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Browning BR16F Home Safety Product User Manual

1. FURNACE AIR CONDITIONER FURNACE HEADPUME NOTE 11 N HEAT STAGE 2 O W2 W2 RVS COOLING 0 W2 1 _ COOL STAGE 1 Y1 W2 ____________ sao Eee L Y1 W2 HEAT STAGE 1 W W1L 4 WIW1 HEAT COOL STAGE 1 Y1W2 ___________ spo ees ees t 1 V COMPRESSOR LO COOL STAGE 2 L NOTE12 l Y2 HEAT STAGE 3 WWI J J Ww1 1 w1 xi zm FURNACE HEAT COOL STAGE 2 Y Y2 NOTE 12 YN2 Y2 G Lj 6 32 14 ME peegescs COMPRESSOR HI FANI G LJ_ J 6 24 VAC HOT Re bay a UR i R LN 24VACHOT R LJ I R Hd R DEHUMIDIFY DHUML J 4 DHUM DEHUMIDIFY 1 DHUM 24VAC COMM C Com L C EM 24VACCOMM C _________ HUM o HUM p UNE HUMIDIFY HUM LJ HUMIDIFIER 1 HUMIDIFIEER 24 VAC HUMIDIFY HUM J 24 VAC zn N A B NA B OUTDOOR 7 7 OUTDOOR len SENSOR i OUTDOOR a sss SENSOR SENSOR SENSOR CONNECTION COEM CONNECTION Spe notes 2 5 8 10 Land 12 _ See notes 1 2 3 4 6 8 9 10
2. 2 ONRIIM TONINOO ANOLOWS OVASLL ONRIIM 4 31 TOSINOO 82d Q3 VIANT AVE WOO uo 9 TYNIWYAL 9 1531 ININOdNOD INTED CIRCIUT BOARD SdH OVAPZ OVASLL HBIAPIOJSNVMIL YOLOINNOD 1531 OIOV IInOMIO E Nel BM YOLOINNOO ISH WAI NIMLLSAL NMOHS LON 4OLO3NNOO YOLOW WOI LINDUID 9 YOLDINNOD ISH 24 8O193NNOO 80d 2935 JONINOO NOYO 804 HOLMS YOLOW TWNYAINI 13535 1 10 1545 13838 O1NV HOLIMS 219 CO N ISdS HOLIMS 5384 IV3H MO1 E CON ISAS HOLMS 349339 SVO MOT 491 3009 SNIWIS 30010 an XO8 NOIIONnr ar O N ISdS HOLIMS MOO RI3INI TANYA SS3OOV 1045 03345 YOLOW JONAN NOVHI O N ISds JIOd G3GVHS YOLON wal XVIN AV S 0 NOILO3NNOO YIHIAINNH 2VAvZ 1545 Av 133 YALINDI JOWAYNS LOH OVASLL 1 LOH O N 1545 HOLIMS 55389 IV3H H IH ON 185 HOLIMS 38n5S38id IV3H HOIH SdH 1540 AVIA SYO z LuA INVGN0G33 3AWA 9 o ANNOYS IN3 dInO3 Q3TWVISNI
3. FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B c D Upflow Applications on Combustible or Noncombustible a E E Flooring KGASB subbase not required 21 58 1930 16 SESIA Downflow Applications on Noncombustible Flooring KGASB subbase not required 12 9 16 19 13 3 16 19 5 8 14 3 16 Downflow applications on combustible flooring E P KGASB subbase required 11 13 16 19 13 7 16 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box 12 5 16 19 13 5 16 20 KGASB subbase not required Upflow Applications on Combustible or Noncombustible E Flooring KGASB subbase not required 16 21 58 16 58 Pe Es Downflow Applications on Noncombustible Flooring 6 2 e KGASB subbase not required 13 7 8 13 16 12 19 58 17 1 2 Downflow applications on combustible flooring _ KGASB subbase required ue 18 16 3 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box 15 1 2 19 16 1 2 20 KGASB subbase not required Upflow Applications on Combustible or Noncombustible _ 2 Flooring KGASB subbase not required 21598 20 1 8 PR NA Downflow Applications on Noncombustible Flooring E _ KGASB subbase not required 19 3 8 13 a 19 9 8 21 Downflow applications on combustible flooring 2 KGASB subbase required 6 58 19 20 1 4 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly
4. pei2ejes eui oj suni uone1edo jeuuoN HO ASLI H3 LHV NO H3MO 18 eL ueis s Jo yno uiejs s ung peidnuejul At 10 ASLL paseia aq osje sepoo sniejs sinou ZZ Jaye 1 3909 SnOlA 3Hd ON 56 57 2007 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 Printed in U S A Edition Date 02 07 Catalog No 11I312A 45 8 anutacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Replaces 1312 45 7
5. 340 4984 3 HO 35010 LON GIG Av 13H HO HOLIMS 3Hf1SS3Hd IV3H H9IH HOUS 0 spee 1 1uouS 40940 N3dO SI SSNs AHVONOO3S peso 5 uols einssejgd 91155949 X99490 N3dO LON GIG HOLIMS 53 eNe yeaj 10 uedo xonis palea Si unu peziBueue SI 526 panoid IVNO9IS ONIAOHd 3IAV 14 TVINHONSV 0 HOUS 10 04u09 uo se xoniS 40949 0 pue yo 100901 SVO ve smels 995 sinou e eye 1 Ao1d pue 91 pajre 1 68 5 e 19591 II IonuoO g uey uedo s pesn J JUBA JO eure j prenBayes yeup J sunooo yN04907 10901 ponad fejep uo y Buunp suado LAWM H JO LM M H 1209 104 eo e Buunp dn si J Aejap
6. Line chimney with property lined with properly sized listed flexible metal sized listed liner or liner or Type B vent per vent NFGC or NSCNGPIC Vent i Sizing Tables and liner or d coe vent manufacturer s IRICEN Installation instructions Condensate drainage at bottom of chimney Not Suitable Consult Chimney s chimney art o exposed to to be dedicated to 1 outdoors below a single instructions for roof line furnace application suitability Install chimney adapter per instructions Chimney is acceptable for use Fig 35 Chimney Inspection Chart 28 A03206 The Chimney Adapter Kit is a listed alternative venting system for these furnaces See the kit instructions for complete details Canada and U S A This furnace is permitted to be vented into a clay tile lined masonry chimney that is exposed to the outdoors below the roof line provided 1 Vent connector is Type B double wall and 2 This furnace is common vented with at least 1 draft hoodequipped appliance and 3 The combined appliance input rating is less than the maximum capacity given in Table 8 and 4 The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99 Winter Design Temperature Chimneys having internal areas greater than 38 square inches require furnace input rati
7. e e 208 230 2 I VOLT D 9 SINGLE 115 VOLT FIELD JUNCTION Mob JPHASE SUPPLIED BOX t t 9 ND FUSED CONTROL DISCONNECT BOX GH et eee ee 24 VOLT TERMINAL NOTES 1 Connect Y Y2 terminal as shown for proper operation BLOCK 2 Some thermostats require a C terminal connection as shown FURNACE 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A95236 Fig 24 Field Wiring Diagram Piping should be pressure and leak tested in accordance with NFGC in the United States or CAN CSA B149 1 05 in Canada local and national plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 in wo turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF
8. Vent dampers on any appliance connected to the common vent SEE NOTES 1234789 can cause condensation and corrosion in the venting system Do on the page s foll owing not use vent dampers on appliances common vented with this these figures furnace ADDITIONAL VENTING REQUIREMENTS A03209 A 4 in round vent elbow is supplied with the furnace A 5 in or Fig 37 Upflow Application Vent Elbow Right 6 in vent connector may be required for some model furnaces A field supplied 4 in to 5 in or 4 in to 6 in sheet metal increaser fitting is required when 5 in or 6 in vent connector is used See Fig 36 48 Venting Orientation for approved vent configurations See Venting Notes after Fig 48 SEE NOTES 1 2 3 4 5 7 8 9 on the page following SEE NOTES 1 2 4 7 8 9 these figures on the page following these figures A03208 A03210 Fig 36 Upflow Application Vent Elbow Up Fig 38 Downflow Application Vent Elbow Up then Left 30 ho EA SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 39 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these
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10. Fig 24 3 Move J Box to desired location 22 6 Reinstall cover to J Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 26 A WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components A03221 Fig 26 Field Supplied Electrical Box on Furnace Casing 1 Select and remove a hole knockout in the casing where the electrical box is to be installed NOTE Check that duct on side of furnace will not interfere with installed electrical box 2 Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing 3 Fasten the electrical box to casing by driving two fieldsupplied screws from inside electrical box into casing steel 4 Remove and save two screws holding J Box See Fig 25 5 Pull furnace power wires out of 1 2 inch diameter hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electrical box and into electrical box 7 Pull field power wires into electrical box 8 Remove cover from furnace J Box 9 Route field ground wire through holes in elec
11. 19 13 16 13 16 4 13 16 OUTLET 1 2 DIA K O THERMOSTAT WIRE ENTRY 1 3 4 DIA RIGHT HAND GAS ENTRY ET 7 8 DIA WIRE ENTRY ALTERNATE JUNCTION BOX LOCATIONS TYP VENT OUTLET 5 PLACES TYP 7 8 DIA ACCESSORY 5 1 2 11 16 22 1 16 SIDE INLET 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in round or 14 1 2 x 12 in rectangle b For 1200 CFM 20 in round or 14 1 2 x 19 1 2 in rectangle c For 1600 CFM 22 in round or 14 1 2 x 22 in rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM NOTES 1 Two additional 7 8 in diameter holes are located in the top plate A04037 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters For 800 CFM 16 in round or 14 1 2 x 12 in rectangle b For 1200 20 in round or 14 1 2 x 19 1 2 in rectangle For 1600 CFM 22 in round or 14 1 2 x 22 1 rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Produ
12. 90 Elbow g n I I 2 Nipple Street Elbow Gas Valve 02327 Fig 22 Right Side Gas Entry Example 2 Install a sediment trap in riser leading to furnace as shown in Fig 23 Connect a capped nipple into lower end of tee Capped nipple should extend below level of furnace gas controls Place a ground joint union between furnace gas control valve manifold and exterior manual equipment gas shutoff valve GAS T SUPPLY MANUAL CERES SHUTOFF VALVE REQUIRED SEDIMENT ET TRAP UNION A02035 Fig 23 Typical Gas Pipe Arrangement A 1 8 in NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve 20 FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 1 FIVE THERMOSTAT FIELD SUPPLIED WIRE FUSED DISCONNECT THREE WIRE HEATING ONLY _ 9 208 230 OR 1 460 VOLT THREE 1 1 a Io PHASE B ee e BELA leve 1 EN E wal _____ T ae
13. 3 4 SHEET METAL SCREWS 2 SCREWS IN SIDE AND 2 SCREWS IN AIR OPENING A03176 Fig 16 Horizontal Suspension with Straps 14 LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING EQUIPMENT MANUAL SHUT OFF GAS VALVE SEDIMENT TRAP 17 3 4 OVER ALL 4 3 4 UNDER DOOR 1 UNDER FURNACE EXTEND OUT 12 OUT FROM FACE OF DOOR MONK ANEA WHENUSED WITH SINGLE WALL VENT CONNECTIONS A03177 Fig 17 Typical Attic Installation Not all horizontal furnaces are approved for side return air connections See Fig 20 FILTER ARRANGEMENT 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Never operate a furnace without a filter or with filter access door removed There are no provisions for an internal filter rack in these furnaces An external filter rack is required This furnace is shipped with a factory supplied Media Filter Cabinet The Media Filter Cabinet uses either a factory supplied standard 1 inch filter or 4 inch wide Media Filter which can be purchased separately Refer to the instructions supplied with Media Cabinet for assembly and installation options AIR DUCTS General Requirements The duct system should be designed and sized according to accepted national standards suc
14. 1545 High Me 2225 2190 2135 2075 1995 1910 1805 1695 1565 1430 Bottom Only gn 1895 1885 1865 1820 1770 1700 1610 1520 1410 1290 1565 1555 1585 1505 1465 1410 1350 1265 1175 1050 LOW 1820 1295 1265 1285 1205 1160 1105 1035 950 870 Bottom Sidesor 2415 2830 2285 2125 1995 1860 1735 1605 1 Side amp Bottom 2205 2175 2120 2065 1975 1900 1790 1685 1580 1460 2485 2430 2360 2270 2175 2070 1950 1825 1685 1535 High Me 2155 2185 2100 2040 1970 1885 1790 1680 1560 1420 1Side Only gnMe 1830 1830 1810 1780 1730 1665 1595 1505 1395 1275 1520 1505 1490 1470 1430 1385 1330 1250 1165 1055 LOW 1275 1260 1240 1210 1180 1135 1090 1025 930 840 A filter is required for each return air inlet Airflow performance included 1 in washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions 17 Table 5 Air Delivery With Filter Cont FURNACE RETURN AIR BREED EXTERNAL STATIC PRESSURE IN WC SIZE INLET 0 1 0 2 0 3 0 4 0 5 0
15. Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws HORIZONTAL INSTALLATION The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad 4 WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace Suspended Furnace Support The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the furnace from each bottom corner To prevent screws from
16. ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access panel door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 24 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 33 C rise WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2006 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground CAUTION FURNACE MAY NOT OPERATE HAZARD Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else control will lock out Control must remain grounded through green yellow wire routed t
17. If the furnace control CPU switches from low cooling to high cooling the furnace control CPU will energize the air conditioning relay ACR When the air conditioning relay ACR is energized the R to Y1 and Y2 circuits switch the outdoor unit to high cooling speed and the R to G and Y1 and Y Y2 circuits switch the furnace blower motor BLWM to COOL speed NOTE When transitioning from low cooling to high cooling the outdoor unit compressor will shut down for 1 minute while the BLWM continues to run at low cool speed same speed LO HEAT until the outdoor unit compressor comes back on at high speed The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuit are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 34 c Two Stage Thermostat and Two Speed Cooling See Fig 32 for thermostat connections NOTE The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging See Fig 34 The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and
18. Relocating J Box J BOX RELOCATION f ELECTRICAL CONNECTION J BOX NOTE If factory location of J Box is acceptable go to next section ELECTRICAL CONNECTION TO 1 Field Supplied Electrical Box on Furnace J Box Bracket See Fig 26 TE 14 wid i dels the J B hall not b NO on Wide casing models the J Box shall not be 1 Remove cover from furnace J Box relocated to other side of furnace casing when the vent pipe is routed within the casing 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will not pierce wire insulation 1 Remove and save two screws holding J Box See Fig 25 NOTE The J Box cover need notbe removed trom th J Box 3 Route furnace power wires through holes in electrical box in order to move the J Box Do NOT remove green ground and J Box bracket and make field wire connections in screw inside J Box The ground screw is not threaded into the electrical box Use best practices NEC in U S and CSA casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J box outboard of the casing C22 1 in Canada for wire bushings strain relief etc 4 Route and secure field ground wire to green ground screw on J Box bracket 2 Cut wire tie on loop in furnace wires attached to J Box 5 Connect line voltage leads as shown
19. 1 1 4 1 380 1400 950 770 660 580 1 1 2 1 610 2100 1460 1180 990 900 Cubic ft of natural gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 12 2 ANSI Z223 2006 NFPA 54 2006 Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts Refer to Table 6 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage If local codes allow the use of a flexible gas applia
20. 19 3349338 ISNA 2nd Q3TIVISNI ANOLOVS 30V18 IALOWOINY AW 3505 ind 3008931 ONIAONd 3AV I 354 07 1545 13539 MS IDOTIOH3AVH 2199 NOWWOO NOILO3NNOO 5140310313 XW O L OVA SLL NOILO3NNOO YANW3TO 2INOSIO313 Lowa e 1565 3638 O n v HOLMS 3495 Livi ssa NOILO3NNOO wna NIW IS3I YOSSIDOUOYIIN Ndo dvo O N 1545 1353 HOLMS 4 1 IN3A 342018 SSA8 914 34 IOLOI waa vid CO N ISdS NOLO 3MO 18 E eld 1045 AV 03345 OIOV H3MOT8 wlO lH8 zd 104 AV 03395 S3MOT8 NOVIHS Ud YANN 31894 rayoy 1545 01 0103 1 CQ3N GNdS41 g31 Ave IGODSNIWIS Y ZAJA WWM W09 WAHC LA JV3H IH l Rant A Tawar 938 amen ind OVASLL Did SSO qasn NaHW 2 H 9 238 795 3A 1 ed HH lou 0 b ie d 3513 NIMUIS3L a mM SONILL3S
21. 24 WIRING Make field 24 v connections at the 24 v terminal strip See Fig 34 Connect terminal Y Y2 as shown in Fig 27 33 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size 23 THERMIDISTAT TWO STAGE TWO SPEED THERMIDISTAT TWO STAGE TWO SPEED
22. W1 circuit remains closed the furnace control CPU will switch the inducer motor IDM speed from high to low The high heat pressure switch relay HPSR is energized to open the NC contact and de energize the high heat gas valve solenoid GV HI When the inducer motor IDM reduces pressure sufficiently the high heat pressure switch HPS will open The gas valve solenoid GV M will remain energized as long as the low heat pressure switch LPS remains closed The blower motor BLWM will switch to LO HEAT speed five seconds after the R to W2 circuit opens 3 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 28 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 seconds See Fig 25 b Single Stage Thermostat and Two Speed Cooling Adaptive Mode See Fig 33 for thermostat connections This furnace can operate a two speed cooling unit with a single stage thermostat because the furnace con
23. the National Building Code of Canada and must be in good condition U S A Refer to Sections 13 1 9 and 13 2 20 of the NFGC or the authority having jurisdiction to determine whether relining is required If relining is required use a properly sized listed metal liner Type B vent or a listed alternative venting design NOTE See the NFGC 13 1 9 and 13 2 20 regarding alternative venting design and the exception which cover installations such as the Chimney Adapter Kits KGACAO02014FC and KGACAO02015FC which are listed for use with these furnaces 27 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian installation Code CSA B149 1 in Canada Crown condition Missing mortar or brick Rebuild crown Is chimney property lined with clay tile liner Is liner and top seal in good condition Repair liner or top seal or reline chimney as necessary Reline Repair Debris in cleanout Mortar Mortar tile metal vent or tile fuel oil residue debris No Remove metal vent or liner Clay tile misalignment missing sections gaps Consult Part B of chimney adapter venting instructions for application suitability Not Suitable
24. 43 3 5 1 7 and Canada 900 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 43 3 3 1 6 Canada Altitudes 925 44 3 2 1 5 44 3 3 1 6 44 3 5 1 6 44 3 6 1 7 2001 to 950 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 4500 975 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 44 3 2 1 5 1000 46 3 5 1 7 46 3 6 1 7 46 3 8 1 8 45 3 7 1 8 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE rare 0 58 0 60 0 62 0 64 FT BTUH CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 775 43 3 5 1 7 43 3 7 1 7 43 3 8 1 8 42 3 2 1 5 800 43 3 3 1 6 43 3 4 1 6 43 3 5 1 7 43 3 7 1 7 825 44 3 6 1 7 43 3 2 1 5 43 3 3 1 6 43 3 4 1 6 U S A 3001 to 850 44 3 4 1 6 44 3 5 1 7 44 3 6 1 7 43 3 2 1 5 Only 4000 875 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 900 46 3 8 1 8 45 3 8 1 8 44 3 2 1 5 44 3 3 1 6 925 46 3 6 1 7 46 3 7 1 8 45 3 7 1 8 45 3 8 1 8 950 46 3 4 1 6 46 3 5 1 7 46 3 7 1 7 46 3 8 1 8 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE n 0 58 0 60 0 62 0 64 FT BTUH CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 750 43 3 3 1 6 43 3 4 1 6 43 3 5 1 7 43 3 6 1 7 775 44 3 6 1 7 43 3 2 1 5 43 3 3 1 6 43 3 4 1 6 800 44 3 3 1 6 44 3 4 1 6 44 3 6 1 7 43 3 2 1 5 U S A 4001 to 825 45 3 8 1 8 44 3 2 1 5 44 3 4 1 6 44 3 5 1 6 Only 5000 850 46 3 8 1 8 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 875 46 3 5 1 7 46 3 7 1 7 46 3 8 1 8 45 3 7 1
25. 44 3 4 1 5 950 46 3 8 1 6 45 3 7 1 6 45 3 8 1 7 44 3 3 1 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 750 43 3 6 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 775 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 43 3 8 1 6 800 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 U S A 4001 to 825 44 3 4 1 5 44 3 6 1 5 43 3 2 1 4 43 3 3 1 4 Only 5000 850 44 3 2 1 4 44 3 4 1 5 44 3 5 1 5 44 3 6 1 6 875 45 3 7 1 6 45 3 8 1 7 44 3 3 1 4 44 3 4 1 5 900 46 3 7 1 6 46 3 8 1 7 45 3 7 1 6 44 3 2 1 4 925 46 3 5 1 5 46 3 6 1 6 46 3 7 1 6 46 3 8 1 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 725 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 43 3 7 1 6 750 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 775 44 3 4 1 5 44 3 5 1 5 43 3 2 1 4 43 3 3 1 4 U S A 5001 to 800 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 Only 6000 825 46 3 8 1 7 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 850 46 3 6 1 6 46 3 7 1 6 46 3 8 1 7 45 3 8 1 6 875 47 3 8 1 7 46 3 5 1 5 46 3 6 1 6 46 3 7 1 6 900 47 3 6 1 6 47 3 8 1 6 46 3 4 1 5 46 3 5 1 5 Orifice numbers 43 are factory installed 42 Table 15 Orifice Size and Mani
26. 44 3 6 1 6 43 3 2 1 4 43 3 4 1 5 43 3 5 1 5 1075 44 3 4 1 5 44 3 5 1 5 43 3 2 1 4 43 3 3 1 4 1100 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 43 3 2 1 4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 800 42 3 4 1 5 42 3 5 1 5 42 3 6 1 6 42 3 7 1 6 U S A 825 42 3 2 1 4 42 3 3 1 4 42 3 4 1 5 42 3 5 1 5 Altitudes 850 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 U S A one e 875 43 3 5 1 5 43 3 6 1 6 43 3 7 1 6 43 3 8 1 7 and Canada 900 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 Canada attitudes 925 44 3 5 1 5 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 2001 to 950 44 3 4 1 5 44 3 5 1 5 44 3 6 1 6 43 3 2 1 4 4500 975 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 1000 45 3 7 1 6 45 3 8 1 7 44 3 2 1 4 44 3 4 1 5 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 775 42 3 2 1 4 42 3 3 1 4 42 3 4 1 5 42 3 5 1 5 800 43 3 6 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 825 43 3 4 1 5 43 3 5 1 5 43 3 7 1 6 43 3 8 1 6 U S A 3001 to 850 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 43 3 6 1 5 Only 4000 875 44 3 5 1 5 44 3 6 1 6 43 3 3 1 4 43 3 4 1 5 900 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 43 3 2 1 4 925 45 3 8 1 6 44 3 2 1 4 44 3 3 1 5
27. 47 3 6 1 7 750 48 3 5 1 7 48 3 6 1 7 48 3 7 1 8 48 3 8 1 8 775 49 3 8 1 8 48 3 4 1 6 48 3 5 1 7 48 3 6 1 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure 600 46 3 6 1 7 46 3 7 1 8 46 3 8 1 8 45 3 7 1 8 625 47 3 7 1 8 47 3 8 1 8 46 3 5 1 7 46 3 6 1 7 U S A 9001 to 650 47 3 4 1 6 47 3 6 1 7 47 3 7 1 8 47 3 8 1 8 Only 10 000 675 48 3 6 1 7 48 3 8 1 8 47 3 4 1 6 47 3 5 1 7 700 48 3 4 1 6 48 3 5 1 7 48 3 6 1 7 48 3 7 1 8 725 49 3 7 1 8 49 3 8 1 8 48 3 4 1 6 48 3 5 1 7 Orifice numbers 43 are factory installed SERVICE AND MAINTENANCE PROCEDURES WARNING FIRE PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual 45 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before servicing disconnect all electrical power t
28. 6 0 7 0 8 0 9 1 0 Bottom High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835 135 16 pa Med High 1790 1755 1705 1640 1550 1465 1360 1210 945 785 048135 Side s Med Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670 Low 1325 1320 1295 1265 1210 1150 995 865 745 540 High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355 Bottom Med High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255 Only Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040 EOM SEES High 2385 2305 2195 2085 1960 1825 1670 1465 135 22 or Med High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325 066135 4 Side amp Bottom Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040 High 2320 2250 2155 2055 1970 1855 1725 1600 1450 1280 1 Side Only Med High 2125 2065 1995 1910 1815 1710 1610 1490 1340 1175 Med Low 1845 1825 1765 1710 1650 1570 1475 1370 1240 1100 Low 1640 1620 1580 1540 1485 1410 1330 1220 1080 960 High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545 Bottom Only Med High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 Med Low 1
29. 8 900 47 3 8 1 8 46 3 5 1 7 46 3 6 1 7 46 3 7 1 8 925 47 3 6 1 7 47 3 7 1 8 47 3 8 1 8 46 3 5 1 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT ATALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTUH CU FT No Pressure No Pressure No Pressure No Pressure 725 44 3 5 1 7 43 3 2 1 5 43 3 3 1 6 43 3 4 1 6 750 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 775 45 3 7 1 8 44 3 2 1 5 44 3 3 1 6 44 3 4 1 6 U S A 5001 to 800 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 44 3 2 1 5 Only 6000 825 46 3 5 1 7 46 3 6 1 7 46 3 7 1 8 46 3 8 1 8 850 47 3 7 1 8 47 3 8 1 8 46 3 5 1 7 46 3 6 1 7 875 47 3 5 1 7 47 3 6 1 7 47 3 7 1 8 46 3 4 1 6 900 48 3 8 1 8 47 3 4 1 6 47 3 5 1 7 47 3 7 1 7 Orifice numbers 43 are factory installed 44 Table 16 Orifice Size and Manifold Pressure for Gas Input Rate cont Tabulated Data Based on 21 000 Btuh High Heat 14 500 Btuh for Low Heat Per Burner Derated 4 for Each 1000 Ft Above Sea level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT ATALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTUH CU FT No Pressure No Pressure No Pressure No Pressure 675 44 3 5 1
30. Cu FT 2 Cu Fr 5 Cu Fr REVOLUTION 1CuFrT 2 Cu Fr 5 Cu Fr 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 c Adjust air temperature rise by adjusting blower speed a Remove high fire regulator adjustment cap from gas Increase blower speed to reduce temperature rise valve pressure regulator Decrease blower speed to increase temperature rise For b Manually close blower ac
31. Fig 19 Downflow Return Air Configurations and Restrictions RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS SUPPLY AIR RETURN AIR IHH HH 39 IHH 6 SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS 4 HORIZONAL RETURN AIR NOTE RESTRICTION SAME FOR RETURN RESTRICTIONS HORIZONAL LEFT HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS DOWNFLOWRETURNAIRCONFIGURATIONSAND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION 3 ONLY ONLY ONLY RETURN AIR COMBINATIONS OF 1 2 AND3 AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTION3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES NO NO NO 20 MODELS ALL OTHER MODELS YES YES YES YES Fig 20 Horizontal Return Air Configurations and Restrictions 19 A02075 A02163 A02162 Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S and the CAN CSA B149 1 05 in Canada Table 6 Maximum Capacity of Pipe NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE DIAMETER NT IN 10 20 30 40 50 1 2 0 622 175 120 97 82 73 3 4 0 824 360 250 200 170 151 1 1 049 680 465 375 320 285
32. IN WC SIZE INLET 01 02 05 06 08 09 10 gn 1120 1075 1020 960 805 815 720 605 455 340 045 08 Bottom or Hign 990 890 850 805 750 680 600 500 345 195 024045 Side s Med Low 820 785 750 700 650 585 505 400 235 E 725 690 655 605 555 495 405 35 1465 1400 1325 1250 1175 1085 980 860 725 560 ER High Me 1295 1260 1210 1155 1090 1015 930 830 700 545 gnMe 4150 1120 1085 1040 985 920 835 740 620 510 1030 1010 980 945 805 835 765 685 570 345 oe 860 835 810 780 745 700 635 555 445 260 1140 1105 1055 1010 955 885 815 715 545 390 070 081 Bottom or High 915 885 855 825 785 725 655 530 420 200 024070 Side s Med ow 75 770 740 700 655 600 510 420 35 ge 690 665 630 590 550 475 415 340 245 1440 1400 1355 1300 1240 1170 1090 1000 890 745 RT High Me 1180 1165 1150 1125 1085 1030 970 890 785 645 gnMe 4015 1020 1010 990 965 925 875 800 700 560 885 885 880 865 845 815 770 700 605 475 ne 695 700 700 690 670 640 600 540 460 345 ech 1840 1790 1730 1670 1605 1530 1450 1370 1275 1170 Bones High Me 161
33. The hot surface igniter blower motor LO HEAT speed blower motor HI HEAT speed and blower motor COOL speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on When the blower is turned OFF the inducer will be switched to low speed for 10 seconds 11 12 13 14 21 22 23 24 31 LOW HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry ens during blower on delay for Defective inducer motor Low inducer voltage 115 VAC Low inlet gas pressure if LGPS used period blower will come on for the selected blower off delay Excessive wind Restricted vent Proper vent sizing Defective pressure switch Inadequate combustion air supply Disconnected or obstructed pressure tubing LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame rollout or blocked vent switch if used is open Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rollout switch and BVSS require manual reset Check for Dirty filter or restricted duct system Defective blower motor or capacitor Proper vent sizing Restricted vent Defective switch or connections Loose blower wheel Excessive wind Inadequate combustion
34. UP 115 VAC or 24 VAC Blower runs for the selected blower off delay time if unit is powered up during a call for heat R W W1 closed or R W W1 opens during blower on delay LIMIT CIRCUIT LOCKOUT Lockout occurs if a limit draft safeguard flame rollout or blocked vent switch if used is open longer than 3 minutes Control will auto reset after three hours Refer to 33 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring HIGH HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Control relay may be defective refer to status code 32 COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED will flash last status code and then turn ON the inducer motor The inducer motor will start in HIGH speed and remain on HIGH speed until the end of the test then shift to LOW speed for 7 to 15 seconds
35. Y1 circuit starts the furnace blower motor BLWM on low cool speed same speed as LO HEAT The R to Y1 and Y2 circuits start the outdoor unit on high cooling speed and the R to G and Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM 15 operating When the thermostat is satisfied the R to G and Y1 Or R to G and Y1 and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 34 4 Thermidistat Mode See Fig 27 29 for Thermidistat connections The dehumidification output DHUM the Thermidistat should be connected to the furnace control thermostat terminal DHUM When there is a dehumidify demand the DHUM input is activated which means 24 vac signal is removed from the DHUM input terminal In other words the DHUM input logic is reversed The DHUM input is turned ON when no dehumidify demand exists Once 24 vac is detected by the furnace control on the DHUM input the furnace control operates in Thermidistat mode If the DHUM input is low for more than 48 hours the furnace control reverts back to non Thermidistat mode The cooling operation described in item 3 above also applies to operation with a Thermidistat The exceptions are list
36. equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residential construction practices We require these instructions as a minimum for a safe installation CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or dea
37. figures 03207 Fig 40 Downflow Application Vent Elbow Left then Up o SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 Fig 41 Downflow Application Vent Elbow Up then Right NA SEE NOTES 1 2 4 7 8 9 on the page following these figures 03213 Fig 42 Horizontal Left Application Vent Elbow Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures 03214 Fig 43 Horizontal Left Application Vent Elbow Right then Up 31 ER EI IE _ E LL SEE NOTES 1 2 4 7 8 9 on the page following these figures SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03218 A03216 Fig 44 Horizontal Right Application Vent Elbow Right Fig 46 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page SEE NOTES 1 2 4 5 7 8 9 on the page following these figures following these figures A03215 03219 Fig 45 Horizontal Left Application Vent Elbow Up Fig 47 Horizontal Right A
38. installation reliability or operation 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a 2 Install this furnace only in a location and position as specified in the Location section of these instructions 3 Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section 4 Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in the Venting section of these instructions 5 Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate 7 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section 8 A gas fired furnace for installation in a residential garage must b
39. jeay 10 spuozas Seb spuooes jeeu uBiu Kel p uo IeMo g 3344 Jaye OUD uoniuBI 10 s e Jaye 41230 3n020 UOU uonoojes uinuindo 10 uonelle su eas 5 10 suonoejes peads 1030 JeMo g pesn 1 54971 u0joe4 p lle su 1 y 1e3depy 2 SSAg pej2euuoo 1 4 yoojq TYYLNIN 94 suonoeuuoo 3199148939 10 WAI 1oJouu 1 pue NM 18 10 samog 32165 qi snj dwe e juo asejd y y ui jou pue s10jonpuoo pJeoq 99 pos ANNOYS 1N3INaIno3 uogejuesaidei e2unoe e sloquKs eurej A01d o 044405 40 4994 aoetunj pajoeuuoo aq SIL GNNOYS Hiiv3 uonounf y pue YoyIMs j2euuoosip y uaewjeq 1 Ajuo esf MYDS ONIYIM CH 2801 10 as m osn pooejdoi 51 jueuidinbe euibuo jo Aue J 82d 1O3INOO NO SSLON SH 31ON TONINOO C7314 99 OWASLL
40. la tasas Re ack 36 Check Safety Controls 40 Checklist icici cic ker een thus sates ER eb En 41 SERVICE AND MAINTENANCE PROCEDURES 45 Introdutio n l us ee e ERROR eR 46 and Maintenance 46 Sequence of Operation 51 Wiring Diagrams 54 Troubleshooting 54 EFFICIENCY RATING CERTIFIED ama ISO 9001 2000 CERTIFIED REGISTERED NOTE Read the entire instruction manual before starting the installation Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2006 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety 26 1 8 FLUE COLLAR 25 1 4 22 916 JUNCTION BOX LOCATION 7 8 DIA ACCESSORY 1 2 DIA THERMOSTAT WIRE ENTRY 3 15 16 LEFT HAND GAS ENTRY 33 5 16 2 24 7 8 7 8 DIA ACCESSORY AL 1116 5 1 2 21 5 8 1 11 16 BOTTOM INLET 24 CASING NOTES 1 Two additional 7 8 in diameter holes are located in the top plate 276 x AIRFLOW
41. mode when ON see item 2 below or the adaptive heating mode when OFF in response to a call for heat See Fig 34 When the W2 thermostat terminal is energized it will always cause high heat operation when the R to W circuit is closed regardless of the setting of the low heat only switch This furnace can operate as a two stage furnace with a single stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation which selects low heat or high heat operation This selection is based upon the stored history of the length of previous gas heating periods of the single stage thermostat The furnace will start up in either low or high heat If the furnace starts up in low heat the control CPU determines the low heat on time from 0 to 16 minutes which is permitted before switching to high heat If the power is interrupted the stored history is erased and the control CPU will select low heat for up to 16 minutes and then switch to high heat as long as the thermostat continues to call for heat Subsequent selection is based on stored history of the thermostat cycle times The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open and starts the inducer motor IDM in high speed a Inducer Prepurge Period 1 If the furnace control CPU selects low heat op
42. non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multi story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the CAN CSA B149 1 05 local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the requirements defined in the NFGC or the CAN CSA B149 1 05 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Do not bypass the draft safeguard switch as an unsafe condition could exist which must be corrected 1 If a vent common or dedicated becomes blocked the furnace will be shut off by the draft safeguard switch located on the vent elbow 2 Two stage furnaces require Type B vent connectors outside the casing in all configurations Single wall vent connector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing Size the connector so that the FAN Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN Max vent connector capacity is equal to or higher than the furnace high fire rate 3 Do not vent this Category I furnace into a sing
43. number of ACH and shall be determined per Table 3 or Equations 1 and 2 Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space Table 3 Minimum Space Volumes for 100 Combustion Ventilation and Dilution from Indoors OTHER THAN FAN ASSISTED TOTAL FAN ASSISTED TOTAL 1 000s BTUH GAS INPUT RATE 1 000s BTUH GAS INPUT RATE ACH 30 40 50 44 66 88 110 132 154 Space Volume ft 3 0 60 1 050 1 400 1 750 1 100 1 650 2 200 2 750 3 300 3 850 0 50 1 260 1 680 2 100 1 320 1 980 2 640 3 300 3 960 4 620 0 40 1 575 2 100 2 625 1 650 2 475 3 300 4 125 4 950 5 775 0 30 2 100 2 800 3 500 2 200 3 300 4 400 5 500 6 600 7 700 0 20 3 150 4 200 5 250 3 300 4 950 6 600 8 250 9 900 11 550 0 10 6 300 8 400 10 500 6 600 9 900 13 200 16 500 19 800 23 100 0 00 NP NP NP NP NP NP NP NP NP NP Not Permitted Table 3 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 9 3 2 2 J If lother Iran ACH For other than fan assisted appliances such as a draft hood equipped water heater Volume 2113 Other ACH 1000 Btu hr 04002 For fan assisted applicances such as this furnace Volume 158 tn _ Fan ACH 1000 Btu hr 04003 combined input of all other than fan assiste
44. outside this range change main burner orifices i Install low heat regulator adjustment cap j Leave manometer or similar device connected and proceed to Step 4 NOTE If orifice hole appears damaged or it is suspected to have been re drilled check orifice hole with a numbered drill bit of correct size Never re drill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 4 Verify natural gas low heat input rate by clocking meter NOTE valve regulator adjustment caps must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter b Run for 3 minutes in low heat operation c Measure time in sec for gas meter to complete 1 revolution and note reading The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow d Refer to Table 12 for cubic ft of gas per hr e Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain input If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct low heat input is achieved Re install low heat regulator seal cap on gas valve 5 Set low heat temperature rise The furnace must operate within the temperature rise ranges specified on the furnace rating plate Do not exceed temperature rise ranges specified on unit rating plate
45. pulling out use 2 8 x in screw into the side and 2 8 x in screw in the bottom of the furnace casing for each strap See Fig 15 and 16 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment screws are not in tension are loaded in shear for reliable support Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Fig 2 and 17 For furnaces with 1 in clearance requirement on side set furnace on non combustible blocks bricks or angle iron For crawlspace installations if the furnace is not suspended from the floor joists the ground 11 underneath furnace must be level and the furnace set on blocks or bricks Roll Out Protection Provide a minimum 17 3 4 in X 22 in piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 inches to joists The sheet metal MUST extend underneath the furnace casing by 1 in with the door removed The bottom closure panel on furnaces of widths 17 1 2 in and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 17 for proper orientation of roll out shield Bottom Return Air Inlet These furnaces are ship
46. thermostat will shift the continuous blower speed from HI HEAT to COOL Repeating the procedure will shift the continuous blower speed from COOL to LO HEAT speed The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption NOTE If the blower off delay is set to the maximum the adjustable continuous fan feature is locked i e fan speed cannot be changed from its current setting 6 Heat Pump See Fig 28 through 31 for thermostat connections When installed with a heat pump the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles When the W W1 and Y1 or R to W W1 and Y1 and G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at low cool speed same speed as LO HEAT and begin a low heat cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at LO HEAT speed When the W W1 input signal disappears the furnace control begins a normal inducer post purge period and the blower remains running at LO HEAT speed If the R to W W1 and Y1 and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W W1 and Y1 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected b
47. 0 1575 1535 1485 1435 1370 1305 1230 1145 1055 ipu E ghMe 1460 1430 1400 1360 1315 1260 1205 1130 1055 965 12960 1240 1215 1180 1145 110 1040 985 915 835 0 00 1065 1040 1015 985 955 915 875 825 765 695 1650 1600 1535 1465 1385 1285 1175 1055 895 645 090 14 Bottom or High 1815 1485 1440 1380 1300 1220 1115 990 830 600 042090 Side s 1985 1360 1820 1260 1195 1120 1025 915 710 565 DOLO 4205 1180 1160 1120 1065 1005 925 810 630 510 High 2060 2000 1930 1835 1755 1620 1490 1315 1115 910 PT Med 1710 1695 1665 1585 1480 1390 1245 1110 955 775 iens ae High 1470 1475 1450 1390 1335 1230 1120 1005 855 690 Med Low 1260 1365 1245 1225 1165 1090 995 880 750 600 Low _ 1030 1025 1020 990 940 890 810 720 615 500 2880 2205 2205 2105 2005 1900 1775 1650 1510 1335 High Me 2185 2115 2045 1960 1875 1770 1655 1595 1400 1240 Bottom Only 1905 1865 1815 1740 1670 1590 1490 1390 1245 1110 Med tow 1895 1565 1590 1485 1430 1355 1275 1160 1055 920 0 00 1340 1310 1280 1225 1170 1120 1040 955 850 750 veo Bas EIE IE EIE IE n 090 20 Both Side ort High 1g45 181
48. 10 11 and 15 on the page following these figures on the page following these figures 03180 03181 Fig 28 Two Stage Furnace with Single Speed Heat Pump Fig 30 Dual Fuel Thermostat with Two Stage Furnace Dual Fuel and Single Speed Heat Pump 24 DUAL FUEL TWO STAGE TWO SPEED TWO STAGE TWO STAGE TWO SPEED THERMSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE AIR CONDITIONER RVS COOLING O W2 J I s w NOTE11 Two W2 Y oe eco A vues erem J HEAT COOL STAGE 1 Y1 N2 ___________ llb 1 1 L COMPRESSOR LO HEAT STAGE 3 W W1 1 ___________ Pwwi __ _ zl 7 4 4 IWW1 FURNACE LN f HEAT COOL STAGE 2 NOTE 12 vrz l L ej Y2 Y2 NOTE 12 YN2 Y2 COMPRESSOR HI ml pee LE 7 FAN G ________ 24VACHOT R 1 1 ef IR n aaa zl R Ro
49. 12 13 and 15 on the page following these figures on the page following these figures A03179 A03178 Fig 27 Two Stage Furnace with Two Speed Air Fig 29 Two Stage Furnace with Two Speed Heat Pump Conditioner Dual Fuel THERMIDISTAT TWO STAGE SINGLE SPEED FURNACE HEAT PUMP DUAL FUEL TWO STAGE SINGLE SPEED THERMOSTAT FURNACE HEAT PUMP RVS COOLING O W2 41 F HEAT STAGE 3 1 2 __ NOTE 1 wa RVS COOLING OMIA FURNACE HEAT STAGE 3 vuw2 NOTE 11 wa Y1 FURNACE HI HEAT STAGE 2 W W1 _________ __ _____ 1 w2 X T HEAT STAGE 2 J ____________ wa HEAT COOL STAGE 1 YY2 2 L I Y FURNACE LO FA COOL STAGE 1 2 YIY2 Y HEAT J FAN 8 COMPRESSOR L 24VACHOT R _________ 3 RC Love s L I R G p 176 DEHUMIDIFY DHUM ___________ DHUM ANAG HOTI AL BS ops R 24vaccomM C J Com L C DHUM D 24VACCOMM C L eost 1 B HUM LA L HUMIDIFY HUM 1 AN ES RVS SENSING NA B m OUTDOOR 3 A OUTDOOR SENSOR T OUTDOOR LA SENSOR OUTDOOR 4 SENSOR CONNECTION 52 ___________________ ___ _ ____ SENSOR CONNECTION Sev See notes 1 2 4 11 14 15 and 16 zx See notes 1 2 4 6 7 9
50. 312A 2 Stage Deluxe Induced Combustion 4 Way Multipoise Furnace Installation Start up Operating and Service and Maintenance Instructions Series 120 C SAFETY CONSIDERATIONS 2 INTRODUCTION 3 CODES AND STANDARDS 5 Safety esc vad ick dere UHR E ERR usia 5 General Installation 5 Combustion and Ventilation Air 5 DuctSystems isse t mm e ss exa 5 Acoustical Lining and Fibrous Glass Duct 5 Gas Piping and Gas Pipe Pressure Testing 5 Electrical Connections 2 sss asss sasa 5 Venne DRE 5 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE tees EU PETRUS 5 LOCATION net eR Res he RI RE asas 6 AIR FOR COMBUSTION AND VENTILATION 8 INSTALLATION e ke RR rey e 10 UPFLOW INSTALLATION 10 DOWNFLOW INSTALLATION 11 HORIZONTAL INSTALLATION 11 FILTER ARRANGEMENT 15 AIR DUGCIS 15 GAS PIPING ereere titeit p EE a EEEE ES 18 ELECTRICAL CONNECTIONS 21 VENTING iet ete bin eier eiks kei ELE PEE 26 START UP ADJUSTMENT AND SAFETY 35 General esee ne t pt e en tope 35 Start Up Procedures 4 cece ccc ees 35 Adjustments
51. 5 1770 1720 1655 1580 1500 1395 1270 1090 060000 Side amp Bottom adum a 1940 1515 1475 1435 1385 1335 1270 1175 1045 915 eO LOW 1280 1250 1220 1190 115 1105 1035 945 845 745 2420 2345 2265 2165 2070 1960 1850 1720 1570 1420 High Me 2160 2110 2045 1960 1885 1790 1695 1570 1445 1305 1Side Only gnMe 1850 1815 1765 1710 1635 1560 1480 1380 1250 1110 1580 1490 1455 1420 1375 1320 1250 1160 1055 905 U LOW 1290 1250 1220 1190 115 1110 1040 950 835 740 1625 1575 1515 1445 1355 1260 1165 990 785 595 110 12 Bottom or High 1510 1470 1415 1355 1285 1185 1070 890 725 530 036110 Side s Med 1360 1385 1205 1250 1180 1100 985 810 670 475 DOLO 1195 1180 1155 1115 1065 980 860 740 605 410 eg 2055 1990 1910 1815 1695 1575 1425 1280 1090 910 T PTY High 1750 1725 1670 1605 1515 1400 1255 1120 975 785 E E ghMe 1545 1525 1490 1445 1355 1260 1135 1020 880 750 1800 1200 1275 1285 1165 1085 1005 895 750 620 0 00 1050 1045 1015 975 935 880 815 715 610 515 16 110 22 066110 High 2530 2460 2380 2285 2200 2085 1970 1835 1695
52. 6 1 5 46 3 7 1 6 46 3 8 1 6 775 47 3 6 1 6 47 3 8 1 6 46 3 4 1 5 46 3 6 1 5 800 47 3 4 1 5 47 3 5 1 5 47 3 7 1 6 47 3 8 1 6 825 48 3 7 1 6 48 3 8 1 6 47 3 4 1 5 47 3 6 1 5 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 625 44 3 3 1 5 44 8 5 1 5 44 3 6 1 6 43 3 2 1 4 650 45 3 7 1 6 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 675 46 3 6 1 6 46 3 8 1 6 45 3 7 1 6 45 3 8 1 7 y d 8001 t0 700 47 3 8 1 7 46 3 5 1 5 46 3 6 1 6 46 3 7 1 6 nly 9000 725 47 3 6 1 6 47 3 7 1 6 47 3 8 1 7 46 3 5 1 5 750 48 3 8 1 7 47 3 5 1 5 47 3 6 1 6 47 3 7 1 6 775 48 3 6 1 5 48 3 7 1 6 48 3 8 1 7 47 3 5 1 5 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE T ASIDE 0 58 0 60 0 62 0 64 FT BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 600 45 3 7 1 6 45 3 8 1 7 44 3 3 1 4 44 3 4 1 5 625 46 3 6 1 6 46 3 7 1 6 46 3 8 1 7 45 3 8 1 6 U S A 9001 to 650 47 3 8 1 6 46 3 4 1 5 46 3 6 1 5 46 3 7 1 6 Only 10 000 675 47 3 5 1 5 47 3 6 1 6 47 3 7 1 6 46 3 4 1 5 700 48 3 7 1 6 48 3 8 1 7 47 3 5 1 5 47 3 6 1 6 725 48 3 5 1 5 48 3 6 1 6 48 3 7 1 6 48 3 8 1 7 Orifice numbers 43 are factory installed 43 Table 16 Orifice Size and Manifold Pressure for Gas I
53. 6nidun pesn 5491 eunsseud seb seuois eunsseud peJiwstA eqni eunsseid 10 pejoeuuoosiq uedo xonis eunsseid jeeu wo 10 49949 038010 SI HOLIMS gdunssaud IV3H HOIH TIHM N3dO HOLIMS 5 IWAHMO1 SSA ON ponad puosas s ay Jo pue eui s oq avu nb s 159 jueuoduio2 QU pue Y uonoeuuoo 151 jeyuBi eui xoeup 159 ui payesado eq ueo uu ls s eui Josues 10 y 1 OL jou 1snuu Josues 4 jeeus 1 SNWN JJO Inus IenueW Yo pauan seo deis 1xeu y Buipeeooud 152 SW eui xoeuo p lo l s eui 10 uo poued eur 350 awey J sinooo t euojeq eouenbes eui y poled 40 ei ay pesues jou s NOLLIN I AISS 9X3 Burzis JUBA uado
54. 7 43 3 2 1 5 43 3 3 1 6 43 3 4 1 6 700 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 725 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 U S A 6001 to 750 46 3 6 1 7 46 3 8 1 8 45 3 7 1 8 45 3 8 1 8 Only 7000 775 46 3 4 1 6 46 3 5 1 7 46 3 6 1 7 46 3 8 1 8 800 47 3 6 1 7 47 3 8 1 8 46 3 4 1 6 46 3 5 1 7 825 47 3 4 1 6 47 3 5 1 7 47 3 6 1 7 47 3 8 1 8 850 48 3 7 1 7 48 3 8 1 8 47 3 4 1 6 47 3 5 1 7 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 650 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 675 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 700 46 3 6 1 7 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 U S A 7001 to 725 47 3 8 1 8 46 3 5 1 7 46 3 6 1 7 46 3 7 1 8 Only 8000 750 47 3 5 1 7 47 3 7 1 8 47 3 8 1 8 46 3 5 1 6 775 48 3 8 1 8 47 3 4 1 6 47 3 6 1 7 47 3 7 1 7 800 48 3 6 1 7 48 3 7 1 8 48 3 8 1 8 47 3 4 1 6 825 48 3 3 1 6 48 3 5 1 6 48 3 6 1 7 48 3 7 1 8 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 625 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 650 46 3 6 1 7 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 675 47 3 8 1 8 46 3 4 1 6 46 3 5 1 7 46 3 7 1 7 cay pe 700 47 3 5 1 7 47 3 6 1 7 47 3 7 1 8 46 3 4 1 6 725 48 3 7 1 8 48 3 8 1 8 47 3 5 1 7
55. 800 1790 1770 1735 1695 1640 1570 1465 1345 1225 155 20 Low 1570 1565 1550 1525 1495 1445 1370 1270 1175 1070 060155 Both Sides Or 1 High e 2375 2285 2200 2105 1995 1870 1730 1570 Side amp Bottom Med High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400 1 Side Only High 2260 2180 2085 1975 1865 1740 1605 1455 Med High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325 A filter is required for each return air inlet Airflow performance included 1 in washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions NOTE For horizontal applications the top most flange may be bent past 90 to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed Downflow Furnaces Connect supply air duct to supply air outlet on furnace Bend flange inward past 90 with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASBO201ALL a factory ap
56. ASOLOV 935 935 OSL 23S WAH ux Ol 93 V3H YISH NON 13q 44O A INO amoa IHOT 193 13S PRINTED CIRCIUT BOARD L Wal a3sn 5 Sd BASS LL 31ON x ILON yt aasn N3HW 9 933 N3HM HOLMS qas 9 SVD TWYNLLWN 1O3NNOOSIG 9 349389 151 251 OLLVIW3HOS HOLIMS 193NNOOSIQ Q T3IH OVASLL OL YO ISNA aasn 550 OL ILON NOLLO3NNOO 48 CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application NOTE If the filter has an airflow direction arrow the arrow must point towards the blower CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces Media cabinet filter procedures NOTE Media Cabinet is included with two stage furnace Table 17 Filter size information in FURNACE FILTER SIZE CASING Bottom Re FILTER TYPE WID
57. Altitude Derate Multiplier for U S A FIRE HAZARD T ALTITUDE 926 DERATE MULTIPLIER Failure to follow this warning could result in injury death FT OF DERATE FACTOR and or property damage 0 2000 0 100 DO NOT bottom out gas valve regulator adjusting screw 2001 3000 8 12 0 90 This can result in unregulated manifold pressure and result 3001 4000 12 16 0 86 in excess over fire and heat exchanger failures 4001 5000 16 20 0 82 5001 6000 20 24 0 78 6001 7000 24 28 0 74 7001 8000 28 32 0 70 y C AUTION 8001 9000 32 36 0 66 9001 10 000 36 40 0 62 FURNACE DAMAGE HAZARD multiplier factors are based on midpoint altitude for altitude Failure to follow this caution may result in reduced furnace Low NOx models in downflow or horizontal positions MUST life use Table 16 21 000 BTUH per burner See input listed on DO NOT re drill orifices Improper drilling burrs out of rating plate round holes etc can cause excessive burner noise and a Obtain average yearly gas heat value at installed altitude misdirection of burner flames This can result in flame from local gas supplier impingement of heat exchangers causing failures See Fig b Obtain average yearly gas specific gravity from local gas 50 supplier c Find installation altitude in Table 15 or 16 d Find closest natural gas heat value and specific gravity in Table 15 or 16 Furnace gas input rate on rating plate is for
58. C22 1 Step 8 Venting US NFGC chapters 12 and 13 CANADA CAN CSA B149 1 05 Part 8 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity for example DO NOT move or shuffle your feet do not touch ungrounded objects etc 4 If you
59. INSTALLATION Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 3 4 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 Rotate bottom filler panel downward to release holding tabs Remove bottom closure panel Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used NOT most E Side return air openings can be used in UPFLOW and HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration 10 e BOTTOM CLOSURE BOTTOM FILLER PANEL PANEL A02098 Fig 9 Removing Bottom Closure Panel Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 10 Install field supplied 5 16 X 1 1 2 in max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see item 1 in Bottom Return Air Inlet section in Step 1 above To install leveling legs 1 Position furnace on
60. ITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT F CIRCUIT HOOK AROUND AMMETER gt FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 9 0 AMPS ON AMMETER 10 TURNS AROUND JAWS _ 0 5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING A96316 Fig 56 Amp Draw Check with Ammeter Step 4 Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch es This control shuts off combustion system and energizes air circulating blower motor if furnace overheats By using this method to check limit control it can be established that limit is functioning properly and will operate if there is a restricted return air supply or motor failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace cools down 2 Check draft safeguard switch The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temp
61. NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 www NFPA org or for only the NFGC contact the American Gas Association 400 N Capitol Street N W Washington DC 20001 www AGA org CANADA CAN CSA B149 1 05 For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario MOW 1R3 Canada Step Step 3 Combustion and Ventilation Air e US Section 8 3 of the NFGC Air for Combustion and Ventilation CANADA Part 7 of CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances Step 4 Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16 Step 5 Acoustical Lining and Fibrous Glass Duct US and CANADA current edition of SMACNA and 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 6 Gas Piping and Gas Pipe Pressure Testing US NFGC chapters 5 6 and 7 and National Plumbing Codes CANADA CAN CSA B149 1 05 Parts 4 5 6 and 9 and Appendices A B E and H Step 7 Electrical Connections US National Electrical Code NEC ANSI NFPA 70 2006 CANADA Canadian Electrical Code CSA
62. NG HAZARD Failure to follow this warning could result in personal injury or death Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Sealany unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7
63. ON MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air fumace is equipped for use with This fumace is approved for UPFLOW DOWNFLOW and natural gas at altitudes 0 10 000 ft 0 3 050m HORIZONTAL installations An accessory supplied by the Cette foumaise est approuv e pour installation HORIZONTALE manufacturer shall be used to convert to propane et la circulation d air VERS LE HAUT et VERS LE BAS gas use or may be required for some natural gas applications Clearance arrows This fumace is for indoor installation in a donotchange with building constructed on site fumace orientation This fumace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combusitble material This fumace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances RES Les fl ches de d gagement ne change pas avec l orientation de la foumaise PLENUM DESSUS CHAMBREDAIR Cette foumaise air puls est quip e pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000 pi Utiliser une trousse de conversion foumie par le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel Cette foumaise est pr vue pour tre install e dans un b timent construit sur place Cette foumaise peut tre install e su
64. T speed High Heat 25 seconds after the gas valve GV M is energized the BLWM is energized at HI HEAT speed Simultaneously the electronic air cleaner EAC 1 terminal is energized and remains energized as long asthe BLWM is energized f Switching from Low to High Heat If the furnace control CPU switches from low heat to high heat the furnace control CPU will switch the inducer motor IDM speed from low to high The high heat pressure switch relay HPSR is de energized to close the NC contact When sufficient pressure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV Hl is energized The blower motor BLWM will switch to HI HEAT speed five seconds after the furnace control CPU switches from low heat to high heat g Switching from High to Low Heat The furnace control CPU will not switch from high heat to low heat while the thermostat R to W circuit is closed when using a singlestage thermostat h Blower OFF Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV M stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 5 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 seconds depending on selection at blower OFF delay switches The furnace control CPU is factory set for a 120 second blower OFF
65. TH Side Return turn 14 1 2 16X25X1 14X25X1 Cleanable 17 1 2 16X25X1 16X25X1 Cleanable 21 16X25X1 20X25X1 Cleanable 24 16X25X1 24X25X1 Cleanable Recommended 1 Turn off electrical supply to furnace before removing filter access door 2 Remove filter cabinet door 3 Slide filter out of cabinet 4 If equipped with permanent washable 1 in filter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended See Table 17 for size information 5 If equipped with factory specified disposable media filter replace only with media filter having the same part number and size For expandable replacement media refer to the instructions included with the replacement media If equipped with accessory KGAFRO301ALL external filter rack See Table 17 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace BLOWER MOTOR AND WHEEL 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes NOTE The blower wheel should not be dropped or bent as balance will be affected The following steps should be performed by a qualified service agen
66. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use Vent system or vent connectors may need to be resized Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC or CAN CSA B149 1 05 GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements including local building codes the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 NFGC Parts 10 and 13 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 00 CAN CSA B149 1 05 Section 8 and Appendix C in Canada the local building codes and furnace and vent manufacturers instructions These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47 2003 CSA 2 3 2003 and operate with a
67. a per 2 000 Btuh 1 100 mm2 kW of combined input for all gas appliances in the space per Fig 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 square inch of free area per 4 000 Btuh 550 mm2 kW for combined input of all gas appliances in the space per Fig 7 and Table 2 3 ONE OUTDOOR OPENING requires 1 square inch of free area per 3 000 Btuh 734 mm2 kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connectors in the space Table 2 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO DUCI VERTICAL FURNACE 1 SQ IN 2 000 BTUH 1 SQ IN 3 000 BTUH 1 SQ IN 4 000 BTUH INPUT 1 100 SQ MM KW 734 SQ MM KW 550 SQ MM KW BTUH Free Area of Free Area of Free Area of Opening and Duct nm Opening and Duct i i Opening and Duct MD Sq In sq In Sq In 44 000 22 6 14 7 5 11 4 66 000 33 7 22 6 16 5 5 88 000 44 8 29 3 7 22 6 110 000 55 9 36 7 7 27 5 6 132 000 66 10 44 8 33 7 154 000 77 10 51 3 9 38 5 8 FURNACE WATER HEATER TOTAL INPUT 110 000 30 000 140 000 divided by 4 000 35 0 Sq In for each two Vertical Ducts or Openings 66 000 40 000 106 000 dividedby 3 000 35 3 Sq In for a Single Duct or Opening 88 000 30 000 118 000 divided by 2 000 59 0 Sq In for each of two Horizonta
68. above sea level by an Furnace is shipped with No 43 orifices In this example authorized Gas Conversion Station or Dealer To determine correct input rate for altitude see example and use 0 90 as derate multiplier factor to be changed to obtain proper input rate 2 Determine the correct orifice and manifold pressure adjustment All models in all positions except Low NOx all main burner orifices are the correct size and do not need 3 Adjust manifold pressure to obtain low fire input rate See Fig 54 36 a Turn gas valve ON OFF switch to OFF b Remove manifold pressure tap plug from gas valve c Connect a water column manometer or similar device to manifold pressure tap d Turn gas valve ON OFF switch to ON e Move setup switch LHT SW 1 on furnace control to ON position to lock furnace in low heat operation See Fig 34 and Table 10 f Manually close blower door switch g Jumper and W W1 thermostat connections on control to start furnace See Fig 34 h Remove regulator adjustment cap from low heat gas valve pressure regulators See Fig 54 Turn low heat adjusting screw 3 16 in or smaller flat tipped screwdriver counterclockwise out to decrease input rate or clockwise in to increase input rate A06667 Fig 54 Redundant Automatic Gas Control Valve NOTE DO NOT set low heat manifold pressure less than 1 4 in wc or more than 1 7 in wc for natural gas If manifold pressure is
69. adings can beobtained at the wires normally connected to thermostat subbase terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Set LHT switch on furnace control board to ON 2 Remove thermostat from sub base or from wall 3 Connect an amp meter as shown in Fig 56 across the R and W subbase terminals or R and W wires at wall 4 Record amp draw across terminals when furnace is in low heat and after blower starts 5 Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall 6 Turn LHT switch OFF 7 Install blower access door b Electronic thermostat Set cycle rate for 3 cycles per hr 11 Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow See Table 5 Air Delivery CFM With Filter See Table 13 for lead color identification Table 13 Speed Selection COLOR SPEED AS SHIPPED White Common BLW Black High COOL Yellow Med High SPARE Oranget Med SPARE Blue Med Low Red Low LO HEAT Continuous blower speed as shipped default T Not all models equipped with 5 speed motors 39 Table 14 2 Stage Furnace Blower OFF delay Setup Switch DESIRED HEATING MODE SETUP SWITCH SETUP SWITCH BLOWER OFF DELAY SEC SW 2 SW 3 90 OFF OFF 120 OFF ON 150 ON OFF 180 ON ON THERMOSTAT SUBBASE TERMINALS W
70. air Supply Flame Roll out Switch open IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Manual valve shut off Control ground continuity Gas valve defective or gas valve turned off Low inlet gas pressure Inadequate flame carryover or rough ignition Defective Hot Surface Ignitor Flame sensor must not be grounded Green Yellow wire MUST be connected to furnace sheet metal LOW HEAT PRESSURE SWITCH OPEN WHILE HIGH HEAT PRESSURE SWITCH IS CLOSED Check for Disconnected or obstructed pressure tubing Mis wired pressure switches Low heat pressure switch stuck open Low inlet gas pressure if LGPS used CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats 327598 101 REV C 04210 Fig 57 Service Label 47 ScLZ0V SULA 8S 814 BARIL S WNHA UYM SPU0I S G 40 spuoses 06 jeay Bujjooo 081 05 021 06 suonoejes seb Aejap yo amog LOL L9SZZE pui 0295 z
71. ate a NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST be provided for the ventilation devices in addition to that required by the furnace Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make up air is available The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1 000 Btuh input rating for all gas appliances installed in the space Spaces having less than 50 cubic feet per 1 000 Btuh require the Outdoor Combustion Air Method Spaces having at least 50 cubic feet per 1 000 Btuh may use the Indoor Combustion Air Standard or Known Air Infiltration Method Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combustion ventilation and dilution of flue gases using permanent horihorizontal or vertical duct s or opening s directly communicating with the outdoors or spaces that freely communicate with the outdoors 2 Fig 7 illustrates how to provide TWO OUTDOOR OPENINGS one inlet and one outlet combustion and ventilation air opening to the outdoors a One opening MUST commence within 12 in 300 mm of the ceiling and the second opening MUST commence within 12 in 300 mm of the floor b Size openings and ducts per Fig 7 and Table 2 c TWO HORIZONTAL DUCTS require 1 square inch of free are
72. ated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connection diagram on wiring label if wires were not marked for reconnection locations Draft safeguard switch Inducer motor Pressure switches Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode m gQ oan m Flame rollout switches 14 Reinstall internal vent pipe if applicable 15 Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 180 apart A01026 Fig 60 Igniter Position Top View 91252 Fig 61 Cleaning Heat Exchanger Cell 16 Replace blower access door only if it was removed 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warn
73. aterials could lead to corrosion of the heat exchanger For continuing high performance and to minimize possible furnace failure periodic maintenance must be performed on this furnace Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract 4 WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace 4 WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate unit without a filter or with filter access door removed 46 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces The minimum maintenance on this furnace is as follows 1 Check and clean atr filter each month or more frequently if required Replace if torn 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean as necessary Check electrical connections for tightness and controls for proper operation each heating season Service a
74. ating component s full load amps plus 10096 of all other potential operating components EAC humidifier etc full load amps T Time delay type is recommended t Length shown is as measured 1 way along wire path between unit and service panel for maximum 296 voltage drop U S Installations Make all electrical connections in accordance 4 Fasten J Box to casing with the two screws removed in with National Electrical Code NEC ANSI NFPA 70 2006 and Step 1 any local codes or ordinances that might apply 5 Route J Box wires within furnace away from sharp edges Canadian Installations Make all electrical connections in rotating parts and hot surfaces accordance with Canadian Electrical Code CSA C22 1 or FACTORY authorities having jurisdiction INSTALLED LOCATION FIRE HAZARD TWO Failure to follow this warning could result in personal ALTERNATE injury death or property damage FIELD s LOCATION Do not connect aluminum wire between disconnect switch and furnace Use only copper wire s Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 7 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash A02099 rapidly and furnace will NOT operate Fig 25
75. aution may cause personal injury Hot vent pipe is within reach of small children when installed in downflow position See the following instruction An accessory Vent Guard KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall slope upwards not less than 1 4 in per linear ft 21 mm m from the furnace to the vent and shall be rigidly supported every 5 ft or less with metal hangers or straps to ensure there is no movement after installation SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting In the U S Per section 10 3 4 of the NFGC any listed mechanical venter may be used when approved by the authority having jurisdiction 34 In Canada Per section 8 24 2 of the CAN CSA B149 1 05 any listed mechanical venter may be used when approved by the authority having jurisdiction Select the listed mechanical venter to match the Btuh input of the furnace being vented Follow all manufacturer s installation requirements for venting and termination included with the listed mechanical venter START UP ADJUSTMENT AND SAFETY CHECK Step 1 General 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage This furnace is eq
76. be adequate to provide air for combustion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a continuous sealed vapor barrier Openings are gasketed or sealed and b Doors and openable windows are weatherstripped and c Other openings are caulked or sealed These include joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines etc Combination of Indoor and Outdoor Air 1 Indoor openings shall compy with the Indoor Combustion Air Method below and Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below b Outdoor opening size reduction Factor is 1 minus the Ratio in a above c Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor in b above The minimum dimension of air openings shall be not less than 3 in 80 mm INSTALLATION UPFLOW
77. beckons essai wal R DHUM 24VACCOMM C J 4 I DHUM B HUM C Li 4 Teom LoL Ei RVSSENSING L HUM OUTDOOR iL OUTDOOR deesse SENSOR SENSOR CONNECTION S2 J____ _ _ See notes 2 11 and 12 on the See notes 1 2 3 4 12 13 14 15 and 17 page following these figures on the page following these figures A03182 A03183 Fig 31 Dual Fuel Thermostat with Two Stage Furnace Fig 32 Two Stage Thermostat with Two Stage Furnace and Two Speed Heat Pump and Two Speed Air Conditioner SINGLE STAGE TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER w2 err d beet 21 Y1 We gt kausa ss asss IWW1 2 s 24 Y2 c E G RU Edom RR Ube a n ee J L IR DHUM Com L_ L EN C See notes 1 and 2 on the page following these figures A03184 Fig 33 Single Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner NOTES For Figures 25 31 1 Heat pump MUST have a high pressure switch for dual fuel applications DA E Eni 12 18 14 15 16 Refer to outdoor equipment Installation Instructions for additional information and setup procedure Outdoor Air Temperature Sensor must be attached in all dual fuel applications Dip switch No 1 on Thermidistat should be set in OFF position for air conditioner installations This is fac
78. cess door switch low heat speed selection can be low factory setting c Jumper R W W1 and W2 thermostat connections on med low or med 5 speed blowers only i control to run furnace in high heat See Fig 34 d Remove thermostat jumpers and release Blower Access d d Turn high heat adjusting screw 3 16 in or smaller flat Door Switch tipped screwdriver counterclockwise out to decrease To change motor speed selection for low heat remove input rate or clockwise in to increase rate blower motor lead from control LO HEAT terminal See Fig 34 Select desired blower motor speed lead from 1 of the other terminals and relocate it to the e Re install high fire adjustment caps f Leave manifold or similar device connected and proceed LO HEAT terminal See Table 13 for lead color to Step 7 identification Reconnect original lead to SPARE NOTE DO NOT set high heat manifold pressure less than terminal 3 2 in wc or more than 3 8 in wc for natural gas If manifold f Repeat steps a through e pressure is outside this range change main burner orifices 7 Verify natural gas high heat input rate by clocking meter 4 CAUTION NOTE Gas valve regulator adjustment caps must be in place for proper input to be clocked FURNACE OVERHEATING HAZARD a Turn off all other gas appliances and pilots served by the Failure to follow this caution may result in reduced furnace meter life b Run for 3 minutes in high heat
79. ckout in door NOTE A number of techniques can be used to remove these knockouts as seen in Fig 49 through 53 The knockout in the bottom of the door is unique due to its flanging and is more easily removed by first cutting the two tie points at the edge of the door using aviation type tin snips See Fig 49 A sharp blow to the rounded end of the knockout See Fig 50 will separate more tie points and allow the knockout to be pulled loose See Fig 51 Remove all burrs any sharp edges For the rectangular J box knockout use tin snips along the door edge and use a sharp blow with a hammer to remove the knockout Remove any burrs and sharp edges For the knockouts in the other locations on the door top and sides tin snips can also be used along the door edges however the preferred method is to use a hammer and screwdriver to strike a sharp blow See Fig 52 directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout See Fig 53 Remove any burrs and sharp edges NOTE If a knockout does not come out after two sharp blows pull and snip as needed to remove the knockout Additional blows may cause damage to the door 33 Fig 50 Rounded End of Knockout Fig 51 Knockout Pulled Loose A04128 A04129 A04130 Fig 52 Hammer and Screwdriver Used for Knockout A04131 Fig 53 Remove Knockout with Hammer CAUTION BURN HAZARD Failure to follow this c
80. condensation in the furnace and vent system the following precautions must be observed 1 The return air temperature must be at least 60 F db except for brief periods of time during warm up from setback at no lower than 55 F 13 db or during initial start up from a standby condition 2 Adjust the gas input rate per the installation instructions Low gas input rate causes low vent gas temperatures 29 causing condensation and corrosion in the furnace and or venting system Derating is permitted only for altitudes above 2000 ft 3 Adjust the air temperature rise to the midpoint of the rise range or slightly above Low air temperature rise can cause low vent gas temperature and potential for condensation problems 4 Set the thermostat heat anticipator or cycle rate to reduce Short cycling Air for combustion must not be contaminated by halogen compounds which include chlorides fluorides bromides and iodides These compounds are found in many common home products such as detergent paint glue aerosol spray bleach cleaning solvent salt and air freshener and can cause corrosion of furnaces and vents Avoid using such products in the combustion air supply Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting System due to corrosion
81. ct Data literature for specific use of single side inlets The use of both side in lets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM Fig 1 Dimensional Drawing SAFETY CONSIDERATIONS WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation serious injury death or property damage Improper installation adjustment alteration service maintenance or use could cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or accessories when modifying this product CAUTION FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating
82. cy To ensure long life and high efficiency clean accumulated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Loosen the thumbscrew from outer door and remove outer door 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door a Disconnect vent connector from furnace vent elbow b Disconnect and remove short piece of vent pipe from within furnace 4 Remove 2 screws from blower access door and remove blower access door 5 Disconnect blower leads from furnace control Record wire color and location for reassembly All other factory wires can be left connected but field thermostat connections may need to be disconnected depending on their length and routing 6 Remove 2 screws holding control box to blower shelf 7 Hang control box from front of furnace casing and away from blower compartment 8 Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace 9 Clean blower wheel and motor using a vacuum with soft brush attachment Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blad
83. d appliances in Btuh hr combined input of all fan assisted appliances in Btuh hr air changes per hour ACH shall not exceed 0 60 The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method 1 2 Adjoining rooms can be considered part of a space if a There are no closable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 8 c Combining space on different floor levels The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in 2 1 000 Btuh 4 400 mm2 kW of total input rating of all gas appliances An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1 in 2 4 000 Btuh of total input rating for all gas appliances in the space In spaces that use the Indoor Combustion Air Method infiltration should
84. delay 2 Two Stage Thermostat and Two Stage Heating See Fig 32 for thermostat connections NOTE In this mode the LHT must be ON to select the low heat only operation mode in response to closing the thermostat R to W1 circuit Closing the thermostat R to W1 and W2 circuits always causes high heat operation regardless of the setting of the low heat only switch The wall thermostat calls for heat closing the R to W1 circuit for low heat or closing the R to W1 and W2 circuits for high heat The furnace control performs a self check verifies the 52 low heat and high heat pressure switch contacts LPS and HPS are open and starts the inducer motor IDM in high speed The start up and shut down functions and delays described in item 1 above apply to the 2 stage heating mode as well except for switching from low to high Heat and vice versa a Switching from Low to High Heat If the thermostat R to W1 circuit is closed and the R to W2 circuit closes the furnace control CPU will switch the inducer motor IDM speed from low to high The high heat pressure switch relay HPSR is de energized to close the NC contact When sufficient pressure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV HI is energized The blower motor BLWM will switch to HI HEAT speed five seconds after the R to W2 circuit closes b Switching from High to Low Heat If the thermostat R to W2 circuit opens and the R to
85. e installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions 10 These Multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA A G A and C G A listed accessory gas conversion kit is required to convert furnace for use with propane gas 11 See Fig 2 for required clearances to combustible construction 12 Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace See NFPA 90B or local code for further requirements 13 These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installations factory accessory floor base MUST be used when installed on combustible materials and wood flooring Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part No CD5 or CK5 or when Coil Box Part No KCAKC is used See Fig 2 for clearance to combustible construction information INTRODUCTION The Serie
86. e located at least 18 inches above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the CAN CSA B149 1 05 See Fig 5 18 IN MINIMUM TO BURNERS A93044 Fig 5 Installation in a Garage 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace See Fig 6 BACK FRONT A02054 Fig 6 Prohibit Installation on Back CAUTION PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause premature component failure This gas furnace may be used for construction heat provided that The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame roll out and or drawing combusti
87. ed below a Low cooling When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will continue running at low cool speed same speed as LO HEAT 53 b High cooling When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower speed from COOL to HI HEAT for a maximum of 10 minutes before reverting back to COOL speed If there is still a demand for dehumidification after 20 minutes the furnace control CPU will drop the blower speed back to HI HEAT speed This alternating 10 minute cycle will continue as long as there is a call for cooling c Cooling off delay When the gcall for cooling his satisfied and there is a demand for dehumidification the cooling blower off delay is decreased from 90 seconds to 5 seconds Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed can be set to LO HEAT HI HEAT or COOL speed Factory default is LO HEAT speed Terminal 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 seconds ignition 7 seconds and blower ON delay 45 seconds in low heat and 25 seconds in high heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON dela
88. efore beginning the call for heat again 1 Furnace should ignite normally Step 5 Checklist 1 2 Put away tools and instruments Clean up debris Verify that switches for LHT and OFF DELAY are blower OFF DELAY are selected as desired Verify that blower and burner access doors are properly installed Cycle test furnace with room thermostat Check operation of accessories per manufacturer fs instructions Review User s Guide with owner Attach literature packet to furnace 41 Table 15 Orifice Size and Manifold Pressure for Gas Input Rate Tabulated Data Based on 22 000 Btuh High Heat 14 500 Btuh for Low Heat per Burner Derated 4 for Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE HEAT VALUE 0 58 0 60 0 62 0 64 FT BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 900 42 8 5 1 5 42 3 6 1 6 42 3 7 1 6 41 3 5 1 5 925 42 3 3 1 4 42 3 4 1 5 42 8 5 1 5 42 3 7 1 6 950 43 3 8 1 7 42 3 3 1 4 42 3 4 1 5 42 3 5 1 5 U S A 975 43 3 6 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 and 0 to 2000 1000 43 8 5 1 5 43 3 6 1 6 43 3 7 1 6 43 3 8 1 7 Canada 1025 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 1050
89. equirements are met in addition to all local codes and ordinances The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms and Chemical storage areas If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion Permanent wave solutions e Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc e Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials fuel burning equipment must be supplied with air for fuel combustion Sufficient air must be provided to avoid negative pressure in the equipment room or space A positive seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and from draft safeguard opening 4 WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage When the furnace is installed in a residential garage the burners and ignition sources must b
90. eration the inducer motor IDM comes up to speed the low heat pressure switch LPS closes and the furnace control CPU begins a 15 second prepurge period After the low heat pressure switch re closes the furnace control CPU will begin a 15 second prepurge period and continue to run the inducer motor IDM at high speed 2 If the furnace control CPU selects high heat operation the inducer motor IDM remains running at high speed and the high heat pressure switch relay HPSR is de energized to close the NC contact When sufficient pressure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV HI is energized The furnace control CPU begins a 15 second prepurge period after the low heat pressure switch LPS closes If the high heat pressure switch HPS fails to close and the low heat pressure switch LPS closes the furnace will operate at low heat gas flow rate until the high heat pressure switch closes for a maximum of 2 minutes after ignition b Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR 1 and 2 close to energize the gas valve solenoid GV M the gas valve opens and 24 vac power is supplied for a field installed humidifier at the HUM terminal The gas valve solenoid GV M permits gas flow to the bur
91. erature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 80 of vent area with a piece of flat sheet metal e Furnace should cycle off within 2 minutes If gas does not shut off within 2 minutes determine reason draft 40 safeguard switch did not function properly and correct condition f Remove blockage from furnace vent elbow g Switch will auto reset when it cools h Re install vent connector NOTE Should switch remain open longer than 3 minutes furnace control board will lockout the furnace for 3 hours To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115 v power OFF then back ON 3 Check Pressure Switch es This control proves operation of the draft inducer blower a Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control diagnostic light flashes a status code 32 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power h Blower will run for 90 seconds b
92. ervice purposes 20 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 21 Turn on gas supply and cycle furnace through one complete heating and cooling cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70 F turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service agency NOTE If the heat exchangers get a heavy accumulation of soot and carbon they should be replaced rather than trying to clean them thoroughly A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal fur
93. es 10 Vacuum any loose dust from blower housing wheel and motor 11 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel NOTE Before disassembly mark blower mounting arms motor and blower housing so motor and each arm is positioned at the same location during reassembly a Disconnect capacitor wires if equipped and ground wire attached to blower housing b Remove screws securing cutoff plate and remove cutoff plate from housing c Loosen set screw holding blower wheel on motor shaft 160 20 in Ib when reassembling d Remove bolts holding motor to blower housing and slide motor out of wheel 40 10 in Ib when reassembling e Remove blower wheel from housing f Clean wheel and housing 12 Reassemble motor and blower by reversing steps 11 through 11a Be sure to reattach ground wire to the blower housing 13 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in furnace 49 16 Reinstall control box assembly in furnace 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger life Heating fan speed s MUST be adjusted t
94. fold Pressure for Gas Input Rate cont Tabulated Data Based on 22 000 Btuh High Heat 14 500 Btuh for Low Heat per Burner Derated 4 for Each 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0 58 0 60 0 62 0 64 AT ALTITUDE BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 675 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 43 3 7 1 6 700 44 3 6 1 6 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 725 44 3 4 1 5 44 3 5 1 5 44 3 6 1 6 43 3 2 1 4 U S A 6001 to 750 45 3 8 1 7 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 Only 7000 775 46 3 7 1 6 45 3 7 1 6 45 3 8 1 7 44 3 2 1 4 800 46 3 5 1 5 46 3 6 1 6 46 3 8 1 6 45 3 7 1 6 825 47 3 7 1 6 46 3 4 1 5 46 3 5 1 5 46 3 6 1 6 850 47 3 5 1 5 47 3 6 1 6 47 3 8 1 6 46 3 4 1 5 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 BTUH CU Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold FT No Pressure No Pressure No Pressure No Pressure 650 44 3 6 1 6 43 3 2 1 4 43 3 4 1 5 43 3 5 1 5 675 44 3 3 1 5 44 3 5 1 5 44 3 6 1 6 43 3 2 1 4 700 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 U S A 7001 to 725 46 3 7 1 6 46 3 8 1 7 45 3 7 1 6 44 3 2 1 4 Only 8000 750 46 3 4 1 5 46 3
95. for high and low heat Determine the temperature rise as follows NOTE Blower access door must be installed when taking temperature rise reading Leaving blower access door off will result in incorrect temperature measurements 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power before changing speed tap D BURNER x ORIFICE Fig 55 Orifice Hole A93059 a Verify unit is running in low heat per Step 4 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE If the temperature rise is outside this range first check 1 Gas input for low heat operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in wc 37 Table 12 Gas Rate cu ft hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 FOR 1 REVOLUTION 1
96. four applications shown in Fig 4 NOTE For high altitude installations the high altitude conversion kit MUST be installed at or above 5500 ft above sea level Obtain high altitude conversion kit from your area authorized distributor This furnace must be installed so the electrical components are protected from water not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label A WARNING CARBON MONOXIDE POISONING DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and furnace damage AND UNIT Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products Do not install furnace in a corrosive or contaminated atmosphere Make sure all combustion and circulating air r
97. furnace control Failure to make proper connections will result in improper operation See Fig 24 3 Gas supply pressure to the furnace must be greater than 4 5 wc 0 16 psig but not exceed 14 in we 0 5 psig A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Setup switch descriptions The 2 stage furnace has DIP switches used to select thermostat staging and blower off delay timings For switch locations on Furnace control board See Fig 34 and 58 7 Setup switch descriptions See Table 10 Step 2 Start Up Procedures WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage 35 Component test feature will not operate if any thermostat signal is present at the control Refer to service label attached to furnace or See Fig 57 Component test sequence is as follows a LED will display previous
98. g in high heat per Step 6 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE If the temperature rise is outside this range first check 1 Gas input for low and high heat operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in wc 4 Dirty filter c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise For high heat speed selection can be med high med 5 speed blowers only or med low factory setting 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power before changing speed tap d To change motor speed selection for high heat remove blower motor lead from control HI HEAT terminal See Fig 34 Select desired blower motor speed lead from 1 of the other terminals and relocate it to the HI HEAT terminal DO NOT use the low heat tap that was already set See Table 13 for lead color iden
99. h as those published by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guidelines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design external static pressure The furnace airflow rates are provided in Table 5 Air Delivery CFM With Filter When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal d
100. have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces NOTE Vent connector length for connector sizing starts at furnace vent elbow The 4 inch vent elbow is shipped for upflow configuration and may be rotated for other positions Remove the 3 screws that secure vent elbow to furnace rotate furnace vent elbow to position desired re install screws The factory supplied vent elbow does NOT count as part of the number of vent connector elbows The vent connector can exit the door through one of 5 locations on the door 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart NOTE An accessory flue extension KGAFEO112UPH is available to extend from the furnace elbow to outside the furnace casing If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 36 48 3 Orient the door to determine the correct location of the door knockout to be removed 4 Remove the correct U shaped kno
101. ing could result in personal injury death and or property damage Never use a match or other open flame to check for gas leaks Use a soap and water solution 19 Check for gas leaks 20 Replace outer access door Step 3 Sequence of Operation NOTE Furnace control must be grounded for proper operation or control will lockout Control is grounded through green wire connected to gas valve and burner bracket screw Using the schematic diagram in Fig 58 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W W1 or W W1 and W2 the control run the blower for the selected blower off delay period two seconds after power is restored and if the thermostat is still calling for gas heating The LED light will flash code 12 during this period after which the LED will be ON continuous as long as no faults are detected After this period the furnace will respond to the thermostat normally The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace 51 control CPU transformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV 1 Two Stage Heating Adaptive mode with Single Stage Thermostat See Fig 24 or 33 for thermostat connections NOTE The low heat only switch LHT selects either the low heat only operation
102. installations at altitudes up to 2000 ft Furnace input rate must be within 2 of furnace rating plate input For altitudes above 5500 ft a e Follow heat value and specific gravity lines to point of field supplied high altitude pressure switch is required intersection to find orifice size and low and high heat 1 Determine the correct gas input rate manifold pressure settings for proper operation In the U S f Check and verify burner orifice size in furnace NEVER The input rating for altitudes above 2 000 ft must be re ASSUME ORIFICE SIZE ALWAYS CHECK AND duced by 4 for each 1 000 ft above sea level VERIFY For installations below 2000 ft refer to the unit rating g Replace orifice with correct size if required by Table 15 plate or 16 Use only factory supplied orifices See For installations above 2000 ft multiply the input on the EXAMPLE 2 rating plate by the derate multiplier in Table 11 for the cor rect input rate EXAMPLE 2 0 2000 ft altitude For 22 000 Btuh per burner application use Table 15 EXAMPLE 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT Heating value 1000 Btuh cu ft Derate Furnace Input Rate Specific gravity 0 62 Furnace Input Rate X Multiplier at Installation at Sea Level Factor Altitude Therefore Orifice No 43 88 000 X 0 90 79 200 Manifold pressure 3 7 in wc for high heat 1 6 in wc for low heat In Canada The input rating must be reduced by 10 for altitudes of 2 000 ft to 4 500 ft
103. its back Locate and drill a hole in each bottom corner of furnace See Fig 10 2 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement 5 Reinstall bottom closure panel if removed 546 134 134 w A02071 Fig 10 Leveling Legs DOWNFLOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used Special Base KGASB Cased Coil Assembly Part No CD5 or CK5 Coil Box Part No KCAKC 1 Determine application being installed from Table 4 2 Construct hole in floor per Table 4 and Fig 11 3 Construct plenum to dimensions specified in Table 4 and Fig 11 4 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part No CD5 or 5 or Coil Box Part No KCAKC is used install as shown in Fig 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14
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105. l Ducts 1SQIN PER 4000 DUCTS TO BTUH OUTDOORS TC E 12 MAX D 12 150 Ou VENT PER 2000 B THROUGH FS BTUH 45 ROOF 3a 1SQIN pr PER ot 4000 BTUH YD tc DUCTS E ru 8 TO 6am OUTDOORS 22 42 z 5045 TI 1SQIN nua m PER zaomn 4000 c BTUH 1SQIN lt 2000 BTUH I ooo 12 12 1 j42 MAX 1 1 SQ IN TO PER 4000 OUTDOORS BTUH CIRCULATING AIR DUCTS Minimum dimensions of 3 in NOTE Use any of the following combinations of openings A amp B C amp D D amp E F amp G A03174 Fig 7 Air for Combustion Ventilation and Dilution for Outdoors The opening shall commence within 12 in 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 150 mm from the front The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors Indoor Combustion Air NFPA amp AGA Standard and Known Air Infiltration Rate Methods Indoor air is permitted for combustion ventilation and dilution if the Standard or Known Air Infiltration Method is used WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warni
106. lc ve on doit maintenir un d gagement l avant de 18 po 450mm La poistion indiqu e conceme le c t d entr e ou de retour quand la foumaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la cherrise de la fournaise et les solives montant sous cadre de charpente 327590 101 REV C F BOTTOM DESSOUS Clearance in inches D gagement po 04123 Fig 2 Clearances to Combustibles MAX80 F AE RETURN AIR MIN60 F Iw A04036 Fig 3 Return Air Temperature CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following Step 1 Safety US National Fuel Gas Code NFGC NFPA 54 2006 ANSI Z223 1 2006 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CSA B149 1 00 National Standard of Canada Natural Gas and Propane Installation Code CAN CSA B149 1 05 Step 2 General Installation US Current edition of the NFGC and the
107. le wall dedicated or common vent The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors 4 Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 5 In the US Do not vent this appliance with any solid fuel burning appliance In Canada Check with the authority having jurisdiction for approval on use with solid fuel burning appliance 6 Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter See the SIDEWALL VENTING section 7 Do not vent this appliance into an unlined masonry chimney Refer to Chimney Inspection Chart Fig 35 MASONRY CHIMNEY REQUIREMENTS NOTE These furnaces are CSA design certified for use in exterior tile lined masonry chimneys with a factory accessory Chimney Adapter Kit Refer to the furnace rating plate for correct kit usage The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate If a clay tile lined masonry chimney is being used and it is exposed to the outdoors below the roof line relining might be required Chimneys shall conform to the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 2003 in the United States and to a Provincial or Territorial Building Code in Canada in its absence
108. lower OFF delay period then switch to continuous blower speed When the R to W W1 and Y Y2 R to W W1 and Y Y2 and G R to W Wi and Yl1 and Y Y2 R to W W1 and Y1 and Y Y2 and G circuits energized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed and begin a high heat cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HI HEAT speed When the W W1 input signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the R to W W1 and Y Y2 and G or R to W W1 and Y1 and Y Y2 and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W W1 and Y Y2 or R to W W1 and Y1 and Y Y2 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed Step 4 Wiring Diagrams Refer to wiring diagram Fig 58 Step 5 Troubleshooting Refer to the service label See Fig 57 Service Label The Troubleshooting Guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After re
109. nace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when disconnecting wires from switches because damage may occur Draft safeguard switch Inducer motor Pressure switches Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode Emo gt Flame rollout switches 6 Remove screws that fasten the collector box assembly to the cell panel Be careful not to damage the collector box Inducer assembly and elbow need not be removed from collector box 7 Disconnect gas line from gas manifold 8 Remove the 5 screws that attach the burner assembly to the cell panel The gas valve and individual burners need not be removed from support assembly Remove NOx baffles if installed NOTE Be very careful when removing burner assembly to avoid breaking igniter See Fig 59 and 60 for correct igniter location 9 32 05025 Fig 59 Igniter Position Side View 9 Using field provided 25 caliber rifle cleaning brush 36 in long 1 4 diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows 50 a Remove metal screw fitting from wire brush to allow insertion into cable b Insert the twisted wire end of bru
110. nce connector always use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in outside the furnace CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner misalignment An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve NOTE The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas control valve See Fig 54 Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21 and 22 TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY o FIT N 90 Elbow gt o M To Gas 2 Supply O Z 2 2 Nipple 90 Elbow z Close Nipple iL Gas Valve A05028 Fig 21 Right Side Gas Entry Example 1 r
111. ners where it is ignited by the HSI Five sec after the GVR closes a 2 sec flame proving period begins The HSI igniter will remain energized until the flame is sensed or until the 2 sec flame proving period begins If the furnace control CPU selects high heat operation the high heat gas valve solenoid GV HI is also energized d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the inducer motor IDM switches to low speed unless running at high speed and the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV M open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV M and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ignition Lockout Lockout will be reset automatically after three hours by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W W1 R etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved e Blower ON Delay If the burner flame is proven the blower ON delay for low heat and high heat are as follows Low Heat 45 seconds after the gas valve GV M is energized the blower motor BLWM is energized at LO HEA
112. ng could result in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual CIRCULATING AIR DUCTS 2 VENT THROUGH ROOF I I Il I I I h x lt 12 MAX z o 2 1 SQ IN PER 1000 m BTUH IN DOOR ORWALL Q Ok INTERIOR UNCONFINED HEATED a SPACE oz 6 MIN FRONT we oZ 1 SQ IN Z PER 1000 co BTUH IN DOOR ORWALL mI 12 CIRCULATING AIR DUCTS Minimum opening size is 100 sq in with minimum dimensions of 3 in t Minimum of 3 in when type B1 vent is used A03175 Fig 8 Air for Combustion Ventilation and Dilution from Indoors The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to be 1 Less than 0 40 ACH and 2 Equal to or greater than 0 10 ACH Infiltration rates greater than 0 60 ACH shall not be used The minimum required volume of the space varies with the
113. ngs greater than the input ratings of these furnaces See footnote at bottom of Table 9 and 5 The authority having jurisdiction approves If all of these conditions cannot be met an alternative venting design shall be used such as the listed chimney adapter kit with a furnace listed for use with the kit a listed chimney lining system or a Type B common vent Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and or re lining Refer to Fig 35 to perform a chimney inspection If the inspection of a previously used tile lined chimney a Shows signs of vent gas condensation the chimney should be relined in accordance with local codes and the authority having jurisdiction The chimney should be relined with a listed metal liner vent or a listed chimney adapter kit shall be used to reduce condensation If a condensate drain is required by local code refer to the NFGC Section 10 9 for additional information on condensate drains b Indicates the chimney exceeds the maximum permissible size in the tables the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt to conform to ANSI NFPA 211 or be lined with a UL listed ULC listed in Canada metal liner or UL listed T
114. nput Rate Tabulated Data Based on 21 000 Btuh High Heat 14 500 Btuh for Low Heat Per Burner Derated 4 for Each 1000 Ft Above Sea level SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE H ATVALUE 0 58 0 60 0 62 0 64 FT BTUH CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 900 42 3 2 1 5 42 3 3 1 6 42 3 4 1 6 42 3 5 1 7 925 43 3 7 1 8 43 3 8 1 8 42 3 2 1 5 42 3 3 1 6 950 43 3 5 1 7 43 3 6 1 7 43 3 7 1 8 43 3 8 1 8 U S A 975 43 3 3 1 6 43 3 4 1 6 43 3 5 1 7 43 3 7 1 7 and 2000 1000 44 3 6 1 7 43 3 3 1 6 43 3 4 1 6 43 3 5 1 7 Canada 1025 44 3 4 1 6 44 3 6 1 7 43 3 2 1 5 43 3 3 1 6 1050 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 1075 45 3 8 1 8 44 3 2 1 5 44 3 3 1 6 44 3 4 1 6 1100 46 3 8 1 8 45 3 7 1 8 44 3 2 1 5 44 3 3 1 6 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE RANGE 0 58 0 60 0 62 0 64 BTUH CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure No Pressure 800 43 3 8 1 8 42 3 2 1 5 42 3 3 1 6 42 3 4 1 6 U S A 825 43 3 5 1 7 43 3 7 1 7 43 3 8 1 8 42 3 2 1 5 Altitudes 850 43 3 3 1 6 43 3 5 1 6 43 3 6 1 7 43 3 7 1 8 U S A 1 875 43 3 2 1 5 43 3 3 1 6 43 3 4 1 6
115. o furnace Verify proper operation after servicing CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in improper unit operation or failure of unit components Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Step 1 Introduction GENERAL These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 4 you must revise your orientation to component location accordingly ELECTRICAL CONTROLS AND WIRING 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Fig 24 for field wiring information and to Fig 58 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the cont
116. o gas valve and manifold bracket screw 115 V_ WIRING Verify that the voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or Table 7 for equipment electrical specifications 21 Table 7 Electrical Data OPERATING VOLTAGE MAXIMUM MAXIMUM HERE RANGE NT FURNACE UNIT WIRE FUSE OR EM PHASE _ _ AMPS SIZE AMPACITY LENGTH CKT BKR AUGE MAX MIN 1 AMPSt 115 60 1 127 104 5 3 045 08 024045 7 42 49 15 14 115 60 1 127 104 7 1 045 12 036045 9 67 38 15 14 115 60 1 127 104 5 2 070 08 024070 7 22 51 15 14 115 60 1 127 104 7 8 070 12 036070 9 90 37 15 14 115 60 1 127 104 10 1 070 16 048070 13 42 27 15 14 115 60 1 127 104 8 2 090 14 042090 10 84 34 15 14 115 60 1 127 104 9 9 090 16 048090 13 0 28 15 14 115 60 1 127 104 12 9 090 20 060090 16 70 34 20 12 115 60 1 127 104 8 2 110 12 036110 10 76 34 15 14 115 60 1 127 104 10 1 110 16 048110 13 19 28 15 14 115 60 1 127 104 18 7 110 22 066110 17 60 32 20 12 115 60 1 127 104 10 2 135 16 048135 13 28 27 15 14 115 60 1 127 104 14 5 135 22 066135 18 61 30 20 12 115 60 1 127 104 15 0 155 20 060155 19 34 29 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 12596 of largest oper
117. o provide proper air temperature rise as specified on the rating plate Recommended operation is at the midpoint of the rise range or slightly above Refer to SET TEMPERATURE RISE under START UP ADJUSTMENT and SAFETY CHECK NOTE Refer to Table 13 for motor speed lead relocation if leads were not identified before disconnection 17 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected 18 To check blower for proper rotation a Turn on electrical supply b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door d Verify blower is rotating in the correct direction 19 If furnace is operating properly RELEASE BLOWER ACCESS DOOR SWITCH Remove any jumpers or reconnect any disconnected thermostat leads Replace blower access door 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for s
118. on products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55 F 13 C and 80 F 27 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the gas input rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on the downst
119. on Dual Fuel Thermostat should be set in ON position for two speed compressor operation 25 ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation See Fig 34 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum humidifer if used to the 1 4 male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip The HUM terminal is energized when gas valve relay GVR is energized See Fig 34 NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation SETUP SWITCHES LOW HEAT ONLY AND BLOWER OFF DELAY NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or similar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING The furnace shall be connected to a listed factory built chimney or vent or a clay tile lined masonry or concrete chimney Venting into an unlined masonry chimney or concrete chimney is prohibited When an existing Category I furnace is removed or replaced the original ven
120. operation c Measure time in sec for gas meter to complete 1 Recheck temperature rise It must be within limits specified on the rating plate Recommended operation is at the revolution and note reading midpoint of rise range or slightly above d Refer to Table 12 for cubic ft of gas per hr e Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain i t g When correct low heat input rate and temperature rise is achieved proceed to Step 6 6 Adjust Manifold Pressure to Obtain High Heat Rate NOTE Using the 2 cu ft or 5 cu ft gas meter dial provides greater accuracy in verifying gas input rate 38 If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct high heat input is achieved Re install high heat regulator seal cap on gas valve 8 Set high heat temperature rise Jumper R to W W1 and W2 to check high gas heat temperature rise Do not exceed temperature rise ranges specified on furnace rating plate for high heat The furnace must operate within the temperature rise ranges specified on the furnace rating plate Determine the air temperature rise as follows NOTE Blower access door must be installed when taking temperature rise reading Leaving blower access door off will result in incorrect temperature measurements a Verify the furnace is operatin
121. or KCAKC coil box 19 19 20 20 KGASB subbase not required Upflow Applications on Combustible or Noncombustible 2 Flooring KGASB subbase not required 23 23 5 8 Downflow Applications on Noncombustible Flooring E _ e KGASB subbase not required Pee 13 25 19 5 8 24 1 2 Downflow applications on Combustible flooring KGASB subbase required Secum 19 28 84 20 5 8 Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box 22 1 2 19 23 1 2 20 KGASB subbase not required UPFLOW DOWNFLOW HORIZONTAL 90 90 p pm YES YES YES YES EN YES YES MIN NOT NOT NOT RECOMMENDED RECOMMENDED RECOMMENDED Fig 14 Duct Flanges 13 A02329 1 THREADED ROD 4 REQ OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 48 s SCREWS MIN FOR DOOR TYPICAL FOR 2 SUPPORTS REMOVAL 1 SQUARE 11 4 x 11 4 x 1 4 ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD A02345 Fig 15 Horizontal Unit Suspension 22 GAUGE GALVANIZED STRAPS TYPICAL j FOR 4 STRAPS OPENING OUTER DOOR ASSEMBLY METHOD 2 USE 42 8 x 3 4 SHEET METAL SCREWS TYPICAL FOR EACH STRAPS THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES BACK FURNACE METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH 42 8
122. or lower Not recommended for any vent configuration The 99 Winter Design Dry Bulb db temperatures are found in the 1993 ASHRAE Fundamentals Handbook Chapter 24 Table 1 United States and 2 Canada or use the 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chapter Table 1A United States and 2A Canada APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable listings standards and codes The furnace should be sized to provide 100 of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive over sizing of the furnace could cause the furnace and or vent to fail prematurely When a metal vent or metal liner is used the vent must be in good condition and be installed in accordance with the vent manufacturer s instructions To prevent
123. paced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations The total height of the vent and connector shall be at least seven feet for the 154 000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward See Fig 41 32 Caution For the following applications use the minimum vertical heights as specified below For all other applications follow exclusively the National Fuel Gas Code FURNACE VENT ORIENTA FURNACE IN MINIMUM VENT MINIMUM VERTICAL VENT ORIENTATION TION PUT BTUH HR DIAMETER IN HEIGHT FT 154 000 Downflow 132 000 5 12 p rg 110 000 036 12 only Vent elbow right 154 000 Horizontal Left then up Fig 43 132 000 5 7 Vent Elbow up Fig 154 000 Horizontal Left 44 132 000 5 7 Horizontal Left Vent Fig 154 000 5 7 Vent elbow up then Downflow left Fig 38 110 000 036 12 only 5 10 Vent elbow up then Downflow right Fig 41 110 000 036 12 only 5 10 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in inside casing or vent guard Including 4 in vent section s A04127 Fig 49 Using Tin Snips to Cut Tie Points CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may
124. ped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s are used without a bottom return air inlet PLENUM OPENING D FLOOR OPENING A096283 Fig 11 Floor and Plenum Opening Dimensions 12 FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING SUBBASE SHEET METAL PLENUM FLOOR OPENING Kaq ee IN DOWNFLOW PA SS A096285 Fig 12 Furnace Plenum and Subbase installed on a Combustible Floor FURNACE 5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING PZV 22 A04140 A04140 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor Table 4 Opening dimensions In
125. placing any component verify correct operation sequence 54 20120 AU eoejdei JO jejsouueu jeuiuuej APZWOD eui 1 1O1SIS 1 1S eq Jeuyr3 lonuoo eoeuunj jou s eu L am 1eduunf uaym ay s oq eoeuunj y Y 39euuoosiq 04u09 BDEUIN y uo speura 5 9 10 ZA A ZM LAVM asad SI ejgeo Bunoeuuoo1ejul 10 jejsouli8u WOO Y90049 LHVLS 01 06 pue jexeeuq 95019 eoeuunj Jjexeeuq 104 pesojo 1exeeuq S JOOP S pin5 79 814 Jo31u09 st 10 ASI peseje osje sepoo snes 1 q31 qat sinou ZZ Jaye pasei sepoo snjeis uonejedo 0 10 jeeu uf amp iu e yno uiejs s uny amp Speubis pue ZA A uey ZM LAVM 01 puodsai eui seoq epoo 5 e SEM spuooes 0 10 peeds wo 440 peuuni s JOJOW
126. poo snieis eui 10 uonoes 0 09 s usel jo eui q Bip puooes eui pue seusej uoys jo eui Aq 1814 eut jequunu Z snjeis L 5 euiuuejeg S usel pue uous jo A mo s JJO NO 1461 snyes q31 SI gasned e Ajpides Buyung seys q31 SI uo seys 097 SI LYVLS 55 L00S0V eoeuunj pono l uoneoo 10sues eurej pue je o ueo 1eunq MO JI ensseud YAMS ueu 1 sjeuung j eoejdei 100 IINS yeay yBiy u yoayo uo eis IIIA sieuunq pue 0 9 0 t jeoid A Sijueuno j pue suomnoeuuoo uomneJedo 10 y9 u5 0 139 pue uo o Sp0 sano 10 payoojg eje Bury ainsseid uDnou X99490 uo peuunj seb yey 10940 YO J suonoeuuoo Y09049 jueuoduioo eoejdeud
127. pplication Vent Elbow Left then Up aa T O SEE NOTES 1 2 4 5 7 8 9 A02068 Fig 48 Horizontal Right Application Vent Elbow Left NOTES Venting Notes for Fig 36 48 1 2 3 10 For common vent vent connector sizing and vent material United States use the NFGC Canada use the CAN CSA B149 1 05 Immediately increase to 5 inch or 6 inch vent connector outside furnace casing when 5 inch vent connector is required refer to Note 1 above Side outlet vent for upflow and downflow installations must use Type vent immediately after exiting the furnace except when KGAVGO0101DFG Downflow Vent Guard Kit is used in the downflow position Type B vent where required refer to Note 1 above Four inch single wall 26 ga min vent must be used inside furnace casing and when the KGAVGO101DFG Downflow Vent Guard Kit is used external to the furnace Accessory Downflow Vent Guard Kit KGAVGO101DFG required in downflow installations with lower vent configuration Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACA02015FC for Sizing and complete application details Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart Secure all other single wall vent connector joints with 3 corrosion resistant screws s
128. proved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace casing Return Air Connections 4 WARNING FIRE HAZARD Failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furnace Follow instructions below Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 1 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most horizontal furnaces Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace See Fig 19 Upflow and Horizontal Furnaces The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 1 Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 18 and 20 Not all horizontal furnaces are approved for side return air connections See Fig 20 GAS PIPING 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made
129. r un plancher combustible dans une alc ve ou dans un garde robe en respectant le minimum d espace libre des mat riaux combustibles tel Vent Clearance to combustibles qu indiqu sur le diagramme For Single Wall vents 6 inches 6 po Cette umaise peut tre uec un Eger event avec conduite Pour conduit d vacuation paroi simple 6 po 6 inches au conduit ommun d autres appareils gaz Pour conduit d vacuation de Type B 1 1 po 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS Installation on non combusibible floors only For Installation on combustible flooring only when installed on special base Part No KGASBO201ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC 18 inches front clearance required for alcove Indicates supply or return sides when furnace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket and building joists studs or framing D GAGEMENT MINIMUM EN POUCES AVEC L MENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pourl installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale pi ce n KGASBO201ALL l ensemble serpentin pi ce n ou 5 ou le carter de serpentin pi ce m KCAKC Dans une a
130. ream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S installations Section 8 3 of the NFGC Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian installations Part 8 of the CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction CAUTION FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could cre
131. rol and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 32 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced Proper instrumentation is required to service electrical controls The control in this furnace is equipped with a Status Code LED Light Emitting Diode to aid in installation servicing and troubleshooting It can be viewed through the sight glass in blower access door The furnace control LED is either ON continuously rapid flashing or a code composed of 2 digits The first digit is the number of short flashes the second digit is the number of long flashes For an explanation of status codes refer to service label located on blower access door or Fig 57 and the troubleshooting guide which can be obtained from your distributor See Fig 62 for a brief Troubleshooting guide For Controls with an Amber LED The stored status codes will NOT be erased from the control memory if 115 or 24 v power is interrupted The control will store up to five 5 status codes 1 To retrieve status codes proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 v power to furnace turned on b Remove o
132. s necessary Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have furnace and burner serviced by a qualified service agency Inspect the vent pipe vent system before each heating season for rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the accessory instructions LED CODE RAPID FLASHING Line voltage 115V SERVICE If status code recall is needed briefly remove then reconnect one main limit wire to display last stored status code On RED LED boards do not remove power or blower door before initiating status code recall STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has RANAC power C polarity reversed If twinned refer to twinning kit instructions EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES NO PREVIOUS CODE Stored status code is erased automatically after 72 hours 32 On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to control is interrupted BLOWER ON AFTER POWER
133. s 120 C 4 way multipoise Category I fan assisted furnace is CSA formerly A A A and C G A design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger The furnace is factory shipped for use with natural gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors These furnaces shall not be installed directly on carpeting tile or any other combustible material other than wood flooring For downflow installations a factory accessory floor base must be used when installed on combustible materials and wood flooring This special base is not required when this furnace is installed on the manufacturer s coil assembly or when the manufacturer s coil box is used See Fig 2 for clearance to combustible material information This furnace is designed for minimum continuous return air temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed 80 db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before operating the furnace INSTALLATI
134. sh into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush 2 Insert brush end of cable into the outlet opening of cell and slowly rotate with drill DO NOT force cable Gradually insert cable into upper pass of cell See Fig 61 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of cell and proceed to clean 2 lower passes of cell in same manner as upper pass 5 Repeat foregoing procedures until each cell in furnace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor with fine steel wool 9 Install NOx baffles if removed 10 Reinstall burner assembly Center burners in cell openings 10 Remove old sealant from cell panel and collector box flange 11 Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel NOTE releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogen
135. specifically for the detection of leaks to check all connections 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Use proper length of pipe to avoid stress on gas control manifold and a gas leak WARNING FIRE OR EXPLOSION HAZARD Failure to protect gas valve inlet from water and debris could result in death personal injury and or property damage Gas valve inlet and or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris Also install a sediment trap in the gas supply piping at the inlet to the gas valve 18 SUPPLY AIR dU HILL UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIRFLOWMODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION2 CONNECTIONS COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES YES YES YES 20 MODELS ALLOTHERMODELS YES YES YES YES lt gt RETURN RETURN AIR AIR RETURN UPFLOW AR RESTRICTIONS Fig 18 Upflow Return Air Configurations and Restrictions 1 RETURN AIR RETURN AIR SIDE RETURN NOT PERMITTED FOR ANY MODEL SIDE RETURN NOT PERMITTED FOR ANY MODEL 066 060 22 AND 20 MODELS ALL OTHER MODELS SUPPLY AIR
136. status code 4 times b Inducer motor starts on high speed and continues to run until Step g of component test sequence Hot surface igniter is energized for 15 sec then off Blower motor operates on LO HEAT speed for 10 sec Blower motor operates on HI HEAT speed for 10 sec Blower motor operates on COOL speed for 10 sec Inducer motor goes to low speed for 10 sec then stops Reconnect lead to furnace control board remove tape from blower door switch and re install blower door 4 Operate furnace per instruction on inner door 5 Verify furnace shut down by lowering thermostat setting below room temperature 6 Verify furnace restarts by raising thermostat setting above room temperature Table 10 2 Stage Furnace Setup Switch Description SETUP SWITCH NORMAL DESCRIPTION SWITCH NO NAME POSITION OF USE When OFF allows 2 stage operation with a single stage thermostat Turn ON when using 2 stage thermostat to allow Low Heat opera en Adaptive keat Mode one tion when R to W W1 closes and High Heat operation when R to W W1 W2 close SW 2 Blower OFF delay ON or OFF Control blower OFF conjunction with SW 3 Control blower OFF delay time Used in conjunction with SW 2 SW 3 Blower OFF delay ON or OFF See Table 14 Step 3 Adjustments models in downflow and horizontal positions use Table 15 22 000 BTUH per burner PIN WARNING Table 11
137. th WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify hazards which may result in minor personal injury or Table 1 Dimensions In A B FILTER FURNACE Size CABINET SUPPLY AIR RETURN AIR SEM ee COLLAR SHIP WT LB GAENT WIDTH IN WIDTH IN IN IN COLLAR IN SIZE IN 045 08 024045 14 3 16 12 9 16 12 11 16 9 5 16 4 116 16 045 12 036045 14 3 16 12 9 16 12 11 16 9 5 16 4 119 16 070 08 024070 14 3 16 12 9 16 12 11 16 9 5 16 4 120 16 070 12 036070 14 3 16 12 9 16 12 11 16 9 5 16 4 124 16 070 16 048070 17 1 2 15 7 8 16 11 9 16 4 188 16 090 14 042090 17 1 2 15 7 8 16 11 9 16 4 186 16 090 16 048090 51 19 3 8 19 1 2 18 5 16 4 151 20 090 20 060090 51 19 3 8 19 1 2 18 5 16 4 156 20 110 12 036110 17 1 2 15 7 8 16 11 9 16 4 144 16 110 16 048110 21 19 3 8 19 1 2 18 5 16 4 158 20 110 22 066110 21 19 3 8 19 1 2 18 5 16 4 163 20 185 16 048135 21 19 3 8 19 1 2 18 5 16 at 163 20 135 22 066135 24 1 2 22 78 23 15 1 16 at 174 24 155 20 060055 24 12 22 78 23 15 1 16 at 181 24 5 or 6 vent connector may be required in some cases T 135 and 155 size furnaces require five inch or larger vents Use a 4 5 or 4 6 inch vent adapter between furnace and vent connector product and property damage NOTE is used to highlight suggestions which will result in enhanced
138. tification Reconnect original lead to SPARE terminal e Repeat steps a thru e f When correct high heat input rate and temperature rise is achieved turn gas valve ON OFF switch to OFF g Release Blower Access Door switch h Remove manometer or similar device from gas valve i Re install manifold pressure tap plug in gas valve use 3 16 in head allen wrench See Fig 54 4 WARNING FIRE HAZARD Failure to reinstall manifold pressure tap plug in gas valve could result in personal injury property damage or death Reinstall manifold pressure tap plug in gas valve to prevent gas leak j Remove thermostat jumper wire from furnace control board k Turn LHT switch OFF 1 Turn gas valve ON OFF switch to ON m Proceed to Step 9 Set Blower Off Delay before installing blower access door CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace life Recheck temperature rise It must be within limits specified on the rating plate Recommended operation is at the midpoint of rise range or slightly above 9 Set Blower Off Delay a Remove Blower Access Door if installed b Turn Dip switch 2 and 3 ON or OFF for desired blower off delay See Table 14 and Fig 34 10 Set thermostat heat anticipator a Mechanical thermostat Set thermostat heat anticapator to match the amp draw of the electrical components in the R W W1 circuit Accurate amp draw re
139. ting system may no longer be sized to properly vent the attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of condensate and combustion products and spillage of combustion products into the living space TWINNING AND OR COMPONENT TEST TERMINAL AIR CONDITIONING RELAY DISABLE JUMPER j n ni 24 V THERMOSTAT TEST TWIN E 5 HUM 0 5 AMP024 VAC g e TERMINALS 4 gi z E E HUMIDIFIER TERMINAL TRANSFORMER 24 VAC CONNECTIONS 24 0 5 ap 3 FUSE 5 v LED OPERATION amp 2007 mm 5 DIAGNOSTIC LIGHT 5 115 VAC L2 NEUTRAL SE BHT CLR BLWR CONNECTIONS HI HEAT LO HEAT PRA PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR PL3 WISH Wat YOTIHI Ll amp dui LIB HI LO J COOL 1 115 SPARE 1 SPARE 2 EAC 1 SPARE 1 BLOWER SPEED SPARE 2 COOL SELECTION TERMINALS 115 VAC L1 LINE VOLTAGE CONNECTION PL2 HOT SURFACE IGNITER amp INDUCER MOTOR CONNECTOR EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02017 Fig 34 Furnace Control PSC Blower Motor 26 WARNING CARBON MONOXIDE POISONI
140. tory default Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations Dip switch No 2 on Thermidistat should be set in OFF position for single speed compressor operation This is factory default Dip switch No 2 on Thermidistat should be set in ON position for two speed compressor operation Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel applications NO connection should be made to the furnace HUM terminal when using a Thermidistat Optional connection If wire is connected dip switch SW1 2 on furnace control should be set in ON position to allow Thermidistat Thermostat to control furnace staging Optional connection If wire is connected ACRDJ jumper on furnace control should be removed to allow Thermidistat Thermostat to control outdoor unit staging When using both a two stage furnace and a two stage heat pump the furnace must control its own high stage heating operation via furnace control algorithm The RVS Sensing terminal L should not be connected This is internally used to sense defrost operation DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internally by the Thermidistat Dual Fuel Thermostat Dip switch D on Dual Fuel Thermostat should be set in OFF position for single speed compressor operation This is factory default Dip switch D
141. touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control Or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the furnace Put all used and new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage gt AIRFLOW THE BLOWER IS LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER IS LOCATED T TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT A lt HORIZONTAL LEFT HORIZONTAL RIGHT Es AIREEOW AIRFLOW DOWNFLOW THE BLOWER 18 THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION AND OF THE BURNER SECTION CONDITIONED AIR 18 AND CONDITIONED AIR IS DISCHARGED DOWNWARD m DISCHARGED TO THE RIGHT A02097 Fig 4 Multipoise Orientations LOCATION GENERAL This multipoise furnace is shipped in packaged configuration Some assembly and modifications are required when used in any of the
142. trical box and casing and into furnace J Box 10 Reattach furnace J Box to furnace casing with screws removed in Step 4 11 Secure field ground wire to J Box green ground screw 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Fig 24 Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electrical requirements listed in Table 7 Refer to power cord manufacturer s listings 1 Remove cover from J Box 2 Route listed power cord through 7 8 inch diameter hole in J Box 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 24 6 Reinstall cover to J Box Do not pinch wires between cover and bracket BX CABLE INSTALLATION IN FURNACE J BOX 1 Remove cover from J Box 2 Route BX cable into 7 8 inch diameter hole in J Box 3 Secure BX cable to J Box bracket with connectors approved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 24 6 Reinstall cover to J Box Do not pinch wires between cover and bracket
143. trol CPU includes a programmed adaptive sequence of controlled operation which selects low cooling or high cooling operation This selection is based upon the stored history of the length of previous cooling period of the single stage thermostat NOTE The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling See Fig 34 When ACRDJ is in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling The furnace control CPU can start up the cooling unit in either low or high cooling If starting up in low cooling the furnace control CPU determines the low cooling on time from 0 to 20 minutes which is permitted before switching to high cooling If the power is interrupted the stored history is erased and the furnace control CPU will select low cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling as long as the thermostat continues to call for cooling Subsequent selection is based on stored history of the thermostat cycle times The wall thermostat calls for cooling closing the R to G and Y circuits The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuits starts the furnace blower motor BLWM at low cool speed same speed as LO HEAT
144. uct systems that do not have a 90 elbow and 10 ft of main duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA as tested by UL Standard 181 for Class 1 Rigid air ducts Supply Air Connections For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible Openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks Upflow and Horizontal Furnaces Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace main casing 15 Table 5 Air Delivery With Filter FURNACE RETURN AIR spEED EXTERNAL STATIC PRESSURE
145. uipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame roll out or overheating condition occurs in the gas control area DO NOT bypass the switches Correct problem before resetting the switches 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 3 To Begin Component Self Test Remove blower access door Disconnect the thermostat R lead from furnace control board Manually close blower door switch Short jumper the COM 24v terminal on control to the TEST TWIN 3 16 inch quick connect terminal on control until the LED goes out approximately 2 sec Gas valve and humidifier will not be turned on Remove jumper from terminals See Fig 34 and Table 10 NOTE The furnace control allows all components except the gas valve to be run for short period of time This feature helps diagnose a system problem in case of a component failure 1 Maintain 115 v wiring and ground Improper polarity will result in rapid flashing LED and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the
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147. uter access door c Look into blower access door sight glass for current LED status Removing blower access door will open blower access door switch and terminate 115 v power to control so that status code is not displayed d BRIEFLY remove insulated terminal wire from the draft safeguard DSS switch until LED goes out then reconnect it NOTE If wire to DSS is disconnected longer than 4 sec main blower starts and retrieval request is ignored 2 When above items have been completed the LED flashes status code 4 times Record this status code for further troubleshooting After the LED flashes status code four times BRIEFLY remove wire again from DSS switch until LED goes out then reconnect it to retrieve previous status code if available Repeat as needed for more previous status codes or until Code 11 appears Step 2 Care and Maintenance 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products Explosure to these m
148. y period at LO HEAT or HI HEAT speed respectively The blower motor BLWM will revert to continuous blower speed after the heating cycle is completed In high heat the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower OFF delay period before reverting to continuous blower speed When the thermostat calls for low cooling the blower motor BLWM will switch to operate at low cool speed same speed as LO HEAT When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on low cool speed before reverting back to continuous blower speed When the thermostat calls for high cooling the blower motor BLWM will operate at COOL speed When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous blower speed When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower speeds from the room thermostat momentarily turn off the FAN switch or pushbutton on the room thermostat for 1 3 seconds after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower speed from the factory setting of LO HEAT to HI HEAT speed Momentarily turning off the FAN switch again at the
149. ype B vent Relining with a listed metal liner or Type B vent is considered to be a vent in a chase If a metal liner or Type B vent is used to line a chimney no other appliance shall be vented into the annular space between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors ONFPA amp Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ IN FT Uer 12 19 28 38 6 74 119 178 1257 8 80 130 198 279 10 84 138 207 299 15 NR 152 283 334 20 NR NR 250 368 30 NR NR NR 1 404 Table 9 Minimum Allowable Input Rating of Space Heat ing Appliance in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ IN FT 12 19 28 38 Local 99 Winter Design Temperature 17 to 26 F 6 0 55 99 141 8 52 74 111 154 10 NR 90 125 169 15 NR NR 167 212 20 NR NR 212 258 30 NR NR NR 362 Local 99 Winter Design Temperature 5 to 16 F 6 NR 78 121 166 8 NR 94 135 182 10 NR 111 149 198 15 NR NR 193 247 20 NR NR NR 293 30 NR NR NR 377 Local 99 Winter Design Temperature 10 to 4 F 6 NR NR 145 196 8 NR NR 159 218 10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333 30 NR NR NR NR Local 99 Winter Design Temperature 11 F

Browning BR16F Home Safety Product User Manual

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