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Kelvinator KG7SD 072D-35C Installation Guide

1. NOTES 1 2 3 4 5 el 46 T Rubber a See VIEW D for Grommet See VIEW E for Plug X drain line positions 3 drain line positions 3 iL See u 2 P NOTE 5 Plug d cowBusrioN S COMBUSTION AIR AIR OPTION SE OPTION U 7 el 3 8 3 amp Cy Ns eL Eig L Plug Plug VIEW F VIEW G Inline Drain Drain Line Factory Supplied Attached to See NOTE 4 PVC Trap Field Supplied ne Field Supplied See NOTES 2 amp 3 Inline Drain Field Supplied See NOTES 2 amp 3 Inline Drain N Field Supplied See NOTES2 amp 3 Collector Box Drain 4 Factory Equipped See NOTE 2 Collector Box Drain 4 Factory Equipped See NOTE 2 See Accessories section page 20 for optional PVC Tee configurations and drainage options Rubber Grommet Plug Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the cabinet All drain lines must be routed externally from the cabinet Inline drain is required on
2. First Support as Close to Furnace as Possible Flue Pipe must slope per foot Coupling with 2 hose Straps or other suitable supports at minimum 5 ft intervals both pipes 90 Elbows L Y x Seal caulk around pipes at wall 90 Elbow Normal snow level Support system on rtical rise ve FLUE PIPE Rubber Grommet 4 COMBUSTION AIR Flue Pipe must slope upward 1 4 per foot Coupling with 2 hose 4 clamps optional id o TE See Table 2 for 5 2 pipe lengths field supplied LA LSU A SL XS H Figure 34 Horizontal amp Vertical Venting 90 Elbow FLUE PIPE gt 92 1 UPFLOW 1 PIPE OPTIONS
3. Rubber COMBUSTION COMBUSTION Grommet AIR AIR AIR Plu de 3 g E E a B Tee X 5 NOTE 5 2 lt gt 2 ABL a LE ad i See b 2 NOTE 5 eS amp Rubber D Grommet T H d dq OPTION 2 Rubber M Le beoe HE ET PvCTrap Grommet 1 See VIEW A for drain line positions See VIEW B for drain line positions See VIEW C for drain line positions VIEW A Inline Drain Tube VIEW B q VIEW C a D 71 LA Inline Drain Tube Factory Equipped Ls ET See NOTE 4 Factory Supplied Collector Box Drain NOTE 4 Sge NG Factory Equipped 4 See NOTE 2 Drain Line Attached Collector Box Drain to PVC Trap Field Supplied Factory Equipped NOTES See NOTE 2 1 See Accessories section page 20 for optional PVC Tee configurations and drainage opt
4. See VIEW T for drain line positions See VIEW U for drain line positions Inline Drain VIEW T VIEW U VIEW S Factory Supplied U See NOTE 4 Drain Line Attached to PVC Trap Inline Drain lt Drain Line Attached Field Supplied Factory Supplied to PVC Trap RV See NOTE 4 Field Supplied gt Collector Box Drain Collector Box Drain i Sa Factory Equipped ENTE pec Inline Drain Collector Box Drain NOTES See NOTE 2 Field Supplied Factory Equipped See NOTES 2 amp 3 See NOTE 2 1 See Accessories section page 20 for optional PVC Tee configurations and drainage options 2 Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the cabinet drain lines must be routed externally from the cabinet 3 Inline drain is required only if X is greater than 6 feet 4 Tubing needs to be cut to length and attached during unit installation 5 Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trap 95 0 DOWNFLOW 2 PIPE OPTIONS
5. ma ma c c lt lt 2 F E Rubber 2 Grommet 2 8 Flange 5 Plug zy ma a Option J 32 T See gt X gt NOTE 5 amp E gt 4 PVC Tee u amp Dy Y 3 See L LL d L NOTES PVC Trap Rubber PVC Grommet ES PVC Trap m h de 5 D Rubber is E Grommet See VIEW S for drain line positions See VIEW T for drain line positions See VIEW U for drain line positions Figure 42 Venting Options for Downflow Installations SM Series 52 TROUBLESHOOTING IMPORTANT NOTE The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains If the furnace fails to operate check the following s the thermostat operating properly Are the blower compartment door s in place s the furnace disconnect closed Hasthecircuit breaker tripped or the control board fuse burned open Is the gas turned on Are any manual reset switches open Is the filter dirty or plugged Is the flame sensor coated Remove and clean with steel wool Do not use emery cloth or sandpaper Is there blockage in the condensate drain switch Also verify that there is no double trapping of condensate Is the secondary heat exchanger free of debris an
6. 21 Optional PVC Pipe Installation 21 Condensate Drain 21 Bottom Panel 22 Alternate Bottom Panel Removal 22 GAS SUPPLY amp 23 EF geo p 23 High Altitude Application Natural Gas Only 24 Converting from Natural Gas to LP Propane 27 ELECTRICAL WIRING 28 innuens 27 Line Voltage Wiring Lio erectis 28 RE EE ET 28 Thermostat Low Voltage Connections 29 Heat i T M 29 Eun nn te ns 29 START UP amp 30 Pre Start Check Lennon asm niha 30 Start up Procedures uui eese ted atc eden 30 Verifying amp Adjusting Input 30 Verifying amp Adjusting Temperature Rise 31 Verifying Burner 31 Verifying Operation of the Supply Air Limit Switch 31 OPERATING SEQUENCE 31 Heating Crea PER dua AI MORD 31 ONIN EI eue ut 31 31 MAINTENANCE dun 32 FIGURES amp TAB ES ee rta rbd n i t 33 Figure 31 SL amp SM Cabinet Dimensions 33 Figure 32 SC amp
7. OPTION a 11 12 8 f Flange 1 SLT h Plug Plug VIEW 1 VIEW J VIEW K Inline Drain lt ou Factory Supplied a ached to a See NOTE 4 PVC Trap e CES X Field Supplied LS 3 al ei eU y im MN y d MAU s n 4 1 Inline Drain n Inline Drain i Field Supplied NUE des See NOTES 2 amp 3 27 Collector Box Drain Inline Drain Factory Equipped i i See NOTE 2 Bip pe Collector Box Drain 4 Factory Equipped NOTES See NOTE 2 1 See Accessories section page 20 for optional PVC Tee configurations and drainage options 2 Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the cabinet All drain lines must be routed externally from the cabinet 3 Inline drain is required only if X is greater than 6 feet 4 Tubing needs to be cut to length and attached during unit installation 5 Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trap 92 1 HORIZONTAL LEFT 2 PIPE OPTIONS F Es Plug S
8. NOTE Vent Configuration to Provide 12 Minimum height above Snow Level Plumbing Vent Roof Boot th Pi Elbows on the combustion air Bo ipes inlet must be positioned pointing DN away from the exhaust vent 12 Above Maximum Expected Snow Level Both pipes Figure 10 Vertical Vent Termination Outdoor Terminations Vertical Venting Termination spacing requirements from the roof and from each other are shown in Figure 10 The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing Vent and combustion air piping may be installed in an existing chimney which is not in use provided that Both the exhaust vent and air intake run the length of the chimney The top of the chimney is sealed and weatherproofed The termination clearances shown in Figure 10 are maintained No other gas fired or fuel burning equipment is vented through the chimney Vent Freezing Protection A CAUTION When the vent pipe is exposed to temperatures below freezing i e when it passes through unheated spaces chimneys etc the pipe must be insulated with 1 2 inch thick sponge rubber insulation Armaflex type insulation or equivalent Insulating pipe is important to avoid condensate icing Table 2 page 14 lists the maximum length of flue pipe that can travel through an unconditioned space or an exterior space The total vent length must not exc
9. usepjDupeueyy H use 3ne4 Auejog e1neN LT 18MOd ON no aa uonduoseg onsoubeia SNOILIANO9 1 1nv4 xxO 02 0002 MOTI3A MOTI3A L YOLOW Q334 v YOSNAS 3v 13 4v MOTI3A L uo 0 s13d0N 109135 NO 39 Figure 33 Wiring Diagram yava ALIHM HOLIMS 3unssdud 3dlH1S HW a8 Vc ddlH 1S H4 HM 3ONVHO s130OW 19313S NO HOLIMS SHNSSAYd ouo ama PH ae 3 ama UNN Alddns INA 1NOTIOH HOLIMS LINN HOOGLNO OL IVLSONHAHL 39VLS FIONIS speeds pue eu 10 eui suononuajsuj 159 SU 01 sooeuunJ ajbuls 06 pue 08 104 INVHSOVIG ONIHIM Gas Information GAS FLOW RATES GAS FLOW RATES CUBIC FEET PER HOUR CUBIC FEET PER HOUR TIME FOR CUBIC FEET PER TIME FOR CUBIC FEET PER ONE REVOLUTION REVOLUTION OF GAS METER ONE REVOLUTION REVOLUTION OF GAS METER SECONDS SECONDS DE PE EE DET Sd Table 10 Gas Flow Rates Capacity of Black Iron Gas Pipe ft per hour for Natural Gas w Specific Gravity 0 60 Nominal Pipe Length of Pipe Run Feet Diameter IN 10
10. dananesssaiernenenaadeenuss 11 Vent Pipe Length 4 11 Vent Pipe Installation rtr ratos 12 Outdoor Terminations Horizontal Venting 12 Outdoor Terminations Vertical Venting 13 Vent Freezing Protection 13 Existing Instants 14 Condensate 14 CIRCULATING AIR REQUIREMENTS 14 Plenums amp DUCES erre 14 Alr Connections saisine 15 Upflow 4 Horizontal Furnaces 15 FUE BE ass E bt do ducta us d 15 Supply Air Connections 15 Acoustical Treatments issues 15 FURNACE INSTALLATION ns 16 General Requirements 16 FLAG E 16 Horizontal FUITdbes caeco itte ntes 16 Special Instructions for SC038 23A Furnaces 16 Downilow FUMATO S m 17 Installation on a Concrete Slab 17 Inducer amp Venting 18 Inducer Assembly Rotation 18 Pressure Switch Tub orto 18 Alternate Pressure Switch Location 18 cci i MEE 20 PME T 20 Rubber DFOIITIBIS sessirnir 20 PYCO COmMPOMED S nds na seine 21 Typical Otlentattoli siiicar 21 Alternate
11. Hose Barb C_ 1 2 Tubing Formed into a Loop Field Supplied Installation of PVC Components Alternate Orientation Figure 21 PVC Components Typical Orientation 1 Install the PVC Tee vertically on the 2 vent pipe that is extending outthe side of the cabinet Permanently bond them together using appropriate primer and cement Refer to the typical orientation shown in Figure 21 2 Install the reducer or PVC trap if supplied on the bottom end of the PVC Tee Permanently bond them together using appropriate primer and cement 3 Install the 1 2 x 1 2 hose barb on the 2 PVC reducer NOTE Do not over tighten Use an adequate amount of Teflon tape on the threads Do not use liquid sealants 4 Verify all connections and joints for tight fit and proper alignment with other vent pipes Alternate Orientation 1 Install the 2 PVC Tee horizontally on the 2 vent pipe that is extending out the side of the cabinet Permanently bond them together using appropriate primer and cement Refer to the alternate orientation shown in Figure 21 2 Install the 2 PVC Elbow on the end of the 2 PVC Tee Permanently bond them together using appropriate primer and cement 3 Install the reducer or PVC trap if supplied on the bottom end of the PVC Tee Permanently bond them together using appropriate primer and cement 4 Install the 1 2 x 1 2 hose barb on the 2 PVC reducer NOTE Do not over tighten
12. LOCAL HEATING VALUES FOR NATURAL GAS BTU PER CUBIC FOOT 650 700 750 800 850 900 950 1 000 1 050 ALTITUDE ABOVE SEA LEVEL 2 000 FT 3 000 FT 4 000 FT 5 000 FT 6 000 FT 7 000 FT 8 000 FT 9 000 FT 10 000 FT Table 13 Natural Gas Heating Values 41 HIGH ALTITUDE DERATION NATURAL GAS WITH HIGH HEATING VALUE INPUT BTU ALTITUDE ABOVE SEA LEVEL 38 000 SC Models 38 000 SD Models 51 54 000 47 72 000 47 90 000 47 108 000 47 118 000 46 120 000 45 0 to 1 999 FT 3 5 3 45 5 ORIFICE SIZE 2 000 to 2 999 FT 3 0 3 MANIFOLD PRESSURE 5 3 5 3 5 3 5 3 5 3 5 1 47 47 47 47 46 45 2 3 2 3 2 3 2 3 2 3 2 3 3 1 47 47 47 47 46 5 45 3 000 10 3 999 2 8 45 5 ORIFICE SIZE 4 000 to 4 999 FT 2 7 2 MANIFOLD PRESSURE 45 5 000 to 5 999 FT 2 5 5 27 2 7 27 27 27 49 53 49 49 49 49 48 48 ORIFICE SIZE 6 000 to 6 999 FT 3 5 3 5 8 5 3 5 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 49 53 49 49 49 49 48 7 000 to 7 999 FT 3 4 49 5 ORIFICE SIZE 8 000 to 8 999 FT 3 2 3 MANIFOLD PRESSURE 49 9 000 to 9 999 FT 3 0 Table 14 High Altitude Deration Natural Gas with HIGH Heating Value 3 ORIFICE SIZE 5 MANIFOLD PRESSURE ORIFICE SIZE 3 1 MANIFOLD PRESSURE 5 0 3 0 3 0 3 0 3 0 3 2 1 47 47 47 47 46 45 8 2 8 2 8 2 8 2 8 2 8 2 9 1 47 47 47 47 46 2 ORIFICE SIZE 8 MANIF
13. 6 Pin Wiring Harness 6 Pin Wiring Harness Expansion Port Expansion Port TWINNING CONTROL BOARD TWINNING CONTROL BOARD TWIN TERMINAL TWIN TERMINAL Figure 29 Single Stage Twinning START UP amp ADJUSTMENTS Pre Start Check List Verify the polarity of the connections are correct the line voltage power leads are securely connected and the furnace is properly grounded Verify the thermostat wires R W Y amp G are securely connected to the correct leads on the terminal strip of the circuit board Verifythe gas line service pressure does not exceed 10 0 inches of W C and is not less than 4 5 inches W C for natural gas For LP gas the line service pressure must not exceed 14 in W C and must not be less than 11 0 in W C Verify the roll out and manual reset switch is closed If necessary press the red button to reset a switch DO NOT install a jumper wire across a switch to defeat its function If a switch reopens on startup DO NOT reset the switch without identifying and correcting the fault condition Y Verify blower door is in place closing the door switch in the line voltage circuit Verify the gas line has been purged and all connections are leak free Start up Procedures Do not perform these steps until all of the checks in the previous steps have been completed 1 Set the thermostat to the lowest setting 2 Turn off all ele
14. Ducts must extend above attic insulation fs Furnace Vent or Vent or Chimney Chimney NOTES Each opening must be at least 100 sq in or 1 sq in per 1 000 Btuh of total input rating Water whichever is greater Heater Openings must start at no more than 12 inches y from the top and bottom See of the enclosure Heater Air Duct must be at least 1 sq per 4 000 Btuh of total input rating Y Furnace Notes Y 12 Max 12 Max Total Input Rating Minimum Free Area Round Duct Btuh Each Opening Diameter 40 000 10 sq In 4 inches 60 000 15 sq In 5 inches 80 000 20 sq In 5 inches 100 000 25 sq In 6 inches 120 000 30 sq In 6 inches 140 000 35 sq In 7 inches 160 000 40 sq In 8 inches Total Input Rating Minimum Free Area Round Duct Btuh Each Opening Diameter 40 000 100 sq In 12 inches 60 000 100 sq In 12 inches 80 000 100 sq In 12 inches 100 000 100 sq In 12 inches 120 000 120 sq In 13 inches 140 000 140 sq In 14 inches 160 000 160 sq In 15 inches Figure 2 Combustion Air Drawn from Inside Figure 4 Combustion Air Drawn from Outside Through Vertical Duct Outdoor Air from a Crawl Space or Vented Attic Ou
15. 5 Replace the burner compartment door Verifying Operation of the Supply Air Limit Switch NOTE A properly functioning limit switch should turn off the gas valve when the return is blocked time depends on how well the return air is blocked The circulating air and combustion blowers should continue to run when the limit switch opens 1 Verify the blower door is securely mounted in place and that there is power to the furnace 2 Block the return airflow to the furnace by installing a close off plate in place of or upstream of the filter s 3 Setthe thermostat above room temperature and observe the Operating Sequence 4 Remove the close off immediately after the limit switch opens If the furnace continues to operate with no return air set the thermostat below room temperature shut off power to the furnace and replace the limit switch OPERATING SEQUENCE The operating sequences for the heating cooling and fan modes are described below Refer to the field and furnace wiring diagrams Figure 27 page 28 Figure 28 page 29 and Figure 33 page 39 Heating Cycle 1 The thermostat calls for heat by energizing the W terminal with 24VAC 2 The control verifies the pressure switch is open 3 If the pressure switch is open the control energizes the inducer and waits for the pressure switch to close The pressure switch must close within 10 seconds 4 The control runs the inducer for a 30 second pre purge 5 The cont
16. 2 Two 45 degree elbows are equivalent to one 90 degree elbow 3 This table applies for elevations from sea level to 2 000 ft For higher elevations decrease pipe lengths by 8 per 1 000 ft of altitude 4 A long radius elbow s centerline radius is equal to or greater than 1 5 times the vent diameter Table 1 Vent Pipe Lengths Vent Pipe Installation A CAUTION Combustion air must not be drawn from a corrosive atmosphere This furnace has been certified for installation with zero clearance between vent piping and combustible surfaces However itis good practice to allow space forconvenience in installation and service In the absence of local codes the location of any combustion air inlet relative to any vent terminal must be atleast 8 inches This includes installations involving more than one furnace The quality of outdoor air must also be considered Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion ofthe furnace combustion system See page 5 for a sample list of substances Route piping as direct as possible between the furnace and the outdoors Horizontal piping from inducer to the flue pipe must be sloped 1 4 per foot to ensure condensate flows towards the drain tee or PVC trap Longer vent runs require larger pipe diameters Refer to the Inducer amp Venting Options section on page 18 for additional information If a Direct
17. 2 9 2 9 2 9 2 9 Venting Information IXED gPERABLE CLOSED VENT TERMINAL AIR SUPPLY INLET CANADIAN INSTALLATIONS Q DS AREA WHERE TERMINAL IS NOT PERMITTED US INSTALLATIONS P Direct Vent 2 pipe amp Conventional Vent 1 pipe Furnaces Clearance Location Conventional Vent 1 pipe Furnaces Direct Vent 2 pipe Furnaces Clearance above grade veranda porch deck balcony or maximum expected snow level 12 inches 30cm 12 inches 30cm 12 inches 30cm 6 inches 15cm for appliances lt 10 000 Btuh 3kW 6 inches 15cm for appliances lt 10 000 Btuh 3kW Clearance to window or door that may be opened 12 inches 30cm for appliances 10 000 Btuh 100 000 Btuh 30kW 4 ft 1 2m below or to side 9 inches 23cm for appliances of opening 1 ft 300mm 10 000 Btuh 50 000 Btuh 36 inches 91cm for appliances gt 100 000 Btuh 30Kw above opening 12 inches 30cm for appliances 50 000 Btuh 30Kw Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61cm from the center line of the terminal Clearance to unventilated soffit earance to outside corner earance to each side of center line extended bove meter regulator assembly
18. INSTALLER NAME CITY STATE INSTALLATION ADDRESS CITY STATE UNIT MODEL UNIT SERIAL Minimum clearances Fi 1 inimu per Figure YES page 6 Has the owner s information been YES reviewed with the home owner Has the literature package been YES left near the furnace PROPOSITION 65 WARNING WARNING This product contains chemicals known to the state of California to cause cancer WARNING This product contains chemicals known to the state of California to cause birth defects or other reproductive harm ELECTRICAL SYSTEM Electrical connections tight Line voltage polarity correct Is the thermostat level Is the heat anticipator setting correct GAS SYSTEM Gas Type circle one Gas pipe connections leak tested Gas Line Pressure Natural NO in W C Installation Altitude FT Deration Percentage Furnace Input Supply Air Temperature Return Air Temperature Temperature Rise COMBUSTION AIR amp VENTING SYSTEM 15 there adequate fresh air supply for YES combustion and ventilation Vent free from restrictions Filter s secured in place Filter s clean Flue connections tight Is there proper draft wv MEMBER COMPANY Lr CERTIFIED www ahridirectory org Residential Furnaces DOE 10 CFR Part 430 NORDYNE COMPLETE COMFORT GENUINE VALUE Specifications amp illustrations subject to change without
19. the appropriate valuefor each installation by a qualified installer service agency or the gas supplier A WARNING Do not attemptto drill the gas orifices Use only factory supplied orifices Improperly drilled orifices may cause fire explosion carbon monoxide poisoning personal injury or death a Obtain the manifold pressure setting required for this installation by referring to Table 12 page 41 for Propane or Table 14 page 42 or Table 15 page 42 for Natural Gas b Remove the regulator capscrew Figure 30 from the INLET side of the regulator Slowly turn the adjustment screw inside the regulator to obtain the appropriate manifold pressure NOTE Turning the screw clockwise increases the pressure and turning the screw counter clockwise decreases the pressure To prevent backing the Capscrew Figure 30 Regulator Capscrew screw all the way out from the valve turn the screw slowly d Replace and tighten the regulator capscrew over the adjustment screw Verifying amp Adjusting Temperature Rise After installation of the furnace confirm the temperature rise of the furnace is within the limits specified on the rating plate Any temperature rise outside the specified limits could result in premature failure of the heat exchanger 1 Place thermometers in the return and supply air stream as close to the furnace as possible The thermometer on the supply air side must be shielded from direct radia
20. 10 inches Minimum Free Area Each Opening 20 sq In 30 sq In 40 sq In 50 sq In 60 sq In 70 sq In 80 sq In Total Input Rating Btuh 40 000 60 000 80 000 100 000 120 000 140 000 160 000 Figure 5 Combustion Air Drawn from Outside Through Horizontal Ducts Vent or__ Chimney NOTE Each opening to outside must be at least 1 sq in per 4 000 Btuh of total input rating Water Heater Furnace Minimum Free Area Round Duct Each Opening Diameter 10 sq In 4 inches 15 sq In inches 20 sq In inches 25 sq In inches 30 sq In inches 35 sq In inches 40 sq In inches Total Input Rating Btuh 40 000 60 000 80 000 100 000 120 000 140 000 160 000 Figure 6 Combustion Air Drawn from Outside Through an Exterior Wall Example A space with a water heater rated at 45 000 Btuh input and a furnace rated at 75 000 Btuh requires a volume of 6 000 cubic feet 50 x 45 75 6 000 to be considered unconfined If the space has an 8 foot ceiling the floor area of the space must be 750 sq ft 6 000 8 750 Alternate Method of Providing Air from Outside If acceptable under local Codes it is permitted to provide outside air using one opening See NFGC Generally confined spaces must have two openings in the space for combustion air One opening
21. 3 feet 91cm within a height 15 feet above the meter regulator assembly C Clearance to inside corner Clearance to service regulator vent outlet 3 feet 1 83m 6 inches 15cm for appliances lt 10 000 Btuh SkW 6 inches 15cm for appliances lt 10 000 Btuh SkW earance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 inches 30cm for appliances 10 000 Btuh 100 000 Btuh 30kW 4 ft 1 2m below or to side of opening 1 ft 300mm above opening 9 inches 23cm for appliances 10 000 Btuh 50 000 Btuh 30kW 36 inches 91cm for appliances gt 100 000 Btuh 30Kw 12 inches 30cm for appliances gt 50 000 Btuh 30Kw Clearance to mechanical air supply inlet 6 feet 1 83 3 feet 91cm above if within 10 feet 3m horizontally 3 ft 91cm above if within 10 feet 3m horizontally Clearance above paved sidewalk or driveway c located on public property 7 feet 2 13m 7 ft 2 13 _ Clearance under veranda porch deck or balcony 12 inches 30cm d a In accordance with the current CSA B149 1 Natural Gas and Propane Installation Guide Code b In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code C A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings d Per
22. Remove all screws securing the Manifold Assembly to the Burner Box 9 Carefully remove the burner assembly from the furnace DONOTDAMAGETHE IGNITERWHILE REMOVING THE BURNER ASSEMBLY 10 Inspect the burners for accumulated dust or debris If necessary carefully clean them with a soft wire brush and a vacuum cleaner DO NOT DAMAGETHE IGNITER WHILE CLEANING THE BURNER 11 Replace all the parts in reverse order from which they were removed 12 Follow the lighting instructions found on the furnace door to return the furnace to operation Verify proper operation after servicing Vent System Check the inlet pipe if applicable and outlet pipe to ensure they are not blocked by debris Any damaged section of vent pipe must be replaced and any obstruction or blockage must be removed prior to operating the furnace Heat Exchanger amp Burner Maintenance The furnace should operate for many years without soot buildup in the flue passageways however the flue vent system and burners should be inspected and cleaned if required by aqualified service technician annually to ensure continued safe operation Pay attention to any deterioration from corrosion or other sources A WARNING Holes in the vent pipe or heat exchanger can cause combustion products to enter the home Replacethe vent pipe or heatexchanger if leaks are found Failure to prevent the circulation of combustion products into the living space can create potentially hazard
23. this type of furnace but may be used if allowed by local jurisdiction Only new flexible connectors may be used Do not use a connector which has previously serviced another gas appliance A drip leg should be installed in the vertical pipe run to the unit See Figure 25 or Figure 26 Table 11 page 40 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line The furnace may be installed with either left or right side gas entry When connecting the gas supply provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and or damage to the furnace Typical gas hookups are shown in Figure 25 amp Figure 26 Leak Check WARNING FIRE OR EXPLOSION HAZARD Failureto follow safety warnings exactly could result in serious injury or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may resultcausing property damage personal injury or loss of life 23 A AVERTISSEMENT RISQUE D INDENDIE OU D EXPLOSION Lenon respect des avertissements de s curit pourrait d entrainer des blessures graves la mort ou des dommages mat riels Ne jamais utiliser une flamme nue por v rifier la pr sence des fuites de gaz Pour la v rification de tous
24. 12 5 8 12 7 8 054D 24B 072D 24B 072D 35C 090D 35C 108D 45D 120D 45D 17 1 2 15 7 8 16 1 8 21 19 3 8 19 5 8 22 7 8 23 1 8 NOTE Dimensions shown in inches 2 3 4 22 1 2 gt m 25 3 8 22 1 2 Vent pipe 3 a T stat lig 718 Electric 7 8 Gas O 1 5 8 28 LEFT SIDE SD Upflow Horizontal Furnaces 17 1 2 Model 5 038D 24B 16 1 8 054D 24B 072D 35C 21 19 3 8 19 5 8 090D 35C 108D 45D 24 1 2 22 7 8 23 1 8 120D 45D NOTE Dimensions shown in inches Dim C 15 7 8 2 314 22 1 2 ____25 3 8 22 1 2 Vent pipe Condensate O 1 1 16 T stat 7 8 Electric OQ 7 8 Gas 1 5 8 9 LEFT SIDE Condensate O 1 1 16 TOP VIEW BOTTOM VIEW Front P lssssccosscsscs7l Combustion Air Electric 7 8 sf PR 1 5 8 B o b Knockouts both sides Cond 8 1 1 16 RIGHT SIDE FRONT VIEW TOP VIEW BOTTOM VIEW 4 Front Brace Combustion Air T stat A O8 1 5 8 co B o b Knockouts both sides Cond 1 1 16 23 RIGHT SIDE FRONT VIEW Figure 32 SC amp SD Cabinet Dimensions Model Numb
25. 40 50 Input To Furnace Btu hr Heating Value of Gas Btu Cu Ft Cubic Feet Per Hour Required NOTE The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace To determine the cubic feet per hour of gas flow required by the furnace divide the input rate of the furnace by the heating value from gas sup plier of the gas Table 11 Gas Pipe Capacities 40 ALTITUDE SEA LEVEL 38 000 SC Models HIGH ALTITUDE DERATION PROPANE GAS INPUT BTU 38 000 SD Models 54 000 72 000 90 000 108 000 118 000 120 000 0 to 1 999 FT 2 000 to 2 999 FT 56 60 56 56 56 56 55 55 ORIFICE SIZE 10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0 MANIFOLD PRESSURE 5 6 60 56 56 56 56 55 55 ORIFICE SIZE 9 0 9 0 9 9 9 9 9 9 0 MANIFOLD PRESSURE 8 000 to 4 999 FT 7 5 000 to 5 999 FT 56 60 56 56 56 56 55 55 ORIFICE SIZE 8 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 MANIFOLD PRESSURE 5 61 57 57 57 57 56 56 ORIFICE SIZE 10 0 MANIFOLD PRESSURE 10 0 8 5 10 0 10 0 10 0 10 0 10 0 57 61 57 57 57 57 56 56 ORIFICE SIZE 6 000 to 7 999 FT 9 0 8 0 9 0 9 0 9 0 9 0 9 0 9 0 MANIFOLD PRESSURE 57 61 7 7 7 7 RIFICE SIZE 8 000 to 10 000 FT 3 SES 7 5 8 5 8 5 8 5 8 5 8 5 8 5 MANIFOLD PRESSURE Table 12 High Altitude Deration Propane Gas
26. Drain See NOTE 3 Factory Equipped NOTES See NOTES 2 amp 3 1 See Accessories section page 20 for optional PVC Tee configurations and drainage options 2 Drain lines must be trapped with J Trap or field supplied loop Traps may be positioned inside or outside the cabinet drain lines must be routed externally from the cabinet 3 Inline drain is required only if X is greater than 6 feet 4 Tubing needs to be cut to length and attached during unit installation 5 Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trapt ma Pa 95 0 UPFLOW 2 PIPE OPTIONS i o o 5 5 Ee ea 4 TECH X ia N S E o a See 2 5 E NOTES X a S n 3 in 4 PVC Trap 5 d tT LJ NOTE 5 Rubber PVC Tee gt 1 Grommet d OPTION 23 PVC Ke Rubber el n Dose Grommet io See VIEW O for drain line positions See VIEW P for drain line positions Figure 40 Venting Options for Upflow Installations SD Series 50 95 0 HORIZONTAL RIGHT 1 PIPE OPTI
27. Horizontal Furnaces The return air ductwork may be connected to the left side right side or bottom of the furnace NOTE If using the left or right side of the furnace for return air the bottom panel Figure 32 must not be removed from the bottom of the furnace WARNING The bottom panel of the furnace must be in place when the furnace is installed with side return air ducts Removal of all or part of the base could cause circulation of combustible products into the living space and create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death Side Return Installations To attach the return air duct to the left or right side of the furnace punch out the 4 knockouts from the side of the furnace Figure 32 Using sharp metal cutters cut an opening between all 4 knockouts to expose the blower assembly Position the return air duct over the opening and secure to the side with sheet metal screws Bottom Return Installations If using the bottom of the furnace for return air the bottom panel Figure 32 must be removed from the bottom of the furnace See page 22 for removal instructions Position the furnace over the return air duct and secure together with sheet metal screws Make sure the screws penetrate the duct and furnace casing Downflow Furnaces To attach the return air duct to the furnace bend the flanges on the furnace upward 90 with wide duct
28. Og FIELD WIRING LOW VOLTAGE CONNECTION NEUTRALS MOTOR SPEED TAPS NOT USED ELECTRONIC AIR CLEANER HUMIDIFIER TAP NEUTRAL LEADS Figure 28 Low Voltage Field Four wire Heating Cooling Applications Twinning Single stage furnaces are not supplied with a built in twinning capability Other valuable features and enhancements were made to the new control that made it necessary to remove the twinning capability For twinning of single stage furnaces with PSC motors a twinning kit 920919 is available for purchase Please follow the instructions provided with the kit If both single stage furnaces are upgraded to the fixed speed iSEER blower the twin terminal on the blower control boards Figure 29 may be used to twin the single stage furnaces only if the following criteria are met Both furnaces and motors must be the same size Both motors must be on the same speed for cooling and heating Both furnaces must have a common return duct and common supply plenum Both furnaces must be the same phase and on the same leg of power Furnaces equipped with variable speed iSEER motors may notbetwinned underany circumstances For twinning of single stage furnaces equipped with fixed speed iSEER blowers refer to Figure 29 page 30 and the following instructions WARNING When servicing either twinned furnace power must be turned off on both furnaces Failur
29. S IL Y A UNE ODEUR DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher aucun interrupteur lectrique n utiliser aucun t l phone dans le b timent vacuer l immeuble imm diatement Appeler imm diatement le fournisseur de gaz en employant le t l phone d un voisin Respecter la lettre les instructions du fournisseur de gaz Si personne ne r pond appeler le service des incendies All gas piping must be installed in compliance with local codes and utility regulations In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code ANSIZ223 1 or CAN CGA B149 1 or 2 Installation Codes Some local regulations require the installation of a manual main shut off valve and ground joint union external to the furnace as shown in Figure 25 page 25 amp Figure 26 page 26 The shut off valve should be readily accessible for service and or emergency use Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut off Gas piping must never run in or through air ducts chimneys gas vents or elevator shafts Compounds used on threaded joints of gas piping must be resistant to the actions of LP propane gas The main gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required Flexible gas connectors are not recommended for
30. Series Downflow Furnace Blower Assembly Pinisi Flange behind blower panel Furnace Control Board Blower Door Switch m Transformer behind blower panel Inducer Limit Switch Inducer Assembly Pressure Switch Gas Valve Igniter i be Flame Sensor Burner Roll Out Gas Assembly Switch Manifold SM Series Downflow Furnace Figure 44 SL amp SM Component Locations 55 INSTALLATION PERFORMANCE CHECK LIST ATTENTION INSTALLERS Itis your responsibility to know this product better than your customer This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the deciding factor when installing this product and us ing common sense plays an important role as well Pay attention to all safety warnings and any other special notes highlighted in the manual Improper installation of the furnace or failure to follow safety warnings could result in serious injury death or property damage Theseinstructions are primarily intendedto assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference
31. air that is used for the exhaust vent Table 1 indicates the maximum allowable pipe length for a furnace of known input rate when installed with piping of selected diameter and number of elbows To use the table the furnace input rate the centerline length and the number of elbows on each pipe must be known When estimating the length of vent runs consideration must be made to the effect of elbows and other fittings This is conveniently handled using the idea of equivalent length This means the fittings are assigned a linear length that accounts for the pressure drop they will cause For example a 2 diameter long radius elbow is worth the equivalent of 2 5 feet of linear run A 90 degree tee is worth 7 ft The equivalent lenghts of tees and various elbows are listed in Table 1 Measure the linear length of your vent run and then add in the equivalent length of each fitting The total length including the equivalent fitting lengths must be less than the maximum length specified in the table DUAL VENT PIPE LENGTH FT with 1 long radius elbow on each pipe INLET OUTLET INLET OUTLET 2 Diameter 3 Diameter OUTLET 3 Diameter 1 Subtract 2 5 ft for each additional 2 inch long radius elbow 5 ft for each additional 2 inch short radius elbow 3 5 ft for each additional 3 inch long radius elbow and 7 ft for each additional 3 inch short radius elbow Subtract 5 ft for each 2 tee and 8 ft for each 3 tee
32. and alignment with other vent pipes The 2 PVC components shown in Figure 21 are not provided in the extra parts bag However the PVC Trap P N 664659 can be purchased thru your local distributor The 2 PVC tee reducer PVC Trap and 1 2 X 1 2 hose barb are used when the inducer is rotated to vent out thru the left or right side of the furnace cabinet See Figure 21 NOTE If supplied with your furnace the NORDYNE PVC trap 664659 may be used in place of the reducer and 1 2 X 1 2 hose barb The 1 2 X 3 4 hose barb can be used to route the condensate drain to the outside of the cabinet It must be installed from inside the cabinet with the threaded end inserted thru the 1 1 16 hole The condensate drain should be connected to the barbed end Attach 1 PVC drain line to the threaded end See Figure 31 page 33 or Figure 32 page 34 for hole location 2 PVC Pipe from Inline Drain Assembly Not Included _ 2 PVC Tee E M xumPw Reducer Tc i UM x 1 2 x 1 2 Tubing Hose Barb Supplied PVC Trap 1 2 x 3 4 Hose Barb 4 1 2 Tubing Formed into a Loop Field Supplied 2 PVC Pipe from Inline Drain Assembly Not Included 2 LA 2 ELBOW 4 as Field Supplied uo NR LD on 2 x 1 2 TS a TA x 1 2 1 2 Tubing i Ire Hose Barb ield Supplied PVC Trap 1 2 x 3 4
33. any way by a qualified HVAC technician The furnace shall be inspected and approved by applicable local authority even if this requires redundant inspections Serial numbers for furnaces used during construction must be submitted in writing fax and email also acceptable This information will be used to track the long term affects of the use during construction on furnaces Proof of this submittal shall be available for the final inspection of the furnace prior to occupancy This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences including setbacks Minimum continuous return temperature must not be below 60 F 15 C Occasionally a temporary return temperature of 55 F 12 C is acceptable However operation with a return temperature below 55 F 12 C is not allowed COMBUSTION AIR amp VENTING REQUIREMENTS AVERTISSEMENT 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 resultin carbon monoxide poisoning or death The following steps shall be followed with each individual appliance connected to the venting system being placed in operation while all other appliances connected to the venting system are not in operation 1 Sealany unused openings in the venting system 2 Inspect the venting system for proper size and horizontal pitch
34. are for US installations as found in the NFGC Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code NFGC and all applicable local codes Requirements in Canada B149 1 are structured differently In Canada venting shall conform to the requirements of the current CAN CGA B149 1 2 installation codes Consult local codes for special requirements Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion The combustion air from the outside needs to be clear of chemicals that can cause corrosion The inlet pipe should not be placed near corrosive chemicals such as those listed on page 5 WARNING Upon completion of the furnace installation carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed Leaks in the flue system can result in serious personal injury or death due to exposure of flue products including carbon monoxide WARNING This furnace must not be vented with other appliances even if that appliance is of the condensing type Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents Do not vent the furnace to a fireplace chimney or building chase This condensing furnace is certified for installation either as a D
35. cet appareil ni de tout autre appareil QUE FAIRE S IL Y A UNE ODEUR DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher aucun interrupteur lectrique n utiliser aucun t l phone dans le b timent Evacuer l immeuble imm diatement Appeler imm diatement le fournisseur de gaz en employant le t l phone d un voisin Respecter la lettre les instructions du fournisseur de gaz Si personne r pond appeler le service des incendies DO NOT DESTROY THIS MANUAL KEEP IN A SAFE PLACE FOR FUTURE REFERENCE TABLE 5 IMPORTANT SAFETY INFORMATION 3 CODES amp REQUIREMENTS 4 Combustion Air Quality 5 Feasting hero RP ER E 5 Operation of Furnace During Construction 6 Installation I dx Grasse 6 Clearances to Combustible Materials 6 COMBUSTION AIR amp VENTING REQUIREMENTS 7 Direct Vent FT 8 Conventional Vent Systems Confined Spaces 8 Air From cca mise 9 Outdoor Air from Crawl Space or Vented Attic 9 Outdoor Air Using Vertical Ducts 9 Outdoor Air Using Horizontal Ducts 9 Air Directly Through An Exterior Wall 9 Alternate Method of Providing Air from Outside 10 Conventional Vent Systems Unconfined Spaces 10 Category IY sans sarissa 10 Vent Pipe
36. furnace through wall that experiences the least exposure to winter winds The vent termination shall be located at least 3 ft horizontally from any electric meter gas meter regulator and any relief equipment These distances apply ONLY to U S installations In Canada CSA B149 1 takes precedence over these instructions Do not install the vent terminal such that exhaust is directed into window wells stairwells under decks or into alcoves or similar recessed areas and do not terminate above any public walkways If venting horizontally a side wall vent kit is available according to the pipe diameter size of the installation For 2 inch pipe use side wall vent kit 904617 and for 3 inch pipe use kit 904347 Please follow the instructions provided with the kit Concentric vent termination kits are available for use with these furnaces For 2 Inch pipe use kit 904952 and or 3 inch pipe use kit 904953 Please follow the instructions provided with the kit When the vent pipe must exit an exterior wall close to the grade or expected snow level where itis not possible to obtain clearances shown in Figure 7 a riser may be provided as shown in Figure 9 Insulation is required to prevent freezing of this section of pipe See Table 3 page 17 for vent freezing protection 19 Max See Note lt 12 Above pA Maximum Expected Support gt Snow Level Outside Wall 7 Armaflex Insulation or 2 Equivalent
37. line positions See VIEW N for drain line positions Figure 38 Venting Options for Downflow Installations SL Series 48 SD amp SM Series 95 0 AFUE HORIZONTAL VENTING w 2 Pipes Upflow Furnace Shown Straps or Other Suitable Seal Caulk Supports at minimum of 5 ft Intervals Around Pipes at Building 90 Elbow s 90 d Hi Hd Elbow COMBUSTION AIR ii H H H m d d 90 Elbow 7 T n 9 pward Pitch 1 4 per foot 12 Min 2 4 Flue Pipe a 2 See Table 2 for 2 pipe 6 lengths field supplied E First support placed as close Du to furnace connection as possible Wall 3 Normal GS E m Snow Level 8 O me PVC L VERTICAL VENTING w 2 Pipes Upflow Furnace Shown COMBUSTION AIR Support System on Vertical Rise 1 See Table 2 for 2 PVC pipe lengths field supplied Couplings with 2 Hose Clamps Optional FLUE PIPE me PVC Tee p PVC Trap uw PVC Trap J Support System on 9 Vertical Rise First Support as Close to Furnace as Possible 90 E
38. must be within 12 inches of the ceiling and the other must be within 12 inches of the floor However an alternative method recently adopted by the NFGC uses one opening within 12 inches of the top of the space This method may be used if itis acceptable to the local codes The following conditions must be met 1 The opening must start within 12 of the top of the structure and connect with the out of doors through vertical or horizontal ducts or be ducted to a crawl or attic space that connects with the out of doors 2 The opening must have a minimum free area of 1 sq in per 3 000 Btu per hour of the total input rating of all equipment located in the enclosure 3 The free area must not be less than the sum of all the areas of the vent connectors in the enclosure Conventional Vent Systems Unconfined Spaces An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1 000 Btuh of the combined input rates of all appliances which draw combustion air from that space In general a furnace installed in an unconfined space will not require outside air for combustion However in homes built for energy efficiency low air change rates it may be necessary to provide outside air to ensure adequate combustion and venting eventhough the furnace is located in an unconfined space See example below Category IV Venting WARNING Upon completion of the furnace installa
39. of the equipment Use caution when handling this appliance or removing components Personalinjury can occur from sharp metal edges presentin all sheet metal constructed equipment Do not store any of the following on or in contact with the unit Rags brooms vacuum cleaners or other cleaning tools spray or aerosol cans soap powders bleaches waxes cleaning compounds plastics or plastic containers paper bags or other paper products gasoline kerosene cigarette lighter fluid dry cleaning fluids paint thinners or other volatile fluids Theinstaller should become familiar with the units wiring diagram before making any electrical connections to the unit See Figure 33 page 39 or the unit wiring label Always reinstall the doors on the indoor blower after servicing or cleaning changing the filters Do not operate the indoor blower without all doors and covers in place CODES amp REQUIREMENTS A WARNING The information listed below must be followed during the installation service and operation of this furnace Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death This furnace must be installed in accordance with these instructions all applicable local building codes and the current revision of the National Fuel Gas Code NFPA54 ANSI 2223 1 orthe Natural Gas and Propane Installation Code CAN CGA B149 1 Use only with type of gas approved for thi
40. pliers See Figure 31 for furnace flange locations NOTE If system installation includes AC coil casing bend the flanges on the coil casing upward 90 before attaching the return air duct Secure the return air ductwork to the furnace or coil casing if installed with sheet metal screws Make sure the screws penetrate the sheet metal casing and flanges Supply Air Connections The supply air must be delivered to the heated space by duct s secured to the furnace or coil box casing running full size and without interruption To attach the supply air duct to upflow amp horizontal furnaces bend the flanges on the furnace upward 90 with wide duct pliers See Figure 32 page 34 for furnace flange locations NOTE If system installation includes AC coil casing bend the flanges on the coil casing upward 90 before attaching the supply air duct Position the supply air ductwork onto the furnace ensuring even alignment of furnace air opening and supply air duct NOTE The ductwork must have an opening equal to that of the supply air opening of the furnace See Figure 31 and Figure 32 for supply air opening size Acoustical Treatments Damping ducts flexible vibration isolators or pleated media style filters on the return air inlet of the furnace may be used to reduce the transmission of equipment noise eminating from the furnace These treatments can produce a quieter installation particularly in the heated space However they ca
41. section page 18 Each of the condensate drain lines must be J trapped using field supplied parts After the condensate lines are J trapped they may be combined together when routed to the drain For Installations where there is limited clearance for the J Trap such as an attic where it may be installed between ceiling joists either side of the J Trap can be shortened to a minimum of 3 Inches See Figure 11 page 16 CIRCULATING AIR REQUIREMENTS A WARNING Do not allow combustion products to enter the circulating air supply Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death return ductwork must be secured to the furnace with sheet metal screws For installations in confined spaces all return ductwork must be adequately sealed When return air is provided through the bottom of the furnace the joint between the furnace and the return air plenum must be air tight The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps cracks or sagging between the furnace and the floor or platform Return air and circulating air ductwork must not be connected to any other heat producing device suchas afireplace insert stove etc This may result in fire explosion carbon monoxide poisoning personal injury or property dama
42. the furnace blower to provide airflow over the indoor coil the coil must be installed downstream on the outlet side of the furnace or in parallel with the furnace If a cooling system is installed in parallel with the furnace a damper must be installed to prevent chilled airfrom entering the furnace and condensing on the heat exchanger If a manually operated damper is installed it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position Seal all connections and joints with industrial grade sealing tape or liquid sealant Requirements for sealing ductwork vary from region to region Consult with local codes for requirements specific to your area Return Air Connections In applications where the supply ducts carry heated air to areas outside the space where the furnace is installed the return air must be delivered to the furnace by duct s secured to the furnace casing running full size and without interruption Do not use the back of the furnace for return air Position the furnace with the return air ductwork ensuring even alignment of furnace or coil casing air opening and return air duct NOTE The ductwork must have an opening equal to that of the return air opening of the furnace or coil casing See Figure 31 page 33 or Figure 32 page 34 for return air opening size Upflow amp
43. while sliding the bottom panel 2 out through the front of the furnace 7 Reassemble the furnace in reverse order Figure 24 Alternate Removal Method GAS SUPPLY amp PIPING WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Installation and service must be performed by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department A AVERTISSEMENT RISQUE D INCENDIE OU D EXPLOSION e Le non respect des avertissements de s curit pourrait entrainer des blessures graves la mort ou des dommages mat riels L installation et l entretien doivent tre effectu s par un installateur qualifi un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ni de tout autre appareil QUE FAIRE
44. 12 page 41 to determine the correct orifice size and regulator pressure See example below When conversionis complete verify the manifold pressure and input rate are correct as listed in the table Installation Example 5 000 feet Type of Gas Propane Gas From Table 12 find 5 000 and follow across the row stop at the 72 000 btu column The manifold pressure listed is 10 0 and the orifice size is 57 ELECTRICAL WIRING WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace Whenservicing controls labelall wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUEDECHOC LECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourraitentrainer unfonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Un entretein incorrect pourrait entrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Couper toute alimentation lectrique au g n rateur d air chaud avant de prod der aux travaux d entretein Au moment d
45. 2 52 2046 53 1985 55 1932 57 1862 59 1777 61 Top Return 118 000 MED L 1873 58 1852 59 1816 60 1790 61 1750 62 1699 64 1643 66 1571 70 LOW 1544 1528 1514 1499 1462 1441 1429 1386 5 Factory Set Cooling Speed Factory Set Heating Speed 1 Two openings are recommended for airflows above 1 600 if filter s is are adjacent to furnace 2 Temperature rises in the table are approximate Actual temperature rises may vary 3 Cells shaded in gray indicate a temperature rise outside of the recommended range Table 9 SM Downflow Furnaces 38 Electrical Information 1 20 ADVLIOA HDIH WSZLLLZ ONnOHS MOVIE 3LIHM ONIHIM 971913 HOLIMS ore _ J ALIHM 1eddoo 951 0 901 15291 Je Jo 1 e Guim snu ji eq 1snui e2euunj ou perjddns se aim eu Aue HOLINOI yse 4 SNONURUOY 10SU8S MOT __ 37 ______ __________ uo ue ine uis Nur uedo uo usen une yms einsseid used vo YAMS einsseig uo w uomejedo
46. 48 SD amp SM Series 95 0 AFUE Figure 39 Horizontal amp Vertical Venting 49 Figure 40 Venting Options for Upflow Installations 50 Series 50 Figure 41 Venting Options for Horizontal Installations 50 Series 51 Figure 42 Venting Options for Downflow Installations SM Series 52 TROUBLESHOOTING accu recu 53 Table 17 Control Board Fault Conditions 53 FURNACE COMPONENTS 53 Figure 43 SC amp SD Component Locations 54 Figure 44 SL amp SM Component Locations 55 INSTALLATION PERFORMANCE CHECK LIST 56 IMPORTANT SAFETY INFORMATION INSTALLER Please read instructions before servicing this equipment Pay attention to all safety warnings and any other special notes highlighted in the manual Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not beignored WARNING Indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION Indicates a potentially hazardous situationthatif notavoided may resultin minoror moderate injury or property damage WARNING The safety information listed in this manual must be followed during the installation service and operation of this unit Unqualified individuals should notattemptto interpretthese instruc
47. Equipped NOTES See NOTES 2 amp 3 See NOTE 2 1 See Accessories section page 20 for optional PVC Tee configurations and drainage options 2 Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the cabinet All drain lines must be routed externally from the cabinet 3 Inline drain is required only if X is greater than 6 feet 4 Tubing needs to be cut to length and attached during unit installation 5 Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trap 92 1 DOWNFLOW 2 PIPE OPTIONS 79 n2 E tr ME E z z E ao ao gt gt Rubber amp 2 Grommet Q Flange FI u 8 8 ange Y Plug 3 Y y xl uw a I p gt Option m n 19 See X 5 a 5 PVC i 5 Tn p See Y SN p 5 SL 5 GH n a 10 H Lp Lp Rubber 0 L Grommet PVC N 7 Trap Rubber 5 Grommet I See VIEW L for drain line positions See VIEW M for drain
48. HOT line is connected to the black wire The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 27 Grounding WARNING To minimize personal injury the furnace cabinet must have an uninterrupted or unbroken electrical ground The controls used in this furnace require an earth ground to operate properly Acceptable methods include electrical wire or conduit approved for ground service Do not use gas piping as an electrical ground Maximum Furnace Model Number 038D 24A Furnace Input Btuh 38 000 Cabinet Width in Nominal Electrical Supply 115 60 1 Maximum Operating Voltage D I Minimum Operating Voltage E Furnace Amperes e D Fuse or Circuit Breaker Amps m zx o m o o A a 038D 23B 054D 24B 072D 24B 38 000 54 000 72 000 115 60 1 115 60 1 115 60 1 afa D NIN a a ojo ojo ets aya D 2 A D I A o to S a 072D 35C 090D 35C 108D 45D 118D 45D 120D 45D 72 000 90 000 108 000 118 000 120 000 A 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 zx rs nx D D E D I Thermostat Wire Gauge Time delay fuses or circuit breakers are required 2 wire Heati
49. Inducer Blower Options Inducer Assembly Rotation A WARNING Inducer rotation must be completed before the furnace is connected to gas and electric If both utilities have been connected follow the shutdown procedures printed on the furnace label and disconnect the electrical supply A CAUTION It is good practice to label all wires prior to disconnection Wiring errors can cause improper and dangerous operation 1 Disconnect the electrical harness from the inducer assembly 2 Remove the inducer assembly ground wire from the blower deck 3 Remove 3 screws securing the inducer assembly to the header box 4 Rotate the inducer assembly to its new position 5 Secure the inducer assembly to the header box by reinstalling the three screws If the inducer assembly is rotated to the left or right side of the furnace use the extra screw provided in the parts package 6 Remove the cabinet plug from side of furnace and reinstall in hole on opposite side of cabinet 7 Install in line drain assembly and tubing 8 Install all condensate drain lines For 92 1 series refer to Figure 34 Figure 35 Figure 36 Figure 37 or Figure 38 For 95 0 series refer to Figure 39 Figure 40 Figure 41 or Figure 42 9 Reconnect the electrical harness to the inducer assembly 10 Reconnect the inducer assembly ground wire to the blower deck or door 11 Verify operation as detailed on the furnace label Pressure Switch Tubing All upf
50. NFLOW FURNACES SM SERIES Model Number External Static Pressure Inches Water Column TNR 0 3 0 4 0 5 0 6 Btuh i i Rise Rise Rise Rise HIGH 1590 31 1563 32 1538 33 1513 33 1477 34 1430 35 1370 36 1312 38 MED H 1228 41 1207 41 1193 42 1169 43 1157 43 1127 44 1084 46 1037 48 54 000 MED L 1096 46 1079 46 1061 47 1038 48 1010 50 986 51 957 52 919 54 LOW 855 58 825 800 777 753 723 696 665 HIGH 2235 2176 2121 2067 2010 1936 1864 36 1783 37 MED H 2095 2052 2005 1957 1906 35 1852 36 1781 37 1709 39 72 000 MED L 1871 36 1838 36 1797 37 1761 38 1716 39 1667 40 1602 42 1536 43 LOW 1568 43 1552 43 1527 44 1485 45 1457 46 1418 47 1370 49 1343 50 HIGH 2208 38 2150 39 2089 40 2026 41 1959 43 1893 44 1825 46 1738 48 MED H 2065 40 2015 41 1970 42 1910 44 1866 45 1805 46 1737 48 1668 50 90 000 MED L 1802 46 1773 47 1750 48 1703 49 1670 50 1623 51 1556 54 1490 56 LOW 1490 56 1482 56 1464 57 1436 58 1407 59 1380 60 1329 63 1271 HIGH 2358 46 2299 48 2253 48 2191 50 2130 51 2060 53 1990 55 1903 57 SM118D 45D MED H 2176 50 2135 51 210
51. OLD PRESSURE 3 2 3 ORIFICE SIZE 3 MANIFOLD PRESSURE 5 2 3 3 3 3 3 3 3 3 3 3 3 49 49 49 49 48 48 0 3 0 3 0 3 0 3 0 3 0 3 0 3 49 49 49 49 48 45 3 45 45 48 48 2 8 2 8 2 8 2 8 2 8 2 8 ORIFICE SIZE 2 8 MANIFOLD PRESSURE HIGH ALTITUDE DERATION NATURAL GAS WITH LOW HEATING VALUE INPUT BTU 42 ALTITUDE ABOVE SEA LEVEL 0 to 1 999 FT 2 000 to 2 999 FT 3 000 to 3 999 FT 4 000 to 4 999 FT 5 000 to 5 999 FT 6 000 to 6 999 FT 7 000 to 7 999 FT 8 000 to 8 999 FT 9 000 to 9 999 FT 38 000 SC Models 38 000 SD Models 54 000 72 000 90 000 108 000 118 000 120 000 45 51 47 47 47 47 46 45 ORIFICE SIZE 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 5 ORIFICE SIZE 5 MANIFOLD PRESSURE 51 47 47 47 47 46 45 3 5 3 5 3 5 3 5 3 5 3 5 3 5 51 47 47 47 47 46 45 3 4 3 3 3 3 3 3 3 3 3 3 3 4 4 3 45 ORIFICE SIZE 5 ORIFICE SIZE 9 MANIFOLD PRESSURE 51 47 47 47 47 46 45 3 2 3 1 3 1 3 1 3 1 3 1 3 2 51 47 47 47 47 46 45 3 1 2 9 2 9 2 9 2 9 2 9 3 1 4 2 45 ORIFICE SIZE 5 ORIFICE SIZE 2 6 MANIFOLD PRESSURE 4 51 47 47 47 47 46 45 29 2 8 2 8 2 8 2 8 2 8 2 9 48 53 49 49 49 49 48 48 ORIFICE SIZE 48 53 49 49 49 49 48 48 ORIFICE SIZE 48 53 49 49 49 49 48 48 _ ORIFICE SIZE Table 15 High Altitude Deration Natural Gas with LOW Heating Value 3 1 2 9
52. ON 95 0 HORIZONTAL LEFT 1 PIPE OPTION c Rubber a Rubber Option 5 Grommet Option w Grommet 25 26 di HM COMBUSTION Sle E o Go a EN LF X T 1 Ie m ue C y See VIEW Q for 3 See VIEW R for t drain line positions E drain line positions 9 Inline Drain EI Factory Supplied le oe IP See NOTE 3 E JF m gt VIEW Q E A ON VIEW je Inline Drain Sy Factory Supplied See NOTE 2 ETS i Collector Box Drain Collector Box Drain Factory Equipped I Factory Equipped See NOTE 2 See NOTE 2 NOTES 1 See Accessories section page 20 for optional PVC Tee configurations and drainage options 2 Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the cabinet All drain lines must be routed externally from the cabinet 3 Tubing needs to be cut to length and attached during unit installat
53. SD Cabinet Dimensions 34 RIMON EIOS dan in nee 35 Table 6 SC Upflow Horizontal Furnaces 35 Table 7 SL Downflow Furnaces 36 Table 8 SD Upflow Horizontal Furnaces 37 Table 9 SM Downflow Furnaces 38 argen EE proa E 39 Figure 33 Wiring Diagram 39 PMOL ON 40 Table 10 Gas Flow Rates ur 40 Table 11 Gas Pipe 40 Table 12 High Altitude Deration Propane Gas 41 Table 13 Natural Gas Heating Values 41 Table 14 High Altitude Deration Natural Gas with HIGH Heating Value 42 Table 15 High Altitude Deration Natural Gas with LOW Heating Value 42 venting IMAMAN a 43 Table 16 Vent Termination Clearances 43 SC amp SL Series 92 1 AFUE Figure 34 Horizontal amp Vertical Venting 44 Figure 35 Venting Options for Upflow Installations SC Series 45 Figure 36 Venting Options for 1 Pipe Horizontal Installations SC Series 46 Figure 37 Venting Options for 2 Pipe Horizontal Installations SC Series 47 Figure 38 Venting Options for Downflow Installations SL Series
54. Single Stage Condensing Gas Furnaces INSTALLATION INSTRUCTIONS 92 1 amp 95 0 AFUE D A amm Jw ODA SY SC Upflow Horizontal SL amp SM Downflow Model Models SD Upflow Horizontal Models WARNING FIRE OR EXPLOSION HAZARD Failuretofollow safety warnings exactly could result in serious injury or property damage Installation and service must be performed by aqualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department AVERTISSEMENT RISQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourrait entrainer des blessures graves la mort ou des dommages mat riels L installation et l entretien doivent tre effectu s par un installateur qualifi un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables dans le voisinage de
55. Use an adequate amount of Teflon tape on the threads Do not use liquid sealants 5 Verify all connections and joints for tight fit and proper alignment with other vent pipes Optional PVC Pipe Installation When running the 2 PVC pipe out through the top of the SD upflow furnace there may be possible clearance issues when transitioning the PVC pipe from 2 to 3 If the size of the PVC flue needs to be increased from 2 to 3 two 2 x 45 PVC elbows may be used to achieve the clearances needed between the coil box and the 2 x 3 coupling See Figure 22 page 22 Install the 2 x 3 coupling in the vertical run only If the couplingis installed horizontally it will allow water to build up inside the furnace and cause a lock out condition To avoid the clearance issue it is recommended that the furnace be vented through the left side or the right side of the cabinet Condensate Drain Lines Ifthe furnace is installed in an area where temperatures fall below freezing special precautions must be made for insulating condensate drain lines that drain to the outdoors If condensate freezes in the lines this will cause improper operation or damage to the furnace It is recommended that all drain lines on the outside of the residence be wrapped with an industry approved insulation or material allowed by local code The placement of the condensate drain lines will depend on the configuration selected in Table 4
56. Ve Figure 13 SC038 23A Pressure Switch 1 Shut off any electrical power to the furnace 2 Label and disconnect the tubing and wires from the pressure switch 1 3 Remove two screws 2 securing the pressure switch 1 to the side of the furnace 4 Remove two 1 4 black plugs 3 on the opposite side of the cabinet that the pressure switch will be relocated to 5 Position the pressure switch 1 in its new location and secure it in place using the same screws 2 removed in step 2 6 Insert the plugs 3 into the holes on the side that the pressure switch 1 was removed from 7 Reconnect the tubing and wiring to the pressure switch 1 being careful that they will not fall into the burner box A CAUTION Itis extremely importantthatall wires and tubes be correctly reattached to the pressure switch s Failure to do so will result in malfunction or compromised safety functions of the furnace 8 Check the furnace for proper operation as directed in Startup and Adjustments section If the furnace shuts down during the pre purge the switch that measures pressure in the header needs to be checked for correct tubing connections Downflow Furnaces N WARNING The furnace must not be installed directly on carpeting or any combustible material other than wood flooring N WARNING Failure to install downflow sub base kit may resultin fire property damage or pe
57. Vent 2 pipe system is used the combustion air intake and the vent exhaust must be located in the same atmospheric pressure zone This means both pipes must exit the building through the same portion of exterior wall or roof as shown in Figure 34 page 44 or Figure 39 page 49 Piping mustbe mechanically supported sothat its weight does not bear on the furnace Pipe supports must be installed a minimum of every five feet along the vent run to ensure no displacement after installation Supports may be at shorter intervals if necessary to ensure that there are no sagging sections that can trap condensate It is recommended to install couplings along the vent pipe on either side of the exterior wall Figure 34 or Figure 39 These couplings may be required by local code If breakable connections are required inthe combustion air inlet pipe if present and exhaust vent piping then straight neoprene couplings for 2 or 3 piping with hose clamps can be used These couplings can be ordered through your local furnace distributor To install a coupling Slide the rubber coupling over the end of the pipe that is attached to the furnace and secure it with one of the hose clamps 2 Slide the other end of the rubber coupling onto the other pipe from the vent 3 Secure the coupling with the second hose clamp ensuring that the connection is tight and leak free Outdoor Terminations Horizontal Venting Vent and combustion air i
58. as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Close fireplace dampers Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner 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 Afterithas been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplac
59. cate a temperature rise outside of the recommended range Table 7 SL Downflow Furnaces 36 Model Number amp Heating Input Btuh SD038D 24B Bottom Return 38 000 SD038D 24B Side Return 38 000 SD054D 24B Bottom Return 54 000 MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR SD SERIES UPFLOW HORIZONTAL FURNACES External Static Pressure Inches Water Column 0 3 0 4 0 5 0 6 CFM CFM CFM Rise CFM Rise SD054D 24B Side Return 54 000 SD072D 35C Bottom Return 72 000 SD072D 35C Side Return 72 000 SD72D 35C Side Bottom or 2 Sides 72 000 SDO90D 35C Bottom Return 90 000 SDO90D 35C Side Return 90 000 SD90D 35C Side Bottom or 2 Sides 90 000 Table 8 SD Upflow Horizontal Furnaces 37 MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR UPFLOW HORIZONTAL FURNACES SD SERIES Model Number External Static Pressure Inches Water Column amp Heating Input o os os oe Btuh SD108D 45D Bottom Return 108 000 SD108D 45D Side Return 108 000 SD120D 45D Bottom Return 120 000 SD120D 45D Side Return 120 000 Table 8 Continued MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR DOW
60. ctrical power to the furnace 3 Follow the Operating Instructions on the label attached to the furnace 4 Set the thermostat above room temperature and verify the Operating Sequence page 31 5 After 5 minutes of operation set the thermostat below room temperature and verify steps 9 10 ofthe Operating Sequence Verifying amp Adjusting Input Rate The input rate must be verified for each installation to prevent over firing of the furnace NOTE The input rate 30 must not exceedthe rate shown on the furnace rating plate At altitudes above 2 000 feet it must not exceed that on the rating plate less 4 for each 1 000 feet To determine the exact input rate perform the following procedures 1 Shut off all other gas fired appliances 2 Start the furnace and run it for at least 3 minutes 3 Measure the time in seconds required for the gas meter to complete one revolution 4 Convert the time per revolution to cubic feet of gas per hour using Table 10 page 40 5 Multiply the gas flow rate in cubic ft per hr by the heating value of the gas in Btu per cubic ft to obtain the input rate in Btuh See the example below Example Time for 1 revolution of a gas meter with a 1 cubic ft dial 40 seconds From Table 10 read 90 cubic ft gas per hr Local heating value of the gas obtained from gas supplier 1 040 Btu per cubic ft Input rate 1 040 x 90 93 600 Btuh The manifold pressure must be
61. d clogs Is evaporator coil clean andfree of debris If applicable Areallthe LED s onthe furnace control board constantly ON not refer to Table 17 or the wiring diagram Figure 33 page 39 to determine fault condition ftheInducerBloweris operating and items above have been verified check the Blower Limit Switch and reset if necessary See Figure 43 page 54 or Figure 44 page 55 for component location fthe furnace operates when the Blower Limit Switch is reset contact a qualified service technician to identify and repair the problem f the furnace still doesn t operate check the Flame Roll out Switches and reset if necessary f the furnace operates when the Flame Rollout Switch is reset contacta qualified service technician to identify and repair the problem Green LED Red LED Control Fault No Power Off Off L1 Neutral Polarity Fault Flash Flash Alternating Flash Diagnostic Description 1 Hour Lockout Normal Operation On Flash Pressure Switch Closed Fault Pressure Switch Open Fault Open Limit Switch Fault Diagnostic Description Low Flame Sensor Signal Yellow LED Continuous Flash Flame Present On Table 17 Control Board Fault Conditions FURNACE COMPONENTS The descriptions below are various functional components that affect the operation and shutting down of this furnace Some of these components and their locations are shown in Figure 43
62. d der aux travaux d entretein Au moment de l entretien des commandes tiqueteztous les fils avant de les d brancher S assurer de les raccorder correctement S assurer que l appareil fonctionne ad quatement apr s l entretien 32 These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance Always reinstall the doors on the furnace after servicing or cleaning changing the filters Do not operate the furnace without all doors and covers in place Verify the thermostat is properly installed and will not be affected by drafts or heatfrom lamps or other appliances To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed At a minimum this check should include the following items Air Filter s Air filter s are not supplied with the furnace as shipped from the factory The installer must provide a high velocity filter that is appropriately sized to the return air duct opening or external filter rack A WARNING Never operate the furnace without a filter in place Dust and lint can build up on internal components resulting in loss of efficiency equipment damage and possible fire It is recommended that filter s be 1 or 2 thick and be cleaned or replaced monthly New or newly renovated homes may require more frequent chang
63. e If suspending the furnace from the ceiling assemble a support frame Figure 12 using slotted iron channel and full threaded rod Fasten the frame together with nuts washers andlockwashers Secure the supportframe to the rafters with lag bolts The furnace can also be suspended using steel straps around each end of the furnace The straps should be attached to the furnace with sheet metal screws and to the rafters with bolts It is recommended for further reduction of fire hazard that cement board or sheet metal be placed between the furnace and the combustible floor and extend 12 inches beyond the front of the door and top of the furnace Two pipe installation shown Flue pipe vented to outside Wood or M e non combustible XY platform Combustion Air Condensate Drain Lines Figure 12 SC Horizontally Suspended in Attic Special Instructions for 8C038 23A Furnaces Ifinstalling an SCO38 23A furnace horizontally with airflow going from left to right the pressure switch will need to be moved to the side of the furnace that is not facing the ground See Figure 13 page 17 Moving the switch will make it easier to replace in the future
64. e Entry Right Side Entry SD SERIES See Note B Left Side Entry Right Side Entry 1 Automatic Gas Valve w manual shut off 2 Burner Assembly 3 Dripleg 4 Elbow 5 Ground Joint Union 6 Manifold 7 Pipe Nipple 8 Plug 9 Shut Off Valve NOTE A Consult local codes for Shut Off Valve location requirements NOTE B Inducer assembly omitted for clarity of pipe installation Figure 25 Typical Gas Connections Upflow Models 25 26 SL SERIES See Note B Right Side Entry SM SERIES See Note A 9 gt See Note B Right Side Entry 1 Automatic Gas Valve w manual shut off 2 Burner Assembly 3 Dripleg 4 Elbow 5 Ground Joint Union 6 Manifold 7 Pipe Nipple 8 Plug 9 Shut Off Valve NOTE A Consult local codes for Shut Off Valve location requirements NOTE B Inducer a
65. e dampers and any other gas fired burning appliance to their previous conditions of use RISQUE D EMPOISONNEMENT AU MONOXYDE DE CARBONED Le non respect des consignes suivantes portant sur chacun des appareils raccord s au syst me d vacuation mis en service pourrait entra ner l empoisennement au monoxyde de carbone ou la mort Les consignes suivantes doivent tre observ es pour chaque appareil raccord au systeme d vacuation mis en service si les autres appareils raccord s au syst me ne sont pas service 1 Sceller toute ouverture non utilis e de la syst me d vacuation S assurerquelasyst me d vacuation pr sente des dimensions etune pente horizontale conformes la norme ANSI Z223 1 NFPA 54 intitul e National Fuel Gas Code ou aux codes d installation CSA B149 1 ainsiqu aux pr sentes instructions S assurer que la syst me d vacuation n est pas bloqu e restreinte corrod e qu elle ne fuit pas et qu elle ne pr sente aucun autre d faut potentiellement dangereux Danslamesure du possible fermertoutes les portes et fen tres du b timent et toutes les portes entre la piece o se trouve l appareil raccord la syst me d vacuation et les autres pieces du b timent Fermer les registres des foyers Mettreenserviceles s cheuses et tout autre appareil qui n est pas a la syst me d vacuation Faire fonctionner a r gime maximal tout ventilateur d vacua
66. e l entretien des commandes tiqueteztous les fils avant de les d brancher S assurer de les raccorder correctement S assurer que l appareil fonctionne ad quatement apr s l entretien Electrical connections must be in compliance with all applicable local codes with the current revision of the National Electric Code ANSI NFPA 70 For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes IMPORTANT NOTE If replacing any of the original wires supplied with the furnace the replacement wire must be copper wiring and have a temperature rating of at least 105 F 40 C For electrical specifications refer to the furnace nameplate or Table 5 page 28 27 Line Voltage Wiring It is recommended that the line voltage 115 to the furnace be supplied from a dedicated branch circuit containing the correctfuse or circuit breakerforthe furnace as listed in Table 17 IMPORTANT NOTES An electrical disconnect must be installed readily accessible from and located within sight of the furnace See Figure 27 page 28 or the wiring diagram label inside of the control door Any other wiring methods must be acceptable to authority having jurisdiction Proper line voltage polarity must be maintained in order for the control system to operate correctly Verify the incoming neutral line is connected to the white wire and the incoming
67. e to comply may resultin improper operation leading to damage to the furnaces or personal injury 1 Turn off all power to both furnaces 2 Attach a wire between the two twin terminals on the twinning control boards Use field supplied wire and two 3 16 wire terminals NOTE One furnace can be used for one stage of heating and the other furnace can be used for the second stage of heating The installer also has the choice of running one furnace only or both furnaces In both cases the blowers will run at the same time and at the same speeds Single stage heating The W connection on each furnace must be connected together and then connected to the W connection of the thermostat This will allow both furnaces to ignite at the same time for one stage heating Two stage heating The W connection on one furnace must be connected to the W1 connection of the thermostat The W connection of the second furnace must be connected to the W2 connection of the thermostat This will allow one furnace to ignite for one stage of heating and the second furnace to ignite for the second stage of heating 3 Refer to Figure 29 for the remaining thermostat connections The C connection must be made between the twinned furnaces to ensure proper performance 29 THERMOSTAT WG Y R 985 FURNACE 1 FURNACE 2 Expansion FURNACE BOARD
68. ee VIEW J for Rubber a See VIEW K for drain line positions Grommet drain line positions 4 HEC i X omg M See p OPTION Flange OPTION Z NOTES 13 14 Y COMBUSTION AIR t NU coweusrioN AIR gt 1 7 T Plug 3 DE e s 8 7 7 U Grommel ot Plug Figure 37 Venting Options for 2 Pipe Horizontal Installations SC Series 47 4 92 1 DOWNFLOW 1 PIPE OPTIONS a COMBUSTION m COMBUSTION AIR y nm Plug Plug i m Y n i a 5 16 See t X NOTE 5 A pvc 8 5 1 307 D i See E LJ NX NOTES LD b o XL e Rubber Grommet PVC U Rubber Grommet See VIEW M for drain line positions See VIEW N for drain line positions VIEW M 7 Drain Line Attached p to PVC Trap Field Supplied em ok Inline Drain p nline Drain 1 Factory Supplied Factory Supplied T See NOTE 4 Ez e Ve Collector Box Drain pee Factory Equipped Inline Drain Collector Box Drain See NOTE2 Field Supplied Factory
69. eed the lengths noted in Table 1 For Canadian installations please refer to the Canadian Installation Code CAN CGA B149 1 or 2 and or local codes For extremely cold climates or for conditions of short furnace cycles i e set back thermostat conditions the last 18 inches of vent pipe can be reduced It is acceptable to reduce from 3 to 2 1 2 3 to 2 or 2 to 1 1 2 if the total vent length is at least 15 feet in length and the vent length is within the parameters specified in Table 1 page 11 The restriction should be counted as 3 equivalent feet Smaller vent pipes are less susceptible to freezing but must not be excessively restrictive The length of the 2 inch pipe must not be longer than 18 inches If furnace is installed horiziontally make sure the drainage port on the in line drain assembly is pointed downward to ensure proper drainage of condensate For 92 1 series see Figure 36 page 46 amp Figure 37 page 47 For 95 0 series see Figure 41 page 51 To prevent debris or creatures from entering the combustion system a protective screen may be installed over the combustion air intake opening The screens hole size must be large enough to prevent air restriction 13 Winter Design Temperature Maximum Flue Pipe Length FEET in Unconditioned amp Exterior Spaces Without Insulation With Insulation o 4 70 __ 2 o 20 ___ _ __ NOTE Insulation thickness g
70. er amp Heating Input Btuh SCO038D 23A Bottom Return 38 000 Motor Speed High Med High Med Low Low Airflow Data MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR SC SERIES UPFLOW HORIZONTAL FURNACES 01 EM ne CPI or ne GE mie SC038D 23A Side Return 38 000 SC054D 24B Bottom Return 54 000 High Med High Med Low Low High Med High Med Low Low SC054D 24B Side Return 54 000 SC072D 24B Bottom Return 72 000 High Med High Med Low Low High Med High Med Low Low SC072D 24B Side Return 72 000 SC072D 35C Bottom Return 72 000 High Med High Med Low Low High Med High Med Low Low SC072D 35C Side Return 72 000 High Med High Med Low Low SC072D 35C Side Bottom or 2 Sides 72 000 SC090D 35C Bottom Return 90 000 High Med High Med Low Low High Med High Med Low Low SCO90D 35C Side Return 90 000 SC090D 35C Side Bottom or 2 Sides 90 000 High Med High Med Low Low High Med High Med Low Low Table 6 SC Upflow Horizontal Furnaces 35 MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR SC SERIES UPFLOW HORIZONTAL FURNACES Model Number External Static Pressure Inches Water Column amp Heatin
71. es 7 14 for venting guidelines and specifications Upflow Furnaces A WARNING The furnace must not be installed directly on carpeting tile or any combustible material other than wood flooring SC amp SD series gas furnaces are shipped with the bottom panel installed as shown in Figure 32 page 34 If the furnace is installed with side return air the bottom panel must not be removed If the furnace is installed with bottom return air the bottom panel must be removed See Bottom Panel Removal on page 22 Horizontal Furnaces WARNING The furnace must not be installed directly on carpeting tile or any combustible material other than wood flooring SC amp SD series gas furnaces can be installed horizontally Figure 11 in an attic basement crawl space or alcove It can also be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow as shown in Figure 12 These furnaces are shipped with the bottom panel installed If the furnace is installed horizontally remove the bottom panel from the furnace before attaching the duct system See Bottom Panel Removal on page 22 If installing the furnace in an attic it is required that a drip pan be placed under the furnace If the installation is on a combustible platform as shown in Figure 11 it is recommended that the drip pan extend least 12 inches past the top and front of the furnac
72. flange on top of the flange gasket NOTE Make sure the flange is properly oriented so that the FRONT lettering is located near the front of the furnace as shown in Figure 19 3 Secure flange and gasket to cabinet with three field supplied sheet metal screws 20 FRONT lettering must be located near front Finish Flange of furnace Flange Gasket Hole for Flue Vent Pipe Hole for Inlet Air Vent Pipe Figure 19 Finish Flange Rubber Grommets The 2 1 4 rubber grommet is used to seal the opening between the furnace cabinet and the 2 PVC vent pipe The rubber grommet should be installed in the 3 hole prior to running the vent pipe out of cabinet No sealants are required See Figure 20 The 7 8 rubber grommet is used to seal the opening between the furnace cabinet and the gas pipe The rubber grommet should be installed in the 1 5 8 hole prior to running the gas pipe into the cabinet No sealants are required The 3 4 rubber grommet is used if venting out the left side of the cabinet and the drain tube is routed through the blower deck Remove the plastic plug from the hole and install the grommet before routing the drain tube 2 1 4 Rubber Grommet see note lt 7 8 Rubber 1l Grommet Figure 20 Rubber Grommets Grommet PVC Components IMPORTANT NOTES Before permanently installing these components it is recommended you dry fit them first to ensure proper fit
73. g Input Btuh ind SC108D 45D jum Bottom only Med High or 2 openings Med Low 108 000 Low High SC108D 45D Side Return Med Flgh 108 000 Med Low Low A SC120D 45D High Bottom only Med High or 2 openings Med Low 120 000 Low High SC120D 45D Side Return Med higks 120 000 Med Low Low NOTES Factory Set Cooling Speed Factory Set Heating Speed 1 Two openings are recommended for airflows above 1 600 CFM if filter s is are adjacent to furnace 2 Temperature rises in the table are approximate Actual temperature rises may vary 3 Cells shaded in gray indicate a temperature rise outside of the recommended range Table 6 Continued MAXIMUM AIRFLOW amp TEMPERATURE RISES F FOR SL SERIES DOWNFLOW GAS FURNACES Model Number External Static Pressure Inches Water Column amp Heating Input oe os a _ en eru wee sra see sra ne era mee er mee eru me em we ru ve HIGH SL054D 24B MED HIGH 54 000 MED LOW LOW HIGH SLO72D 24B MED HIGH 72 000 MED LOW LOW HIGH SLO90D 35C MED HIGH 90 000 MED LOW LOW HIGH SL120D 45D MED HIGH 120 000 MED LOW LOW NOTES Factory Set Cooling Speed Factory Set Heating Speed 1 Temperature rises in the table are approximate Actual temperature rises may vary 2 Cells shaded in gray indi
74. ge Plenums amp Air Ducts Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems NFPA No 90A or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems NFPA No 90B Table 6 page 35 Table 7 page 36 Table 8 page 37 and Table 9 page 38 contain the maximum airflow and temperature rise data for each furnace input rate If the maximum airflow is 1 600 CFM or it is recommended that two openings be used for return air on upflow furnaces Downflow furnaces can only use one return opening It is recommended that the outlet duct contain a removable access panel The opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger The cover for the opening shall be attached in a way that prevent leaks If outside air is used as return air to the furnace for ventilation or to improve indoor air quality the system must be designed so that the return air is not less than 60 F 15 C during operation If a combination of indoor and outdoor air is used the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal indoor return air applications When a cooling system is installed which uses
75. housing 4 Remove the pressure switch from the mounts on the inducer housing and relocate it to the other set of mounts 90 from previous location 5 Secure the pressure switch with two screws 6 Reconnect the tubes and wires to the pressure switch og PE DDUDDDDD ALTERNATE LOCATION PRIMARY LOCATION Figure 18 Alternate Pressure Switch Location Accessories The components below are included in the extra parts bag that is supplied with the purchase of your furnace Depending on your particular installation some of these components are optional and may not be used Please refer to the descriptions and accompanying figures when installing these items NOTE Some parts may not be supplied with each furnace Refer to the literature in the extra parts bag for the parts included witht he particular furnace Finish Flange The finish flange must be installed to vent the combustion air pipe through the top of the furnace NOTE For proper installation it is important that the pipe and screw holes in the finish flanges gasket and cabinet are aligned See Figure 19 1 Position flange gasket over hole in the furnace cabinet 2 Position finish
76. ing until the construction dust has minimized Filters designed to remove smaller particles such as pollen may require additional maintenance Filters for side return and bottom return applications are available from most local distributors Blower Compartment Dirt and lint can create excessive loads onthe motor resulting in higher than normal operating temperatures and shortened service life Itis recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection Cleaning of Burners If the burners must be cleaned follow steps 1 12 See Figure 43 page 54 or Figure 44 page 55 for component location 1 Shut off gas supply to the furnace at the meter or at a manual valve in the supply piping 2 Turn off all power to the furnace and set the thermostat to it s lowest setting 3 Remove the burner door from the furnace 4 Turn the gas control switch to the OFF position 5 Disconnect the wires from the gas valve igniter flame sensor and flame rollout switch A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening ortightening nuts Do not over tighten 6 Using two wrenches separate the ground joint union in the gas supply piping at the furnace 7 the piping between the Gas Valve and the ground joint union If applicable 8
77. inside wall DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical appliances Refertothethermostat manufacturer s instruction sheet for detailed mounting information The six pin terminal marked Expansion Port Figure 28 is not used in the single stage furnace as shipped from the factory It is used for the furnace control board to communicate to a fixed speed or variable speed high efficiency motorthat may be optionally installed Please contact your distributor for the proper upgrade motor kit Heat Anticipator Set the heat anticipator according to the instructions supplied by the thermostat manufacturer To determine the heat anticipator setting 1 Add the current draw of the system components or 2 Measure the current flow on the thermostat R W circuit after the circulating blower motor has started A C CONDENSING UNIT CONDENSING UNIT CONTROL BOX EXPANSION PORT MOTOR CONNECTION ROOM SPEED THERMOSTAT STATUS pi 1 RED d GREEN FLAME TH L vELLOW Connect For Heating Only 2 o lt o BLOWER NOTE The Y terminal OFF on the control board must be connected to the thermostat for proper cooling mode operation 610 DO ao Gl DO
78. ion 95 096 HORIZONTAL RIGHT 2 PIPE OPTION 95 0 HORIZONTAL LEFT 2 PIPE OPTION Option gue qee Option 27 2 2 28 LL LL E AIR L Flange SE el din Flange 1 m s 1 JO d s d 21 COMBUSTION AIR N a See VIEW Q for See VIEW R for drain line positions Plug drain line positions Plug Figure 41 Venting Options for Horizontal Installations SD Series 51 95 0 DOWNFLOW 1 PIPE OPTIONS 4 COMBUSTION Rubber COMBUSTION AIR Grommet COMBUSTION Gi AIR r u X 4 6 u Option 8 4 5 See 30 B NOTE 5 Es a 1 lt PVC Tee 5 j 2 gt D oa Y See PVC Trap Lp 5 Rubber PVC Tee Grommet 3 PVC Trap Rubber Grommet
79. ion the method by which the air is brought to the space and by the total input rate of all appliances in the space In all cases the minimum dimension of any combustion air Vent or opening is 3 inches Chimney Ventilation Louvers each end of attic Air From Inside If combustion air is taken from the heated space the two openings must each have a free area of atleast one square Kir NOTE Air openings shall inch per 1 000 Btuh of total input of all appliances in the Water each have a free area of confined space but not less than 100 square inches of TR on Heater not less than one square inch 4 000 Btuh of the free area See example and Figure 2 total input rating of equipment in the enclosure Outlet Alternate Inlet Air Air Inlet Example If the combined input rate of all appliances is less than or equal to 100 000 Btuh each opening must have a free area of at least 100 square inches If the combined input rate of all appliances is 120 000 Btuh each opening must have a free area of at least 120 square inches Figure 3 Combustion Air Drawn from a Crawl Space or Vented Attic pet Ventilation Louvers For Unheated Crawl Space Ventilation Louvers at each end of attic Air Duct must be at least 1 sq in per 4 000 Btuh of Attic i i insulation total input rating
80. ional for the minimum clearances to combustible materials NOTE The furnace is listed for installation on combustible or non combustible flooring However wood is the only combustible flooring allowed forinstallation Downflow models must use the appropriate subase kit when installing over a wood floor To obtain model number and specific clearance information refer to the furnace rating plate located inside of the furnace cabinet Access for positioning and servicing the unit must be considered when locating unit The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements Allow 24 inches minimum clearance from the front of the unit However 36 inches is strongly recommended See Figure 1 for minimum clearance requirements CLEARANCES TO COMBUSTIBLE MATERIALS UPFLOW DOWNFLOW APPLICATIONS APPLICATIONS HORIZONTAL APPLICATIONS F SIDE Y 4 x LEFT SIDE RIGHT SIDE Allow 24 in minimum clearance for servicing Recommended clearance is 36 in Figure 1 Minimum Clearances to Combustible Materials Operation of Furnace During Construction CAUTION Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the furnace and or result in other unsafe conditions It is the responsibility of the installing contractor to insure these provisi
81. ions Inline Drain 2 Drain lines must be trapped with a J Trap or field supplied loop Traps may be positioned inside or outside the Field Supplied cabinet All drain lines must be routed externally from the cabinet See NOTES 2 amp 3 3 Inline drain is required only if X is greater than 6 feet 4 Tubing needs to be cut to length and attached during unit installation 5 Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trap 92 1 UPFLOW 2 PIPE OPTIONS lt lt 2 2 o a 8 Rubber amp z Q Q Grommet Flange PVC 9 ange 7 Y 1 Plug Y a T E ii 1 pe i See Fr 4 2 NOTES a gt d a 43 See Q CLASS r NOTES P AM Rubber Grommet c OPTION 4 OPTION 5 9 Rubber El D od AL PVC Grommet J 1 See VIEW for drain line positions See VIEW B for drain line positions See VIEW C for drain line positions Figure 35 Venting Options for Upflow Installations SC Series 45 92 1 HORIZONTAL RIGHT 1 PIPE OPTIONS
82. irect Vent 2 pipe or Conventional 1 pipe appliance Direct Vent appliances draw combustion air from the outdoors and vent combustion products back outside Installation with air taken from around the furnace is often referred to as Conventional installation i e only the vent exhaust pipe is provided Another important consideration when selecting one or two pipe installation is the quality of the Indoor air which can sometimes be contaminated with various household chemicals These chemicals can cause severe corrosion in the furnace combustion system A 2 pipe installation has the additional advantage that it isolates the system from the effects of negative pressure in the house A CAUTION Exhaust fans clothes dryers fireplaces and other appliances that force air from the house to the outdoors can create a negative pressure inside the house resulting in improper furnace operation orunsafe conditions such as flame roll out It is imperative that sufficient air exchange with the outdoors is provided to prevent depressurization Additional information about howto test for negative pressure problems can be found in the NFGC Air openings on top of the furnace and openings in closet doors or walls must never be restricted If the furnace is operated without adequate air for combustion the flame roll out switch will open turning off the gas supply to the burners This safety device is a manually reset switch DO NOT install jumpe
83. lbow both ends OMBUSTION AIR s See Table 2 for 2 PVC pipe lengths field supplied FLUE PIPE Figure 39 Horizontal amp Vertical Venting PVC Tee F PVC Trap 49 95 0 UPFLOW 1 PIPE OPTIONS COMBUSTION COMBUSTION AIR AIR ax moe a ac L See d B 5 ui X il 4 PVC Tee a 2 a e 7 ek gd See D C lt PVC Trap NOTE 5 m PVC Tee ubber 2 LH Grommet 7 21 PVC Trap Rubber S rs Grommet Sa See VIEW for drain line positions See VIEW P for drain line positions VIEW P Drain Line Attached to PVC Trap Field Supplied Inline Drain Tube m Factory Supplied __ 4 e ollector Box Drain Factory Equipped 2 See NOTES 2 amp 3 Inline Drain Tube Field Supplied Collector Box
84. les joints utiliser plut t une solution savonneuse commerciale fabriqu e sp cifiquement pur la d tection des fuites de gaz Un incendie ou une explosion peut entrainer des dommages mat riels des blessures ou la mort After the gas piping to the furnace is complete all connections must be tested for gas leaks This includes pipe connections at the main gas valve emergency shutoff valve and flexible gas connectors if applicable The soap and water solution can be applied on each joint or union using a small paintbrush If any bubbling is observed the connection is not sealed adequately and must be retightened Repeat the tightening and soap check process until bubbling ceases IMPORTANT NOTE When pressuretesting gas supply lines at pressures greater than 1 2 psig 14 inch W C the gas supply piping system must be disconnected from the furnace to prevent damage to the gas control valve If the test pressure is less than or equal to 1 2 psig 14 inch W C close the manual shut off valve High Altitude Application Natural Gas Only High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas Installation of this furnace at altitudes above 2 000 feet shall be in accordance with local codes or in the absence of local codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 or National Standard of Canada Natural Gas amp Propane Installation Code CGA B149 1 Please consult your
85. local code authority A WARNING Thereduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices Do not attemptto drill out orifices in the field Improperly drilled orifices may cause fire explosion carbon monoxide poisoning personal injury or death The furnaces are shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes At 2 000 feet the NFGC requires that this appliance be derated 4 for each 1 000 feet of altitude 24 For example the input needs to be reduced 8 at 2 000 feet 12 at 3 000 feet etc This deration is in reference to the input rate and gas heating value at sea level To derate the furnace requires knowing the heating value of the gas at the installation site Heating values at particular job sites vary for two reasons 1 The chemical mixture of the gas varies across regions and is expressed as the sea level heating value 2 The heating value varies by altitude For this reason especially in high altitude areas the local gas utility specifies the heating value atthe residence s gas meter as the local value For added flexibility two tables have been provided for natural gas installations with high or low heating values at sea level Table 14 amp Table 15 page 42 contain the manifold pressure and orifice sizes to use at various altitudes Table 14 HIGH is for nat
86. low horizontal furnaces have two switches one connected to the static tap on the inducer assembly and the other to the collector box Figure 15 page 19 amp Figure 16 page 19 display the proper routing of pressure switch tubing for SC amp SD furnaces Downflow SL amp SM furnaces require only one switch connected to the inducer s static tap as shown in Figure 17 page 19 Alternate Pressure Switch Location In some inducer orientations the inducer pressure switch may interfere with gas pipe installation Determine the side of the cabinet the gas pipe will enter and see if the inducer pressure switch needsto be moved Ifthe pressure switch interferes with the gas pipe use these instructions for relocating it to an alternate location Figure 15 Pressure Switch Tubing for 50038 Furnaces Only Figure 16 Pressure Switch Tubing for Upflow Furnaces Models SC054 SC072 SC090 SC108 amp SC120 Models 50054 SD072 50090 SD108 amp SD120 Figure 17 Pressure Switch Tubing for Downflow Furnaces Models SL054 SL072 SL090 amp SL120 Models 5 054 SM072 SM090 amp SM118 19 1 Shut off any electrical power to the furnace 2 Label and disconnect the tubing and wires from the pressure switch Figure 18 3 Remove two screws securing the pressure switch to the inducer
87. ly if X is greater than 6 feet Tubing needs to be cut to length and attached during unit installation Horizontal piping from inducer to flue pipe must be sloped 1 4 per foot to ensure drainage to PVC trap 92 1 HORIZONTAL LEFT 1 PIPE OPTIONS 1 EN Plug See VIEW F for Rubber T See VIEW G for i drain line positions Grommet 2 drain line positions LL E T 1 ow a a OPTION OPTION 9 10 OMBUSTION COMBUSTION AIR AIR Plug gt __ Plug Figure 36 Venting Options for 1 Pipe Horizontal Installations SC Series 92 1 HORIZONTAL RIGHT 2 PIPE OPTIONS t 0 Rubber X See VIEW for t Grommet See VIEW for Plug 2 drain line positions drain line positions 5 See 7 NOTE 5 Plug 1 COMBUSTION AIR COMBUSTION AIR OPTION
88. mitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 the following statement shall be included Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturers installation instructions Table 16 Vent Termination Clearances 43 SC amp SL Series 92 1 AFUE HORIZONTAL VENTING w 2 Pipes Upflow Furnace Shown Straps or other suitable supports at minimum 5 ft intervals both pipes First support as close to furnace as possible 90 Elbows rH FLUE PIPE gt Rubber Grommet i COMBUSTION AIR VENT PIPE upward 1 clamps optional See Table 2 for 2 PVC pipe lengths field supplied VERTICAL VENTING w 2 Pipes Upflow Furnace Shown Rubber Grommet FLUE PIPE gt i COMBUSTION AIR Support system on vertical rise Coupling with 2 hose 4 clamps optional E 44 CLE Q 1 8 naa LE 9 SES Te LS c cen eee cl 5
89. n without calling for heat or cooling the 31 indoor fan is energized on the selected FAN speed If a call for cooling occurs during continuous fan the blower will switch over to the selected COOL speed ftheWterminalreceives callforheat during continuous fan the blower will de energize A call for fan is ignored while in lockout MAINTENANCE Proper maintenance is most importantto achieve the best performance from a furnace Follow these instructions for years of safe trouble free operation A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failureto follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace Whenservicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUE DE CHOC LECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourraitentrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Un entretein incorrect pourrait entrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Couper toute alimentation lectrique au g n rateur d air chaud avant de pro
90. n increase the pressure drop in the duct system Care mustbe taken to maintain the proper maximum pressure rise across the furnace temperature rise and flow rate This may mean increasing the duct size and or reducing the blower speed These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards Consult with local codes for special requirements For best sound performance install all the needed gaskets and grommets around penetrations into the furnace such as for electrical wiring 15 FURNACE INSTALLATION SC amp SD series gas furnaces offer a wide range of installation options including installation in the upflow or horizontal positions with either right left or upflow return air SL amp SM series gas furnaces may only be installed as a downflow application General Requirements The furnace must leveled at installation and attached to a properly installed duct system See Figure 1 page 6 for the required clearances needed to move the furnace to its installation point hallways doorways stairs etc The furnace must be installed so that all electrical components are protected from water The furnace must be installed upstream from a refrigeration system If applicable The cabinet plug must always be used to close the hole in the side of the furnace when rotating the inducer The furnace requires special venting materials and installation procedures See pag
91. ng Recommended Thermostat Wire Length 4 or 5 wire Cooling Table 5 Wire Length amp Voltage Specifications Field Supplied Fused Service Panel Field Supplied Disconnect w in Sight of Furnace Junction Box may be int or ext to the furnace These connections can be made in the field supplied disconnect at the furnace NOTE Connections made within the furnace burner compartment do not require a junction box Black Hot White Neutral Green or Bare Ground Ground Ground Ground Field Line Voltage Wiring Factory Line Voltage Wiring Field Supplied Panel Connector Figure 27 Line Voltage Field Wiring 28 Thermostat Low Voltage Connections The furnace is designed to be controlled by 24 thermostat The thermostat s wiring must comply with the current provisions of the NEC ANSI NFPA 70 and with applicable local codes having jurisdiction The thermostat must be installed according to the instructions supplied by the thermostat manufacturer Low voltage connections 24 VAC from the thermostat are wired to the terminal strip on the integrated control in the furnace Figure 28 contains the proper connections for heating only two wire and heating cooling four wire applications Recommended minimum wire gauge for thermostat wiring is shown in Table 5 page 28 The thermostat should be mounted about 5 feet above the floor on an
92. notice or incurring obligations 01 14 E 709367A Replaces 7093670
93. ntake terminations shall be installed as shown in Figure 7 amp Figure 8 and in accordance with these instructions Venttermination clearances must be consistent with the NFGC ANSI 2223 1 NFPA 54 and or the CSA B149 1 Natural Gas and Propane Installation Code Table 16 page 43 lists the necessary distances from the vent termination to windows and building air intakes Vent and combustion air intake terminations must be located to ensure proper furnace operation and conformance to applicable codes A vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet This does not apply to the combustion air inlet of a direct vent two pipe appliance In Canada CSA B149 1 takes precedence over these instructions See Table 16 page 43 All minimum clearances must be maintained to protect building materials from degradation by flue gases ee Figure 8 77 ing A Mout wal wi So secure both pipes LT nt paust vent _ EX ption UJ 8 Max air inlet aximu 12 fo ow level expert pipes Figure 7 Inlet amp Exhaust Pipe Clearances Mechanical draft vent terminal NOTES 1 All dimensions shown are minimum requirements 2 Exterior vent terminations must Direct vent be located at least 12 above the terminal more maximum expected snow level than 50 000 Btuh Figure 8 Vent Locations For optimal performance vent the
94. o o L The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes Always consult with local authorities before installing any gas appliance Combustion amp Ventilation Air US National Fuel Gas Code NFGC Air for Combustion and Ventilation CANADA Natural Gas and Propane Installation Codes NSCNGPIC Venting Systems and Air Supply for Appliances Duct Systems USand CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE Fundamentals Handbook Electrical Connections US National Electrical Code NEC ANSI NFPA 70 CANADXA Canadian Electrical Code CSA C22 1 Gas Piping amp Gas Pipe Pressure Testing US NFGC and National Plumbing Codes CANADA NSCNGPIC General Installation US Current edition of the NFGC and the NFPA 90B For copies contactthe National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or American Gas Association 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 Toronto Ontario M9W 1R3 Canada Safety US NFGC NFPA54 1999 ANSI 2223 1 andthe Installation Standards Warm Air Heating and Air Conditioning S
95. o the top drain of the collector This drain must not sag in the middle Options 2 5 7 11 15 16 18 19 21 23 25 27 29 30 32 amp 33 Bottom Panel Removal The steps listed below describe how to remove the bottom panel from the furnace See Figure 23 1 Remove the door 1 from the blower compartment 2 Disconnect the blower motor wiring harness 2 from the control board 3 Remove two screws 3 securing the blower assembly 4 to the furnace 22 4 Carefully pull the blower assembly 4 out thru the front of the furnace 5 Remove all screws 5 securing bottom panel 6 to bottom of furnace and front brace 7 6 Lift up and slide bottom panel 6 out through front of furnace 7 Reinstall the blower assembly 4 in reverse order Figure 23 Bottom Panel Removal Alternate Bottom Panel Removal If the bottom panel cannot be removed using the previous instructions the steps below are an alternate method for removing the bottom panel See Figure 24 1 Remove the door 1 from the blower compartment 2 Remove all screws securing the bottom panel 2 to the front brace 3 3 Remove two screws 4 securing the furnace cabinet to the blower deck 5 4 Remove all screws 6 securing the furnace cabinet to the bottom panel 2 5 Remove the screw 7 securing the bottom corner of the furnace cabinet to the front brace 3 6 Carefully spread the bottom corner of the furnace cabinet outwards
96. ons are met Operating gas furnaces in construction environments can cause a variety of problems with the furnace Proper use of commercial portable space heating equipment during construction is recommended This gas furnace may be used during construction if it is not in violation of any applicable codes and the following criteria are met The installation must meet all applicable codes The furnace must be permanently installed according to the instructions supplied with the furnace including electrical supply gas supply duct work and venting The furnace must be controlled by a thermostat properly installed according to the instructions supplied with the furnace andthermostat The installation must include a properly installed filter in the return air system with no by pass air Thefilter mustbe inspected frequently and replaced when necessary Combustion air must be supplied from outside the structure and located such that dust and gases from construction activity are not introduced into the combustion system Provisions must be made to insure that condensate does not freeze in the furnace or condensate drain lines during operation and during idle times for example overnight if turned off Before occupying the structure The filter must be replaced or cleaned the duct work must be inspected and cleaned of any construction debris and the furnace must be cleaned and or repaired if found to be dirty damaged or malfunctioning in
97. ous conditions including carbon monoxide poisoning that could result in personal injury or death Lubrication The bearings in the blower motor and inducer blower used in these furnaces are pre lubricated and sealed by the manufacturer No further oiling of the bearings is required for the life of the motor FIGURES amp TABLES SL amp SM Downflow Furnaces Model s Dim B Dim C 054D 24B 15 7 8 072D 24B 072D 35C 090D 35C 118D 45D 120D 45D 17 1 2 21 19 3 8 24 1 2 22 7 8 NOTE Dimensions shown in inches 16 1 8 19 5 8 23 1 8 lt 28 2 3 4 TOP VIEW BOTTOM VIEW C Front Brace 18 1 2 Combustion Air 4 7 1 2 T stat 7 8 lt 22 1 4 gt 25 1 2 gt 22 1 2 Electric O 7 8 Gas 8 1 5 8 Vent pipe 8 Cond 1 1 16 17 1 4 LEFT SIDE gt 10 1 4 lt FRONT VIEW Electric 7 8 Gas 1 5 8 i 17 1 4 IN o 25 Vent pipe 3 lt 22 1 2 gt 25 3 8 gt Cond 1 1 16 lt 17 7 16 gt 29 1 2 Figure 31 SL amp SM Cabinet Dimensions RIGHT SIDE 33 34 SC Upflow Horizontal Furnaces Modelf s Dim A Dim B Dim C 038D 23A 14 1 4
98. overs varnishes etc Hydrochloric Acid Cements and glues Antistatic fabric softeners Masonry acid washing materials Heating Load Thisfurnace should be sizedto provide the design heating load requirement Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the furnace could cause the furnace and or vent to fail prematurely The ductwork should be appropriately sizedto the capacity of the furnace to ensure its proper airflow rating For installations above 2 000 ft the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude Installation in Garage A WARNING Do not place combustible material on or against the furnace cabinet or within 6 inches of the vent pipe Do not place combustible materials including gasoline or any other flammable vapors and liquids in the vicinity of the furnace This gas fired furnace may be installed in a residential garage with the provision that the burners and igniter are located no less than 18 inches 457mm above the floor The furnace must be located or protected to prevent physical damage by vehicles Clearances to Combustible Materials This furnace is Design Certified in the U S and Canada by CSA Internat
99. page 18 21 2 x 3 PVC Coupling Coil Box 2 x 45 PVC Elbow 2 PVC Pipe C Figure 22 Optional PVC Pipe Installation The drain lines can be routed out the left or right side of the furnace but must maintain a downward slope to ensure proper condensate drainage The J trap may need to be rotated to the side that matches your setup For 92 1 series see Figure 36 page 46 amp Figure 37 page 47 For 95 0 series see Figure 41 page 51 To rotate the J trap loosen the clamp on the drain tube rotate the J trap to either side and retighten the clamp Three general principles apply Each condensate drain mustbetrapped separately using aJ Traporfield supplied loop After individually trapping the condensate lines it is acceptable to combine the drains There must always be a drain attached to the collector at the outlet of the secondary heat exchanger There must always be a drain at the lowest point of the venting system NOTE If using a condensate pump the furnace drain line must be installed above the pumps water line Exceptions amp clarifications to the general rules If the vent exits the furnace horizontally the vent may be turned vertically with a tee The drip leg formed by the tee must include a drain Options 2 3 5 6 8 9 12 19 16 17 19 20 21 23 24 31 32 amp 34 In certain cases itis permitted to drain the inducer back int
100. page 54 or Figure 44 page 55 If any component of the furnace must be replaced use only factory authorized replacement parts specified in the Replacement Parts List provided online Condensate Drain Switch The Condensate Drain Switch will shut down the furnace if the condensate drain from the Collector Pan becomes clogged Blower Limit Switch Prevents operation when blower is not operational Flame Sensor Verifies when a flame has carried over from the igniter to the opposite end burner If no flame is detected the furnace will shut down within 4 seconds Flame Roll Out Switch Verifies that the burner flames are drawn into the heat exchanger tubes If the burner flames are not properly drawn into the heat exchanger the flame roll out switch will close the gas valve and initiate the shutdown cycle Gas Valve Controls the flow of gas to the burners When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold Inducer Assembly Vents products of combustion to the outside Pressure Switches Verifies that the inducer is drawing the combustion gases through the heat exchanger The pressure switch prevents furnace operation with excessive flue condensate blockage or improper inducer operation Supply Air Limit Switch Prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature 53 54 Finish Flange Igniter Flame Roll Out Burner Senso
101. r Switch Assembly L Gas Manifold Ep 4 Control Board Main Air Limit Switch Gas Valve Vent Limit Switch et jet Pressure Switch Condensate Inducer Assembly e s B C 8 D cabinets only Pressure Switch 1 4 Transformer Inducer Blower Door Switch Blower Assembly SC Series Upflow Horizontal Furnace Finish Flange Flame Roll Out Burner Sensor Switch Assembly ET Igniter Main Air Limit Switch i a Gas Valve Inducer Limit Switch Pressure Switch z A Inducer e 1 ES Pressure Switch Inducer Assembly 29 SAP fa Condensate Blower Door Switch X ts lt Blower Assembly SD Series Upflow Horizontal Furnace Figure 43 SC amp SD Component Locations Blower Finish Assembly Flange Control Board Blower Door Switch behind blower panel Vent Limit Switch Inducer Assembly Pressure Switch Pa Gas Manifold Igniter Burner Roll Out Flame Assembly Switch Sensor SL
102. r wires across these switches to defeat their function or reset a switch without identifying and correcting the fault condition If a Switch must be replaced use only the correct sized part specified in the Replacement Parts List provided online Direct Vent Furnaces Direct Vent 2 pipe furnaces draw combustion air directly from the outdoors and then vent the combustion products back outside isolating the entire system from the indoor space Itis important to make sure that the whole system is sealed and clearances to combustibles are maintained regardless of the installation being in a confined or unconfined space Conventional Vent Systems Confined Spaces A confined space is an area with volume less than 50 cubic feet per 1 000 Btuh of the combined input rates of all appliances drawing combustion air from that space Furnace closets small equipment rooms and garages are confined spaces Furnaces installed in a confined space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace Ducts must havecross sectional areaatleastas large asthe free area of their respective openings to the furnace space Attics or crawl spaces must connect freely with the outdoors if they are the source of air for combustion and ventilation The required sizing of these openings is determined by whether inside or outside air is used to support combust
103. reater than 3 8 inch based on an R value of 3 5 ft x F x hr BTU x in Table 2 Vent Protection Existing Installations When an existing furnace is removed from a vent system serving other appliances the existing vent system may not be sized properly to vent the remaining appliances For example water heater An improperly sized venting system result in the formation of condensate leakage or spillage The existing vent system should be checked to make sure it is in compliance with NFGC and must be brought into compliance before installing the furnace NOTE If replacing an existing furnace it is possible you will encounter an existing plastic venting system that is subjectto a Consumer Product Safety Commission recall The pipes involved in the recall are High Temperature Plastic Vent HTPV If your venting system contains these pipes DO NOT reuse this venting system This recall does not apply to other plastic vent pipes such as white PVC or CPVC Check for details on the CPSC website or call their toll free number 800 758 3688 Condensate Disposal The method for disposing of condensate varies according to local codes Consult your local code or authority having jurisdiction Neutralizer kit P N 902377 is available for use with this furnace Please follow the instructions provided with the kit This furnace has multiple options for positioning the vent pipe as described in the Vent and Inducer Assembly Options
104. rol energizes the Hot Surface Igniter HSI output for the appropriate warm up time limit 6 The control energizes the main gas valve for 3 seconds 7 If the flame proved and ignites the gas the control de energizes the HSI The gas valve and inducer remains energized The control goes to blower on delay 8 If flame is present the control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened The gas valve and inducer remain energized 9 When the thermostat demand for heat is satisfied the control de energizes the gas valve The Inducer output remains on for a 30 second post purge period 10 Blower off timing begins when the thermostat is satisfied The control will operate at the selected HEAT speed of 60 90 120 or 180 seconds If the blower off delay jumper is not present the fan should still operate for 120 seconds at the selected HEAT speed The Indoor blower motor is de energized after a blower off delay as selected by the movable jumper Cooling Cycle 1 The thermostat calls for cooling by energizing the terminal with 24VAC 2 The control energizes the blower in cooling speed and sends 24VAC to the contactor in the condensing unit 3 When the thermostat removes the call for cooling the contactor in the outdoor condensing unitis de energized and the control continues to run the fan for a period of 60 seconds Fan Mode When the thermostat energizes the terminal for continuous fa
105. rsonal injury Toinstall an SL amp SM series gas furnace on combustible flooring a special sub base is required Downflow sub base kits are factory supplied accessories and are listed according to the cabinet letter of the furnace For B and D size cabinets use Kit 904911 Please follow the instructions provided with the kit A downflow sub base kit is not necessary if the furnace is installed on a factory or site built cased air conditioning coil However the plenum attached to the coil casing must be installed so that its surfaces are at least 1 from combustible construction Installation on a Concrete Slab 1 Create an opening in the floor according to the dimensions in Table 3 2 Position the plenum and the furnace as shown in Figure 14 Opening in concrete floor 4 Model 054D 24B 072D 24B 072D 35C 090D 35C 118D 45D 120D 45D Dim Dim NOTE Dimensions shown in Inches Table 3 Cutout Dimensions Concrete Floor Furnace L 1 Sheet Metal Plenum Figure 14 Furnace on a Concrete Slab Inducer amp Venting Options Toincreaseinstallationflexibility the inducer assembly can be rotated up to 3 different positions Each variation has slightly different requirements with regard to condensate disposal and in some cases the need to seal the furnace cabinet IMPORTANT NOTE The Inducer Assembly mu
106. s furnace Refer to the furnace rating plate Install this furnace only in a location and position as specified on page 6 Provide adequate combustion and ventilation air to the furnace space as specified on pages 7 10 Provide adequate clearances around the vent air intake terminal as shown in Figure 7 Figure 8 Figure 9 amp Figure 10 pages 12 13 Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified on pages 7 10 Never test for gas leaks with an open flame Use a commercially available soap solution to check all connections See pages 23 amp 24 i This furnace is designed to operate with a maximum external pressure rise of 0 5 inches of water column Consult Table 6 Table 7 Table 8 amp Table 9 pages 35 38 and the rating plate for the proper circulating air flow and temperature rise Itis important thatthe duct system be designed to provide the correct flow rates and external pressure rise An improperly designed duct system can result in nuisance shutdowns and comfort or noise issues When 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 in the conditioned space See pages 14 25 A gas fired furnace for installation in a residential garage must be installed as specified on page 6 This furnace may be
107. ssembly omitted for clarity of pipe installation Figure 26 Typical Gas Connections Downflow Models Converting from Natural Gas to LP Propane WARNING The furnace was shipped from the factory equipped to operate on natural gas Conversion to LP Propane gas must be performed by qualified service personnel using a factory supplied conversion kit Failure to use the proper conversion kit can causefire explosion property damage carbon monoxide poisoning personal injury or death Conversion to LP Propane is detailed in the installation instructions provided with the conversion kit Generally this will require the replacement of the burner orifices and the spring found under the cap screw on the pressure regulator Approved conversion kits are listed below Installations in the United States For Propane LP conversion orfor LP gas installations in altitudes between 2 000 ft and 10 000 ft above sea level use the LP amp High Altitude LP Gas Conversion Kit P N 904914 for Installations in the United States Please follow the instructions provided with the kit Installations in Canada For Propane LP conversion or for LP Gas installations in altitudes between zero and 4 500 ft above sea level use the LP amp High Altitude LP Gas Conversion Kit P N 904915 for Installations in Canada Please follow the instructions provided with the kit If the installation is in the U S and above 2 000 ft refer to Table
108. st never be positioned to vent downwards on horizontal installs Before using Table 4 the number of pipes 1 pipe or2 pipe connected to the furnace must be known Find the proper furnace style upflow horizontal or downflow and then the side that the pipes will exit from the furnace Finally select the option that properly matches your installation type For 92 196 series Figure 34 Figure 35 Figure 36 Figure 37 or Figure 38 For 95 096 series see Figure 39 Figure 40 Figure 41 or Figure 42 NOTE It is important that Direct Vent 2 pipe systems maintain an airtight flow path from the air inlet to the flue gas outlet The furnace ships from the factory with two holes in the cabinet for the air inlet and flue gas outlet In certain configurations it is necessary to remove and relocate a plastic plug in the furnace cabinet If changing the position of the air inlet and flue gas outlet itis required thatthe previous hole be closed off with the plastic plug to maintain airtightness in the furnace The hole locations for all furnace series are shown in Figure 31 and Figure 32 92 1 Conventional 1 Pipe kn i e Direction Right Left Option 15 Option 16 Option 17 92 1 Direct Vent 2 pipe itn om cud Direction Right Left Option 18 Option 19 Option 20 95 0 Conventional 1 Pipe Horizontal Direction Right Left 95 0 Direct Vent 2 pipe em gr rm nn Direction Right Left Table 4 Vent amp
109. t conform to ASTM Standard D2564 for PVC and Standard D2235 for ABS PVC primer must meet standard ASTM F656 When joining PVC piping to ABS use PVC solvent cement See procedure specified in ASTM Standard 03138 In Canada all plastic vent pipes and fittings including any cement cleaners or primers must be certified as a system to ULC S636 However this requirement does not apply to the finish flanges or piping internal to the furnace Materials Standards SCHEDULE 40 D1785 T D2665 SDR 21 amp 26 D2241 ABS DWV ee d E 02661 SCHEDULE 40 F628 FOAM CELLULAR CORE PVC F891 SINGLE VENT PIPE LENGTH FT with 1 long radius elbow FURNACE MODELS BTU 38 000 Upflow Upflow 54 000 FURNACE INSTALLATION OUTLET 2 Diameter Upflow 90 000 108 000 Upflow Upflow 120 000 0 0 0 0 0 5 7 7 Upflow 5 72 000 5 N A N A Vent Pipe Length amp Diameter In order for the furnace to operate properly the combustion air and vent piping must not be excessively restrictive The venting system should be designed to have the minimum number of elbows or turns Transition to the final vent diameter should be done as close to the furnace outlet as practical Always use the same size or a larger pipe for combustion
110. tdoor Air Using Horizontal Ducts When the openings can freely exchange air with the If combustion airis taken from outdoors through horizontal outdoors each opening shall have a minimum free area ducts the openings and ducts must have a minimum free of 1 square inch per 4 000 Btuh of total appliance input area of one square inch per 2 000 Btuh of total appliance The openings shall exchange directly or by ducts with input Ducts must have cross sectional area at least as the outdoor spaces crawl or attic that freely exchange large as the free area of their respective openings to the with the outdoors Figure 3 furnace space See Figure 5 page 10 Outdoor Air Using Vertical Ducts Air Directly Through An Exterior Wall If combustion air is taken from outdoors through vertical If combustion air is provided directly through an exterior ducts the openings and ducts must have a minimum free wall the two openings must each have free area of at area of one square inch per 4 000 Btuh of total appliance least one square inch per 4 000 Btuh of total appliance input Figure 4 input See Figure 6 page 10 K Vent or Chimney Air Duct E Water Heater Air Ducts must be at least 1 sq in per 2 000 Btuh of total input rating Furnace Air Duct Round Duct Diameter 5 inches 6 inches 7 inches 8 inches 9 inches 10 inches
111. tion carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed Leaks in the flue system can result in serious personal injury or death due to exposure of flue products including carbon monoxide This furnace is classified as a Category IV appliance which requires special venting materials and installation procedures This section specifies installation requirements for Conventional 1 pipe and Direct Vent 2 pipe piping For 1 pipe installations install vent piping as described in this section and provide air for combustion and ventilation according to pages 7 10 The length of vent and combustion air piping for either type of installation are listed in Table 1 page 11 Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed They also produce liquid condensate which is slightly acidic and can cause severe corrosion of ordinary venting materials Furnace operation can be adversely affected by restrictive vent and combustion air piping The inducer assembly on this furnace can be rotated to vent the flue products out of the top left or right side This increases the flexibility of which direction the vent pipe can exit the furnace Vent Pipe Material Vent and combustion air pipe and fittings must be one of the following materials in the list and must conform to the indicated ANSI ASTM standards Cement mus
112. tion from the heat exchanger to avoid false readings 2 Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes before taking any temperature readings The temperature rise is the difference between the supply and return air temperatures For typical duct systems the temperature rise will fall within the limits specified on the rating plate with the blower speed at the factory recommended setting If the measured temperature rise is outside the specified limits it may be necessary to change the speed of the blower NOTE Lowering the blower speed will increase the temperature rise and a higher blower speed will decrease the temperature rise The furnace is equipped with a multi speed motor Heating and cooling speed selection is made by moving the switch on the integrated control located in the furnace Verifying Burner Operation CAUTION The door over the burners may only be open for inspection purposes only The door must be installed during unattended operation 1 Remove the burner compartment door 2 Setthe thermostat above room temperature and observe the ignition sequence NOTE The burner flame should carry over immediately between all burners without lifting off curling or floating The flames should be blue without yellow tips 3 After validating the flame change thermostat setting to below room temperature 4 Verify the burner flame is completely extinguished
113. tion tel que les hottes de cuisini re et les ventilateurs de salles de bains Ne pas mettre en service les ventilateurs d t Respecter les instructions d allumage Mettre en service l appareil l essai R gler le thermostat de mani re ce que l appareil fonctionne sans interruption V rifier s il ya d bordement l orifice d vacuation du coupe tirage des appareils dot s d un coupe tirage 5 minutes apr s l allumage du br leur principal Utiliser la flamme d une allumette ou d une chandelle Si l on constate au cours de l un des essais qui pr cedent que l vacuationest d ficiente corriger le systeme d vacuation conform ment la norm ANSI Z223 1 NFPA 54 National Fuel Gas Code et ou aux codes d installation CSA B149 1 Apres avoir d termin que tous les appareils raccord s la syst me d vacuation vacuent correctement tel que prescrit ci dessus rouvrir les portes et les fen tres et remettre les ventilateurs d vacuation les registres de foyers et tout autre appareil fonctionnant au gaz leur tat de fonctionnement initial Important Information This furnace must be vented in compliance with the current revision of the National Fuel Gas Code ANSI Z223 1 NFPA54 Instructions for determining the adequacy of an installation can be found in the current revision ofthe NFGC ANSIZ223 1 NFPA54 codes for special requirements These requirements
114. tions or install this equipment Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death A WARNING Unless otherwise noted in these instructions only factory authorized kits or accessories may be used with or when modifying this product WARNING Improper installation service adjustment or maintenance may cause explosion fire electrical shock or other hazardous conditions which may result in personal injury or property damage Unless otherwise noted in these instructions only factory authorized kits or accessories may be used with this product WARNING Do not install this furnace if any part has been submerged under water A flood damaged furnace is extremely dangerous Attempts to use the furnace may resultin fire or explosion A qualified service agency should be contacted to inspectthe furnace and to replace any electrical or control system parts that have been wet or under water To minimize equipment failure or personal injury it is essentialthat only qualified individuals install service or maintain this equipment If you do not posses mechanical skills or tools call your local dealer for assistance Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout
115. ural gas installations with a heating value of more than 1 000 Btu per cubic foot and Table 15 LOW is for less than 1 000 Btu per cubic foot To determine which table to use 1 Consult the local utility for the local heating value at your installation site 2 From Table 13 page 41 find your local heating value as supplied by the utility company Follow down the column and stop at your altitude level 3 If your sea level heating value is HIGH use Table 14 or if its LOW use Table 15 See example below Installation Example 5 000 feet Type of Gas Natural Gas From Table 13 find 750 and follow down the column stop at the 5 000 feet row The heating value listed is LOW Table 15 will be used to determine orifice size and manifold pressure After changing the regulator pressure or the orifices it is required that you measure the gas input rate This may be accomplished in the usual way by clocking the gas meter and using the local gas heating value See Verifying and Adjusting the Input Rate section on page 30 IMPORTANT NOTE Observe the action of the burners to make sure there is no yellowing lifting or flashback of the flame SC SERIES See Note A 4 9 A Left Sid
116. used for temporary heating of buildings or structures under construction See the guidelines listed on page 6 This furnace is not approved for installation in mobile homes Installing this furnace in a mobile home could cause fire property damage and or personal injury The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows direct vent appliances mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied a A carbon monoxide CO detector and alarm shall be placed on each floor level where there are bedrooms The detector shall comply with NFPA 720 2005 Edition and be mounted in the living area outside the bedroom s A CO detector shall be located in the room that houses the appliance or equipment and shall Be powered by the same electrical circuit as the appliance or equipment Only one service switch shall power the appliance and the CO detector e Have battery back up power e Meet ANSI UL 2034 Standards and comply with NFPA 720 2005 Edition and Approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR A Product approved vent terminal must be used and if applicable a product approved air intake m
117. ust be used Installation shall be in strict compliance with the manufacturers instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation A metal or plastic identification plate shall be mounted at the exterior of the building four feet directly above the location of vent terminal The plate shall be of sufficient size easily read from a distance of eight feet away and read Gas Vent Directly Below o o 2 direct vent appliances mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied a A CO detector and alarm shall be placed on each floor level where there are bedrooms The detector shall comply with NFPA 720 2005 Edition and be mounted in the living area outside the bedroom s The CO detector shall Belocated in the room that houses the appliance or equipment Be hard wired or battery powered or both Shall comply with 720 2005 Edition A product approved vent terminal must be used andif applicable a product approved air intake must be used Installation shall be in strict compliance with the manufacturers instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation
118. ystems ANSI NFPA 90B CANADA CAN CGA B149 1 and 2 MO00 National Standard of Canada NSCNGPIC Combustion Air Quality CAUTION Combustion air must not be drawn from a corrosive atmosphere To maximize heat exchanger life the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases The recommended source of combustion air is to use outdoor air However the use of indoor air in most applications is acceptable except as listed f the furnace is installed as a single pipe installation in a confined space it is required that the necessary combustion air come from the outdoors by way of attic crawl space air duct or direct opening For Installations in confined spaces see pages 8 10 for combustion air requirements Installations in these locations may require outdoor air for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces installed in hobby or craft rooms Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply may require outdoor air for combustion Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon Tetrachloride Halogen type refrigerants Cleaning solvents perchloroethylene Printing inks paint rem

Kelvinator KG7SD 072D-35C Installation Guide

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