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Bryant 313AAV User's Manual

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1. 26 THERMIDISTAT SINGLE STAGE TWO SPEED FURNACE HEAT PUMP RVS COOLING O W2 ___________________________ LI s HEAT COOL STAGE 1 Y1 W2 ____________ alr cue kel Y1 COMPRESSOR LO HEAT STAGE 3 WW1 ____________ PAM ouh L_ w2 FURNACE HEAT COOL STAGE 2 YiY2 L NOTE 12 2 __ ____ lus Y2 COMPRESSOR HI FAN G __________ J 6 w3 24VACHOT R _________ R Lt R DEHUMIDIFY ____________ _ DHUM 24VAC COMM C Lj _ Com e HUM HUMIDIFY __ HUMIDIFIER 24 B L OUTDOOR EX OUTDOOR Passe SENSOR SENSOR CONNECTION 52 J See notes 1 2 3 4 6 8 9 10 and 12 on the page following these figures A04218 Fig 29 Single Stage Furnace with Two Speed heat Pump Dual Fuel DUAL FUEL SINGLE STAGE SINGLE SPEED DUAL FUEL SINGLE STAGE TWO SPEED
2. THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE HEAT PUMP RVS COOLING J RVS COOLING O W2 Ll E Y1W2 Yi HEAT COOL STAGE 1 YUW2 zooms Dae eet ET Yi COMPRESSOR LO HEAT STAGE 2 WAW11 ___________ eMe o E oe I Twa HEAT STAGE 3 ___________ W 1 2 FURNACE FURNACE HEAT COOL STAGE 1 YIY2 1 1 BETETE Lose l Y HEAT COOL STAGE 2 YIY2 L __________ DIN Le den Ed Y2 COMPRESSOR COMPRESSOR FAN G J J FAN 3 24 1 S ORE ess l R 24VACHOT R R ose 24 R DHUM DHUM 24VACCOMM 4 4 ed 24VACCOMM I c B Aten NA B HUM RVS SENSING T RVS SENSING T ee ee ourooor ST H SENSOR vo AC ourooor 3 H J SENSOR r SENSOR 24VAC I SENSOR 24VAC CONNECTION SA Liu se ss su CONNECTION BR Cole none sense messe See notes 1 2 4 11 12 and 13 on the page following these figures See notes 1 2 3 4 11 12 and 14 on the page following these figures A04220 A0421 el Fig 31 Dual Fuel Thermostat with Single Stage Furnace 12 Dual Fue ermostat wr ingle 5tage Furnace 8 5 8 and Two Spee
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5. SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION c 2CuFt SCuFt FORTREVOLUTION 1CuFL 2CuFt 5CuFt 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 Checklist 1 Put away tools and instruments Clean up debris 2 Verify that blower OFF DELAY time is selected as desired 3 Verify that blower and burner access doors are
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7. 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 Fig 8 Air for Combustion Ventilation and Dilution from Indoors b Doors and openable windows are weatherstripped and c Other openings are caulked or sealed These include joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines etc Combination of Indoor and Outdoor Air 1 Indoor openings shall comply with the Indoor Combustion Air Method below and 2 Outdoor openings shall be located as required in the Outdoor Combustion Air Method menioned previously and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below or BOTTOM CLOSURE BOTTOM FILLER PANEL PANEL A02098 Fig 9 Removing Bottom Closure 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 minimum 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 retu
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9. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT BURNER SECTION AND DISCHARGED DOWNWARD CONDITIONED AIR IS AIRFLOW UPFLOW NN lt HORIZONTAL LEFT AIRFLOW DOWNFLOW THE BLOWER 1 LOCATED ABOVE THE AIRFLOW BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER 1 LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT A02097 Fig 4 Multipoise Orientations Before removing a new control from its container discharge 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 furnace Put all used and new controls into containers before touching ungrounded objects An ESD service kit available from commercial sources may also be used to prevent ESD damage LOCATION 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 Fig 4 This furnace must be installed so the electrical components are protected from water not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS be located as close to the ch
10. WIRE ENTRY ENTRY ALTERNATE 22mm 33 5 16 v 24 7 8 JUNCTION BOX 846mm 632mm LOCATIONS TYP VENT OUTLET 5 PLACES TYP 14 7 8 378i 7 8 22mm DIA 7 8 DIA ACCESSORY rem ACCESSORY 22mm 5 1 2 140mm Eo 11 16 5 1 2 17mm Gamm 140mm E 116 334 1 1 4 21 5 8 141 16 17mm 95mm 560mm 32mm BOTTOM INLET 43mm 22 1 16 1 24 SIDE INLET 25mm CASING 610mm A04037 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 20 in 508 mm round or 14 1 2 x 19 1 2 in 368 x 495 mm rectangle 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 Fig 1 Dimensional Drawing Table 1 Dimensions B CL Tap AND FLUE MEDIA FURNACE SIZE CABINET SUPPLY AIR RETURN AIR BOTTOMFLUE COLLAR SHIPWT CABINET WIDTH WIDTH
11. 1 Heating See Fig 25 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch contacts PRS close to begin a 15 second prepurge period b Igniter Warm Up At the end of the prepurge period the Hot Surface igniter HSI is energized for a 17 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens and 24 vac power is supplied for a field installed humidifier at the HUM terminal The gas valve GV permits gas flow to the burners where it is ignited by the HSI Five seconds after the GVR closes a 2 second flame proving period begins The HSI igniter will remain energized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition bef
12. A93059 Fig 53 Orifice Hole Failure to follow this warning could result in personal injury death and or property damage g To change motor speed selection for heating remove blower motor lead from control HEAT terminal See Fig 24 Select desired blower motor speed lead from one of Reinstall manifold pressure tap plug in gas valve to prevent the other terminals and relocate it to the HEAT terminal gas leak See Table 11 for lead color identification Reconnect original lead to SPARE terminal h 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 c k Reinstall manifold pressure tap plug in gas valve 38 Table 11 Speed Selection COLOR SPEED AS SHIPPED Gray 5 COOL Yellow 4 SPARE Blue 3 HEAT Orange 2 SPARE Red q CONT FAN Continuous blower speed as shipped default 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 6 Set thermostat heat anticipator a Mechanical thermostat Set thermostat heat anticipator to match the amp draw of the electrical components in the R W circuit Accurate amp draw readings can
13. If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the CAN CSA B149 1 05 in Canada Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts Refer to Table 6 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft 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
14. 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS AIR OPENING OUTER DOOR ASSEMBLY N METHOD 2 USE 4 8 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 AIR OPENING A03176 Fig 16 Horizontal Suspension with Straps LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNACE EXTEND OUT 12 305mm FROM FACE OF DOOR TN ders MM WHEN USED WITH SINGLE WALL VENT CONNECTIONS EQUIPMENT MANUAL SHUT OFF GAS VALVE SEDIMENT TRAP A03177 Fig 17 Typical Attic Installation 16 Return Air Connections A 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 Follow instructions below Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 19 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and m
15. A03214 A03212 Fig 41 Horizontal Left Application Vent Elbow Right Fig 39 Downflow Application Vent Elbow Up then Right then Up 32 Tm mmt SEE NOTES 1 2 4 7 8 9 on the page following these figures SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03214 A03219 Fig 42 Horizontal Right Application Vent Elbow Right Fig 44 Horizontal Right Application Vent Elbow Left then Up WLLL LU i y O o bd E 4 E E SEE NOTES 1 2 4 5 7 8 9 on the page SEE NOTES 1 2 4 5 7 8 9 on the page following these figures following these figures A03215 A03216 Fig 43 Horizontal Left Application Vent Elbow Up Fig 45 Horizontal Left Application Vent Elbow Right E o i X DIE iL SEE NOTES 1 2 4 5 7 8 9 A02068 Fig 46 Horizontal Right Application Vent Elbow Left 33 Venting Notes for Figures 34 46 For common vent vent connector sizing and vent material United States use the NFGC Canada use the CAN CSA B149 1 05 Immediately increase to 5 inch 12
16. 1 PLUS 80X 4 WAY MULTIPOISE INDUCED COMBUSTION GAS FURNACE INPUT CAPACITIES 45 000 THRU 135 000 BTUH Installation Start up Operating and Service and Maintenance Instructions Series 100 A SAFETY CONSIDERATIONS 2 INTRODUCTIONS sean 3 CODES AND STANDARDS 4 Safety 4 General Installation 5 Combustion and Ventilation Air 5 Duct Systems cee t n e rh eee 5 Acoustical Lining and Fibrous Glass Duct 5 Gas Piping and Gas Pipe Pressure Testing 5 Electrical Connections 5 Venig RES ELECTROSTATIC DISCHARGE PRECAUTIONS PROCEDURE 5 LOCATION sds ie se eae be ne me Er EE 6 INSTALLATION 2 sue sut ets peto e oe etes 10 Upflow Installation 10 Downflow Installation 11 Horizontal Installation 13 Filter Arrangement 14 sis dise des CH eee daw E ER aes 14 Gas agen ERE 17 1155 V Wine 22 START UP ADJUSTMENT AND SAFETY CHECK 36 General eR UR bie los eee 36 Start up Procedures 36 Adjustments 36 Check Safety Controls 39 Checkliste reete
17. 1435 1380 2 1630 1575 1510 1435 1365 1300 1245 1185 1130 1065 1 1430 1355 1285 1200 1125 1075 1015 945 855 800 A filter is required for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions Table 6 Maximum Capacity of Pipe NOMINAL IRON INTERNAL PIPE DIAMETER LENGTH OF PIPE FT SIZE IN mm In mm 10 20 30 40 50 1 2 13 0 622 16 175 53 120 37 97 30 82 25 73 22 3 4 19 0 824 21 360 110 250 76 200 61 170 52 151 46 1 25 1 049 27 680 207 465 142 375 114 320 98 285 87 1 1 4 82 1 380 35 1400 427 950 290 770 235 660 201 580 177 1 1 2 38 1 610 41 2100 640 1460 445 1180 360 990 301 900 274 Cubic ft of natural gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Chapter 6 ANSI 2223 2006 NFPA 54 2006 Piping should be pressure and leak tested in accordance with NFGC in the United States or CAN CSA B149 1 05 in Canada local and national plumbing and gas codes before the furnac
18. 20 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 21 Reinstall casing door 22 Turn on gas supply and cycle furnace through one complete heating and cooling cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70 F 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 47 them thoroughly A heavy build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elb
19. Chlorine based swimming pool chemicals Wate softening chemicals De icing salts or chemicals Carbon tetrachloride e Haloge type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause premature furnace component failure 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 seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and from draft safeguard opening This gas furnace may be used for heating buildings under construction provided that The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to
20. safeguard switch did not function properly and correct condition f Remove blockage from furnace vent elbow g h NOTE Switch will auto reset when it cools Re install vent connector Should switch remain open longer than 3 minutes furnace control board will lockout the furnace for 3 hours To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115v power OFF then back ON 3 Check Pressure Switch This control proves operation of the draft inducer blower a b d Turn off 115 v power to furnace Disconnect inducer motor lead wires from wire harness Turn on 115 v power to furnace Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control diagnostic light flashes a status code 32 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace 39 Reconnect inducer motor wires replace outer door and turn on 115 v power Blower will run for 90 sec before beginning the call forheat again Furnace should ignite normally Table 12 Gas Rate Cu Ft Hr
21. shorten furnace life Air contaminants are found in aerosol Spaces having at least 50 cubic feet per 1 000 Btuh sprays detergents bleaches cleaning solvents salts air may use the INDOOR COMBUSTION AIR fresheners and other household products STANDARD or KNOWN AIR INFILTRATION METHOD LOCATION RELATIVE TO COOLING EQUIPMENT Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combustion ventilation and dilution of flue gases using permanent horizontal or vertical duct s or opening s directly communicating with the outdoors or spaces that freely communicate with the outdoors 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 2 Fig 7 illustrates how to provide TWO OUTDOOR the damper is in the full heat or full cool position OPENINGS one inlet and one outlet combustion and ventilation airopening to the outdoors a One opening MUST commence within 12 in 300 mm of the ceiling and the second opening MUST commence within 12 in 300 mm of the floor b Size openings and ducts per Fig 7 and Table 2 c TWO HORIZONTAL DUCTS require 1 square inch of free area per 2 000 Btuh 1 100 mm2 k
22. striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT 9 32 7 1mm 5 16 7 9mm 1 4 A05025 Fig 56 Igniter Position Side View A05026 Fig 57 Igniter Position Top View 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 Fig 58 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 furnace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor with fine steel wool 9 Install NOx baffles if removed 10 Reinstall burner assembly Center burners in cell openings 10 Remove old sealant from cell panel and collector box flange 11 Spray releasing agent on the heat exchanger cell panel where collector
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24. 29 for Thermidistat connections The dehumidification output DHUM on the Thermidistat should be connected to the furnace control thermostat terminal DHUM When there is a dehumidify demand the DHUM input is activated which means 24 vac signal is removed from the DHUM input terminal In other words the DHUM input logic is reversed The DHUM input is turned ON when no dehumidify demand exists Once 24 vac is detected by the furnace control on the DHUM input the furnace control operates in Thermidistat mode If the DHUM input is low for more than 48 hours the furnace control reverts back to non Thermidistat mode The cooling operation described in item 2 above also applies to operation with a Thermidistat The exceptions are listed below a When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will continue running at low cool speed same speed as FAN b When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower speed from COOL to HEAT for a maximum of 10 minutes before reverting back to COOL speed If there is still a demand for dehumidification after 20 minutes the furnace control CPU will drop the blower speed back to HEAT speed This alternating 10 minute cycle will continue as long as there is a call for cooling 50 c When the call for cooling is satisfied and there is a demand f
25. Canada or the 2005 ASHRAE Fundamentals handbook Climatic Design Information chapter and the CD ROM in cluded with the 2005 ASHRAE Fundamentals 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 28 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code 54 ANSI 7223 1 and 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian insta
26. be installed external to furnace casing and within 6 ft 2 M of furnace A 1 8 in 3 mm NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve NOTE The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas control valve See Fig 52 Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21 Install a sediment trap in riser leading to furnace as shown in Fig 22 Connect a capped nipple into lower end of tee Capped nipple should extend below level of furnace gas controls Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve A 1 8 in 3 mm NPT 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 17 Table 5 Air Delivery CFM With Filter RETURN AIR EXTERNAL STATIC PRESSURE In wc UNIT SIZE SUPPLY SPEED 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 5 1185 1145 1115 1075 1035 980 905 820 720 580 4 920 880 835 800 755 720 680 645 605 540
27. box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated 48 hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant 162 P771 9003 is available through RCD in 3 07 tubes 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connection diagram on wiring label if wires were not marked for reconnection locations Draft safeguard switch Inducer motor Pressure switch es Limit over temperature switch Gas valve Hot surface igniter Flame sensing electrode EUR c 00 0 c Flame rollout switches i Install NOx baffles if removed 14 Reinstall internal vent pipe if applicable 91252 Fig 58 Cleaning Heat Exchanger Cell 15 Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 180 apart 16 Replace blower access door only if it was removed 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed chang
28. ces demiers la norme ANSI Z223 1 NFPA54 intitul e National Fuel Gas Code ou les code d installation CSAB149 1 2 This fumace must be installed so there are provisions for combustion and ventilation air See manufacturer s installation information provided with this appliance Ce foumaise air chaud doit tre install de mani re ce qu ilyait ait suffisamment d air de ventilation et combustion Consulter les instructions d installation du fabricant foumies avec cet appareil OPERATION This furnace is equipped with manual reset limit switch es in bumer 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 limit opens call a quallified serviceman to correct the condition and reset limit switch INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air fumace is equipped for use with natural gas at altitudes 0 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 fumace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material This fumace may
29. ee res 40 SERVICE AND MAINTENANCE PROCEDURES 43 Introduction strates ck ad ah alone 43 Care and Maintenance 46 Sequence of Operation 49 Wiring Diagrams 51 Troubleshooting 51 EFFICIENCY RATING CERTIFIED ama Ki ISO 9001 2000 6 CERTIFIED REGISTERED NOTE Read the entire instruction manual before starting the installation Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2006 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety 733mm 664mm _7 Q 28 7 8 FLUE COLLAR 641mm 7716 2 716 22 9 16 62mm 573mm rite AIRFLOW mm JUNCTION BOX 19 13 16 LOCATION 13 16 1 8 483mm 21mm 5 15 16 21mm OUTLET 135mm 122mm 1 2 DIA K O THERMOSTAT 22mm WIRE ENTRY 13mm 11 16 7 3 4 958 1 3 4 DIA RIGHT HAND 47mm i97mm 244mm ACCESSORY TES mm DIA GAS ENTRY 44mm THERMOSTAT WIRE ENT 292mm 3 15 16 84mm LEFT HAND GAS 7 8 DIA
30. 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 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 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a location and position as specified in the Location section of these instructions 3 Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section 4 Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified inthe Venting section of these instructions 5 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 c
31. furnace is used for return air connection See Fig 17 for proper orientation of roll out shield Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove two screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 13 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 Fig 20 FILTER ARRANGEMENT A 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 Deluxe furnaces are shipped with a factory supplied Media Filter Cabinet The Media Filter Cabinet uses either the factory supplied standard 3 4 in 19 mm filter or a 4 in 102 mm wide Media Filter which can be purchased separately Refer to the
32. 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 13 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 manufacturer s Coil Assembly Part No CAR CAP and or when Coil Box Part No KCAKC is used See Fig 2 for clearance to combustible construction information INTRODUCTION Series 100 A 4 way multipoise Category I fan assisted furnace is CSA design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger The furnace is factory shipped for use with natural gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum continuous return air temperature of 60 F 16 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 85 F 29 C db Failure to follow these return air temperature limits may affect reliabil
33. instructions supplied with media Cabinet 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 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 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
34. or ordinances that might apply Canadian Installations Make all electrical connections in accordance with Canadian Electrical Code CSA 22 1 or authorities having jurisdiction A WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Use a separate fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 7 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace will NOT operate J BOX RELOCATION NOTE If factory location of J Box is acceptable go to next section ELECTRICAL CONNECTION TO J BOX 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 NOTE The J Box cover need not be removed from the J Box in order to move the J Box Do NOT remove green ground screw inside J Box The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J Box outboard of the casing 2 Cut wir
35. period and the blower remains running at HEAT speed for the selected blower OFF delay period then switches to low cool speed same speed as FAN If the R to W and Y1 and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W and Y1 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed When the R to W and Y Y2 R to W and Y Y2 and G R to W and Y1 and Y Y2 or R to W and Y1 and Y Y2 and G circuits are energized the furnace control CPU will switch to or 51 turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When theWinput signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the R to W and Y Y2 and G or R to W and Y1 and Y Y2 and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W and Y Y2 or R to W and Y1 and Y Y2 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed Wiring Diagrams Refer to Fig 59 for wiring diagram Tro
36. properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instructions 6 Review User s Guide with owner 7 Attach literature packet to furnace 40 Table 13 Orifice Size and Manifold Pressure In wc 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 U S A and Canada U S A 2001 611 to 3000 914 Canada 2001 611 U S A and Canada 915 to gt 4 o 2 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to U S A Only 7000 2133 A08220 41 Table 13 Orifice Size and Manifold Pressure In wc for Gas Input Rate CONT 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 2134 to U S A Only 8000 2438 8001 2439 U S A Only U S A Only Orifice numbers shown inBOLD are factory installed A08220A 42 SERVICE AND MAINTEN
37. provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55 F 13 C and 80 F 27 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the gas input rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions 18 IN 457 2 mm MINIMUM TO BURNERS 93044 Fig 5 Installation in a Garage WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury death a
38. rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency Never store anything on near or in contact with the 6 Inspect any accessories attached to the furnace such as a furnace such as humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the accessory instructions CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application The filter is exterior to the furnace casing 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 of other Yolatile fuds NOTE If the filter has an airflow direction arrow the arrow Paint thinners and other painting compounds paper must point towards the blower bags or other paper products Table 15 Filter Size Information In mm For continuing high performance and to minimize possible equipment failure periodic maintenance must be performed on FURNACE FILTER SIZE In mm this equipment Consult your local dealer about proper frequency E FILTER TYPE of maintenance and the availability of a maintenance contract In mm Side Return Bottom Return 14 1 2 16 x 25 x 3 4 14 x 25 x 3 4 PIN WARNI
39. 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 mm kW of total input rating of all gas appliances 2 An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1 in 2 4 000 Btuh of total input rating forall gas appliances in the space 3 In spaces that use the Indoor Combustion Air Method infiltration should be adequate to provide air for combustion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section Unusually tight construction is defined as construction with a Walls and ceilings exposed to the outdoors have a continuous sealed vapor barrier Openings are gasketed or sealed and CIRCULATING AIR DUCTS VENT THROUGH ROOF 12 MAX 305mm 1 SQ 1000 BTUH IN DOOR OR WALL UNCONFINED INTERIOR SPACE HEATED SPACE 6 MIN 152mm FRONT U 1 SQIN PER 1000 BTUH IN DOOR OR WALL OPENINGS SHALL BE AT LEASTS IN CLEARANCE IN FRONT OF COMBUSTION AIR L 42 MAX 305mm CIRCULATING AIR DUCTS
40. the Exception which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACAO02015FC which are listed for use with these furnaces The Chimney Adapter Kit is listed alternative venting system for these furnaces See the kit instructions for complete details 25 THERMIDISTAT N A N A HEAT STAGE 1 COOL STAGE 1 FAN 24 VAC HOT DEHUMIDIFY 24 VAC COMM HUMIDIFY N A OUTDOOR SENSOR CONNECTION O W2 Y1 W2 W W1 2 DHUM HUM B 1 2 Fig 26 Single Stage Furnace with Single Speed Air THERMIDISTAT N A COOL STAGE 1 HEAT STAGE 1 COOL STAGE 2 FAN 24 VAC HOT DEHUMIDIFY 24 COMM HUMIDIFY N A OUTDOOR SENSOR CONNECTION O W2 YA1W2 W W1 2 DHUM HUM 1 2 Fig 27 Single Stage Furnace with Two Speed Air Condi SINGLE STAGE FURNACE Y1 SINGLE SPEED AIR CONDITIONER 2 ls L I G R DHUM LJ HUM HUMIDIFIER 24 OUTDOOR X SENSOR See notes 2 5 7 and 10 on the page following these figures ditione
41. with media filter having the same part number and size For expandable replacement media refer to the instructions included with the replacement media If equipped with accessory KGAFRO301ALL external filter rack See Table 15 CUT HAZARD 6 Slide filter into cabinet Failure to follow this caution may result in personal injury 7 Replace filter cabinet door CAUTION Sheet metal parts may have sharp edges or burrs Use care 8 Turn on electrical supply to furnace and wear appropriate protective clothing safety glasses and BLOWER MOTOR AND WHEEL gloves when handling parts and servicing furnaces A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death 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 Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary 46 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 agenc
42. 149 1 05 Section 8 and Appendix C in Canada the local building codes and furnace and vent manufacturers instructions These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47 2006 CSA 2 3 2006 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFGC or the CAN CSA B149 1 05 the local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the requirements defined in the NFGC and the CAN CSA B149 1 05 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 I furnace into a single wall dedicated or common vent The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors 3 Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 4 In the U S Do not vent this appliance with any solid fuel burning appliance In Canada Check with the au
43. 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 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 Fig 14 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other acce
44. 6 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 3 Adjust manifold pressure to obtain correct input rate a Turn gas valve ON OFF switch to OFF b Remove manifold pressure tap plug from gas valve See Fig 52 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 adjusting screw counterclockwise out to decrease input rate of clockwise in to increase input rate EXAMPLE 2 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 we 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 h 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 we or more than 3 8 in we for natural gas at sea level If manifold pressure is
45. 7 mm or 6 inch 152 mm vent connector outside furnace casing when 5 inch 127 mm vent connector is required refer to Note 1 above Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when KGAVGO0101DFG Downflow Vent Guard Kit is used in the downflow position Type B vent where required refer to Note 1 above Four inch single wall 26 ga min vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace 6 Accessory Downflow Vent Guard Kit KGAVG0101DFG required in downflow installations with lower vent configuration Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACAO02015FC for sizing and complete application details Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart 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 04127 Fig 47 Using Tin Snips to Cut Tie Points A04128 04130 Fig 48 Rounded End of Knockout Fig 50 Hammer and Screwdriver Used for Knockout 04129 04131 Fig 49 Knockout Pulled Loose Fig 51 Remove Knockout
46. ANCE PROCEDURES A 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 this equipment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual 4 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before servicing disconnect all electrical power to furnace Verify proper operation after servicing 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 Fig 4 you must revise your orientation to component location accordingly ELECTRICAL CONTROLS AND WIRING 4 ELECTRICAL SHOCK
47. AS SPECIFIC GRAVITY OF NATURAL GAS Manifold Orifice Manifold Orifice Manifold Orifice Manifold ft m Pressure No Pressure No Pressure No Pressure U S A and Canada U S A 2001 611 to 3000 914 Canada 2001 611 U S A and Canada 915 to 2 c 4 o 2 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to U S A Only 7000 2133 A08221 44 Table 14 Orifice Size And Manifold Pressure In wc 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 RANGE Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold ft m No Pressure 7001 2134 to U S A Only 8000 2438 8001 2439 U S A Only U S A Only Orifice numbers shown inBOLD are factory installed A08221A n UN If status code recall is needed briefly remove then reconnect one main limit wire to display stored status code On RED LED boards do not remove power or blower door before initiating status code recall After status code recall is completed component test will occur LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at
48. HASE AMPS AMPS MAX MIN 045087 024045 115 60 1 127 104 81 10 9 34 10 15 14 070 16 048070 115 60 1 127 104 95 12 6 29 9 15 14 090 16 048090 115 60 1 127 104 10 3 13 4 27 8 15 14 110 20 060110 115 60 1 127 104 13 1 16 9 34 10 20 12 135 20 060135 115 60 1 127 104 13 1 16 9 34 10 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps T Time delay type is recommended Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop GAS TE SUPPLY MANUAL SHUTOFF VALVE ac REQUIRED e SEDIMENT E TRAP UNION A02035 Fig 22 Typical Gas Pipe Arrangement ELECTRICAL CONNECTIONS 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2008 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault sho
49. 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 43 The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Fig 25 for field wiring information and to Fig 59 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 24 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced Proper instrumentation is required to service electrical controls The control in this furnace is equipped with a Status Code LED Light Emitting Diode to aid in installation servicing and troubleshooting It can be viewed through the sight glass in blower access door The furnace control LED is either ON continuously rapid flashing or a code composed of 2 digits The first digit is the number of short flashes the second digit is the nu
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51. L 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 be required for some model furnaces 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 Fig 34 46 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 door through one of 5 locations on the door 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart NOTE An accessory flue extension KGAFE0112UPH is available to extend from the furnace elbow to outside the furnace casing If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at le
52. NEY VENT HEIGHT IN MM FT M 12 19 28 38 7741 12258 18064 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 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 Heat ing Appliance in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT IN2 MM FT M 12 19 28 38 7741 12258 18064 24516 Local 99 Winter Design Temperature 17 to 26 F 8 to 3 6 1 8 0 55 99 141 8 2 4 52 74 111 154 10 8 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 94 185 182 10 3 0 NR 111 149 198 15 4 6 NR NR 193 247 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 99 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 United States and 2A
53. NG 368 406 x 635x 19 356x635x19 Washable 17 1 2 16 X 25 X 3 4 16 X 25 X 3 4 445 406 635 19 406 635 19 Washable ELECTRICAL SHOCK AND FIRE HAZARD xx 21 533 406 635 19 508 635 19 WWashable Failure to follow this warning could result in personal injury death or property damage 16 x 25 x 3 4 24 X 25 X 3 4 jury propery 8 24 610 406 635 19 610 635 19 Washable Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace Recommended Media cabinet filter procedures NOTE Media cabinet is included with single stage deluxe furnace 1 Turn off electrical supply to furnace before removing filter access door A WARNING 2 Remove filter cabinet door Slide filter out of cabinet CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage 4 If equipped with permanent washable 3 4 in 19 mm fil ter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended See Never operate unit without a filter or with filter access door Table 15 for size information removed 5 If equipped with factory specified disposable media filter replace only
54. OWOLNY ISNA QUE x uoasn NIAOSd SWV14 3S4 gr uonounf ay pue uoyws j euuoosip eu Jeddoo juo esf 0 OVAVCIOVNS V H3INHOJSNVML m 3903195139 9601 20 asn paoe deu si quawidinbs et Aue TVNINH3L 9 LSSLINSNOdWOD NIML 1S31 O N LSdS 19538 8 LNOTION 615833 x SILON O N LSdS HOLIMS 055 3 Sud NOININOO NOLLO3NNOO Y3NY379 OINONLOSTA 1 E YOLOANNOD 3921145 YSONGNI LINDUID 07 OVA NOLLO3NNOO W3NV37O 9INOHIO313 gt lt YOLOANNOO H3MOd v 91 CO N LSdS LASSY OLNV HOLIMS JAYS L3vsd 550 N Wd H YOLOANNOD d33ds WM1d LINDUID S Sd AELINOE 9 ANY HOSS3908dOSOIN 3 x ri ISH LINDUID Z ld O N LSdS 13934 RNV HOLIMS 44O LNHS 0332018 SS 8 FE V Td eT YOLOSNNOO Z MWOIOWN3MOTS D 383 3dAL 3OVNUN 809 LINDYIO Hd CON 1SdS AvISHMOIOWN3MOT8 SMIB a H 71041405 GYVOE LINDYID god 1085 13 39NYH9 09395 YOLOW TO LHE 1 x Si DCN O N LSdS 13S33 O10nV HOLIMS 194 Av 13M 19313S NV4 SNONNILNOD 39 noo y x 1 x N3HM O ZAA x D Woo x 5891 A re 3 m VAN LL 9 v 3uvdS 13 x Z ILON
55. QIN TO PER 4000 OUTDOORS BTUH 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 Fig 7 Air for Combustion Ventilation and Dilution from Outdoors Indoor Combustion Air NFPA amp AGA Standard and Known Air Infiltration Rate Methods Indoor air is permitted for combustion ventilation and dilution if the Standard or Known Air Infiltration Method is used A 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 appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to be 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 applian
56. R FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 3 066 060 22 AND 20 MODELS ALLOTHERMODELS YES SUPPLY AIR A02163 Fig 19 Downflow Return Air Configurations and Restrictions 19 RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS SUPPLY AIR RETURN AIR 6 Q SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS HORIZONAL RETURN AIR BERN RESTRICTIONS NOTE RESTRICTION SAME FOR HORIZONAL LEFT HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION ONLY ONLY ONLY 066 060 22 AND 20 MODELS ALL OTHER MODELS YES Fig 20 Horizontal Return Air Configurations and Restrictions TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY o 90 Elbow ur TT 2 51mm Nipple To Gas Supply Street Elbow i Fig 21 Burner and Manifold Gas Valve 20 RETURN AIR COMBINATIONS OF 1 2 AND3 A02162 A08551 Table 7 Electrical Data OPERATING FURNACE HERR VOLTAGE MAX UNIT Ade cae r penea FUSE MIN WIRE MODEL VOLTS AMPS GAGE P
57. SEC 1 and SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status code is erased automatically after 72 hours On 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes RED LED boards stored status codes can also be erased when power inducer shuts off for 15 minutes before retry Check for Excessive wind 115 VAC or 24 VAC to control is interrupted Proper vent sizing Defective inducer motor 12 BLOWER ON AFTER POWER UP 115 VAC or 24 Blower runs for 90 seconds Low inducer voltage 115VAC Defective pressure switch if unit is powered up during a call for heat R W closed or R W opens during blower Inadequate combustion air supply Disconnected or obstructed pressure tubing on delay m Low inlet gas pressure if LGPS used Restricted vent 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit draft safeguard flame rollout or If it opens during blower on delay period blower will come on for the selected blower blocked vent switch if used is open longer than 3 minutes off delay Control will auto reset after three hours Refer to 33 33 LIMIT CIRCUIT FAULT Indicates a limit draft safeguard f
58. See Fig 51 Remove all burrs and sharp edges 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 KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall slope upwards not less than 1 4 in per linear ft 21 mm M from the furnace to the vent 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 In the U S Per section 12 4 3 1 of the NFPAS4 ANSI Z223 1 2006 any listed mechanical venter may be used when approved by the authority having jurisdiction In Canada Per section 8 24 2 of the CAN CSA B149 1 05 any listed venters may be used when approved by the authority having jurisdiction Select the listed mechanical venter to match the Btuh input of the furnace being vented Follow all manufacturer s installation requirements for venting and termination included with the listed mechanical venter 30 SEE NOTES 1 2 4 7 8 9 on the page
59. W of combined input for all gas appliances in the space per Fig 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 square inch of free area per 4 000 Btuh 550 mm2 kW for combined input of all gas appliances in the space per Fig 7 and Table 2 ONE OUTDOOR OPENING requires a 1 square inch of free area per 3 000 Btuh 734 mm2 kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connectors in the space o 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 1SQIN PER 4000 mic BTUH OUTDOORS e S DM 1 1 ri ORY 305mm 12 D 12 395mm 1SQIN VENT MAX PER 2000 B THROUGH FE i BTUH 45 ROOF 5a 1SQIN Qc PER o lt 4000 BTUH a 8 DUCTS TO 258 OUTDOORS gt 1 gt 5 o 2 1SQIN 8202 E PER zaon g 4000 BTUH 1 SQIN lt On lt PER 2000 Qua edeg sue t goo FIT go 305mm 12 MAX C MAx 305mm dz MAX Li 305mm CIRCULATING AIR DUCTS NC DUCT 1S
60. WIDTH LB KG IN MM IN MM IN MM COLLAR IN MM Size IN MM IN MM 045 08 024045 143 16 360 129 16 319 12 11 16 822 9 56 237 4 102 114 62 16 406 070 16 048070 17 12 445 15 778 403 16 406 119 16 294 4 102 136 62 16 406 090 16 048090 21 533 19 3 8 492 9 1 2 495 13 5 16 338 4 102 150 68 20 508 110 20 060110 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 162 73 20 508 185 20 060135 24 1 2 622 22 7 8 581 23 584 15 116 383 4 102 173 78 24 610 5 in or 6 in 127 or 152 mm vent connector may be required in some cases SAFETY CONSIDERATIONS A WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD CAUTION FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure Failure to follow this warning could result in dangerous operation serious injury death or property damage Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing Improper installation adjustment alteration service maintenance or use could cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property Improper installation adjus
61. al box is to be installed NOTE Check that duct on side of furnace will not interfere with installed electrical box 2 Remove the desired electrical box hole knockout and positionthe hole in the electrical box over the hole in the furnace casing 3 Fasten the electrical box to casing by driving two fieldsupplied screws from inside electrical box into casing steel 4 Remove and save two screws holding J Box See Fig 22 5 Pull furnace power wires out of 1 2 in 12 mm diameter hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electrical box and into electrical box 7 Pull field power wires into electrical box 8 Remove cover from furnace J Box 9 Route field ground wire through holes in electrical box and casing and into furnace J Box 10 Reattach furnace J Box to furnace casing with screws 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 Fig 25 Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket 22 A03221 Fig 23 Field Supplied Electrical Box on Furnace Casing POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electrical requ
62. ast two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 34 46 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 3 Orient the door to determine the correct location of the door cutout to be removed 4 Use aviation type tin snips to remove the correct U shaped cut out in door NOTE If this furnace is equipped with knockouts in the door for the vent a number of techniques can be used to remove these knockouts as seen in Fig 47 through 51 The knockout in the bottom of the door is unique due to its flanging and is not easily removed by first cutting the two tie points at the edge of the door using aviation type tin snips See Fig 47 A sharp blow to the rounded end of the knockout See Fig 48 will separate more tie points and allow the knockout to be pulled loose See Fig 49 Remove all burrs and sharp edges For the knockouts in the other locations on the door top and sides tin snips can also be used along the door edges however the preferred method is to use a hammer and screwdriver to strike a sharp blow See Fig 50 directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout
63. at least 60 F 16 C db except for brief periods of time during warm up from setback at no lower than 55 F 13 C db or during initial start up from a standby condition 2 Adjust the gas input rate per the installation instructions Low gas input rate causes low vent gas temperatures causing condensation and corrosion in the furnace and or venting system Derating is permitted only for altitudes above 2000 ft 610 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 reduce 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 can cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with this furnace ADDITIONA
64. be obtained at the wires normally connected to thermostat subbase terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Remove thermostat from subbase or from wall 2 Connect an amp meter as shown in Fig 54 across the R and W subbase terminals or R and W wires at wall 3 Record amp draw across terminals when furnace is in heating and after blower starts 4 Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall b Electronic thermostat Set cycle rate for 4 cycles per hr 7 Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec The blower off delay jumpers are located on the furnace control board See Fig 24 To change the blower off delay setting move the jumper from one set of pins on the control to the pins used for the selected blower off delay Factory off delay setting is 120 sec 8 Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow See Table 5 Air Delivery CFM With Filter See Table 11 for lead color identification 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 overheats By using this method
65. be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Cette fournaise air puls est quip e pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000 pi Utiliser une trousse de conversion foumie par le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel Cette foumaise est pr vue pour tre install e dans un b timent construit sur place Cette fournaise peut tre install e sur un plancher combustible dans une alc ve ou dans un garde robe en respectant le minimum d espace libre des mat riaux combustibles tel qu indiqu sur le diagramme Cette fournaise peut tre utilis e avec un conduit d vacuation de Type B 1 ou connect e au conduit ommun d autres appareils gaz This fumace is approved for UPFLOW DOWNFLOW and HORIZONTAL installations Cette foumaise est approuv e pour installation HORIZONTALE et la circulation d air VERS LE HAUT et VERS LE BAS Clearance arrows do not change with fumace orientation Les fl ches de d gagement ne change pas avec l orientation de la fournaise S RE 3 TOP PLENUM DESSUS CHAMBRE D AI Clearance in inches D gagement po Vent Clearance to combustibles For Single Wall vents 6 inches 6 po For Type B 1 vent type 1 inch 1 po D gagement de l vent avec combustibles Pour conduit d vacuation paroi simple 6 po 6 inches Pour conduit d vac
66. ce in the space and add the volumes together to get the total minimum required volume for the space Table 3 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 9 3 2 2 1 For other than fan assisted appliances such as a draft hood equipped water heater Volume 2113 other Other ACH 1000 Btu hr A04002 2 For fan assisted appliances such as this furnace Volume 151 ten _ Fan ACH 1000 Btu hr A004003 If Iother combined input of all other than fan assisted appliances in Btuh hr Ifan combined input of all fan assisted appliances in Btuh hr ACH air changes per hour ACH shall not exceed 0 60 The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method 1 Adjoining rooms can be considered part of a space if a There are no closable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm2 kW of the total input rating of all gas appliances in the space but not less than 100 in 0 06 m2 One opening shall commence within 12 300 mm of the ceiling and the second opening shall commence within 12 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 8 c Combining space on different floor levels The volumes of spaces on different floor levels
67. d Heat Pump and Single Speed Heat Pump TWO STAGE SINGLE STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER See note 2 on the page following these figures 04221 Fig 32 Two Stage Thermostat with Single Stage Furnace and Two Speed Air Conditioner NOTES FOR FIGURES 26 32 Heat pump MUST have a high pressure switch for dual fuel applications Refer to outdoor equipment Installation Instructions for additional information and setup procedure Outdoor Air Temperature Sensor must be attached in all dual fuel applications Dip switch No 1 on Thermidistat should be set in OFF position for air conditioner installations This is factory default Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations Dip switch No 2 on Thermidistat should be set in OFF position for single speed compressor operation This is factory default Dip switch No 2 on Thermidistat should be set in ON position for two speed compressor operation Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel applications OMAN R D NO connection should be made to the furnace HUM terminal when using a Thermidistat A The Sensing terminal should not be connected This is internally used to sense defrost operation DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internal
68. d Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 seconds See Fig 24 b Two Speed Cooling See Fig 25 32 for thermostat connections The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuit starts the furnace blower motor BLWM on low cool speed same speed as FAN The R to Y1 and Y2 circuits start the outdoor unit on high cooling speed and the R to Gand Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y1 or R to G and Y1 and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 24 3 Thermidistat Mode See Fig 26
69. e has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 in wo turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace 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 18 SUPPLY UPFLOW RETURN CONFIGURATIONS AND RESTRICTIONS Z AIR FLOW MODELS RETURNAIR RETURN RETURN AIR RETURN AIR mE CONNECTION 1 CONNECTION 2 CONNECTION3 COMBINATIONS zr ONLY ONLY ONLY OF 1 2 AND 066 060 22 AND 20 MODELS ALL OTHER MODELS YES voy Rg RETURN RETURN AIR AIR RETURN UPFLOW AIR RESTRICTIONS A02075 Fig 18 Upflow Return Air Configurations and Restrictions RETURN AIR RETURN AIR SIDE RETURN SIDE RETURN NOT PERMITTED NOT PERMITTED FOR ANY MODEL FOR ANY MODEL DOWNFLOW RETURNAIR CONFIGURATIONS AND RESTRICTIONS AI
70. e tie on loop in furnace wires attached to J box 3 Move J Box to desired location 4 Fasten J Box to casing with two screws removed in Step 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX Field Supplied Electrical Box on Furnace J Box Bracket See Fig 23 1 Remove cover from furnace J Box 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will not pierce wire insulation 3 Route furnace power wires through holes in electrical box and J Box bracket and make field wire connections in electrical box Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 4 Route and secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 23 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 electric
71. el perform the following 1 Tilt or raise furnace and remove two screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws PLENUM OPENING D FLOOR OPENING A96283 Fig 11 Floor and Plenum Opening Dimensions RM FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING DOWNFLOW SUBBASE 4 SHEET METAL gt PLENUM FLOOR OPENING 7222 gt A96285 Fig 12 Furnace Plenum and Subbase Installed on a Combustible Floor 11 ANR on FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM 44 FLOOR 4 OPENING 22552225 42202222 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor 12 A08556 Table 4 Opening Dimensions In mm FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B c D Upflow Applications on Combustible or Noncombustible Floor 12 11 16 21 5 8 13 5 16 22 1 4 ing KGASB subbase not required 322 549 338 565 Downflow Applications on Noncombustible Flooring KGASB 12 9 16 19 13 3 16 19 5 8 14 3 16 subbase not required 319 483 335 498 Downflow ap
72. es between heating and cooling 19 Check for gas leaks 20 Replace outer access door A 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 Sequence of Operation NOTE Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw Using the schematic diagram in Fig 59 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W the control will start a 90 second blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The Amber LED light will flash code 12 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normally The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU transformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV
73. following these figures A03208 Fig 34 Upflow Application Vent Elbow Up SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures 03209 Fig 35 Upflow Application Vent Elbow Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures 03210 Fig 36 Downflow Application Vent Elbow Up then Left o o o e SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 37 Downflow Application Vent Elbow Up 31 SEE NOTES 1 2 4 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 03213 Fig 40 Horizontal Left Application Vent Elbow Left Fig 38 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures o SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures
74. g Refer to the Fig 33 to perform a chimney inspection If the inspection of a previously used tile lined chimney a Shows signs of vent gas condensation the chimney should be relined in accordance with local codes and the authority having jurisdiction The chimney should be relined with a listed metal liner Type B vent or a listed chimney adapter kit shall be used to reduce condensation If a condensate drain is required by local code refer to the NFGC NFPAS4 ANSI Z223 1 2006 Section 12 10 for additional information on condensate drains b Indicates the chimney exceeds the maximum permissible sizein the tables the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt to conform to ANSI NFPA 211 or be lined with a UL listed ULC listed in Canada metal liner or UL listed Type B vent Relining with a listed metal liner or Type B vent is considered to be a vent in a chase If a metal liner or Type B vent is used to line a chimney no other appliance shall be vented into the annular space between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors ONFPA amp AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour INTERNAL AREA OF CHIM
75. ic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115 VAC 1 0 amps maximum and are energized during blower motor operation See Fig 24 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the 1 4 in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip The HUM terminal is energized when gas valve relay GVR is energized See Fig 24 NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or similar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING The furnace shall be connected to a listed factory built chimney or vent or a clay tile lined masonry or concrete chimney Venting into an unlined masonry chimney or concrete chimney is prohibited When an existing Category I furnace is removed or replaced the original venting system may no longer be sized to properly vent the attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of condensate and combusti
76. imney or vent and attached to an airdistribution system Refer to Air Ducts section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible 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 A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products Do not install furnace in a corrosive or contaminated atmosphere Make sure all combustion and circulating air requirements are met in addition to all local codes and ordinances If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion Permanent wave solutions Chlorinated waxes and cleaners
77. ir e US NGFC NFPAS4 ANSI Z223 1 2006 Section 9 3 Air for Combustion and Ventilation e Part 8 of CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2005 Fundamentals Handbook Chapter 35 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16 Acoustical Lining and Fibrous Glass Duct US and CANADA current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Gas Piping and Gas Pipe Pressure Testing e US NFGC NFPAS4 ANSI Z223 1 2006 chapters 5 6 7 and 8 and National Plumbing Codes CANADA CAN CSA B149 1 05 Parts 4 5 and 6 Appendices A B E and H Electrical Connections e US National Electrical Code NEC ANSI NFPA 70 2008 CANADA Canadian Electrical Code CSA C22 1 Venting US NFGC 54 ANSI Z223 1 2006 Chapters 12 and 13 CAN CSA B149 1 05 Part 8 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 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 Precaution
78. irements 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 diameter 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 Fig 25 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 approved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover and bracket 24 WIRING Make field 24 v connections at the 24 v terminal strip See Fig 23 Connect terminal Y Y2 as shown in Fig 24 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electron
79. ity of heat exchangers motors and controls See Fig 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before operating the furnace 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 Une r glage une modification un reparation un enretien ou une installation incorrect puet entrainer des blessures graves ou la mort Suivre les instructions et les consignes qui figurent dans notice d utilisation qui accompagne g n rateur d air chaud L installation et l entretien doivent tre effectur s par un r parateur qualifi ou par le fournisseur de gaz Check entire gas assembly for leaks after lighting this appliance V rifier tous les l ments gaz pour rechercher les fuites apr s avoir allum cet appareil INSTALLATION 1 This fumace 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 Ce foumaise air chaud doit amp tre install conform ment aux instructions du fabricant et aux codes locaux En l absence de
80. l 10 UBD snjejs UO sunoy 22 Jaye sepoo uonejedo yoayo 0 10 yno ung eoeuunj y WO eu 10euuoosiq eoeuin eui speuiuuie esleuBis 9 pue 10 ZA A Queseid ji LA MW s d SI ueseJd LA 01 puodsai eui S80q ON ejqeo JO 2 SOULOU UJ00J Y90949 LHVLS yoeq pue 18 281q 95015 eoguJnj Jayeaq JO 49949 yams Joop SHA SHA pasoj Jayeaq S yams AG S SHA YMS JOOP S YMS JOOP S Uo peuJni IM pue eA e sed yoke spuooes 91 01 10 uni peeds 1009 pue peeds 1v3H iuo peeds ISH SUL 1591 jueuodujoo eJnue eu 40 pue JIM y eouenbes 1591 jueuoduuoo e JIM eu epoo ay sjeedei OU JOY ou sew usejj
81. l flat washer if desired 10 44mm 1 3 4 44mm 3 aN A89014 Fig 10 Leveling Legs 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement 5 Reinstall bottom closure panel if removed DOWNFLOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used Special Base KGASB e Cased Coil Assembly Part No CNPV CNRV or CAR Box Part No KCAKC 1 Determine application being installed from Table 4 2 Construct hole in floor per Table 4 and Fig 11 3 Construct plenum to dimensions specified in Table 4 and Fig 11 4 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part No CNPV CNRV CAP and CNR or Coil Box PartNo KCAKC is used install as shown in Fig 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14 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 pan
82. lame rollout or blocked vent 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 switch if used is open Blower will run for 4 minutes or until open switch remakes 21 GAS HEATING LOCKOUT Control will NOT auto reset whichever is longer If open longer than 3 minutes code changes to lockout 13 SIGN Ate control relay Ive is d If open less than 3 minutes status code 33 continues to flash until blower shuts off 22 NAL Flame Is proved while gas valve 15 de Flame rollout switch and BVSS require manual reset Check for Restricted vent energized Inducer will run until fault is cleared Check for Leaky gas Proper vent sizing Loose blower wheel Excessive wind Stuck open gas valve Dirty filter or restricted duct ystem 23 PRESSURE ee OPEM es fer AK closed Defective blower motor or capacitor Defective switch or connections 24 SECONDARY VOLTAGE FUSE 1s OPEN Chock for Inadequate combustion air supply Flame Roll out Switch open Short circuit in secondary voltage 24VAC wirin 34 IGNITION PROVING FAILURE Control will try three more times before lockout 14 9 g occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Flame sensor must not be grounded Ex COM PONENT TEST Oxide buildup on flame sensor clean with fine steel wool To initiate
83. llation Code CSA B149 1 in Canada Crown condition Missing mortar or brick Rebuild crown Is chimney property lined with clay tile liner Repair liner or top seal or reline chimney as necessary Is liner and top seal in good condition Reline Debris in cleanout Mortar Mortar tile metal vent or tile pelts e fuel oil residue debris No Remove metal vent or liner Clay tile misalignment missing sections gaps Consult Part B of chimney adapter venting instructions for application suitability Not Suitable Is chimney ee ned with propery eee drainage t bottan sized listed liner or qud 3 of chimney liner or Type B vent per Type B vent NFGC or NSCNGPIC Vent Sizing Tables and liner due vent manufacturer s instructions Installation instructions Not Suitable Consult Part C of Chimney exposed to outdoors below roof line Is chimney to be dedicated to a single furnace instructions for application suitability Install chimney adapter per instructions Chimney is acceptable for use Fig 33 Chimney Inspection Chart 29 A03206 To prevent condensation in the furnace and vent system the following precautions must be observed 1 The return air temperature must be
84. ly by the Thermidistat Dual Fuel Thermostat m 12 Dip switch D on Dual Fuel Thermostat should be set in OFF position for single speed compressor operation This is factory default 13 Dip switch D on Dual Fuel Thermostat should be set in ON position for two speed compressor operation 27 Canada and U S A This furnace is permitted to be vented into a clay tile lined masonry chimney that is exposed to the outdoors below the roof line provided 1 Vent connector is Type B double wall and 2 This furnace is common vented with at least 1 draft hoodequipped appliance and 3 The combined appliance input rating is less than the maximum capacity given in Table A and 4 The input rating of each space heating appliance is greater than the minimum input rating given in Table B for the local 99 Winter Design Temperature Chimneys having internal areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces See footnote at bottom of Table B and 5 The authority having jurisdiction approves If all of these conditions cannot be met an alternative venting design shall be used such as the listed chimney adapter kit with these furnaces 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 linin
85. may be used to suspend the furnace from each bottom corner To prevent screws from pulling out use 2 8 x 3 4 in 19 mm screws into the side and 2 8 x 3 4 in 19 mm screws in the bottom of the furnace casing for each strap See Fig 15 and 16 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment screws are not in tension are loaded in shear for reliable support Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Fig 2 and 17 For furnaces with 1 in 25 mm clearance requirement on side 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 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
86. mber of long flashes For an explanation of status codes refer to service label located on blower access door or Fig 55 and the troubleshooting guide which can be obtained from your distributor See Fig 60 a brief Troubleshooting Guide For Controls With an Amber LED The stored status code will not be erased from the control memory if 115 or 24 v power is interrupted 1 To retrieve status code proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 v power to furnace turned on b Remove outer access door c Look into blower access door sight glass for current LED status Removing blower access door will open blower access door switch and terminate 115 v power to control so that status code is not displayed d BRIEFLY remove insulated terminal wire from the draft safeguard DSS switch until LED goes out then reconnect it NOTE If wire to LS or DSS is disconnected longer than 4 sec main blower starts and retrieval request is ignored 2 When above items have been completed the LED flashes status code 4 times Record this status code for further troubleshooting 3 Check LED status If no previous faults in history control will flash status code 11 Table 14 Orifice Size And Manifold Pressure In wc For Gas Input Rate TABULATED DATA BASED ON 21 000 BTUH PER BURNER DERATED 4 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG G
87. mperature 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 11 for motor speed lead relocation if leads were not identified before disconnection 17 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected 18 To check blower for proper rotation a Turn on electrical supply A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door d Verify blower is rotating in the correct direction 19 If furnace is operating properly RELEASE BLOWER ACCESS DOOR SWITCH Remove any jumpers or reconnect any disconnected thermostat leads Replace blower access door
88. n for each two Vertical Ducts or Openings 66 000 40 000 106 000 divided by 3 000 35 3 Sq In for a Single Duct or Opening 88 000 30 000 118 000 divided by 2 000 59 0 Sq In for each of two Horizontal Ducts Table 3 Minimum Space volumes for 100 combustion Ventilation and Dilution from Indoors OTHER THAN FAN ASSISTED TOTAL FAN ASSISTED TOTAL 1 000 5 BTUH GAS INPUT RATE 1 000 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 Air Changes Hour PIN ARNIN G AIR FOR COMBUSTION AND VENTILATION FIRE HAZARD Provisions for adequate combustion ventilation and dilution air must be provided in accordance with e US installations Section 9 3 of the NFGC NFPAS54 ANSI Z223 1 2006 Air for Combustion and Ventilation 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 Failure to follow this warning could result in personal injury death and or property damage Do n
89. nd 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 in accordance with the NFGC or CAN CSA B149 1 05 See Fig 5 Table 2 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING FUR 1 SQ IN 2 000 BTUH 1 SQ IN 3 000 BTUH 1 SQ IN 4 000 BTUH NACE 1 100 SQ MM KW 734 SQ MM KW 550 SQ MM KW enue Free Area of Opening Round Duct Free Area of Open Round Duct Free Area of Round Duct 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 FURNACE WATER HEATER TOTAL INPUT 110 000 30 000 140 000 divided by 4 000 35 0 Sq I
90. on products and spillage of combustion products into the living space 23 BLOWER OFF DELAY 10 62021 1932 TWINNING AND OR COMPONENT TEST 24 V THERMOSTAT TERMINALS 3 AMP FUSE LED OPERATION amp DIAGNOSTIC LIGHT TRANSFORMER 24 VAC CONNECTIONS BLOWER SPEED SELECTION TERMINALS PL1 LOW VOLTAGE DRAIN HARNESS CONNECTOR 115 VAC L2 NEUTRAL CONNECTIONS EAC 1 TERMINAL PL2 HOT SURFACE 115 VAC 1 0 AMP MAX IGNITER amp INDUCER 115 VAC L1 MOTOR CONNECTOR NEUTRAL CONNECTIONS A08063 Fig 24 Furnace Control FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE OLO TERMINALS FIELD SUPPLIED HEATING ONLY __ mE en 4 208 230 OR BLOWER DOOR SWITCH 460 V e 1 e THREE 1 PHASE Pee le e _ E W e We ______ 2 0 1 9 N e e eer 208 230 V GND GND I te e 1el ae 2 AUXILIARY 115 V FIELD amp H 4 e SUPPLIED _ J BOX L oe i 5 ND DISCONNECT oS CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown fo
91. onal injury 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 CAUTION death and or property damage FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Fig 53 Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks 3 To Begin Component Self Test Remove blower access door Disconnect the thermostat R lead from the furnace control board Manually close the blower door switch closed Short jumper the COM 24v terminal on control to the TEST TWIN 3 16 inch quick connect terminal on control until LED goes out approximately 2 sec Gas valve and humidifier will not be turned on See Fig 24 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 re
92. onnections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate 7 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space 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 8 A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions 10 These Multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA listed accessory gas conversion kit is required to convert furnace for use with propane gas 11 See Fig 2 for required clearances to combustible construction 12 Maintain a 1
93. or dehumidification the cooling blower off delay is decreased from 90 seconds to 5 seconds Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed can be adjusted to FAN HEAT or COOL speed at the thermostat Factory default is FAN speed Terminal EAC 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 seconds ignition 7 seconds and blower ON delay 25 seconds allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at HEAT speed In heating the furnace control CPU will hold the blower motor BLWM at HEAT speed during the selected blower OFF delay period before reverting to continuous blower speed When the thermostat calls for low cooling the blower motor BLWM will switch to operate at low cool speed same speed as FAN When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on low cool speed same speed as before reverting back to continuous blower speed When the thermostat calls for high cooling the blower motor BLWM will operate at COOL speed When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous blower speed When the R to G circuit is opened the bl
94. ore going to Ignition Lockout Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W G R etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT speed 25 seconds after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC 1 is energized and remains energized as long as the blower motor BLWM is energized f Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 5 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 seconds depending on the blower OFF delay selection The furnace control CPU is factory set for a 120 second blower OFF delay 49 2 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 25 32 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G an
95. ost horizontal furnaces See Fig 19 Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace Upflow_and Horizontal Furnaces The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 18 and 20 Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 18 and 20 Not all horizontal furnaces are approved for side return air connections See Fig 20 GAS PIPING A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Use proper length of pipe to avoid stress on gas control manifold and a gas leak 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
96. ot install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace See Fig 6 The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST be provided for the ventilation devices in addition to that required by the furnace Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make up air is available A02054 Canadian installations Part 8 of the Fig 6 Prohibit Installation on Back CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction A C AUTION The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume FURNACE CORROSION HAZARD of at least 50 cubic feet per 1 000 Btuh input rating for all gas appliances installed in the space Failure to follow this caution may result in furnace damage e Spaces having less than 50 cubic feet per 1 000 Btuh Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and TOUS OUTDOOR COMBUSTIONAIR iodide These elements can corrode heat exchangers and METHOD
97. outside this range change main burner orifices Refer to Table 10 12 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 37 c Measure time in sec for gas meter to complete 1 revolution 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 If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct input is achieved Reinstall regulator seal cap on gas valve 5 Set temperature rise The furnace must operate within the temperature rise ranges specified on the furnace rating plate Do not exceed temperature rise range specified on unit rating plate Determine the temperature rise as follows NOTE Blower access door must be installed when taking tempe
98. ow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when disconnecting wires from switches because damage may occur Draft safeguard switch Inducer motor Pressure switch es Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode EUR 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 removed from collector box 7 Disconnect gas line from gas manifold 8 Remove the 5 screws that attach the burner assembly to the cell panel The gas valve and individual burners need not be removed from support assembly Remove NOx baffles if installed NOTE Be very careful when removing burner assembly to avoid breaking igniter See Fig 56 and 57 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 clean cells as follows a Remove metal screw fitting from wire brush to allow insertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by
99. ower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower speeds from the room thermostat momentarily turn off the FAN switch or pushbutton on the room thermostat for 1 3 seconds after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower speed from the factory setting of FAN to HEAT speed Momentarily turning off the FAN switch again at the thermostat will shift the continuous blower speed from HEAT to COOL Repeating the procedure will shift the continuous blower speed from COOL to FAN speed The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption 5 Heat pump See Fig 25 32 for thermostat connections 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 Y1 or R to W and Y1 and G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge
100. plications on combustible flooring KGASB sub 11 13 16 19 13 7 16 20 5 8 360 base required 284 483 841 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or CAP Coil Assembly or KCAKC coil box m i 163 Mene Eo KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 16 21 5 8 16 5 8 22 1 4 ing KGASB subbase not required 406 549 422 565 Downflow Applications on Noncombustible Flooring KGASB 15 7 8 19 16 1 2 19 5 8 17 12 subbase not required 403 483 419 498 445 Downflow applications on combustible flooring KGASB sub 15 1 8 19 16 3 4 20 5 8 base required 384 483 425 600 Downflow Applications on Combustible Flooring with CNPV 15 1 2 19 16 1 2 20 CNRV CAR or CAP Coil Assembly or KCAKC coil box 394 483 419 508 KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 19 1 2 21 5 8 20 1 8 22 1 4 ing KGASB subbase not required 495 549 511 565 Downflow Applications on Noncombustible Flooring KGASB 19 3 8 19 20 19 5 8 21 subbase not required 492 483 508 498 Downflow applications on combustible flooring KGASB sub 18 5 8 19 20 1 4 20 5 8 533 base required 473 483 514 600 Downflow Applications on Combustible Flooring with CNPV 19 19 20 20 CNRV CAR or CAP Coil Assembly or KCAKC coil box 483 483 508 508 KGASB subbase not required Upflow Applications on Combustible o
101. pue oys apoo snieis 10 eu jo epoo snieis G37 No 5206 037 APZWOD oi NIML IS3 eu Buoys Aq epoo snes snoad 3y 12981 osje 112981 snieis Bureniui jaued sseoo 10 jou op GSH snieis peuois e dsip 0 ou 199UU0981 pue Ayaliq epoo snieis OL peusey jeu epoo sniejs eui 10 05 L L Jeujo epoo smeis snoi aJd 3194 SEM eseysey jo Jaquunu eu Aq puooes au pue seusej jo jequunu y Aq IP 151 eut jequunu Z SI opoo 5 eu snieis pue Yous jo jwo S 440 NO 1461 snes G37 SI ON Buiseud jeuuojsuea eBeyoa mo 10 pauu syun j Ajuejod eBeyon 1294100 SHA amp esned Ajpides snes G37 SI o3u09 eoeuun SHA 65 955 L O3S I 91941 S SHA 59 6671 pue 112 ASIE 91991 uo 1461 snes qan SI LYVLS A02106A Fig 60 Troubleshooting Guide 53 Jejdepy
102. pumped 3 735 685 625 585 530 490 435 305 345 295 2 820 765 725 670 630 580 545 490 455 405 1 650 595 535 490 430 390 330 280 235 5 1625 1585 1535 1495 1460 1415 1365 1295 1220 1125 4 1405 1860 1820 1280 1240 1195 1155 1115 1070 1030 prine pes 3 1240 1200 1155 1110 1065 1020 975 935 895 850 2 1190 1140 1095 1050 1000 955 915 870 830 790 1 1035 985 930 885 835 785 745 695 650 600 5 1845 1800 1755 1710 1665 1595 1500 1400 1275 1105 4 1590 1545 1500 1455 1410 1365 1815 1270 1180 1000 pov Hae 8 1365 1820 1270 1215 1170 1125 1070 1025 955 900 2 1225 1160 1110 1060 1010 950 895 830 770 710 1 1100 1030 960 875 805 730 645 870 505 425 5 2255 2205 2150 2100 2040 1985 1920 1835 1735 1615 4 1600 1525 1465 1400 1335 1275 1210 1150 1080 1015 110 20 Bottom or 3 1945 1890 1830 1770 1715 1655 1600 1545 1480 1430 060110 Side s 2 1420 1340 1280 1200 1140 1065 1005 925 865 790 1 1280 1205 1140 1055 990 910 840 760 695 630 5 2205 2240 2185 2125 2070 2005 1925 1805 1670 1545 220 Bottom 4 1725 1660 1605 1545 1460 1395 1340 1285 1230 1170 imd Side s 8 1910 1865 1800 1745 1685 1610 1545 1485
103. quired 1 Determine the correct gas input rate In the U S A 36 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 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 In Canada The input rating must be derated by 10 percent for altitudes of 2 000 ft 610 M to 4 500 ft 1372 M above sea level by an authorized Gas Conversion Station or Dealer To determine correct input rate for altitude see example 1 and use 0 90 as derate multiplier factor EXAMPLE 1 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT 1310 M Furnace Input X Derate Furnace Input Rate at Sea Multiplier Rate at Level Factor Installation Altitude 88 000 X 0 90 79 200 2 Determine the correct orifice and manifold pressure adjustment 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 positions must use Table 14 21 000 Btuh Burner See input listed on rating plate a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain average yearly gas specific gravity from local gas
104. r SINGLE STAGE FURNACE TWO SPEED AIR CONDITIONER YT Le etes es Y1 G Y2 Re esee DHUM Com HUM s HUMIDIFIER 24 VAC OUTDOOR L See notes 2 5 8 and 10 on the page following these figures SENSOR tioner THERMIDISTAT SINGLE STAGE SINGLE SPEED FURNACE HEAT PUMP RVS COOLING O W2 __________________________ L N A YAWW2 Y1 HEAT STAGE 2 W W1 ___________ ane desine ce w2 FURNACE HEAT COOL STAGE 1 YIY2 ___________ _ 2 __ ____ lS Y COMPRESSOR FAN G _________ X 24VACHOT R L4 EST ne LT R DEHUMIDIFY DHUMLJ DHUM 24VAC COMM C C HUM HUMIDIFY HUM HUMIDIFIER 224 24 B 781 m OUTDOOR m OUTDOOR Free SENSOR SENSOR CONNECTION el Le See notes 1 2 4 6 7 9 10 and 12 on the page following these figures 04217 Fig 28 Single Stage Furnace with Single Speed Heat Pump Dual Fuel
105. r Noncombustible Floor 23 21 1 8 23 5 8 22 1 4 ing KGASB subbase not required 584 537 600 565 Downflow Applications on Noncombustible Flooring KGASB 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 KGASB sub 22 1 8 19 23 3 4 20 5 8 base required 562 483 603 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or CAP Coil Assembly or KCAKC coil box pns i 255 eon 506 KGASB subbase not required HORIZONTAL INSTALLATION 4 WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING 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 The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad Suspended Furnace Support The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps
106. r proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire 99440 Fig 25 Heating and Cooling Application Wiring Diagram with 1 Stage Thermostat 24 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 bath
107. rature 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 before changing speed tap 06666 Fig 52 Gas Control Valve a 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 b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Blower access door must be installed for proper temperature rise measurement D NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation X BURNER 2 Derate for altitude if applicable ES ORIFICE 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in we D 4 Dirty filter c Reinstall blower access door if removed d Turn gas valve ON OFF switch to ON e Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise W Decrease blower speed to increase temperature rise A ARNING f Turn thermostat down below room temperature and FIRE HAZARD remove blower access door
108. rgized for 15 sec then off Blower motor operates on HEAT speed for 10 sec 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 Blower motor operates on COOL speed for 10 sec Inducer motor stops moan Reconnect R lead to furnace control board release blower door switch and re install blower door 1 Maintain 115 v wiring and ground Improper polarity will result in rapid flashing LED and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the furnace control Failure to make proper connections will result in improper operation See Fig 25 3 Gas supply pressure to the furnace must be greater than 4 5 we 0 16 psig but not exceed 14 in we 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to 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 Adjustments 4 WARNING FIRE HAZARD Failure to follow this warning could result in injury death operate furnace and or property damage 6 Replace outer door Start Up Procedures 4 WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause pers
109. rn 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 Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 10 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see Item 1 in Bottom Return Air Inlet section To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace See Fig 10 2 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Instal
110. room 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 operation Use the flame of a match or candle If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use Vent system or vent connectors may need to be resized Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC or CAN CSA B149 1 05 GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements including local building codes the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 NFGC Parts 12 and 13 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 05 CAN CSA B
111. s 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 disconnects maybe required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Firmly touch the clean unpainted metal surface of the furnace 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 nothing to recharge your body with static electricity for example 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 unpainted metal surface of the furnace again before touching control or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces THE BLOWER 15 LOCATED BELOW THE
112. s to Combustibles CODES AND STANDARDS Safety 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 In the United States and Canada follow all codes and standards for the following e 5 National Fuel Gas Code NFGC 54 2006 ANSI Z223 1 2006 and the Installation Stan dards Warm Air Heating and Air Conditioning Sys tems ANSI NFPA 90B CANADA CSA B149 1 05 National Standard of Canada Natural Gas and Propane Installation Codes CAN CSA B149 1 05 Ahya 2 85 F 29 C FRONT 60 F 16 C RETURN AIR A02055 Fig 3 Return Air Temperature General Installation US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 www NFPA org or for only NFGC contact the American Gas Association 400 N Capitol Street N W Washington DC 20001 www AGA org CANADA CAN CSA B149 1 05 For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Combustion and Ventilation A
113. ssories 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 Fig 14 The supply air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASBO201ALL 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 14 UPFLOW DOWNFLOW HORIZONTAL YES YES YES YES 1 EN YES YES NO NO NO 02020 Fig 14 Duct Flanges 1 4 6mm THREADED ROD 4 REQ OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 x3 4 19mm SCREWS TYPICAL FOR 2 SUPPORTS 8 203mm MIN FOR DOOR REMOVAL 1 25mm SQUARE 1 1 4 x1 1 4 x1 8 32x32x3mm ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD A05027 Fig 15 Horizontal Unit Suspension 15
114. supplier c Find installation altitude in Table 13 or 14 d Find closest natural gas heat value and specific gravity 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 f Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY g Replace orifice with correct size if required by Table 10 12 13 and 14 Use only factory supplied orifices See EXAMPLE 2 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 pres MENT ORIENTATION VENT ORIENTATION BTUH HR IN MM FT M Downflow Vent elbow left then up Fig 38 132 000 5 127 12 4 Horizontal Left Vent elbow right then up Fig 41 132 000 5 127 7 2 Horizontal Left Vent elbow right Fig 42 132 000 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 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 1219 12 16 0 8
115. the component test sequence shut OFF the room thermostat or disconnect the R Prop or ga 5 microam aa op nominal thermostat lead Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED Defective Hot Surface Ignitor Control ground continuity will flash code and then turn ON the inducer motor The inducer motor will run for the entire Low inlet gas pressure Inadequate flame carryover or rough ignition component test The hot surface ignitor blower motor fan speed on AMBER LED boards Green Yellow wire MUST be connected to furnace sheet metal only blower motor heat speed and blower motor cool speed will be turned ON for 10 15 45 CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to seconds each Gas Valve and Humidifier will not be turned on Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats Ne 327596 101 REV B 7 7 04223 Fig 55 Service Label 45 CARE AND MAINTENANCE 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 4 Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have furnace and burner serviced by a qualified service agency 5 Inspect the vent pipe vent system before each heating season for
116. thority having jurisdiction for approval on use with solid fuel burning appliance 5 Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed power ventor 6 Do not vent this appliance into an unlined masonry chimney Refer to Chimney Inspection Chart Fig 33 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 2006 in the United States and to a Provincial or Territorial Building Code in Canada in its absence the National Building Code of Canada and must be in good condition U S A Refer to Sections 13 1 8 and 13 2 20 of the NFGC NFPAS54 ANSI Z223 1 2006 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 NFPAS4 ANSI Z223 1 2006 13 1 8 and 13 2 20 regarding alternative venting design and
117. tment alteration service damage Consult a qualified service agency local gas maintenance or use can cause explosion fire electrical shock or supplier or your distributor or branch for information or other conditions which may cause death personal injury or assistance The qualified service agency must use only property damage Consult a qualified installer service agency or factory authorized and listed kits or accessories when your distributor or branch for information or assistance The modifying this product 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 7223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the National Standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation Codes and Canadian Electrical Code CSA C22 1 Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals be alert to the potential
118. 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 failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of 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 shutdown of the furnace during certain blocked vent conditions THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER f S 10 TURNS Ne FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 5 0 AMPS ON AMMETER _ 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING A96316 Fig 54 Amp Draw Check with Ammeter Verify vent pipe is cool to the touch Disconnect power to furnace and remove vent connector from furnace vent elbow Restore power to furnace and set room thermostat above room temperature 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 Furnace should cycle off within 2 minutes If gas does not shut off within 2 minutes determine reason draft
119. uation de Type B 1 1 po 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS Installation on non combustible floors only For Installation on combustible flooring only when installed on special base Part No KGASBO201ALL NAHA01101SB Coil Assembly Part No CAR CAP CNPV WENC or WTNC 18 inches front clearance required for alcove Indicates supply or retum sides when fumace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the fumace jacket and building joists studs or framing DEGAGEMENT MINIMUM EN POUCES AVEC ELEMENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pour l installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale pi ce KGASBO201ALL ou NAHA01101SB l ensemble serpentin pi ce n CAR CAP CNPV WENC ou WTNC ou le carter de serpentin Dans une alc ve on doit maintenir un d gagement l avant de 18 po 450mm La poistion indiqu e conceme le c t d entr e ou de retour quand la foumaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la cherrise de la fournaise et les solives montant sous cadre de charpente 335137 101 REV A 08471 Fig 2 Clearance
120. ubleshooting Refer to the service label See Fig 55 The Troubleshooting Guide See Fig 60 can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After replacing any component verify correct operation sequence XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXx m lt XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXX 0701845 491 LOL ZZZVEE Ne pasn Joonpu 9 319VLd3934 9 1 07 155 HOLIMS 33055344 Sv9 MOT 1 Aq pa ajad 10401 payoo SI IS SL 301195 01915 3009 SNLYLS 303 30010 NE x SI WHC Uaym 10 spuoo s 06 duna yeay ANNOYS LNAWdINOA E YOLOSTSS u3dWnr 430 HIMO T8 OK Jo Buyjooo spuooes 08 10 06 Qa 06 Buljeay seb fejep v KLYVA qid T 914 ILON 218 HOLONON
121. uld occur This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground Blower access panel door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 25 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 35 C rise 21 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 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 U S Installations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2008 and any local codes
122. um any loose dust from blower housing wheel and motor 11 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel NOTE Before 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 reassembling e Remove blower wheel from housing f Clean wheel and housing 12 Reassemble motor and blower by reversing steps 11f through 11a finishing with 11a Be sure to reattach ground wire to the blower housing 13 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in furnace 16 Reinstall control box assembly in furnace 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 te
123. van ma N3HM HOLIMS LOANNOOSIG Z Gyvas YO x LINOHIO HO ISNA 1 PALON x L353 1 WOH 9 Sud H se BNVHL _ asna ILON IST zSH4 x pV Y x ZI OVAS Id zova x 1 4 H lt a Jr me 5 LL ILON d n Na NYO x GNI B4 A 659 aay a Woo d x a 2 3 i AMIE sed E 2 he X lv3H B at rie x RE El aay x ma 94 ILON x ind dasn WAH aw SsAg a NIMLLSAL 580 lt x eu ILON aano ION osl 5 OSL x aay 02 B Q x 27 CE RES RES e 06 SR 25 151 2984 27 d HO 199195 x 1O3NNOOSIG 91315 OVASLI OL INVHOVIO NOLLO3NNOO AVTAC 440 HAMOTE x XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXx A08176 iagram D 52 iring Fig 59 ON JEISOWAY eu 10 ejsouueu eu 0 JEUILW9 SU 40451591 jsej eq 19443 eoeuunj eu jou s 941 aam 1eduunf 4 eu seoq seun eoejde peydnuequ
124. with Hammer 35 START UP ADJUSTMENT AND SAFETY CHECK General A WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switches Correct inadequate combustion air supply problem before resetting the switches NOTE The furnace control allows all components except the gas valve to be run for short period of time This feature helps diagnose a system problem in case of a component failure Component test feature will not operate if any thermostat signal is present at the control Component test sequence is as follows Refer to service label attached to furnace or see Fig 55 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury a LED will display previous status code 4 times b Inducer motor starts and continues to run until Step f of component test sequence Hot surface igniter is ene
125. y 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 Loosen the thumbscrew on outer door and remove outer door 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door a Disconnect vent connector from furnace vent elbow b Disconnect and remove short piece of vent pipe from within furnace 4 Remove two screws from blower access door and remove blower access door 5 Disconnect both harness connectors from blower motor instead of at the circuit board This reduces the chances of a miswire when reconnecting wiring The connectors are polarized to prevent connection in the wrong orientation 6 Remove two screws holding control box to blower shelf 7 Hang control box from front of furnace casing and away from blower compartment 8 Remove two screws holding blower assembly to blower deck and slide blower assembly out of furnace 9 Clean blower wheel and motor using a vacuum with soft brush attachment Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blades 10 Vacu

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