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1. THERMIDISTAT SINGLE STAGE TWO SPEED FURNACE HEAT PUMP THERMIDISTAT SINGLE STAGE TWO SPEED RVS COOLING OW2 1 FURNACE AIR CONDITIONER HEAT COOL STAGE 1 Y1 W2 ___________ Aw Ee 1 WA 2 COMPRESSOR LO HEAT STAGE 3 WWI ___________ w w2 COOL STAGE 1 YIW2 ___________ Payal bed bosse n Y1 FURNACE TA NOTE 12 HEAT COOL STAGE 2 __ 12 JF YN2 __ ____ Y2 HEAT STAGE 1 W W1 4 4 W COMPRESSOR HI COOL STAGE 2 YIY2 __________ 2 l l Y2 G 4 4 6 F W3 SL LL LLLA EG 24VACHOT R __________ URS Eee R AO HOT ER Lee cet He de E R DEHUMIDIFY 1 DHUM DEHUMIDIFY DHUML ____________ DHUM 24 VAC COMM C L 4 H c 24VAC COMM El Com L C HUM Mines ind lu HUMIDIFIER HUMIDIFY HUM 42 A 24 HOMIDIEY HUMIDIFIER m B 24 L M si OUTDOOR N A B OUTDOOR po sec SENSOR 1 L p SENSOR OUTDOOR CON
2. DUAL FUEL SINGLE STAGE TWO SPEED THERMOSTAT FURNACE HEAT PUMP RVS COOLING OWA neue 21 HEAT COOL STAGE 1 Y1 W2 4 E ei Y1 COMPRESSOR LO HEAT STAGE 3 ___________ WES Les zi 2 FURNACE HEAT COOL STAGE 2 YIY2 ___________ Br Lese ces T Y2 COMPRESSOR HI FAN 7G 1 W3 24VACHOT R _________ s Rs 1 R DHUM 24VACCOMM C _________ a DOM I Lc B Hum VE PE CENE RVSSENSING L i 51 OUTDOOR LL FRUMIDFIER ae ease SENSOR SENSOR 24VAC CONNECTION 52 1222222251 ce See notes 1 2 3 4 11 12 and 14 A02103 Fig 30 Dual Fuel Thermostat with Single Stage Furnace and Two Speed Heat Pump TWO STAGE SINGLE STAGE FURNACE THERMOSTAT See note 2 TWO SPEED AIR CONDITIONER HUMIDFIER 24VAC 02161 Fig 31 Two Stage Thermostat with Single Stage Furnace and Two Speed Air Conditioner 20 Notes For Figure 25 31 00 10 D Select the ZONE position on the two speed heat pump control Heat pump MUST have a high pressure switch for dual fuel applications Refer to outdoor equipment Installation Ins
3. SEE NOTES 1 2 4 7 8 9 A02064 Fig 39 Horizontal Left Application Vent Elbow Left SERRES A02067 Fig 42 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 A02065 Fig 40 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 then Up A02068 Fig 43 Horizontal Right Application Vent Elbow Left See Venting Notes on Page 26 SEE NOTES 1 2 4 5 7 8 9 02066 Fig 41 Horizontal Left Application Vent Elbow Up Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting system due to corrosion Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with this furnace ADDITIONAL VENTING REQUIREMENTS 4 round vent elbow is supplied with the furnace A 5 inch or 6 inch vent connector maybe required for some model furnaces A field supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal increaser fitting is required when 5 inch or 6 inch vent connector is used See Fig 33 45 Venting Orienta
4. 16 For BX Cable 16 EFFICIENCY RATING CERTIFIED REGISTERED QUALITY SYSTEM J Box Cover Installation 2 ACCESSOS torre e E EN EA et ehe pde ede General Venting Requirements eee Masonry Chimney Requirements esses Appliance Application Requirements Additional Venting Requirements sess Sidewall Venting eere tete START UP ADJUSTMENT AND SAFETY CHECK 26 c ees Men na trie SR TINTE 26 Start Up Procedures esses 26 Adjustments endete 27 Check Safety eee 30 Checklist e tete e 31 SERVICE AND MAINTENANCE PROCEDURES 31 Introduction otn teen ee ns 31 General 31 Electrical Controls and Wiring 42222422 32 Care and Maintenance eese nennen 33 Cleaning and or Replacing Air Filter 33 Blower Motor and Wheel 33 Cleaning Heat Exchanger esee 34 Sequence of Operation 36 Wiring Diaprams ente De E EE EROR NR Re 37 Troubleshooting heres 37 Manufacture
5. ALTITUDE AVG GAS 0 58 0 60 0 62 0 64 RANGE HEAT VALUE FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 900 42 3 5 42 3 6 42 3 7 41 3 5 8 925 42 3 3 42 3 4 42 3 5 42 3 7 950 43 3 8 42 3 3 42 3 4 42 3 5 0 975 43 3 6 43 3 8 42 3 2 42 3 3 S un 1000 43 3 5 43 3 6 43 3 7 43 3 8 4 1025 43 3 3 43 3 4 43 3 5 43 3 6 1050 44 3 6 43 3 2 43 3 4 43 3 5 gt 1075 44 3 4 44 3 5 43 3 2 43 3 3 1100 44 3 3 44 3 4 44 3 5 43 3 2 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 058 060 82 0 64 FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 800 42 3 4 42 3 5 42 3 6 42 3 7 8 AUT 825 42 3 2 42 3 3 42 3 4 42 3 5 to 850 43 3 7 43 3 8 42 3 2 42 3 3 S 3000 875 43 3 5 43 3 6 43 3 7 43 3 8 S a ERE 900 43 3 3 43 3 4 43 3 5 43 3 6 4 Altitudes 925 43 3 1 43 3 2 43 3 3 43 3 4 2000 950 43 2 9 43 3 0 43 3 1 43 3 2 2 to 975 43 2 8 43 2 9 43 3 0 43 3 1 4500 1000 43 2 6 43 27 43 2 8 43 2 9 SPECIFIC GRAVITY OF NATURAL GAS RENE WERE UA UE 0 58 0 60 0 62 0 64 FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 775 42 3 2 42 3 8 42 3 4 42 3 5 800 43 3 6 43 3 8 42 3 2 42 3 3 3001 825 43 3 4 43 3 5 43 3 7 43 3 8 U S A Only to 850 43 3 2 43 3 3 43 3 4 43 3 6 4
6. p A02069 SEE NOTES 1 2 4 7 8 9 Fig 44 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 A02070 Fig 45 Horizontal Right Application Vent Elbow Left then Up SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting without the use of an add on power venter In the U S Per the NFGC any listed power venter may be used when approved by the authority having jurisdiction In Canada Only power venters approved by the appliance manufacturer and where allowed by the authority having jurisdic tion may be used for sidewall venting The only approved power venter is the Field Controls SWG 4D and SWG 5D sidewall power venter Select the power venter to match the Btuh input of the appliance being vented Follow all manufacturer s installation requirements for venting and termina tion included with the power venter START UP ADJUSTMENT AND SAFETY CHECK Step 1 General A WARNING This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switches Correct inadequate combustion air supply problem and reset the switches Failure to follow this warning can cause fire explosion personal injury or death A CAUTION Personal
7. FURNACE AIR CONDITIONER FURNACE HEAT PUMP N A O W2 RVS COOLING O W2 J L Y1 W2 Y1 N A Y1 W2 HEAT STAGE 1 wiw1 4 4 w Y1 COOL STAGE 1 Y Y2 4 4 MIL ic Dem E L Y HEAT STAGE 2 W W1 _________ Jw LE 1 W2 4 4 FURNACE HEAT COOL STAGE 1 YIY2 ________ _ YN2 LL Y 24 VACHOT R Lj R COMPRESSOR G _________ DEHUMIDIFY DHUM 4 4 DHUM 24 R ll TR LL R 24VACCOMM C 4 2 1 1 ul DEHUMIDIFY ___________ DHUM HUM 24VACCOMM C __________ Com L L 2 HUMIDIFIER HUMIDIFY HUM FT HUM 24 i B HUMIDIFIER HUMIDIFY HUM ________ PR 51 OUTDOOR 24 VAC OUTDOOR rt STE er SENSOR SENSOR B CONNECTION 82 OUTDOOR Sd OUTDOOR See notes 2 5 7 and 10 SENSOR SENSOR 00268 52 eee ee eal See notes 1 2 4 6 7 9 10 and 12 Fig 25 Single Stage Furnace with Single Speed Air Conditioner A00270 Fig 27 Single Stage Furnace with Single Speed Heat Pump Dual Fuel
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11. A89014 Fig 10 Leveling Legs Step 2 Downflow Installation NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the 3 accessories are used Special Base KGASB e Cased Coil Assembly Part No CDS or 5 Coil Box Part No KCAKC 1 Determine application being installed from Table 3 2 Construct hole in floor per Table 3 and Fig 11 PLENUM OPENING D FLOOR OPENING Fig 11 Floor and Plenum Opening Dimensions FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING NO DOWNFLOW P SUBBASE SHEET METAL PLENUM FLOOR OPENING 7222 gt A96285 Fig 12 Furnace Plenum and Subbase Installed on a Combustible Floor 3 Construct plenum to dimensions specified in Table 3 and Fig 11 4 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part No CD5 or CK5 or Coil Box Part No KCAKC is used install as shown in Fig 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14 ooo FURNACE CD5 OR 5 COIL ASSEMBLY OR
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14. COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING 22222222 96284 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor UPFLOW DOWNFLOW HORIZONTAL Ce Cc PREFERRED PREFERRED PREFERRED PREFERRED PREFERRED xs PREFERRED MIN MIN MIN PERMITTED PERMITTED PERMITTED Fig 14 Duct Flanges Table 3 Opening Dimensions In A02329 FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B C D Upflow Applications on Combustible or Noncombustible 2 2 _ Flooring KGASB subbase not required ee 219 SES Downflow Applications on Noncombustible Flooring 3 KGASB subbase not required 12 9 16 19 197916 bas 14 3 16 Downflow applications on combustible flooring KGASB 11 13 16 19 13 7 16 20 5 8 subbase required Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 12 5 16 19 13 5 16 20 not required Upflow Applications on Combustible or Noncombustible 7 5 Flooring KGASB subbase not required 16 eee 1927 Downflow Applications on Noncombustible Flooring 2 KGASB subbase not required 192 19 mos 17 1 2 Downflow applications on combustible flooring KGASB 15 1 8 19 16 3 4 20 5 8 subbase required Downflow Applicatio
15. 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 49 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 A91252 Fig 53 Cleaning Heat Exchanger Cell 10 Remove old sealant from cell panel and inducer backing plate flange 11 Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available
16. Constant fan speed selectable from thermostat LED diagnostics and self test feature Stores fault codes during power outages 4 way Multipoise furnace 13 vent applications Hot surface ignition HSI Draft safeguard switch to ensure proper furnace venting All models are Chimney Friendly when used with accessory vent kit Insulated blower compartment Heat pump compatible Residential installations eligible for consumer financing through the Retail Credit Program Twinning in Upflow Downflow and Horizontal LIMITED WARRANTY 20 year warranty on Super S heat exchanger 3 year warranty on microprocessor control and hot surface ignition 5 year parts warranty on all other components L LI Catalog No 535 80104 Form 58DL 3SI 12 02 Single Stage Deluxe Induced Combustion 4 Wav Multipoise Furn Cancels 311A 45 2 311A 45 3 Installation Start up Operating and Service and Maintenance Instructions Series 100 A NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue TABLE OF CONTENTS SAFETY CONSIDERATIONS 2 INTRODUCTION ette RET OI 3 CODES AND STANDARDS 3 SAVE me greet andi dte 3 General Installation 3 Combustion and Ventilation Air 4 Duct Systems rh enne tenent prion Acoustical Lining and Fibrous Glass Duct Gas Piping and Gas Pipe Pressure Testing Electrica
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19. 58DLA 58DLX 4 Deluxe Induced Combustion 4 Way Multipoise Furnace Installation Start up Operating and Service and Maintenance Instructions Series 100 THE WEATHERMAKER 8000 GAS FURNACE The 58DLA DLX 4 way Multipoise Gas Furnaces offer deluxe features not found in other single stage 80 gas furnaces Carriers QuietTech noise reduction system makes the WeatherMaker 8000 incredibly quiet induced draft gas furnace The exclusive Carrier Media Cabinet provides an economic way to add high performance air filtration to homes The WeatherMaker 8000 control system provides a dehumidification mode a third motor speed selection for continuous fan operation selectable at the thermostat and fault code storage in the event of power outages Applications are easy with 4 way multipoise design through the furnace downflow venting 13 different venting options and a door designed for easy service access An inner blower door is provided for tighter sealing in sensitive applications The 58DLA DLX furnaces are approved for use with natural or propane gas and the 58DLX is also approved for use in Low NOx Air Quality Management Districts VEDO gt STANDARD FEATURES QuieTech noise reduction system Media Filter Cabinet Included Microprocessor based control center Dehumidification selection for summer time cooling Adjustable heating air temperature rise gt Adjustable cooling airflow ComfortFan
20. Flame sensing electrode rm 0 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 4 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 ignitor See Fig 51 and 52 for correct ignitor location 9 32 11 32 02150 Fig 51 Position of Ignitor to Burner A 7 8 A02151 Fig 52 Position of Ignitor to Burner 9 Using field provided 25 caliber rifle cleaning brush 1 4 diameter steel spring cable 36 in long 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 35 b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush
21. SINGLE AUXILIARY p 115 V FIELD 2 er decem e SUPPLIED _ J BOX LE E GND DISCONNECT Cee CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A99440 Fig 24 Heating and Cooling Application Wiring Diagram with 1 Stage Thermostat 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 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 17 The HUM terminal is energized when gas valve is energized NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation A WARNING DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or similar device See Thermidistat Zone Controller thermo stat or controller manufacturer s instructions for proper connection Step 8 Venting gt The furnace shall be connected to a factory built chimney or vent complying with a recogn
22. IRON TO BOTTOM OF FURNACE WITH 3 8 3 4 SCREWS TYPICAL FOR 2 SUPPORTS 1 SQUARE 11 4 x 11 4 x 1 4 ANGLE IRON OR UNI STRUT MAY BE USED A02345 Fig 15 Horizontal Unit Suspension OUTER DOOR ASSEMBLY AIR OPENING 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS n AIR USE 2 8 x 3 4 SHEET METAL SCREWS TYPICAL FOR ALL STRAPS BACK OF FURNACE FOLD ALL STRAPS UNDER FURNACE AND SECURE W 2 8 x 3 4 SHEET METAL SCREWS 02014 Fig 16 Horizontal Suspension with Straps Not all horizontal furnaces are approved for side return air connections See Fig 20 Step 4 Filter Arrangement A WARNING Never operate a furnace without a filter or with filter access door removed Failure to follow this warning could result in fire personal injury or death 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 1 filter or a 4 wide Media Filter which can be purchased separately Refer to the instructions supplied with Media Cabinet for assembly and installation options Step 5 Air Ducts GENERAL REQUIREMENTS The duct system should be designed and sized according to accepted national standards such as those pub
23. PROCEDURE A02055 A CAUTION This gas furnace may be used for construction heat provided that The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents 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 no less than 55 degrees F 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 firing rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must b
24. 155 110 22 066110 21 19 3 8 19 1 2 4 161 135 16 048135 21 19 3 8 19 1 2 4 158 135 22 066135 24 1 2 22 7 8 23 4 173 155 20 060155 24 1 2 22 7 8 23 4 180 5 or 6 vent connector may be required in some cases 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 speci fied 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 is not to be used for temporary heating of buildings or structures under construction gt 10 These Multipoise Gas Fired Furnaces are CSA and C G A design certified for 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 A G A and C G A listed gas conversion kit is required to convert furnace for use with pro
25. 2 4 43 2 5 43 2 6 9000 725 43 2 2 43 2 2 43 2 3 43 2 4 750 43 2 0 43 24 43 22 43 2 2 775 48 3 6 48 3 7 43 2 0 43 24 Orifice numbers 43 are factory installed 39 Table 10 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure A 600 43 2 7 43 2 8 43 2 9 43 3 0 5 625 43 2 5 43 2 6 43 2 6 43 27 ib 650 43 2 3 43 24 43 24 43 2 5 D 10 000 675 43 2 1 43 2 2 43 23 43 2 3 5 700 48 37 43 2 0 43 4 43 2 2 725 48 3 5 48 3 6 48 3 7 43 2 0 Orifice numbers 43 are factory installed 40 TABLE 11 Orifice Size and Manifold Pressure For Gas Input Rate Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS eet 72 217 28 ie i FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 900 42 3 2 42 3 3 42 3 4 42 3 5 3 925 43 3 7 43 3 8 42 3 2 42 3 3 5 950
26. 320 285 1 1 4 1 380 1400 950 770 660 580 1 1 2 1 610 2100 1460 1180 990 900 Cubic ft of gas per hr for gas pressures of 0 5 psig 14 wc or less and pressure drop of 0 5 wc based on 0 60 specific gravity gas Ref Table 12 2 NFPA 54 2002 CAUTION 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 serviced another gas appli ance Black iron pipe shall be installed at the gas valve and extend a minimum of 2 in outside the furnace CAUTION Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls A WARNING Use proper length of pipe to avoid stress on gas control manifold Failure to follow this warning could result in a gas leak resulting in fire explosion personal injury or death gt accessible manual shutoff valve MUST be installed external to 13 furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve SUPPLY AIR UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR
27. 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 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 23 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 Step 4 Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switches This control shuts off combustion control system and ener gizes air circulating blower motor if furnace overheats By using this method to check limit control it can be established that limit is functioning properly and will operate if there is a restricted duct system or motor failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least 5 minutes THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED CLOCK M
28. 40 Horizontal Left ad 1521000 Horizontal Left ME eae er 153 000 Vert ebow phenn i Dountou VOM baw up then right 170 000 i E NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in inside casing or vent guard Including 4 in vent section s 27 EXAMPLE 1 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT Derate Furnace Input Rate Furnace Input Rate X Multiplier at Installation at Sea Level Factor Altitude 88 000 X 0 90 79 200 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 or 11 Use only factory supplied orifices See EXAMPLE 2 22 000 BTUH Burner application use Table 10 EXAMPLE 2 0 2000 ft altitude Heating value 1000 Btu cu ft Specific gravity 0 62 Therefore Orifice No 43 Manifold pressure 3 7 in wc Furnace is shipped with No 43 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate 3 Adjust manifold pressure to obtain correct input rate a Turn gas valve ON OFF switch to OFF b Remove manifold pressure tap plug from gas valve See Fig 47 c Connect
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30. FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND nes 066 060 22 AND YES YES YES YES 20 MODELS ALL OTHER MODELS YES YES YES YES CR 1 8 RETURN RETURN AIR AIR ue lo dEn Eni A02075 Fig 18 Upflow Return Air Configurations and Restrictions RETURN RETURN AIR SIDE RETURN SIDE RETURN NOT PERMITTED NOT PERMITTED FOR ANY MODEL FOR ANY MODEL DOWNFLOWRETURNAIRCONFIGURATIONSANDRESTRICTIONS REPE NP E OE AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR E E IEEE CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS SS ONLY ONLY ONLY OF 1 2 AND P 066 060 22 YES NO NO NO 20 MODELS ALL OTHER MODELS YES NO NO NO SUPPLY AIR 2 Lu A02163 Fig 19 Downflow Return Air Configurations and Restrictions RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR AIR FLOW MODELS WITTY coe 111111 2 RETURN 6 SIDE RETURN AIR PERMITTED FOR 066 060 22 20 AIR FLOW MODELS HORIZONAL NOTE RESTRICTION SAME FOR RETURN RESTRICTIONS HORIZONAL LEFT AR HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND 20 MODELS ALL OTHER MODELS YES YES YES YES A02162 Fig 20 Horizontal Return Air Configurations and Re
31. 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 MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP 17 3 4 OVER ALL 4 3 4 UNDER DOOR 1 UNDER FURNACE EXTEND OUT 12 OUT FROM FACE OF DOOR 30 IN MIN WORK AREA WHEN USED WITH SINGLE WALL VENT CONNECTIONS lnc c A A02164 Fig 17 Typical Attic Installation ONLY be connected to the accessory subbase KGASB or factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accesso ries All accessories MUST be connected external to furnace casing RETURN AIR CONNECTIONS A WARNING Never connect return air ducts to the back of the furnace A failure to follow this warning can cause a fire personal injury or death Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 1 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most horizontal furnaces See Fig 19 Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace Upflow and Horizontal Furnaces The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 1 Bypass humidifier may be a
32. a water column manometer or similar device to manifold pressure tap d Manually close blower door switch e Set thermostat to call for heat f Jumper R and W thermostat connections on furnace control board to start furnace g Remove regulator seal cap and turn regulator adjusting screw counterclockwise out to decrease input rate of clockwise in to increase 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 outside this range change main burner orifices or refer Table 10 or 11 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 b Run furnace for 3 minutes in heating operation c Measure time in sec for gas meter to complete 1 revolu tion and note reading The 2 cubic feet dial provides a more accurate measurement of gas flow d Refer to Table 8 for cubic ft of gas per hr 28 e Multiply gas rate cu ft hr by heating va
33. from the R terminal of the control board 4 Manually close blower access door switch A WARNING Failure to follow this warning could result in electrical shock personal injury or death Blower access door switch opens 115 power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed 6 Component Test will function as follows 1 Check and clean air filter each month or more frequently if a LED flashes a status code 4 times Record this status code required Replace if torn for further troubleshooting 2 Check blower motor and wheel for cleanliness each heating b Inducer motor starts and continues to run until step g of and cooling season Clean as necessary component test sequence 3 Check electrical connections for tightness and controls for Hot surface ignitor is energized for 15 sec then de proper operation each heating season Service as necessary energized 4 Inspect burner compartment before each heating season for d Blower operates at FAN speed for 10 sec then turns off rust corrosion soot or excessive dust If necessary have fi d b iced b lified professional e Blower operates at HEAT speed for 10 sec then turns off ANNE AS DT up 5 I t th t pipe vent system befi h heating s f Blower operates at CO
34. injury can result form sharp metal edges etc Be careful when removing parts Gloves and safety glasses should be worn when servicing equipment 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 24 Venting Notes for Fig 33 45 1 For common vent vent connector sizing and vent material United States latest edition of the National Fuel Gas Code NFGC ANSI Z223 1 NFPA 54 In Canada latest edition of the National Standards of Canada Natural Gas and Propane Installation Code NSCNGPIC CSA B149 1 00 2 Immediately increase to 5 inch vent connector outside furnace casing when 5 inch vent connector required refer to Note 1 above 3 Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when KGAVG0101DFG is used in the downflow position 4 Type B vent where required refer to Note 1 above 5 4 single wall 26 ga min vent must be used inside furnace casing and when the KGAVGOIOIDFG Downflow Vent Guard Kit is used external to the furnace 6 Accessory Downflow Vent Guard Kit KGAVG0101DFG required in downflow installations with bottom vent configuration 7 Chimney Adapter Kit required for exterior masonry chimney applications Ref
35. pi Utiliser une trousse de conversion fournie par le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel Cette fournaise est pr vue pour tre install e dans un batiment construit sur place Clearance in inches Cette fournaise peut tre install e sur D gagement po un plancher combustible dans une alc ve ou dans un garde robe en respectant le minimum d espace libre des mat riaux combustibles tel Vent Clearance to combustibles quindiqu sur le diagramme For Single Wall vents 6 inches 6 po Cette fournaise peut tre utilis e avec un For Type 1 vent type 1 inch 1 po sone D gagement de l vent avec combustibles Conduit d vacuation de Type B 1 ou connect e Pour conduit d vacuation paroi simple 6 po 6 inches au conduit commun d autres appareils gaz Pour conduit d vacuation de Type B 1 1 po 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS Installation on non combustible floors only For Installation on combustible flooring only when installed on special base Part No KGASBO201ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC 18 inches front clearance required for alcove Indicates supply or return sides when furnace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket and building joists studs or frami
36. purge lines and check for leakage 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 Step 7 Electrical Connections A WARNING 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 Failure to follow this warning could result in personal injury or death See Fig 24 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 33 C rise 90 Elbow T UF v mE FL 2 Nipple Street Elbow Gas Valve A02327 Fig 21a Right Side Gas Entry Example 15 s St ft GA Suy 7 MANUAL SHUTOFF VALVE REQUIRED SEDIMENT TRAP UNION A02035 Fig 21b Typical Gas Pipe Arrangement A WARNING The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2002 and Canadian Elec trical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code w
37. the R to G and Y1 circuit starts the furnace blower motor BLWM on low cool speed same speed as FAN The R to Yl and Y2 circuits start the outdoor unit on high cooling speed and the R to G and 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 23 3 Thermidistat Mode See Fig 25 28 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 excep
38. the schematic diagram in Fig 46 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W the control will start a 90 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 1 Heating See Fig 24 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS is open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch contacts PRS close to begin a 15 second prepurge period b Ignitor Warm Up At the end of the prepurge period the Hot Surface ignitor HSI is energized for a 17 second ignitor warm up period c Trial for Ignition Sequence When the ignitor warm up period is completed the main gas valve relay conta
39. through RCD in 3 oz tubes 12 Apply new sealant to flange of inducer assembly and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connec tion diagram on wiring label if wires were not marked for reconnection locations a Draft safeguard switch b Inducer motor c Pressure switch es d Limit over temperature switch e Gas valve f Hot surface ignitor g Flame sensing electrode h Flame rollout switches i Install NOx baffles if removed 14 Reinstall internal vent pipe if applicable 15 Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 180 apart 16 Replace blower access door only 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling 19 Check for gas leaks A WARNING Never use a match or other open flame to check for gas leaks Use a soap and water solution A failure to follow this warning could result in fire personal injury or death 20 Replace outer access door Step 3 Sequence of Operation NOTE Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw Using
40. 000 875 43 3 0 43 3 1 43 3 3 43 3 4 900 43 2 9 43 3 0 43 3 1 43 3 2 925 43 2 7 43 2 8 43 2 9 43 3 0 950 43 2 6 43 2 7 43 2 8 43 2 8 SPECIFIC GRAVITY OF NATURAL GAS e is ie m FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 750 43 3 6 43 3 8 42 3 2 42 3 3 775 43 3 4 43 3 5 43 3 6 43 3 8 5 4001 800 43 3 2 43 3 3 43 3 4 43 3 5 4 to 825 43 3 0 43 3 1 43 3 2 43 3 3 o 5000 850 43 2 8 43 2 9 43 3 0 43 3 1 gt 875 43 2 7 43 2 8 43 2 9 43 2 9 900 43 2 5 43 2 6 43 2 7 43 2 8 925 43 2 4 43 2 5 43 2 6 43 2 6 Orifice numbers 43 are factory installed 38 Table 10 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based On 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS AVG GAS RANCE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 725 43 3 4 43 3 5 43 3 6 43 3 7 750 43 32 43 3 3 43 3 4 43 3 5 T 775 43 3 0 43 3 1 43 3 2 43 3 8 4 ib 800 43 2 8 43 2 9 43 3 0 43 3 1 a 6000 825 43 2 6 43 2 7 43 28 43 2 9 5 850 43 2 5 43 2 5 43 2 6 4
41. 1 4 in 16 BLOWER OFF DELAY TWINNING AND OR TERMINAL Sa COMPONENT TEST 4 lt E 24 V THERMOSTAT TERMINALS lt 5 FUSE 2 5 8 LED OPERATION amp DIAGNOSTIC LIGHT 5 115 VAC L2 NEUTRAL CONNECTIONS OFF DELAY EM 01616016 id BLOWER SPEED SELECTION TERMINALS 1 AMP EAC 1 445yac PR 1 EAC 1 TERMINAL 115 VAC L1 LINE VOLTAGE CONNECTION D HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX TRANSFORMER 24 VAC CONNECTIONS PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR PL2 HOT SURFACE IGNITER amp INDUCER MOTOR CONNECTOR 115 VAC 1 0 AMP MAX A02142 Fig 23 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 4 TERMINALS FIELD SUPPLIED THREE WIRE l DISCONNECT HEATING ONLY 2 E E Ki 208 230 OR BLOWER DOOR SWITCH e 460 V ejre el THREE 41 l Cl BLK ee 1 og 1 La wit ______ SO N e e 1 208 230 V 1e e FOND FP eno lee Fe e ice leT Tie
42. 2000 ft multiply the input on the rating plate by the de rate multiplier in Table 6 for the correct input rate In Canada At installation altitudes from 2000 to 4500 ft this furnace must be derated 10 percent 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 2 Determine the correct orifice and manifold pressure adjust ment There are two different orifice and manifold adjustment tables models in all positions except Low NOx models in downflow or horizontal positions use Table 10 22 000 Btuh Burner Low NOx models in the downflow or horizontal positions must use Table 11 21 000 Btuh Burner See input listed on rating plate a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain average yearly gas specific gravity from local gas supplier c Find installation altitude in Table 10 or 11 d Find closest natural gas heat value and specific gravity in Table 10 or 11 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 ORIENTATION VENT ORIENTATION FURNACE INPUT BTU HR yen DIAMETER MINIMUM VERTICAL VENT HEIGHT ET Vent gt left then up 132 00 5 15 110 000 036 12 Horizontal Left gt i Fig
43. 3 2 7 875 43 2 3 43 2 4 43 2 5 43 2 6 900 43 2 2 43 2 3 43 2 3 43 2 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 675 43 3 4 43 3 5 43 3 6 43 3 7 700 43 3 1 43 3 3 43 3 4 43 3 5 5 725 43 2 9 43 3 0 43 3 1 43 3 2 to 750 43 2 7 43 2 8 43 2 9 43 3 0 d 7000 775 43 2 6 43 27 43 27 43 2 8 5 800 43 2 4 43 2 5 43 2 6 43 2 7 825 43 2 3 43 2 3 43 2 4 43 25 850 43 24 43 2 2 43 23 43 2 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANCE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 650 43 3 1 43 3 2 43 3 4 43 3 5 E 675 43 2 9 43 3 0 43 3 1 43 3 2 5 250 700 43 2 7 43 2 8 43 2 9 43 3 0 2 to 725 43 2 5 43 2 6 43 2 7 43 28 a 8000 750 43 2 4 43 2 4 43 2 5 43 2 6 gt 775 43 2 2 43 2 3 43 2 4 43 2 4 800 43 24 43 2 1 43 2 2 43 2 3 825 48 3 7 43 2 0 43 24 43 2 2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS er HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 625 43 2 9 43 3 0 43 3 1 43 3 2 650 43 27 43 28 43 29 43 3 0 5 8001 675 43 2 5 43 2 6 43 2 7 43 2 8 4 to 700 43 2 3 43
44. 43 3 5 43 3 6 43 3 7 43 3 8 0 975 43 3 3 43 3 4 43 3 5 43 3 7 S ad 1000 44 3 6 43 3 3 43 3 4 43 3 5 4 1025 44 3 4 44 3 6 43 3 2 43 3 3 7 1050 44 3 3 44 3 4 44 3 5 43 3 2 1075 45 3 8 44 3 2 44 3 3 44 3 4 1100 46 3 8 45 3 7 44 3 2 44 3 3 MiG CAS SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 RANGE HEAT VALUE FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure Mie 800 43 3 8 42 3 2 42 3 3 42 3 4 8 206 825 43 3 5 43 37 43 3 8 42 3 2 to 850 43 3 3 43 3 5 43 3 6 43 3 7 3000 875 43 3 2 43 3 3 43 3 4 43 3 5 or 900 43 3 0 43 3 1 43 3 2 43 3 3 5 925 43 28 43 2 9 43 3 0 43 3 1 lt Altitudes 2000 950 43 2 7 43 2 8 43 2 9 43 2 9 to 975 43 2 5 43 2 6 43 2 7 43 2 8 4500 1000 43 2 4 43 2 5 43 2 6 43 2 7 ACTITUDE AUGGAS SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 RANGE HEAT VALUE FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 775 43 3 5 43 3 7 43 3 8 42 3 2 800 43 3 3 43 3 4 43 3 5 43 3 7 3001 825 43 3 1 43 3 2 43 3 3 43 3 4 U S A Only to 850 43 2 9 43 3 0 43 3 1 43 3 2 4000 875 43 2 8 43 2 9 43 3 0 43 3 1 900 43 2 6 43 2 7 43 2 8 43 2 9 925 43 2 5 43 2 6 43 2 7 43 2 7 950 43 2 4 43 2 4 43 2 5 43 2 6 ALTITUDE WG GAS SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 RANGE HEAT VALUE FT BTU CU FT Orifice Man
45. 6 NR 78 121 166 uL 8 NR 94 135 182 o 10 NR 111 149 198 9 15 NR NR 193 247 i 20 NR NR NR 293 30 NR NR NR 377 Local 99 Winter Design Temperature 10 to 4 degrees F 6 NR NR 145 196 TH 8 NR NR 159 213 P 10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333 30 NR NR NR NR Local 99 Winter Design Temperature 11 degrees F or lower Not recommended for any vent 5 configuration 2 5 99 Winter Design Dry Bulb db temperatures are found in the 1993 ASHRAE Fundamentals Handbook Chapter 24 Table 1 United States and 2 Canada or use the 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chap ter Table 1A United States and 2A Canada Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and or re lining Refer to the Fig 32 to perform a chimney inspection If the inspection of a previously used tile lined chim ney a Shows signs of vent gas condensation the chimney should be relined in accordance with local codes and the authority 22 having jurisdiction The chimney should be relined with a listed metal liner Type B vent or a listed chimney adapter kit shall be used to reduce condensation If a condensate drain is required by local code refer to the NFGC Section 7 9 for additional information on condensate drains b Indicates the chimney exceeds the max
46. 800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM Fig 1 Dimensional Drawing SAFETY CONSIDERATIONS CAUTION 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 or misapplication of furnace can require excessive servicing or cause premature component failure A WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning explo sion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency local gas supplier or your distribu tor or branch for information or assistance The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product Failure to follow this warning could result in electrical shock fire personal injury or death gt Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perform bas
47. IA3Hd ON 45 46 47 Copyright 2002 Carrier Corporation 5841351 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations reek M PC 101 Catalog No See Cover Printed in U S A Form 58DL 3SI Pg 48 12 02 Replaces 58DL 2SI al
48. NECTION 52 OUTDOOR Fee SENSOR L SENSOR 1 See notes 1 2 3 4 6 8 9 10 and 12 CONNECTION S2 E A00271 See notes 2 5 8 and 10 Fig 28 Single Stage Furnace with Two Speed Heat Pump Dual Fuel A00269 Fig 26 Single Stage Furnace with Two Speed Air Conditioner 19 DUAL FUEL SINGLE STAGE SINGLE SPEED THERMOSTAT FURNACE HEAT PUMP RVS COOLING O W2 ________________________________ Del 1 2 HEAT STAGE 2 W W1 __________ TIE eds zl 2 FURNACE HEAT COOL STAGE 1 YIY2 ___________ SIN oss tete J Y COMPRESSOR G ________ 24VACHOT R LJ_ 4 ad R DHUM 24 __________ Com 1 B MN EAE RVSSENSING L cA 1 i 51 T OUTDOOR ru cr HUMIDFIER Er OUTDOOR lige ae SENSOR 24VAC SENSOR CONNECTION 52 J See notes 1 2 4 11 12 and 13 A02102 Fig 29 Dual Fuel Thermostat with Single Stage Furnace and Single Speed Heat Pump
49. OL speed for 10 sec then turns off E OE T M for rust corrosion water leakage sagging pipes or broken g Inducer motor turns off fittings Have vent pipes vent system serviced by a qualified Items a through g above will assist in furnace troubleshooting professional since all components are functionally operated except the gas 6 Inspect any accessories attached to the furnace such as a valve This procedure is also referred to as Component Test humidifier or electronic air cleaner Perform any service or Sequence maintenance to the accessories as recommended in the acces 7 Check LED status If no previous faults in history control will sory instructions flash status code 11 8 If LED status indicates proper operation RELEASE CLEANING AND OR REPLACING AIR FILTER BLOWER ACCESS DOOR SWITCH reattach wire to R The air filter arrangement may vary depending on the application terminal on furnace control board replace blower access door The filter is exterior to the furnace casing and replace burner access door 5 NOTE If the filter has an airflow direction arrow the arrow must Step 2 Care and Maintenance point towards the blower A WARNING Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning com Media cabinet filter procedures pounds plastic or
50. RD INSTALLATION 4 Secure J Box cover to bracket with screw provided Power cords must be able to handle the electrical requirements 5 Remove U shaped cut out from outer door to clear J box listed in Table 5 Refer to power cord manufacturer s listings 24 V WIRING l Route aaa Make field 24 v connections at the 24 v terminal strip See Fig 2 Secure power cord to J Box bracket with a strain relief 23 Connect terminal Y Y2 as shown in Fig 24 for proper cooling bushing or a connector approved for the type of cord used operation Use only AWG No 18 color coded copper thermostat 3 Secure ground wire to green screw on J Box bracket wire See Fig 25 31 for additional tstat wiring configurations 4 Connect line voltage leads as shown in Fig 24 The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or FOR BX CABLE INSTALLATION maintenance could cause this fuse to blow If fuse replacement is 1 Route BX cable to hole in J Box required use ONLY a 3 amp fuse of identical size 2 Secure BX cable to J Box bracket with connectors approved ACCESSORIES for the t f cabl d 1 Electronic Air Cleaner EAC 3 Secure ground wire to green screw on J Box bracket Connect an accessory Electronic Air Cleaner if used using 4 Connect line voltage leads as shown in Fig 24 1 4 in female quick connect terminals to the two male
51. SC NGPIC GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements including local building codes the National Fuel Gas Code NFGC ANSI Z223 1 2002 NFPA 54 2002 Parts 7 and 10 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code NSCNGPIC CSA B149 1 00 Section 7 and Appendix C in Canada These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47a CSA 2 3a 2001 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSC NGPIC THERMIDISTAT SINGLE STAGE SINGLE SPEED THERMIDISTAT SINGLE STAGE SINGLE SPEED
52. STI ONIHIM GA OVA SIT HUNDI 32 SANS LOH 5 10 seuoiws 5 pue Jeonpu 7 OvNvZ VA CO N 1SdQ Avid 3AIVA SVO esn dure Ajuo eoejded 9 1 1 5 9 A9 Jou pue sJojonpuoo Yno HO episurseul pos 5 OVASTT AU QLOVA GNNOYD_LNAWdINOA uonejuesaidel 2911998 S OQWAS p 104 10228 a 5 GITIWSNI TA OWE 104 jeeus pejoeuuoo eq JSNUU SIUL GW WNN LNT4N D YAVIY LIN 24 2 CELL pue yams 1oeuuoosip eu am asf Z GHTIVISNI AHOLO V3 AdAL SALOW OLN AWV 3504 TN 0801 10 payed asn s m jueuudinbe y jo Aue 71 NoLoNnf 30043 SNIAOud3WVH Sd SALON VAE DVASTI HA OJSN VuL NVuL 4 45 13534 IWY T TSH 5 TVNIWH3LNIML SIS3LIN3NOdWOO NIMLASEL NOWWOD DINOuLO3H 7 4546 Junssaud Sud XVIN dWY OT OVA STT NOL23NNOO HN VID DINO LITTA HONG no E O N 1SdS 13538 OLN HALIMS Qui v9 33 VS Livia ssa
53. UST BE OUT OF CIRCUIT HOOK AROUND AMMETER PS FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 5 0 AMPS ON AMMETER _ _ 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING 96316 Fig 49 Amp Draw Check With Ammeter Table 9 FILTER SIZE INFORMATION IN FURNACE FILTER SIZE FILTER CASING WIDTH Side Return Bottom Return TYPE 14 1 2 16 25 1 14 X25 X 1 Cleanable 17 1 2 16X25X1 16X25X1 Cleanable 21 16X25X1 20X25X1 Cleanable 24 16X25X1 24 X25 X1 Cleanable Recommended 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 permit the safe shutdown of the furnace during certain blocked vent conditions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal e Furnace should cycle off within 2 minutes f Remove blockage and reconnect vent pipe to furnace vent elbow g Switch will auto reset when it cools h Control board should lock out furnace cycle 115 v
54. WM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge period and 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 signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed Step 4 Wiring Diagrams Refer to Fig 24 and 46 for wiring diagrams Step 5 Troubleshooting Refer to the service label See Fig 50 Service Label The Troubleshooting Guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After replacing any component verify correct operation sequence TABLE 10 Orifice Size and Manifold Pressure For Gas Input Rate Tabulated Data Based 22 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS
55. ac power to reset control 3 Check Pressure Switch es This control proves operation of the draft inducer blower a Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace 31 d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface ignitor should NOT glow and control diagnostic light flashes a status code 32 If hot surface ignitor glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power Step 5 Checklist 1 Put away tools and instruments Clean up debris 2 Check that blower OFF DELAY time is selected as desired 3 Verify that blower and burner access doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Guide with owner 7 Locate literature packet near furnace SERVICE AND MAINTENANCE PROCEDURES A WARNING The ability to properly perform maintenance on this equip ment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those p
56. and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Close fireplace dampers Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appli ance is operating continuously Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Codes After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appli ance to their previous conditions of use gt Vent system or vent connectors may need to be resized For any 18 other appliances when resizing vent systems or vent connectors system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or N
57. area per 4000 Btuh of total input for all equipment within the confined space See Fig 8 and Table 2 b If combustion air is taken from outdoors through 2 hori zontal ducts the openings and ducts must have at least 1 sq in of free area per 2000 Btuh of total input for all equipment within the confined space See Fig 8 and Table 2 c If combustion air is taken from the outdoors through a single opening or duct horizontal or vertical commencing within 12 in of the top of the confined space the opening and duct must have at least 1 sq in of free area per 3000 Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space Equipment clearances to the structure shall be at least 1 in from the sides and back and 6 in from the front of the appliances See Table 2 and Fig 8 When ducts are used they must be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of ducts must not be less than 3 in INSTALLATION Step 1 Upflow Installation BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler
58. arked 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 21 Vents and Soild Fuel Burning Appliances ANSI NFPA 211 2000 in the United States and to a Provincial or Territorial Building Code in Canada in its absence the National Building Code of Canada and must be in good condition U S A Refer to Sections 13 1 9 and 13 2 20 of the NFGC or the authority having jurisdiction to determine whether relining is required If relining is required use a properly sized listed metal liner Type B vent or a listed alternative venting design NOTE See the NFGC 13 2 20 regarding alternative venting design and the Exception which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACA02015FC which are listed for use with these furnaces The Chimney Adapter Kit is listed alternative venting system for these furnaces See the kit instructions for complete details Canada This furnace is permitted to be vented into a clay tile lined masonry chimney that is exposed to the outdoors below the roof line provided 1 Vent connector is Type B double wall and 2 This furnace is common vented with at least 1 draft hood equipped appliance and 3 The combined appliance input rating is less than the maximum capacity given in Table A and 4 The i
59. as many times as desired and is stored in the memory to be automatically used following a power interruption 5 Heat pump See Fig 27 30 for thermostat connections When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off times during demand defrost cycles When the R to W and Y1 or R to W and Y 1 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 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 to W and Y1 and Y Y2 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 BL
60. bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Step 3 Horizontal Installation 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 platform noncombustible blocks bricks or pad SUSPENDED UNIT SUPPORT The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the unit from each bottom corner To prevent screws from pulling out use 2 8 x 24 in screw into the side and 2 8 x 34 in screw in the bottom of the furnace casing for each strap See Fig 15 and 16 PLATFORM UNIT SUPPORT OUTER DOOR ASSEMBLY 8 MIN FOR DOOR REMOVAL 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD ye Construct working platform at location where all required furnace clearances are met See Fig 2 and 17 For furnaces with 1 in clearance requirement on side set un
61. could result in fire personal injury or death See Fig 5 A02054 Fig 5 Prohibit Installation on Back Step 2 Location Relative to Cooling Equipment The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion and ventilation air must be provided in accordance with Section 8 3 of the NFGC Air for Combustion and Ventilation or applicable provisions of the local building codes Canadian installations must be installed in accordance with NSC NGPIC Part 7 and all authorities having jurisdiction 18 IN MINIMUM TO BURNERS A93044 Fig 6 Installation a Garage A WARNING 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 t
62. cts GVR 1 and 2 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 After 5 seconds the ignitor HSI is de energized and a 2 second Flame Proving period begins 36 d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ignition Lockout Lockout will be reset auto matically after three hours 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 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 the
63. dy 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 6 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 AIRFLOW TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR 15 THE BLOWER IS LOCATED UPFLOW DISCHARGED TO THE LEFT THE BLOWER 15 LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR 15 DISCHARGED UPWARD ra AIRFLOW BURNER SECTION AND CONDITIONED AIR 15 DISCHARGED DOWNWARD NN DOWNFLOW THE BLOWER 15 LOCATED ABOVE THE AIRFLOW HORIZONTAL RIGHT gt THE BLOWER 15 LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR 15 DISCHARGED TO THE RIGHT A02097 Fig 4 Multipoise Orientations A WARNING Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control opera tion will be adversely affected Never connect return air ducts to the back of the furnace Failure to follow this warning
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65. e For Gas Input Rate Continued Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANCE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 600 43 2 4 43 25 43 2 6 43 2 7 5 godi 625 43 2 3 43 23 43 24 43 25 650 43 2 1 43 2 2 43 2 2 43 2 3 10 000 675 48 3 6 48 3 8 43 24 43 2 1 5 700 48 3 4 48 3 5 48 3 6 48 3 7 725 49 3 7 49 3 8 48 3 4 48 3 5 Orifice numbers 43 are factory installed 43 e901c0V eu JO 3e1souueu EU ApZWOD eui 10euuoo 40461691 1528 5 19447 104000 jou s 5 y Jeduunf e yeadas eui eu Y 1oeuuoosiq amp 04JUOD eoeuunj BU UO 10 ZA A Queseid LA M JUEseld S ejgeo JO WOO 49049 LHVLS pue 1 95019 1 10 Y90049 4 JexeeJq S
66. e 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 A CAUTION Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from person nel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to elec trostatic discharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DIS CHARGING 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 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 bo
67. e 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 capacitor wires and ground wire attached to blower housing b Remove screws securing cutoff plate and remove cutoff plate from housing c Loosen set screw holding blower wheel on motor shaft d Remove bolts holding motor to blower housing and slide motor out of wheel 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 34 15 Reinstall blower assembly in furnace 16 Reinstall control box assembly in furnace A CAUTION Heating fan speed s MUST be adjusted to provide proper air temperature rise as specified on the rating plate Failure to adjust the heating speed s may shorten heat exchanger life Recommended operation is at the midpoint of the rise range or slightly above Refer to TEMPERATURE RISE under START UP ADJUSTMENT and SAFETY CHECK NOTE Refer to Table 7 for motor speed lead relocation if leads were
68. en blower access door switch and terminate 115 v power to control so A CAUTION i E that status code is not displayed There may be more than 1 electrical supply to the unit Check d BRIEFLY remove insulated terminal wire from the draft accessories and cooling unit for additional electrical supplies safeguard DSS switch until LED goes out then reconnect The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Fig 24 for field wiring information NOTE If wire to LS or DSS is disconnected longer than 4 sec and to Fig 46 for furnace wiring information main blower starts and retrieval request is ignored NOTE If the polarity is not correct the STATUS LED on the 2 When above items have been completed the LED flashes status code 4 times Record this status code for further control will flash rapidly and prevent the furnace from heating troubleshooting The control system also requires an earth ground for proper operation of the control and flame sensing electrode 3 Component self test will begin Refer to COMPONENT The 24 v circuit contains an automotive type 3 amp fuse located TEST section for complete test sequence on the control See Fig 23 Any shorts of the 24 v wiring during 4 Check LED status installation service or maintenance will cause this fuse to blow If 5 Refer to the SERVICE label on the front of the blower access fuse replacement is required use ONLY a 3 amp fuse The c
69. ent salt and air freshener and can cause corrosion of furnaces and vents Avoid using such products in the combustion air supply CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code 54 ANSI 2223 1 and ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian installation Codes CSA B149 1 in Canada Crown condition Missing mortar or brick Rebuild crown Is chimney property lined with clay tile liner Is Repair liner and top liner or top seal Reline seal in good or reline chimney as condition necessary Debris in cleanout Mortar tile metal vent fuel oil residue No Remove metal vent or liner ie Remove mortar debris and tile debris Clay tile misalignment missing sections gaps Consult Part B of chimney adapter venting instructions for application suitability Is chimney Li hi ith t f ine chimney with property lines with properly sized listed flexible metal sized listed liner or liner or Type B vent per Type B vent NFGC or NSCNGPIC Vent Sizing Tables and liner or es vent manufacturer s tone Installation instructions Not Suitable Condensate drainage at bottom of chimney Not Suitable Consult Part C of Chimney adapter vent
70. ent in the confined space but not less than 100 sq in The minimum dimension of air openings should be no smaller than 3 in See Table 2 and Fig 7 b If building construction is unusually tight a permanent opening directly communicating with the outdoors shall be provided See next section c If the furnace is installed on a raised platform to provide a return air plenum and return air is taken directly from the hallway or space adjacent to furnace all air for combustion must come from outdoors 2 Air from outside the structure requires 1 of the following a If combustion air is taken from outdoors through 2 vertical ducts the openings and ducts must have at least 1 sq in of 1SQIN PER 4000 DUCTS BTUH OUTDOORS gt EIS am y 12 MAX D 12 VENT _ PER 2000 THROUGH i BTUH ROOF E DUCTS 1 SQIN 4000 BTUH e a a DUCTS 8 TO OUTDOORS 22 5 85 1SQIN PER 4000 asm D BTUH TSQIN H PER 2000 B EL GE Br VI 12 12 MAX 1 12 AIR DUCT 99 N 1 sain TO PER 4000 OUTDOORS BTUH Minimum dimensions of 3 in NOTE Use any of the following combinations of openings A amp B C amp D D amp E F amp G A02165 Fig 8 Confined Space Air for Combustion and Ventilation from Outdoors free
71. entilation and dilution of flue gases using one of the following methods in Table 2 and Fig 7 and 8 NOTE When determining the free area of an opening the blocking effect of louvers grilles and screens must be considered If the free area of the louver or grille design is unknown assume wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area Screens must not be smaller than 1 4 in mesh Louvers and grilles must be constructed so they cannot be closed AIR DUCTS VENT THROUGH ROOF 12 MAX 1 SQ IN PER 1000 BTUH IN DOOR OR WALL INTERIOR HEATED SPACE CONFINED SPACE UNCONFINED SPACE 6 MIN FRONT t 1 SQIN PER 1000 BTUH IN DOOR OR WALL 12 MAX AIR DUCTS Minimum opening size is 100 sq in with minimum dimensions of 3 in t Minimum of 3 in when type B1 vent is used A02038 Fig 7 Confined Space Air for Combustion and Ventilation from an Unconfined Indoor Space The opening size depends upon whether air comes from outside of the structure or an unconfined space inside the structure 1 Air from inside the structure requires 2 openings for struc tures not of unusually tight construction a Each opening must have a minimum free area of not less than 1 sq in per 1000 Btuh of total input rating for all gas utilization equipm
72. er to Chimney Adapter Kit KGACA02014FC and KGACAO02015FC for sizing and complete application details 8 Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart 9 Secure all other single wall vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations 3 Gas supply pressure to the furnace must greater than 4 5 in wc 0 16 psig but not exceed 14 in wc 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Replace outer door Step 2 Start Up Procedures A WARNING Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage Failure to follow this warning can cause fire explosion personal injury or death 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks A WARNING 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 Failure to follow this warning could result in electrical shock personal injury or death 3 To Begin Component Self Te
73. et Metal and Air Conditioning Con 7 An ESD service kit available from commercial sources may MAX 85 F also be used to prevent ESD damage LOCATION Step 1 General This multipoise furnace is shipped in packaged configuration Some assembly and modifications are required when used in any of the four applications shown in Figure 4 FRONT This furnace must RETURN RIR be installed so the electrical components are protected from water MIN 60 F A notbe installed directly on any combustible material other than wood flooring refer to INTRODUCTION be located as close to the chimney vent and attached to an air Fig 3 Return Air Temperature distribution system Refer to Air Ducts section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the Step 6 Gas Piping and Gas Pipe Pressure Testing furnace clearance to combustible label US NFGC chapters 5 6 7 and 12 and National Plumbing CAUTION Codes CANADA NSCNGPIC Parts 3 4 5 A B E and Do not install furnace in a corrosive or contaminated atmo sphere Make sure all combustion and circulating air require Step 7 Electrical Connections ments are met in addition to all local codes and ordinances US National Electrical Code ANSI NFPA 70 2002 CANADA Canadian Electrical Code CSA C22 1 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS
74. fold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 675 43 3 1 43 3 2 43 3 3 43 3 4 2 700 43 2 9 43 3 0 43 3 1 43 3 2 5 s 725 43 2 7 43 2 8 43 2 9 43 2 9 15 750 43 25 43 2 6 43 27 43 28 ii 7000 775 43 2 3 43 24 43 2 5 43 2 6 3 800 43 2 2 43 2 3 43 2 3 43 2 4 825 43 2 1 43 2 1 43 2 2 43 2 3 850 48 3 7 43 2 0 43 2 1 43 2 1 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 650 43 2 9 43 3 0 43 3 1 43 3 2 B 675 43 2 7 43 2 7 43 2 8 43 29 5 700 43 25 43 2 6 43 2 6 43 2 7 4 6 725 43 23 43 2 4 43 25 43 25 a 8000 750 43 2 1 43 2 2 43 2 3 43 2 4 5 775 43 2 0 43 2 1 43 2 2 43 2 2 800 48 3 6 48 3 7 43 2 0 43 2 1 825 48 3 3 48 3 5 48 3 6 48 3 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS TERME HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 625 43 2 7 43 27 43 2 8 43 2 9 gt 650 43 25 43 25 43 2 6 43 27 5 8001 675 43 2 3 43 24 43 24 43 2 5 lt 55 700 43 2 1 43 2 2 43 2 3 43 2 3 2 725 48 3 7 43 2 0 43 2 1 43 2 2 750 48 3 5 48 3 6 48 3 7 43 2 0 775 49 3 8 48 3 4 48 3 5 48 3 6 Orifice numbers 43 are factory installed 42 Table 11 Orifice Size And Manifold Pressur
75. 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 30 TABLE 8 5 RATE CU FT HR SECONDS SIZE TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 1 2 5 FOR 1 1 2 5 REVOLUTION Cu Ft Cu Ft Ft REVOLUTION Cu Ft Cu Ft Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94
76. he NFGC or NSCNGPIC See Fig 6 A CAUTION Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements are found in aerosol sprays deter gents bleaches cleaning solvents salts air fresheners and other household products 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 blocked vent safeguard opening Table 2 Free Area of Combustion Air Opening AIR FROM INDOOR OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH FURNACE UNCONFINED SPACE VERTICAL DUCTS HORIZONTAL DUCTS SINGLE DUCT INPUT BTUH Seis Fiber Duct jus m ponia Gonna did Dia p Do e Sq In Sq In sq In Sq In 44 000 100 11 4 22 6 14 7 5 66 000 100 16 5 5 33 7 22 0 6 88 000 100 22 0 6 44 0 8 29 3 7 110 000 110 27 5 6 55 9 36 7 7 132 000 132 33 7 66 10 44 0 8 154 000 154 38 5 7 77 10 51 3 8 Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space Opening area must be increased if other gas appliances in the space require combustion air A CAUTION The operation of exhaust fans kitchen venti
77. hen installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gage Do not use gas piping as an electrical ground Failure to follow this warning could result in electrical shock fire or death A CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw 115 V WIRING Verify that the voltage frequency and phase correspond to that specified on unit 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 5 for equipment electrical specifications Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2002 and any local codes or ordinances that might apply For Canadian instal lations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authorities having juris diction A CAUTION 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 5 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarit
78. hese 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 from 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 2 screws from blower access door and remove blower access door 5 Disconnect blower leads from furnace control Note wire color and location for reassembly All other factory wires can be left connected but field thermostat connections may need to be disconnected depending on their length and routing 6 Remove 2 screws from control box to blower shelf 7 Hang control box from front of furnace casing and away from blower compartment 8 Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace 9 Clean blower wheel and motor using a vacuum with soft brush attachment Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blades 10 Vacuum any loose dust from blower housing wheel and motor 11 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remov
79. ic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with unit and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation A CAUTION Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing and gloves when han dling parts Failure to follow this caution could result in personal injury Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE 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 a hazard which could result in personal injury or death CAUTION is u
80. ifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure U S A Only 4001 to 5000 750 43 3 3 43 3 4 43 3 5 43 3 6 775 43 3 1 43 3 2 43 3 3 43 3 4 800 43 2 9 43 3 0 43 3 1 43 3 2 825 43 2 7 43 2 8 43 2 9 43 3 0 850 43 2 6 43 2 7 43 2 8 43 2 8 875 43 2 4 43 2 5 43 2 6 43 2 7 900 43 2 3 43 2 4 43 2 5 43 2 5 925 43 2 2 43 2 2 43 2 3 43 2 4 Orifice numbers 43 are factory installed 41 Table 11 Orifice Size And Manifold Pressure For Gas Input Rate Continued Tabulated Data Based On 21 000 Btuh Per Burner Derated 4 Percent For Each 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS AVG GAS RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 725 43 3 1 43 3 2 43 3 3 43 3 4 750 43 2 9 43 3 0 43 3 1 43 3 2 5 Zap 775 43 27 43 28 43 2 9 43 3 0 E 800 43 25 43 2 6 43 27 43 28 Ui 6000 825 43 24 43 2 5 43 2 5 43 2 6 3 850 43 2 2 43 2 3 43 2 4 43 2 5 875 43 2 1 43 2 2 43 2 3 43 2 3 900 43 2 0 43 2 1 43 2 1 43 2 2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Mani
81. imum permissible size in the tables the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt 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 APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable listings standards and codes The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Condi tioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive
82. ing Suitable instructions for application suitability Chimney exposed to outdoors below roof line Is chimney to be dedicated to a single furnace Install chimney adapter per instructions Chimney is acceptable for use 02101 Fig 32 Inspection Chart 23 SEE NOTES 1 2 4 7 8 9 A02058 Fig 33 Upflow Application Vent Elbow Up o SEE NOTES 1 2 4 5 7 8 9 A02061 Fig 36 Downflow Application Vent Elbow Up See Venting Notes on page 26 SEE NOTES 1 2 3 4 7 8 9 A02059 Fig 34 Upflow Application Vent Elbow Right SEE NOTES 1 2 4 5 6 7 8 9 A02062 Fig 37 Downflow Application Vent Elbow Left then Up 24 a SEE NOTES 1 2 3 4 5 7 8 9 A02060 Fig 35 Downflow Application Vent Elbow Up then Left 2 SEE NOTES 1 2 3 4 5 7 8 9 A02297 Fig 38 Downflow Application Vent Elbow Up then Right
83. it on noncombustible blocks bricks or angle iron For crawl space installations if the unit is not suspended from the floor joists the ground underneath unit must be level and the unit set on blocks or bricks ROLL OUT PROTECTION Provide a minimum 17 3 4 X 22 piece of sheet metal for roll out protection in front of burner area for units closer than 12 inches above the combustible deck or suspended units closer than 12 in to joists The sheet metal MUST extend underneath the furnace casing by 1 in with the door removed The bottom closure pan on furnaces of widths 17 1 2 in and larger may be used for roll out protection when bottom of furnace is used for return air connection See Fig 17 for proper orientation of roll out shield BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws SIDE RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only one side return air is used 1 4 THREADED ROD SECURE ANGLE
84. ized standard or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction Venting into an unlined masonry chimney or concrete chimney is prohibited When an existing furnace is removed or replaced in a venting system the venting system may not be properly sized to vent the attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of condensate and combustion products and spillage of combustion products into the living space etc A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Code and these instructions Deter mine 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
85. l Connectloni cree tite de oko Eee ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE neo poe EN E Ese 5 LOCATION ih sss tos te 5 AIR FOR COMBUSTION AND VENTILATION 6 Unconfiried Space eu RID ERR 7 Confined Space iib eae eeu es 7 INSTALLATION sine RP BERE 8 Upflow Inst llati h 4 errem nt neces 8 Bottom Return Air 11 Side Return Air Inlet eese 8 Leveling Legs If Desired sess 8 Downflow Installation eese 9 Bottom Return Air 11 Horizontal Installation 11 Suspended Unit Support 11 Platform Unit Support 11 Roll Out Protection 11 Bottom Return Air Inlet eese 11 Side Return Air Inlet ss 11 Filter Arrangement ien 12 RAS e his eS 12 General Requirements eese 12 Ductwork Acoustical Treatment 12 Supply Air Connections eese 12 Return Air Connections 13 Gas PIDDE ft coc oeste tempe eub s oi en 13 Electrical Connections esee eerte 15 115 V 15 J Box Relocatiori 16 Electrical Connection to J Box 2 16 For Power Cord
86. lation 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 Hazard in venting section of these instructions to determine amount of make up air required The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space Step 1 Unconfined Space An unconfined space has a volume of at least 50 cu ft for each 1000 Btuh total input for all appliances furnaces clothes dryers water heaters etc in the space For example FURNACE MINIMUM WITH INPUT BTUH 7 1 2 FT CEILING SQ FT 44 000 294 66 000 441 88 000 587 110 000 734 132 000 881 154 000 1028 If the unconfined space is constructed unusually tight air for combustion and ventilation must come from either the outdoors or spaces freely communicating with the outdoors Combustion and ventilation openings must be equivalent to those used for a confined space defined below Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room Step 2 Confined Space A confined space has a volume less than 50 cu ft per 1000 Btuh of total input ratings of all appliances installed in that space A confined space must have provisions for supplying air for com bustion v
87. lished by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guide lines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design external static pressure When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace the return air must also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer 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 clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take off may require internal ac
88. lue Btu cu ft to obtain input If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct input is achieved Reinstall regulator seal cap on gas valve 5 Set temperature rise The furnace must operate within the temperature rise ranges specified on the furnace rating plate Do not exceed tempera ture rise range specified on unit rating plate Determine the temperature rise as follows 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 tempera ture rise measurement NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in we 4 Dirty filter A WARNING Disconnect 115 v electrical power before changing speed tap Failure to follow this warning could result in personal injury c Adjust air temperature rise by adju
89. ng D GAGEMENT MINIMUM EN POUCES AVEC L MENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pour l installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale pi ce n KGASBO201ALL l ensemble serpentin pi ce n CD5 ou 5 ou le carter de serpentin pi ce n KCAKC Dans une alc ve on doit maintenir un d gagement l avant de 18 po 450 mm La position indiqu e concerne le c t d entr e ou de retour quand la fournaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la chemise de la fournaise et les solives montant sous cadre de charpente 327590 101 REV B Les fl ches de d gagement ne changent pas avec l orientation de la fournaise J Fig 2 Clearances to Combustibles A02330 tractors National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 Step 5 Acoustical Lining and Fibrous Glass Duct CANADA Part 7 of NSCNGPIC Venting Systems and Air Supply for Appliances US and CANADA current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 4 Duct Systems US and CANADA Air Conditioning Contractors Association ACCA Manual D She
90. not identified before disconnection 17 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 27 18 To check blower for proper rotation a Turn on electrical supply A WARNING Blower access door switch opens 115 v power to furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in electrical shock personal injury or death 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 AC CESS DOOR SWITCH Replace blower access door and remove any jumpers or reconnect any disconnected thermostat leads 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 unit temperature rise a
91. nput rating of each space heating appliance is greater than the minimum input rating given in Table B for the local winter design temperature Chimneys having interanl areas greater than 38 sqyare 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 Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors Table A Combined Appliance Maximum Inut Rating in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY VENT SQ IN HEIGHT FT 12 19 28 38 6 74 119 178 257 8 80 130 193 279 10 84 138 207 299 15 NR 152 233 334 20 NR NR 250 368 30 NR NR NR 404 Table B Minimum Allowable Input Rating of Space Heating Appliance in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY VENT SQ IN HEIGHT FT 12 19 28 38 Local 99 Winter Design Temperature 17 to 26 degrees F 6 0 55 99 141 8 52 74 111 154 a 10 NR 90 125 169 2 15 NR NR 167 212 a 20 NR NR 212 258 30 NR NR NR 362 Local 99 Winter Design Temperature 5 to 16 degrees F
92. ns on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 15 1 2 19 16 1 2 20 not required Upflow Applications on Combustible or Noncombustible A Flooring KGASB subbase not required Te ele udis Downflow Applications on Noncombustible Flooring 3 KGASB subbase not required 1586 19 1998 21 Downflow applications on combustible flooring KGASB 18 5 8 19 20 1 4 20 5 8 subbase required Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or coil box KGASB subbase 19 19 20 20 not required Upflow Applications on Combustible or Noncombustible Flooring KGASB subbase not required 23 ou ae POT Downflow Applications on Noncombustible Flooring KGASB subbase not required PRIS 13 23 12 199 8 24 1 2 Downflow applications on Combustible flooring KGASB subbase required 22 1 8 19 23 3 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box KGASB subbase 22 1 2 19 23 1 2 20 not required 10 A WARNING Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control opera tion will be adversely affected Never connect return air ducts to the back of the furnace Failure to follow this warning could result in fire personal injury or death BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in
93. ommon or dedicated becomes blocked the furnace will be shut off by the draft safeguard switch located on the vent elbow A WARNING Do not bypass the draft safeguard switch as an unsafe condition could exist which must be corrected Failure to follow this warning could result in a build up of carbon monoxide and lead to personal injury or death 2 Do not connect this appliance to a single wall dedicated or common vent The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors 3 Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 4 In the U S do not vent this appliance with any solid fuel burning appliance In Canada check with the authority having jurisdiction for approval on use with solid fuel burning appliance 5 Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed power ventor 6 Do not vent this appliance into an unlined masonry chimney Refer to Chimney Inspection Chart Fig 32 MASONRY CHIMNEY REQUIREMENTS A CAUTION These furnaces are CSA design certified for use in exterior tile lined masonry chimneys with a factory accessory Chim ney 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 m
94. omponents 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 Preliminary NOTE On 14 wide casing models the J Box shall not be FACTORY e yd INSTALLED relocated to other side of furnace casing when the vent pipe is LOCATION routed within the casing 1 Remove screws holding auxiliary J box See Fig 22 TWO ALTERNATE FIELD LOCATION Cut wire tie on loop in wires to J box dad CN nz gt re es 2 3 Locate box to desired location 4 5 Route J box wires within furnace away from sharp edges and hot surfaces ELECTRICAL CONNECTION TO J BOX Fasten J Box to casing with screws A CAUTION If manual disconnect switch is to be mounted on furnace Fig 22 Relocating J Box A02099 select a location where a drill or fastener will not contact electrical or gas components J BOX COVER INSTALLATION 1 Attach electrical box to J Box bracket 1 Remove J Box cover from blower access door on furnace and 2 Route wires through hole in electrical box and J Box bracket reinstall blower access door screw 3 Secure ground wire to green screw on J Box bracket 2 Fold tab on J box bracket with pliers 4 Connect line voltage leads as shown in Fig 24 3 Insert tab of J box cover into slot of J box bracket FOR POWER CO
95. ontrol door for more information LED will display status code 24 when fuse needs to be replaced Component Self Test 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 1 Remove outer access door troubleshooting It can be viewed through the sight glass in blower 2 Remove blower access door access door The furnace control LED is either ON continuously rapid flashing or a code composed of 2 digits The first digit is the number of short flashes the second digit is the number of long flashes For an explanation of status codes refer to service label located on blower access door or Fig 50 and the troubleshooting guide at the end of this procedure For Controls With an Amber LED the stored status codes will not be erased from the control memory even if 115 or 24 v power is interrupted 1 To retrieve status codes proceed with the following 5 BRIEFLY short jumper TEST TWIN 3 16 in quick connect male terminal on control behind Y Y2 terminal to the Com 24V terminal on furnace control See Fig 23 NOTE If TEST TWIN to Cow 24V terminals are jumpered a Leave 115 v power to furnace turned on longer than 2 sec LED will flash rapidly and test request will be b Remove outer access door ignored 32 Component Test can also be initiated by performing the following 3 Remove the wire
96. ostat setting above room temperature Step 3 Adjustments CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures A CAUTION 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 48 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft Furnace input rate must be within 2 percent of furnace rating plate input In the U S A the input rating for altitudes above 2 000 ft must be reduced by 4 percent for each 1 000 ft above sea level In Canada input rating must be reduced by 10 percent for altitudes of 2 000 ft to 4 500 ft above sea level Table 6 Altitude Derate Multipler for U S A ALTITUDE PERCENT DERATE MULTIPLIER FT OF DERATE FACTOR 0 2000 0 1 00 2001 3000 8 12 0 90 3001 4000 12 16 0 86 4001 5000 16 20 0 82 5001 6000 20 24 0 78 6001 7000 24 28 0 74 7001 8000 28 32 0 70 8001 9000 32 36 0 66 9001 10 000 36 40 0 62 Derate multiplier factors are based on midpoint altitude for altitude range Determine the correct gas input rate In the U S For installations below 2000 ft refer to the unit rating plate For installations above
97. oustical 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 12 be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks Upflow and Horizontal Furnaces Connect supply air duct to flange on furnace supply air outlet Bend flange upward to 90 with wide duct pliers The supply air duct attachment must ONLY be connected to furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be con nected external to furnace main casing Downflow Furnaces Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connected to furnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct attachment must
98. oversizing of the fur nace 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 manufac turer s instructions To prevent condensation in the furnace and vent system the following precautions must be observed 1 The return air temperature must be at least 60 F db except for brief periods of time during warm up from setback at no lower than 55 F db or during initial start up from a standby condition 2 Adjust the gas input rate per the installation instructions Low gas input rate causes low vent gas temperatures causing condensation and corrosion in the furnace and or venting system Derating is permitted only for altitudes above 2000 ft A CAUTION Personal injury can result form sharp metal edges etc Be careful when removing parts Gloves and safety glasses should be worn when servicing equipment 3 Adjust the air temperature rise range to the midpoint 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 com pounds which include chlorides fluorides bromides and iodides These compounds are found in many common home products such as detergent paint glue aerosol spray bleach cleaning solv
99. ower 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 FAN 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 ther mostat is satisfied the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous blower speed When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other 37 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 push button 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
100. pane gas gt 11 See Fig 2 for required clearances to combustibles 12 Maintain 1 clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace See NFPA 90B or local code for further requirements 13 These furnaces SHALL NOT be installed directly on carpet ing 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 CD5 or 5 or when Coil Box Part No KCAKC is used INTRODUCTION Series 100 A 4 way multipoise Category I fan assisted furnace is CSA and C G A design certified for natural and propane gas and for installation in alcoves attics basements closets utility rooms crawl spaces and garages A 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 A CSA A G A and C G A listed gas conversion kit is required to convert furnace for use with propane gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum continuou
101. 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 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 Fig 9 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 Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement 5 Reinstall bottom closure panel if removed BOTTOM CLOSURE PANEL BOTTOM FILLER A02098 Fig 9 Removing Bottom Closure Panel
102. plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products A failure to follow this warning could result in corrosion of 2 Remove filter cabinet door the heat exchanger fire personal injury or death 3 Slide filter out of cabinet A CAUTION Personal injury can result from sharp metal edges etc Be careful when removing parts Gloves and safety glasses should be worn when servicing equipment NOTE Media cabinet is included with single stage deluxe fur nace 1 Turn off electrical supply to furnace before removing filter access door For continuing high performance and to minimize possible equip 4 If equipped with permanent washable 1 filter clean filter by ment failure periodic maintenance must be performed on this spraying cold tap water through filter in opposite direction of equipment Consult your local dealer about proper frequency of airflow Rinse filter and let dry Oiling or coating of the filter maintenance and the availability of a maintenance contract is not recommended See Table 9 for size information 5 If equipped with factory specified disposable media filter replace only with media filter having the same part number WARNING and size For expandable replacement media refer to the Turn off the gas and electrical supplies to the unit before instructions included wi
103. r reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No See Cover Tab 8 Printed in U S A Form 58DL 3SI Pg 1 12 02 Replaces 58DL 2SI 28 7 8 25 1 4 a a AIRFLOW 19 13 16 OUTLET i 1 9 16 22 9 16 2 9 16 JUNCTION BOX LOCATION 4 13 16 EH 13 16 i 7 8 DIA ACCESSORY 8 7 16 TIRDA 11 16 Ly a a k 1 2 DIA THERMOSTAT SSS S555 RIGHT HAND WIRE ENTRY GAS ENTRY 3 15 16 SS 1 2 DIA THERMOSTAT WIRE ENTRY LEFT HAND GAS 1 716 ENTRY 33 5 16 ALTERNATE M 24 718 JUNCTION LOCATION TYP VENT OUTLET 5 PLACES TYP LL 11 16 14 7 8 7 8 DIA AGGESSORY s 3 3 4 7 8 DIA ACCESSORY Af 5 1 2 1 11 16 215 BOTTOM INLET 22 1 16 SIDE INLET A02304 NOTES 1 Two additional 7 8 in 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 round or 14 1 2 x 12 in rectangle b For 1200 CFM 20 in round or 14 1 2 x 19 1 2 in rectangle c For 1600 CFM 22 in round or 14 1 2 x 22 in rectangle d For airflow requirements above 1
104. rmostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 5 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 seconds depend ing on the blower OFF delay selection The furnace control CPU is factory set for a 120 second blower OFF delay 2 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 24 25 27 and 29 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y 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 23 b Two Speed Cooling See Fig 28 30 and 31 for thermostat connections The thermostat closes the R to G and Y1 circuits for low cooling or closes R to and Y 1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and
105. rocedures recommended in the User s Manual FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property dam age Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnect ing Reconnect wires correctly Verify proper operation after servicing A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation Step 1 Introduction GENERAL These instructions are written as if the furnace is installed in an upflow application An upflow furnace 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 accord ingly 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
106. s shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70 F turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service technician NOTE If the heat exchangers get a heavy accumulation of soot and carbon they should be replaced rather than trying to clean them thoroughly A heavy build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold ori fice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of a Draft safeguard switch b Inducer motor Pressure switch es a Limit overtemperature switch Gas valve Hot surface ignitor
107. s return air temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed 85 F db Failure to follow these return air limits may affect reliability 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 oper ating the furnace CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following Step 1 Safety US National Fuel Gas Code NFGC NFPA 54 2002 ANSI 27223 1 2002 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 and 2 M00 National Standard of Canada Natural Gas and Propane Installation Codes NSC NGPIC Step 2 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 or for only the NFGC contact the American Gas Associa
108. sed to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a location and position as 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 in the Venting section of these instructions 5 Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detec tion of leaks to check all connections as specified in the Gas Piping section Table 1 Dimensions IN VENT UNIT SIZE A B CONN SHIP WT LB 045 08 024045 14 3 16 12 9 16 12 11 16 4 114 045 12 036045 14 3 16 12 9 16 12 11 16 4 117 070 08 024070 14 3 16 12 9 16 12 11 16 4 121 070 12 036070 14 3 16 12 9 16 12 11 16 4 125 070 16 048070 17 1 2 15 7 8 16 4 133 090 14 042090 17 1 2 15 7 8 16 4 136 090 16 048090 21 19 3 8 19 1 2 4 149 090 20 060090 21 19 3 8 19 1 2 4 155 110 12 036110 17 1 2 15 7 8 16 4 144 110 16 048110 21 19 3 8 19 1 2 4
109. st Disconnect the thermostat R lead from the furnace control board Manually close the blower door switch closed Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED will flash code and then turn ON the inducer motor until the end of the test The hot surface ignitor blower motor FAN speed blower motor HEAT speed and blower motor COOL speed will be turned ON for 10 15 seconds each Gas valve and humidifier will not be turned on See Fig 23 NOTE The furnace control allows all components except the gas valve to be run for short period of time This feature helps diagnose a system problem in case of a component failure Component test feature will not operate if any thermostat signal is present at the control Component test sequence is as follows Refer to service label attached to furnace or see Fig 50 a LED will display previous status code 4 times b Inducer motor starts and continues to run until Step f of component test sequence Hot surface ignitor is energized for 15 sec then off Blower motor operates on HEAT speed for 10 sec e Blower motor operates on COOL speed for 10 sec f Inducer motor stops g Reconnect R lead to furnace control board release blower door switch and re install blower door 4 Operate furnace per instruction on door 5 Verify furnace shut down by lowering thermostat setting below room temperature 6 Verify furnace restarts by raising therm
110. status code recall is completed component test will occur LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 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 e 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
111. sting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise d Turn thermostat down below room temperature and move blower access door Table 7 Speed Selection COLOR SPEED AS SHIPPED White Common BLW Black High COOL Yellowt Med High SPARE Blue Med Low HEAT Red Low SPARE Continuous blower speed as shipped default Not available on 1 5 HP motors e To change motor speed selection for heating remove blower motor lead from control HEAT terminal See Fig 46 Select desired blower motor speed lead from one of the other terminals and relocate it to the HEAT terminal See Table 7 for lead color identification Reconnect original lead to SPARE terminal f Repeat steps a through e g When correct input rate and temperature rise is achieved turn gas valve ON OFF switch to OFF h Remove manometer or similar device from gas valve i Reinstall manifold pressure tap plug in gas valve Ov 20 uejBeiq 614 101 095222 M
112. strictions 14 NOTE The gas valve inlet pressure tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas control valve See Fig 50 Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21a Install a sediment trap in riser leading to furnace as shown in Fig 21b Connect a capped nipple into lower end of tee Capped nipple should extend below level of gas controls Place a ground joint union between gas control manifold and exterior manual equip ment gas shutoff valve A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve gt Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before pressure test If test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on furnace gas control valve and accessible manual shutoff valve before test After all connections have been made
113. th the replacement media If equipped performing any maintenance or service Follow the operating with accessory KGAFRO301ALL external filter rack See instructions on the label attached to the furnace A failure to Table 9 follow this warning could result in personal injury 6 Slide filter into cabinet 7 Replace filter cabinet door A WARNING 8 Turn on electrical supply to furnace Never operate unit without a filter or with filter access door removed A failure to follow this warning could result in fire BLOWER MOTOR AND WHEEL personal injury or death A WARNING Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed A CAUTION Personal injury can result from sharp metal edges etc Be Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death careful when removing parts Gloves and safety glasses should be worn when servicing equipment The minimum maintenance on this equipment is as follows 33 A CAUTION The blower wheel should not be dropped or bent as balance will be affected The following steps should be performed by a qualified service technician 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 T
114. than 3 minutes or 10 successive limit trips off delay occurred during high heat Control will auto reset after three hours Refer to 33 33 LIMIT CIRCUIT FAULT Indicates the limit draft safeguard flame rollout or blocked vent 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 Switch if used is open or the furnace is operating in high heat only mode due to 2 21 GAS HEATING Med one via io will No rauto horis valve relay successive low heat limit trips Blower will run for 4 minutes or until open switch remakes a 2 3 d whichever is longer If open longer than 3 minutes code changes to lockout 13 22 A FLAME ROVINS SINAI Fiame s proved wie a valve 5 de If open less than 3 minutes status code 33 continues to flash until blower shuts off ea nab eae run until fault is cleared Check for Leaky gas valve Flame rollout switch and BVSS require manual reset Check for Restricted vent 23 PRESSURE SWITCH DID NOT OPEN Check for Dee o He _Obstructed pressure tubing _ Pressure switch stuck closed Defective blower motor or capacitor Defective switch or connections 24 SECONDARY VOLTAGE FUSE IS OPEN Check for tor or i x iri Inadequate combustion air supply Flame Roll out Switch open Short circuit in secondary voltage 24VAC wiring 34 IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blo
115. tion 400 N Capitol N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Tor onto Ontario MOW 1R3 Canada Step 3 Combustion and Ventilation Air US Section 8 3 of the NFGC Air for Combustion and Ventilation INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW DOWNFLOW and natural gas at altitudes 0 10 000 ft 0 3 050m HORIZONTAL installations An accessory kit supplied by the Cette fournaise est approuv e pour l installation HORIZONTALE manufacturer shall be used to convert to propane etla circulation d air VERS LE HAUT et VERS LE BAS gas use or may be required for some natural gas applications This furnace is for indoor installation in a building constructed on site This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material This furnace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Clearance arrows do not change with furnace orientation TOP PLENUM DESSUS CHAMBRED AIR Cette fournaise air puls est quip e pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000
116. tion 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 25 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 2 Vent the furnace with the appropriate connector as shown in Fig 33 45 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 on door An accessory Vent Guard KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall maintain a minimum of 1 4 in upward slope per linear ft and it shall be rigidly supported every 5 ft or less with metal hangers or straps to ensure there is no movement after installation O
117. tions 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 c When the call for cooling is satisfied and there is a demand for 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 thermo stat 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 bl
118. tructions 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 inON 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 turnedON in all dual fuel applications 10 NO connection should be made to the furnace HUM terminal when using a Thermidistat 11 The RVS Sensing terminal L should not be connected This is internally used to sense defrost operation 12 DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internally by the Thermidistat Dual Fuel Thermostat 13 Dip switch D on Dual Fuel Thermostat should be set in OFF position for single speed compressor operation This is factory default 14 Dip switch D on Dual Fuel Thermostat should be set in ON position for two speed compressor operation The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC 1 If a vent c
119. ttached to unused side return air portion of the furnace casing See Fig 18 19 and 20 Not all horizontal furnaces are approved for side return air connections See Fig 20 Step 6 Gas Piping A WARNING 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 failure to follow this warning could result in fire explosion personal injury or death Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the NSCNG PIC 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 Refer to Table 4 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas Table 4 Maximum Capacity of Pipe NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE DIAMETER SIZE IN 10 20 30 40 50 IN 1 2 0 622 175 120 97 82 73 3 4 0 824 360 250 200 170 151 1 1 049 680 465 375
120. wer will come on for the COMPONENT TEST selected blower off delay Check for Flame sensor must not be grounded Oxide buildup on flame sensor clean with fine steel wool To initiate the component test sequence shut OFF the room thermostat or disconnect the Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal thermostat lead Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED Gas valve defective or gas valve turned off Manual valve shut off will flash code and then turn ON the inducer motor The inducer motor will run for the entire Defective Hot Surface Ignitor Control ground continuity component test The hot surface ignitor blower motor fan speed on AMBER LED boards Low inlet gas pressure Inadequate flame carryover or rough ignition only blower motor heat speed and blower motor cool speed will be turned ON for 10 15 Green Yellow wire MUST be connected to furnace sheet metal seconds each Gas Valve and Humidifier will not be turned on 45 CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error V 327596 101 REV A Reset power to clear lockout Replace control if status code repeats J A02027 Fig 50 Service Label ELECTRICAL CONTROLS AND WIRING c Look into blower access door sight glass for current LED status Removing blower access door will op
121. y 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 J Box Cover Installation Table 5 Electrical Data VOLTS OPERATING MAXIMUM MAXIMUM UNIT MAXIMUM MINIMUM UNIT SIZE BRACE ee RANCE UNIT AMPS AMPACITY WIRE LENGTH FT FUSE BKR WIRE GAGE 045 08 024045 115 60 1 127 104 56 777 48 15 14 045 12 036045 115 601 127 104 7 0 9 47 40 15 14 070 08 024070 115 60 1 127 104 5 0 7 06 53 15 14 070 12 036070 115 60 1 127 104 6 7 9 19 41 15 14 070 16 048070 115 60 1 127 104 98 12 59 29 15 14 090 14 042090 115 60 1 127 104 8 1 10 83 35 15 14 090 16 048090 115 60 1 127 104 98 12 95 29 15 14 090 20 060090 115 60 1 127 104 12 9 17 60 35 20 12 110 12 036110 115 60 1 127 104 82 10 75 35 15 14 110 16 048110 115 60 1 127 104 10 1 13 12 29 15 14 110 22 066110 115 60 1 127 104 13 7 17 62 33 20 12 135 16 013548 115 60 1 127 104 10 1 13 12 29 15 14 135221066135 115 60 1 127 104 144 18 55 31 20 12 155 20 060155 115 60 1 127 104 15 0 19 33 30 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily 3t Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating c

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