Briefly 2 3 seconds connect the TEST TWIN terminal to the thermostat terminal with jumper wire NOTE If connected for more than 4 5 seconds status code 10 will flash but it will not overwrite the previous status code OR 2 Briefly remove then reconnect one limit wire main rollout or draft safeguard switch NOTE If limit wire is disconnected for more than 4 5 seconds status code 4 will flash and the previous status code will be lost After the status code is flashed 4 times the component test will begin see Component Test Sequence below If no previous status code is available the control will not flash a status code and will immediately start the component test Stored status codes are erased automatically after 72 hours EACH OF THE FOLLOWING STATUS CODES IS A SINGLE OR TWO DIGIT NUMBER WITH THE FIRST NUMBER DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND NUMBER AFTER THE PLUS SIGN IS THE NUMBER OF LONG FLASHES LED STATUS CODES HEARTBEAT bright dim Control has 24VAC power 6 Continued Oxide buildup on flame sensor clean with fine steel wool 2 PRESSURE SWITCH DID NOT OPEN Check for Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Obstructed pressure t
49. UCH 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 furnace chassis which is close to the control 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 discharged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do noth ing to recharge your body with static electricity for ex ample DO NOT move or shuffle your feet do not touch ungrounded objects etc 4 If you touch ungrounded objects and recharge your body with static electricity firmly touch a clean un painted metal surface of the furnace again before touching control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the fur nace Put all used and new controls into containers be fore touching ungrounded objects 7 ESD service kit available from commercial sources may also be used to prevent ESD damage Specifications are subject to change without notice
50. allation 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 EQUIPMENT MANUAL SHUT OFF GAS VALVE SEDIMENT TRAP Return Air Connections 4 WARNING FIRE HAZARD Failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furnace Refer to the following instructions 441 01 1421 01 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNACE EXTEND OUT 12 305mm FROM FACE OF DOOR MIDI AH WHEN USED WITH SINGLE WALL VENT CONNECTIONS 10164 Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Figure 21 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most horizontal furnaces See Figure 21 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 Specifications are subject to change without notice 15 furnace casing as shown in Figure 20 and Figure 22 Bypass humidifier may be attached into unused return air side of the furnace casing See Figure 20 and Figure 22 Not all horizontal furnaces are
51. an cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with this furnace ADDITIONAL VENTING REQUIREMENTS A 4 101 mm round vent elbow is supplied with the furnace A 5 inch 127 mm or 6 inch 152 mm vent connector may 441 01 1421 01 be required for some model furnaces A field supplied 4 inch to 5 inch 101 127 mm or 4 inch to 6 inch 101 152 mm sheet metal increaser fitting is required when 5 inch 127 mm or 6 inch 152 mm vent connector is used See Figure 28 Figure 40 Venting Orientation for approved vent configurations NOTE Vent connector length for connector sizing starts at furnace vent elbow The 4 inch vent elbow is shipped for upflow configuration and may be rotated for other positions Remove the 3 screws that secure vent elbow to furnace rotate furnace vent elbow to position desired 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 furnace through one of 5 locations on the casing 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 resist ant sheet metal screws located 180 apart NOTE A flue extension is recommended to extend from the furnace elbow to outside the furnace casing If flue extension is used fasten the flue extension to the
52. and shall be rigidly supported every 5 ft 2 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 Per section 12 4 3 of the NFPA 54 ANSI Z223 1 2012 any listed mechanical venter 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 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 FURNACE INPUT MIN VENT MIN VERTICAL VENT ORIENTATION VENT ORIENTATION BTUH HR DIAMETER HEIGHT IN MM FT M Downflow Vent elbow left then up Figure 32 132 000 5 127 12 4 Vent elbow right then up Horizontal Left Figure 35 132 000 5 127 7 2 Horizontal Left Vent elbow right Figure 36 132 000 5 127 7 2 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in 102 mm inside casing or vent guard Including 4 in 102 mm vent section s Figure 28 Upflow Application Vent Elbow Up Figure 29 Upflow Application Vent Elbow Right
53. approved for side return air connections See Figure 22 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 fire or explosion may result causing property damage personal injury or loss of life 4 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 4 CAUTION FURNACE OVERHEAT HAZARD Failure to follow this caution may result in property damage Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment 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 51 mm outside the furnace Gas piping must be installed in accordance with national and local co
54. as valve GV permits gas flow to the burners where it is ignited by the HSI Five seconds after the GVR closes a 2 second flame proving period begins The HSI igniter will remain energized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control CPU will repeat the ignition se quence for up to three more Trials For Ignition be fore 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 24VAC or COM to the furnace control CPU not at W G R etc If flame is proved when flame should not be present the fur nace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT speed 25 sec after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC 1 AMP is energized and remains energized as long as the blower motor BLWM is energized 441 01 1421 01 f Heat Off Delay When the thermostat is satisfied the R to W circuit is op
55. ation Use the flame of a match or candle If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI 2223 1 54 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 441 01 1421 01 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 2012 NFPA 54 2012 Parts 12 and 13 the local building codes and furnace and vent manufacturers instructions These furnaces are design certified as Category furnaces in accordance with ANSI Z21 47 2012 CSA 2 3 2012 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category 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 the local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the re
56. ational Electrical Code NEC NFPA 70 Recognize safety information This is the safety alert symbol A 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 441 01 1421 01 servicing furnaces 10 11 12 13 Use only with type of gas approved for this furnace Refer to the furnace rating plate Install this furnace only in a location and position as specified in the Location section of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in the Venting section of these instruc tions Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of
57. des Refer to current edition of NFGC 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 ap proved by the state of Massachusetts 16 Specifications are subject to change without notice Refer to Table 6 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft 2 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 An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft 2 M of furnace A 1 8 in 8 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 control valve inlet pressure tap connection is suitable to use as test
58. e e 208 230 OR 460 VOLT THREE _ PHASE VOLT 9 SINGLE 4 9 69 115 VOLT FIELD SUPPLIED FUSED DISCONNECT 22 JUNCTION BOX CONTROL BOX TERMINAL 24 VOLT BLOCK FURNACE Jen PHASE CONDENSING UNIT NOTES 1 Connect Y Y2 terminal as shown for proper 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 Specifications are subject to change without notice 441 01 1421 01 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 furnace is removed or replaced the original venting system may no longer be sized to properly vent the attached appliances An improperly sized Category 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 re sized Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC
59. ean 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 7 _ Specifications are subject to change without notice 41 Figure 45 Igniter Position Side View 05025 Figure 46 Igniter Position Top View A05026 NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush 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 Figure 47 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 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 fur nace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attach ment clean burner assembly 8 Clean flame sensor with fine steel wo
60. eb 01 pojrej ujeis S 10104901 poued Aejap uo eui Buunp suado LAN d uaym JO LAWM yeay 19 e dn SI HUN spuooes 06 JO sun uogejedo euuoN Abg ASI HHMOd Hd 14V NO H3MO 18 Bulseyd 1euuojsue Avz 10 49949 peuuiw syun Jj Aurejod eDeyo BUI 1991100 104 YOSYUD ALIHVTOd 6JIM 526 POUS 10 eJIMSIIA uo pesojo onis YOOUD 0 G pue Jamod yo uin 3ese1 LON 033002 10104201 9NILV3H SVD pit epoo Snijels SJnOu 2 IIM g uey 19Buo uedo SI pesn YOUMS JUBA 40 yep eui Ji 51200 1n03201 160104201 LINDYIOD pepunoJD jou snu 10sues 4 19095 eoeuuny ISN yo inus enuen UO YOUMS Seb deis eui e10Jeq Buiwojo eui Aejep jo pe1oejes eui 104 JIM 19MOjq ponad eui Buunp 1591 si j sund00 9 110420 eouonbos uoniuBi eui ad 041009 eui poned uoni
61. ecessary 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 to these installation instructions Table 2 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS 1 SQ IN 2 000 BTUH SINGLE DUCT OR OPENING 1 SQ IN 3 000 BTUH TWO OPENINGS OR VERTICAL DUCTS FURNACE 1 SQ IN 4 000 BTUH C 1 100 SQ MM KW 734 SQ MM KW oso MM BTUH Free Area of Open Round Duct Free Area of Open Round Duct Free Area of Round Duct ing and Duct Diameter ing and Duct Diameter Opening and Duct Diameter sq in sq mm in mm sq In sq mm in mm sq In sq mm In mm 44 000 22 14193 6 152 14 7 9484 5 127 11 7097 4 102 66 000 33 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 9 229 36 7 23677 7 178 27 5 17742 6 152 132 000 66 42581 10 254 44 28387 8 203 33 21290 7 178 EXAMPLES Determining Free Area WATER FURNACE 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 2 000
62. econds cooling or heat pump 90 seconds or 5 seconds when J2 is cut BLWM is locked rotor overload protected by redundant electronic control circuits PL5 and PL6 not available on all motors Blower motor BLWM leads may be hardwired at motor 341179 201 REV C 44 Specifications are subject to change without notice 441 01 1421 01 Figure 49 Troubleshooting Guide eui JO OU 01 9 eui 1 101516 1 Ise eq e 10443 y si 1 5 04 am Jeduunf e jeedoi eui eui SAIM SU JOBULIOISIG lonuoo y uo 1e1souueut 9 10 ZAJA M 12 1ueseJd Avz S e qeo DunoeuuooJejul JO WOO LYVLS 0 yorq pue JexeeJq 65019 o1 ul JO 2999 Jeyeelq S U93IMS JOOP OU 95075 eoeuun sunoy 2 peseJe 5 uoljeJado Jo e 5 uny 5 yeysouueuy Arz 5 pue LA M 91 puodsei
63. ect R 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 below room temperature 6 Verify furnace restarts by raising thermostat setting above room temperature aao 441 01 1421 01 Step 3 Adjustments 4 WARNING FIRE HAZARD Failure to follow this warning could result in injury death and or property damage 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 4 CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Figure 42 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft 610 M Furnace input rate must be within 2 percent of furnace rating plate input For altitudes above 5500 ft 1676 M a field supplied high altitude pressure switch is required 1 Determine the correct gas input rate The input rating for altitudes above 2 000 ft 610 M must be reduced by 4 percent for each 1 000 ft 305 M above sea level For installations below 2000 ft 610 M
64. ect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing A CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operation or failure of furnace Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 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 4 you must revise your orientation to component location accordingly 441 01 1421 01 ELECTRICAL CONTROLS AND WIRING A WARNING ELECTRICAL OPERATION 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 Lock out and tag switch with a suitable warning label The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Figure 26 for field wiring information and to Figure 25 for furnace wiring
65. ect to change without notice 17 Figure 20 Upflow Return Air Configurations and Restrictions SUPPLY AIR UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION 2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 5 TONS AND YES YES YES YES GREATER ALL OTHER MODELS YES YES YES YES 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED 4 RETURN RETURN AIR AIR UPFLOW BEN RETURN AIR e RESTRICTIONS Figure 21 Downflow Return Air Configurations and Restrictions RETURN AIR RETURN AIR SIDE RETURN SIDE RETURN NOT PERMITTED NOT PERMITTED FOR ANY MODEL FOR ANY MODEL DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 3 5 TONS AND GREATER ALL OTHER MODELS YES 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED SUPPLY AIR Figure 22 Horizontal Return Air Configurations and Restrictions SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS SUPPLY AIR 6 x RETURN n SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS HORIZONAL RETURN AIR i RESTRICTIONS NOTE RESTRICTION SAME FOR H
66. ed rod angle iron or metal plumber s strap as shown See Figure 15 and Figure 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 Figure 15 and Figure 16 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment 12 Specifications are subject to change without notice 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 Figure 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 two screws holding bottom filler panel See Figure 9 441 01 1421 01 2 Rotate bottom filler panel downward to release
67. ed on the blower access door d Verify blower is rotating in the correct direction 17 If furnace is operating properly RELEASE BLOWER ACCESS DOOR SWITCH Remove any jumpers or re connect any disconnected thermostat leads Replace blower access door 18 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside fur nace to existing vent b Connect vent connector to vent elbow 19 Reinstall outer door 441 01 1421 01 20 Cycle furnace through one complete heating and cool ing cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70 F 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 prob
68. end flange back and forth until it breaks off Be careful of sharp edges See Figure 14 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 two screws holding bottom filler panel See Figure 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws PENS SHEET METAL PLENUM ____ FLOOR 4 OPENING 42250222 020222232 441 01 1421 01 Specifications are subject to change without notice 11 Table 4 Opening Dimensions In mm FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B c D Upflow Applications on Combustible or Noncombustible Flooring 12 11 16 21 5 8 13 5 16 22 1 4 subbase not required 322 549 338 565 Downflow Applications on Noncombustible Flooring 12 9 16 19 13 3 16 19 5 8 14 3 16 subbase not required 319 483 335 498 360 Downflow Applications on Combustible Flooring subbase required P 6 263 ps pe Downflow Applications on Combustible Flooring with Coil ENDAX 12 5 16 19 13 5 16 20 ENWAX or Coil Casing NAEA subbase not required 813 483 338 508 Upflow Applications on Combustible or Noncombustible Flooring 16 21 5 8 16 5 8 22
69. ened de energizing the gas valve GV stopping gas flow to the burners and de energizing the 24 v humidifier terminal HUM 24VAC The inducer motor IDM will remain ener gized for a 5 second post purge period Then turn off the inducer motor and HUM 115 v humidifier terminal The blower motor BLWM and air cleaner terminal EAC 1 AMP will remain energized for 90 120 150 or 180 seconds depending on the HEAT OFF delay selection The furnace control CPU is factory set for 120 second Heat Off Delay 2 Cooling Mode 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 AMP is energized with 115 vac when the blower mo tor BLWM is operating When the thermostat is satis fied the R to G and Y circuits are opened The out door unit will stop and the furnace blower motor BL WM will continue operating on the COOL speed for an addi tional 90 sec Cut jumper J2 to reduce the cooling off delay to 5 sec See Figure 25 3 Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed same as HEAT speed Terminal EAC 1 AMP is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 sec ignition and blower ON delay
70. factory installed 36 Specifications are subject to change without notice Orifice No Manifold Pressure Orifice No SPECIFIC GRAVITY OF NATURAL GAS Manifold Pressure A10180A 441 01 1421 01 Table 14 Orifice Size And Manifold Pressure in w c For Gas Input Rate TABULATED DATA BASED ON 21 000 BTUH PER BURNER DERATED 4 1000 FT 305M 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 2001 611 to 3000 914 3001 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A10181 441 01 1421 01 Specifications are subject to change without notice 37 Table 14 Orifice Size And Manifold Pressure in w c For Gas Input Rate CONT TABULATED DATA BASED ON 21 000 BTUH PER BURNER DERATED 4 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold ft m Btu cu ft No Pressure No Pressure No Pressure No Pressure 7001 2134 to 8000 2438 8001 2439 Orifice numbers shown inBOLD are factory installed A10181A Figure 44 Service Label SERVICE
71. gen type refrigerants e Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc e Hydrochloric acid e Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials 441 01 1421 01 All fuel burning equipment must be supplied with air for fuel combustion Sufficient air must be provided to avoid negative pressure in the equipment room or space A positive must be made between the furnace cabinet and return air duct to prevent pulling air from the burner area and from draft safeguard opening Figure 5 Installation in a Garage 18 IN 457 2 mm MINIMUM TO BURNERS A93044 A WARNING FIRE 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 NFGC seal the 4 CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause premature furnace component failure This gas furnace may be used for heating buildings under construction provided that The furnace
72. hese 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 Figure 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 NFGC NFPA 54 ANSI Z223 1 2012 Section 12 10 for additional information on condens ate drains b Indicates the chimney exceeds the maximum per missible size in the tables the chimney should be re built or relined to conform to the requirements of the equipment being installed and the authority having jur isdiction 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 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
73. holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s is used without a bottom return air inlet Not all horizontal furnaces are approved for side return air connections See Figure 20 FILTER ARRANGEMENT 4 WARNING CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in personal injury or death Never operate a furnace without a filter or with filter access door removed There are no provisions for an internal filter rack in these furnaces A field supplied accessory external filter is required Refer to the instructions supplied with the external filter rack for assembly and installation options AIR DUCTS General Requirements The duct system should be designed and sized according to accepted national standards 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
74. information NOTE If the polarity is not correct the STATUS LED on the control will flash a status code 10 and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Figure 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 be off 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 Status codes can be viewed at the sight glass in blower access door The furnace control LED is either ON continuously flashing a heartbeat or a status code For an explanation of status codes refer to service label located on blower access door or Figure 44 See Figure 49 for a brief Troubleshooting Guide STATUS CODE RECOVERY AND COMPONENT TEST 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 Perform component self test as shown on the SERVICE label located on the of blower access door CARE AND MAINTENANCE 4 WARNING FIRE OR EXPLOSION HAZARD Failu
75. l position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety Printed in U S A 441 01 142101 2 18 2015 Figure 1 Dimensional Drawing a AIR FLOW w 7138 91116 9781 74 Er 290 7 127 THERMOSTAT WIRE ENTRY KNOCK OUTS VENTING 6 PLACES 116 SIDE I BOTH SIDES NOTES 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 or 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 return air openings for airflow requirements above 1800 CFM Table 1 Dimensions A B C D VENT TOP AND BOTTOM CONNECTION CABINET WIDTH OUTLET WIDTH FLUE COLLAR BOTTOM WIDTH
76. leaks to check all connections as specified in the Gas Piping section Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allow able range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section A gas fired furnace for installation in a residential gar age must be installed as specified in the warning box in the Location section The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION sec tion of these instructions These Multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas CSA listed accessory gas conversion kit is required to convert furnace for use with propane gas See Figure 2 for required clearances to combustible constructio
77. lem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when discon necting wires from switches because damage may oc cur Draft safeguard switch Inducer motor Pressure switch es Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode Flame rollout switches 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 re moved 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 Remove NOx baffles if installed NOTE Be very careful when removing burner assembly to avoid breaking igniter See Figure 45 and Figure 46 for correct igniter location 9 Using field provided 25 caliber rifle cleaning brush 36 in 914 mm long 1 4 6 mm diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner cl
78. n Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwork for a distance of 36 inches 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installations factory accessory floor base MUST be used when installed on combustible materials and wood flooring Special base is not required when this furnace is installed on manu facturer s coil model numbers END4X ENWAX or coil casing model number NAEA See Figure 2 for clear ance to combustible construction information Specifications are subject to change without notice 3 INTRODUCTION N8MXN 4 way multipoise Category fan assisted furnace is CSA design certified A Category 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 C 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 80 F 27 C db Failure to follow these return ai
79. n if the Standard or Known Air Infiltration Method is used 441 01 1421 01 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 The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas ap pliances 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 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 2012 NFPA 54 2012 9 3 2 2 1 For other than fan assisted appliances such as a draft hood equipped water heater 2113 other Vol 2183 o
80. njury TABLE OF CONTENTS SAFETY 3 INTRODUCTION t tio asked tana ie naka eatin 4 CODES AND STANDARDS 4 SAFETY herd d eeu 4 GENERAL INSTALLATION 00000 c eee e 5 COMBUSTION AND VENTILATION AIR 5 DUCT SYSTEMS jis nadie A cub dads 5 ACOUSTICAL LINING AND FIBROUS GLASS DUCT 5 GAS PIPING AND GAS PIPE PRESSURE TESTING 5 ELECTRICAL CONNECTIONS 5 5 ELECTROSTATIC DISCHARGE PRECAUTIONS PROCEDURE 5 LOCATION EE 6 LOCATION RELATIVE TO COOLING EQUIPMENT 8 AIR FOR COMBUSTION AND VENTILATION 8 INSTALLATION 2 xerit ans Rede uu S DR Edo dde oA 10 UPFLOW INSTALLATION 2 10 DOWNFLOW INSTALLATION 11 OPENING DIMENSIONS 12 HORIZONTAL INSTALLATION 12 FILTER ARRANGEMENT 13 AIR DUGIS serine ra Cel ose ra ini ike EGRE REIR RU 18 GAS PIPING eye fes 16 ELECTRICAL CONNECTIONS 19 zggcesec IMMTR 23 START UP ADJUSTMENT AND SAFETY CHECK 30 SERVICE AND MAINTENANCE PROCEDURES 39 SEQUEN
81. ns are subject to change without notice 21 Figure 25 Furnace Control J2 JUMPER TWINNING AND OR COMPONENT TEST TERMINAL HEAT OFF DELAY JUMPER SELECTOR N e NO 24 V THERMOSTAT TERMINALS 180 TEST TWIN HUM 24VAC if aa HUMIDIFIER TERMINAL 3 AMP FUSE 24 VAC 0 5 AMP MAX 1 TRANSFORMER 24 VAC CONNECTIONS LED OPERATION amp DIAGNOSTIC LIGHT P1 LOW VOLTAGE MAIN HARNESS CONNECTOR P2 HOT SURFACE IGNITOR HSI amp INDUCER MOTOR IND CONNECTOR P2 Y n L 2 4 IND HSI L1 115 L1 LINE VOLTAGE HUM CONNECTION BLOWER SPEED SELECTION TERMINALS SdYL YLW Ave 12345678910 11 z elelejejejojejojojojo 115 VAC BLOWER POWER BL 1 CONNECTION SPARE 3 mmm L2 NEUTRAL Tm EAC TERMINAL 115 VAC 1 0 AMP MAX 115 VAC TRANSFORMER PRIMARY XFMR BL 1 115 VAC L2 NEUTRAL CONNECTIONS m HUMIDIFIER TERMINAL 115 VAC L15F001 Figure 26 Heating and Cooling Application Wiring Diagram with Single Stage Thermostat FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING NOTE 2 1 STAGE DOGR 8 6 THERMOSTAT NE OOM DO THERMOST THREE WIRE HEATING ONLY FIELD SUPPLIED FUSED DISCONNECT ee e e
82. o change without notice 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 motor Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove outer door 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower ac cess door a Disconnect vent connector from furnace vent elbow b Disconnect and remove short piece of vent pipe from within furnace 4 Remove two screws from blower access door and re move blower access door 5 All factory wires can be left connected but field thermo stat connections may need to be disconnected de pending on their length and routing 6 Remove two screws holding blower assembly to blower deck and slide bl
83. o 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 instruc tions Low gas input rate causes low vent gas temper atures causing condensation and corrosion in the fur nace and or venting 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 the thermostat heat anticipator or cycle rate to re duce short cycling 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 c
84. ode 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 441 01 1421 01 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 through green yellow wire routed to gas valve and manifold bracket screw 115 V WIRING Verify that the voltage frequency and phase correspond to that specified on unit 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 Make all electrical connections in accordance with National Electrical Code NEC NFPA 70 2011 and any local codes or ordinances that might apply 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
85. of free area per 4 000 Btuh 550 mm kW for combined input of all gas appliances in the space per Figure 7 and Table 2 3 ONE OUTDOOR OPENING requires a 1 square inch of free area per 3 000 Btuh 734 mm kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connect ors in the space The opening shall commence within 12 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 25 mm from the sides and back and 6 150 mm from the front The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors Figure 7 Air for Combustion Ventilation and Dilution from Outdoors DUCTS TO OUTDOORS 805mm 12 MAX CIRCULATING AIR DUCTS CLEARANCE IN FRONT OF COMBUSTION AIR OPENINGS SHALL BE AT LEAST 3 IN 805mm 12 G o 12 Lj 305mm DUCT 1SQIN TO PER 4000 OUTDOORS BTUH CIRCULATING AIR DUCTS Minimum dimensions of 3 in 76 mm NOTE Use any of the following combinations of openings A amp B C amp D D amp E F amp G A03174 Indoor Combustion Air amp AGA Standard and Known Air Infiltration Rate Methods Indoor air is permitted for combustion ventilation and dilutio
86. oidA zuN oa viio 9 010 SI JUNO pue 15 Josues Y a o MoJeq yuana eui poled uoniuDi jeu Juano 0 4oeuo pue 10 yeoday uo eys aub 01526 pue uedo seb LAvZ eA e 526 Suonoeuuoo seb ssoJoe joeuuo yeay JO eo jes pue 1e1s0Uuu8U 24 poned puooes 91 eui 1 1ueseud ASLE SEM 10 84 uo z E TVHL SN pue ISH 101 euuoo ASLL 40 498UD 1501 jueuoduioo pue 041009 sayub 8809 HSV l4 SLN3S3Hd3HH H3NHOO 1331 H3ddfl NI H38IAF N dn WEM puooes G OU jo pue Aq ay s eur ueis 19594 ojuoo Y eui y YOY 01 1591 jueuoduioo eq ued ulejs s eui Josues ONLA seb ui si w jqosd JOUJOYM 94 0 Jaye jese ojne s dwaye p Ul pue s
87. ol 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 a vegetable oil cooking spray that does not contain corn oil canola oil halogenated hydrocarbons or aromatic content which may prevent an inadequate seal from occuring and RTV sealant such as 42 Specifications are subject to change without notice G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant are required DO NOT substitute any other type of RTV sealant 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all Screws are secure 13 Reconnect wires to the following components Use connection diagram on wiring label if wires were not marked for reconnection locations Draft safeguard switch Inducer motor Pressure switch es Limit over temperature switch Gas valve Hot surface igniter Flame sensing electrode Flame rollout switches i Install NOx baffles if removed 14 Reinstall internal vent pipe if applicable 15 Reinstall vent connector on furnace vent elbow Se curely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws loc ated 180 apart 16 Re
88. or leaks 3 To Begin Component Self Test Remove blower access door Disconnect the thermo stat R lead from the furnace control board Manually close the blower door switch closed Short jumper the C 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 Figure 25 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 control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 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 Figure 44 a LED will display previous status code 4 times NOTE If no previous code is present go directly to b b Inducer motor starts and continues to run until Step g 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 Reconn
89. or property damage Consult a qualified service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or accessories when modifying this product A CAUTION FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing 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 instructions 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 N
90. orrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products 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 8 Specifications are subject to change without notice AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with e U S installations Section 9 3 of the NFGC NFPA 54 ANSI Z223 1 2012 Air for Combustion and Vent ilation and applicable provisions of the local building codes 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 wa
91. ors National Association SMACNA or an Society of Heating Refrigeration and Air Condi tioning Engineers ASHRAE 2005 Fundamentals Handbook Chapter 35 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16 Acoustical Lining and Fibrous Glass Duct e Current edition of SMACNA and NFPA 908 as tested by UL Standard 181 for Class Rigid Air Ducts Gas Piping and Gas Pipe Pressure Testing e NFGC 54 ANSI Z223 1 2012 chapters 5 6 7 and 8 and National Plumbing Codes Electrical Connections e National Electrical Code NEC NFPA 70 2011 Venting e NFGC 54 ANSI Z223 1 2012 Chapters 12 and 13 441 01 1421 01 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 4 CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure 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 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 discon nects may be required DO NOT TO
92. ower assembly out of furnace 7 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 8 Vacuum any loose dust from blower housing wheel and motor 9 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an ap propriate degreaser To remove wheel NOTE Before disassembly mark blower motor and blower housing so motor and each arm is positioned at the same location during reassembly a Disconnect power choke wires if used 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 441 01 1421 01 10 Reassemble motor and blower by reversing steps 111 through 11a finishing with 11a Be sure to reattach ground wire to the blower housing 11 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 reposi tion if necessary 12 Spin the blower wheel by hand to verify that the wheel does not r
93. place 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 19 Check for gas leaks 20 Replace outer access door Figure 47 Cleaning Heat Exchanger Cell aoro 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 fire or explosion may result causing property damage personal injury or loss of life Step 6 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 441 01 1421 01 Using the schematic diagram in Figure 48 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 GREEN LED light will flash code 1 2 during the 90 sec period afte
94. quirements defined in the NFGC 1 If a vent common or dedicated becomes blocked the furnace will be shut off by the draft safeguard switch located on the vent elbow 2 Do not vent this Category 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 furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 4 Do not vent this appliance with any solid fuel burning appliance 5 Category 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 chimney Refer to Chimney Inspection Chart Figure 27 MASONRY CHIMNEY REQUIREMENTS NOTE These furnaces are CSA design certified for use in exterior tile lined masonry chimneys with a factory accessory Chimney Adapter Kit Refer to the furnace rating plate for correct kit usage The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit 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 2012 and must be in good condition
95. r temperature limits may affect reliability of heat exchangers motors and controls See Figure 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before operating the furnace Figure 2 Clearances to Combustibles 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 furnace Installation and service must be performed by a qualified service agency or the gas supplier Check entire gas assembly for leaks after lighting this appliance INSTALLATION This furnace must be installed in accordance with the manufacturer s instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 NFPA54 or CSA B 149 1 Gas Installation Code This furnace must be installed so there are provisions for combustion and ventilation air See manufacturer s installation information provided with this appliance OPERATION This furnace is equipped with manual reset limit switch es in burner compartment to protect against overheat conditions that can result from inadequate combustion air supply or blocked vent conditions 1 Do not bypass limit switches 2 If a limit opens call a quallified INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION This
96. r until open switch remakes whichever is longer up during call for heat R W closed or R W opens during blower on delay If open longer than 3 minutes code changes to lockout 7 If open less than 3 minutes status during blower on delay code 4 continues to flash until blower shuts off Flame rollout switch and BVSS require 6 1 IGNITION LOCKOUT Control will auto reset after three hours Refer to 6 manual reset Check for Restricted vent Proper vent sizing Loose blower wheel OFF SECONDARY VOLTAGE FUSE IS OPEN Check for Door switch not closed Excessive wind Dirty filter or restricted duct system Defective blower motor or capacitor 115VAC at L1 and Neutral 24VAC at 24VAC RED and COM BLUE 24V Fuse Defective switch or connections Inadequate combustion air supply Flame Roll out Switch open Door switch not closed Short circuit in secondary voltage 24VAC wiring ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized ON CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve SOLID Gas valve relay stuck open sense circuit failure Software check error IGNITION PROVING FAILURE Control will try three more times before lockout 6 1 occurs Reset power to clear lockout Replace control if status code repeats If flame signal lost during blower on delay period blower will come on for the
97. r which the LED will be flashing a heartbeat 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 The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check veri fies the pressure switch contacts PRS are open and starts the inducer motor IDM NOTE There are two humidifier terminals available 24VAC HUM 24VAC and 115VAC HUM Confirm the correct terminal to voltage is being used a Inducer Prepurge Period The inducer enable relay contacts IDR close and allow 115 VAC to in ducer motor and HUM terminal not to be confused with the 24 v HUM 24 VAC terminal As the in ducer motor IDM comes up to speed the pressure switch contacts PRS close 24 VAC power is sup plied for a field installed humidifier at the HUM 24VAC terminal and the control begins a 15 sec prepurge period b Igniter Warm Up At the end of the prepurge peri od the Hot Surface igniter HSI is energized for a 17 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens The g
98. re 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 volatile fluids Paint thinners and other painting compounds paper bags or other paper products Specifications are subject to change without notice 39 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 4 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 and install a lock out tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace A 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 A CAUTION CUT HAZARD Failure to follow this ca
99. ris and tile debris No Remove metal vent or liner Clay tile misalignment missing sections gaps Condensate drainage at bottom of chimney Chimney exposed to outdoors below roof line Chimney is acceptable for use Consult Part B of chimney adapter venting Not Suitable instructions for application Is chimney suitability lined with properly Line chimney with property sized listed flexible metal sized listed liner or liner or Type B vent per vent NFGC Vent Sizing Tables and liner vent manufacturer s instructions Installation instructions Not Suitable Consult Is chimn Part C of to be dedicated to Chimney adapter ventingN Suitable a single instructions for furnace application suitability Install chimney adapter per instructions Specifications are subject to change without notice 441 01 1421 01 4 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 Kit is REQUIRED for downflow applications where the vent exits through the lower portion of the furnace casing See Figure 32 Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall slope upwards not less than 1 4 in per linear ft 21 mm M from the furnace to the vent
100. rning 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 cubic feet per 1 000 Btuh input rating for all gas appliances installed in the space e Spaces having less than 50 cubic feet per 1 000 Btuh require the OUTDOOR COMBUSTION AIR METHOD Spaces having at least 50 cubic feet per 1 000 Btuh may use the INDOOR COMBUSTION AIR STANDARD or KNOWN AIR INFILTRATION METHOD Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combus tion ventilation and dilution of flue gases using per manent horizontal or vertical duct s or opening s dir ectly communicating with the outdoors or spaces that freely communicate with the outdoors 2 Figure 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 Figure 7 and Table 2 441 01 1421 01 c TWO HORIZONTAL DUCTS require 1 square inch of free area per 2 000 Btuh 1 100 mm2 kW of combined input for all gas appliances in the space per Figure 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 square inch
101. s cleaning solvents e notbe installed directly on any combustible material other than wood flooring for upflow applications Downflow installations require use of a factory ap ENWAX or coil casing model number NAEA when salts air fresheners and other household products installed on combustible materials or wood flooring refer to SAFETY CONSIDERATIONS be located as close to the chimney or vent and at tached to an air distribution system Refer to Air Ducts section 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 If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion be provided ample space for servicing and cleaning Always comply with minimum fire protection clear ances shown on the furnace clearance to combust ible label The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms and Chemical storage areas Specifications are subject to change without notice e Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals e De icing salts or chemicals e Carbon tetrachloride Halo
102. selected blower off delay Check for Flame sensor must not be grounded aaa COMPONENT TEST SEQUENCE Gas valve and humidifier will not be turned on Components will be tested in sequence as follows Inducer motor will run for entire component test and the following 1111111 HII MA 3378 components are ON for 10 15 seconds each individually hot surface igniter FAN if equipped HEAT speed COOL speed 7806 201 REV A 38 Specifications are subject to change without notice 441 01 1421 01 SERVICE AND MAINTENANCE PROCEDURES Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel A qualified ser vice person should inspect the furnace once a year 4 WARNING FIRE INJURY OR DEATH 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 Before installing modifying or servicing system main electrical disconn
103. t be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips 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 shut down of the furnace during certain blocked vent condi tions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent con nector 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 hours To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF then back ON Figure 43 Amp Draw Check with Ammeter THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MU
104. ted to ONLY the accessory subbase or a factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace casing Specifications are subject to change without notice 13 Figure 14 Duct Flanges UPFLOW DOWNFLOW HORIZONTAL A02020 Figure 15 Horizontal Unit Suspension 6mm THREADED ROD 4 REQ OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 48 3 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 A10130 14 Specifications are subject to change without notice 441 01 1421 01 Figure 16 Horizontal Suspension with Straps OUTER DOOR ASSEMBLY X AIR OPENING 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS METHOD 2 USE 4 48 x 3 4 19 mm SHEET METAL SCREWS FOR EACH STRAP THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES BACK OF FURNACE METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH 4 8 x 3 4 19 mm SHEET METAL SCREWS 2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM A10131 Figure 17 Typical Attic Inst
105. ther oume other ACH 1000 Btu hr A04002 2 For fan assisted appliances such as this furnace _ 1513 re Vol 1583 ___ an ACH 1000 Btu hr A004003 If lother combined input of all other than fan assisted appliances in Btuh hr 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 mm kW of the total input rating of all gas appliances in the space but not less than 100 in 0 06 m One opening shall commence within 12 300 mm of the ceiling and the second opening shall commence with Specifications are subject to change without notice 9 in 12 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Figure 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 Figure 8 Air for Combustion Ventilation and Dilution
106. this range change main burner orifices Refer to Table 10 11 13 and 14 NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 4 Verify natural gas input rate by clocking meter NOTE Gas valve regulator adjustment cap must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter b Run furnace for 3 minutes in 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 12 for cubic ft of gas per hr e Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain input Specifications are subject to change without notice 31 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 temperat ure rise as follows
107. ub on the housing 13 Reinstall blower assembly in furnace 14 Reinstall two screws securing blower assembly to blower deck 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 under START UP ADJUSTMENT and SAFETY CHECK NOTE Refer to Table 5 for motor speed lead relocation if leads were not identified before disconnection 15 Refer to furnace wiring diagram and connect thermo stat leads if previously disconnected 16 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 f thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label locat
108. ubing Pressure switch stuck closed Gas valve defective or gas valve turned off Manual valve shut off Low inlet gas pressure 3 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five Defective Hot Surface Ignitor Control ground continuity Inadequate flame carryover or rough ignition minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Green Yellow wire MUST be connected to furnace sheet metal Proper vent sizing Defective inducer motor 7 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit draft safeguard flame rollout or blocked vent Low inducer voltage 115VAC Defective pressure switch switch if used is open longer than 3 minutes Control will auto reset after three hours Refer to 4 Inadequate combustion air supply Disconnected or obstructed pressure tubing 8 GAS HEATING LOCKOUT Control will NOT auto reset Check for Low inlet gas pressure if LGPS used Restricted vent Mis wired gas valve Defective control valve relay If it opens during blower on delay period blower will come on for the selected blower off delay 10 POLARITY Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame rollout or blocked vent switch 1 2 BLOWER ON AFTER POWER UP 115 VAC or 24 VAC Blower runs for 90 seconds if unit is powered if used is open Blower will run for 4 minutes o
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110. unning the blower motor at HEAT speed after the selected blower OFF delay period is completed Step 7 Wiring Diagrams Refer to Figure 25 and Figure 48 for wiring diagrams Step 8 Troubleshooting Refer to the service label See Figure 44 or Figure 49 Specifications are subject to change without notice 43 Figure 48 Wiring Diagram GALNIYd HEAT OFF DELAY JUMPER SELECTOR 90 i 180 CONNECTION DIAGRAM FRS2 LS1 152 RED RED RED WHEN USED TEST TWIN Eum HUM 24VAC 24VAC RED 19 RED GRN YEL SVL BIN Ave WHEN USED WHEN USED LGPS 1234567891011 x ele elelelelele RED SPARE ORG SPARE BHT CLR BLWR BLWM BVSS CPU DSS EAC 1 FRS 1 2 FSE FU1 FU2 GND GV GVR HSI HSIR HUM HUM 24VAC IDM IDR ILK J2 JB LED LGPS 151 2 BLOWER MOTOR SPEED CHANGE RELAY SPDT BLOWER MOTOR RELAY SPST N O BLOWER MOTOR ECM BLOCKED VENT SHUTOFF SWITCH MANUAL RESET SPST N C MICROPROCESSOR AND CIRCUITRY DRAFT SAFE GUARD SWITCH AUTO RESET SPST N C ELECTRONIC AIR CLEANER CONNECTION EAC 1 AMP MAX FLAME ROLLOUT SWITCH MANUAL RESET SPST N C FLAME PROVING ELECTRODE FUSE 3 AMP AUTOM
111. ution 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 replace 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 controls for proper operation each heating season Service as necessary 4 Inspect burner compartment before each heating sea son for rust corrosion soot or excessive dust If neces sary 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 recom mended 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 40 Specifications are subject t
112. vent is used to line a chimney other appliance shall be vented into the annular space between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors amp AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT IN MM2 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 3 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 9 Minimum Allowable Input Rating of Space Heating Appliance in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT IN MM2 FT M 12 19 28 38 7741 12258 18064 24516 Local 99 Winter Design Temperature 17 to 26 F 8 to 3 C 6 1 8 0 55 99 141 8 2 4 52 74 111 154 10 3 0 NR 90 125 169 15 4 6 NR NR 167 212 20 6 1 NR NR 212 258 30 9 1 NR NR NR 362 Local 99 Winter Design Temperature 5 to 16 F 15 to 9 C 6 1 8 NR 78 121 166 8 2 4 NR 94 135 182 10 3 0 NR 111 149 198 15 4 6 NR NR 193 247 24 Specifications are subject to change without notice 20 6 1 NR NR NR 293 30 9 1 NR NR NR 377 Local 99 Winter Design Temperature 10 to 4 F 23 to 16 C 6 1 8 NR NR 145 196 8 2 4 NR NR 159 213 10 3 0 NR NR 175 231 15 4 6 NR NR NR 283 20 6 1 NR NR NR 333 30 9 1 NR NR NR NR Local 9
113. wall 2 Connect an amp meter as shown in Figure 43 across the R and W subbase terminals or R and W wires at wall 3 Record amp draw across terminals when fur nace 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 heat off delay The heat off delay has 4 justable settings from 90 sec to 180 sec The heat off delay jumpers are located on the furnace control board See Figure 25 To change the heat off delay setting move the jumper from one set of pins on the control to the pins used for the selected heat off delay Factory heat 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 Air Delivery CFM With Filter for lead color identification Step 4 Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch es This control shuts off combustion control system and energizes air circulating blower motor if furnace over heats By using this method to check limit control it can be established that limit is functioning properly and will operate if there is a restricted duct system or motor fail ure If limit control does not function during this test cause mus
114. ze 441 01 1421 01 ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 AMP and NEUTRAL The termin als are rated for 115 VAC 1 0 amps maximum and are energized during blower motor operation See Figure 25 2 Humidifier HUM 24VAC and HUM HUM 24VAC Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the 1 4 in male quick connect HUM 24VAC terminal and C screw terminal on the control board thermo stat strip The HUM 24VAC terminal is energized when there is a call for heat W and the pressure switch PRS closes See Figure 25 and Figure 48 e b HUM Connect an accessory 115VAC EAC and HUM are 1 amp maximum combined humidifier if used to the Y4 inch male quick connect HUM terminal and NEUTRAL quick connect The HUM terminal is energized when the inducer motor is energized IDR See Figure 25 and Figure 48 NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE DO NOT connect furnace control HUM 24VAC terminal to H humidifier terminal on humidity sensing thermostat or similar device See humidity sensing thermostat thermostat controller manufacturer s instructions for proper connection Specificatio

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