Allied Air Enterprises Downflow or Horizontal 2 Stage Heat Variable Speed Gas Fired Non
Contents
1. R VIAL Ds HI DOO i GAS VALVE QB CHE R Cy RW RL rk RC IKEK FLAME SENSIR SEE NOTE 5 BL 2 e 4 BRN YL ABCT 7 5525 ADJUST PARK 2 lt 1 BLOVER AMBER LEU DEHUM A rT AND MOTOR IGNITION 2 91 12 1170 20 0 97 gt for t Wolke RED LED GREEN LED cial tolg mi w2 S F 499E wS OK an lt FAULT CODE HISTORY SWITCH Ke Oe i CH WER CHOKE HEN LSED lt lt lt a 2 gt lt 212 3 5 R 0000442 DIAGNOSTIC LIGHTS A RED LED IS PROVIDED TO INDICATE SYSTEM FAULTS ERROR CODES ARE AS FOLLOWS LED OFF NO POWER TO CONTROL OR CONTROL HARDWARE FAULT DETECTED LED ON NORMAL OPERATION 1 FLASH FLAME PRESENT WITH GAS VALVE OFF 2 FLASHES PRESSURE SWITCH CLOSED WITH INDUCER OFF 3 FLASHES PRESSURE SWITCH OPEN WITH INDUCER ON OR 185 OPEN 4 FLASHES HIGH LIMIT SWITCH OPEN OR ROS OPEN 5 FLASHES NOT USED 6 FLASHES PRESSURE SWITCH CYCLE LOCKOUT 7 FLASHES LOCKOUT DUE TO NO IGNITION2. J DUCT 7 MUST EXTEND ABOVE ATTIC INSULATION FURNACE 21 00 BOTTOM AIR OPENING 000 1 SQ IN 4 000 OF TOTAL INPUT o Z WATER HEATER 22 N F0000267 VENTILATION LOUVERS CRAWL SPACE ACAUTION For an attic installation it is important to keep insulation 12 or more away from any furnace openings Some types of insulating materials may be combustible 20571201 When horizontal ducts are used to supply air from the outdoors they must be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts must not be less than 3 inches Each opening must have a free area of not less than one square inch per 2 000 Btu per hour of total input of all appliances within the Confined Space These openings must be located 12 in from the top and bottom of the furnace area Neither opening can be blocked at any time See Figure 6 Figure 6 CONFINED SPACE OUTDOOR AIR THROUGH HORIZONTAL DUCTS 12 AIR DucT OPENINGS FURNACE N TO f OUTDOORS 280 1 SQ 2000 BTUH AIR DUCT TOTAL INPUT 12 WATER HEATER 0000268 AWARNING Furnaces
3. 36 Ee 72 51 45 36 275 EA 54 o Ca e 1 4 Calculate the furnace input using the following formula BTUH Cubic Ft Hr x BTU Cubic Foot The local gas supplier should be able to provide the heating value of the gas BTU cubic foot If a specific value is not available use 1000 BTU cubic foot for Natural gas or 2500 BTU cubic foot for Propane LP AWARNING Furnace input should be maintained within 2 of the value on the rating plate or appropriate altitude derate Adjust manifold pressure or change orifices size if required 5 Calculate the unit s actual input rate Example If the heating value of the natural gas is 1015 Btu cu and it takes 60 seconds to burn 2 cu ft of gas then Input 1015 Btu cu ft X 1 rev X 2 cu ft rev X 3600 60 sec Input 121 800 Btu hr Page 20 of 28 Burner Orifice Sizing The furnace is supplied with standard orifices for the gas shown on the rating plate Table 6 shows combinations of heating values and specific gravities for various gases from which proper input can be obtained If changing orifices is required remove the manifold from the furnace following the instructions found on page 24 and replace orifices as required by Table 6 the altitude derating section of this instruction or as local code dictates TABLE 6 Burner Orifice Selection Type of Gas Manif
4. Failure to follow this warning can lead to electrical shock that could result in bodily harm After the ductwork connections have been made gas piping and electrical wiring completed and the furnace has been properly vented the unit should be started and adjusted for proper operation Check off the following steps as they are completed 20571201 Issue 0527 1 Be sure all electrical power is OFF Check all wiring using proper wiring diagram on inside of the control box cover 3 Turn ON the electrical power 4 Set the ignition system control switch in the ON position 5 Set the thermostat above room temperature 6 The hot surface ignitor will heat up to an orange glow the main burners will ignite Figure 14 TYPICAL FLAME APPEARANCE Main Burners HEAT BURNER EXCHANGER ae GAS MANIFOLD BURNER FLAME 0000258 Blue Only 7 Recheck for leaks in the manual shut off valve gas control valve and gas connections using a soap solution AWARNING Never use an open flame when testing for gas leaks Use of an open flame could lead to a fire or explosion A CAUTION Many soaps used for leak testing are corrosive to certain metals Piping must be rinsed thoroughly with clean water after leak check has been completed Manifold Pressure Adjustment Turn OFF the gas and electrical before preceeding Remove the manifold pressure tap pipe plug from the gas valv
5. Issue 0527 Page 2 of 28 FURNACE SPECIFICATIONS RISE CURRENT OPENING OPENING RANGE MODEL LENGTH wine HEIGHT DIA PROTECTION WIRE SIZE AWG ELECTRICAL UNIT DIMENSIONS DUCT SUPPLY DUCT RETURN OVER aes SUPPLY MIN TEMPERATURE 5 mee I I ee Peele AA EE REDUCER SUPPLIED WITH FURNACE WHEN CONNECTION SIZE IS DIFFERENT THAN PIPE DIA REQUIRED H FOR FLUE VENT PIPE TOP VENT CONNECTION H FLUE DIA gt ee A npn 7 3 4 E O D 1 D O D __ 1 LOUVERED ACCESS GAS INLET DOOR EITHER SIDE ELECTRICAL CONNECTIONS EITHER SIDE SIDE VENT CONNECTION FLUE DIA CONTROL BOX ACCESS PANEL THERMOSTAT Fao BLOWER CONNECTIONS ACCESS EITHER SIDE 13 PANEL SIDE RETURN CUT OUT EITHER SIDE 5 0000167 7 5 6 20571201 Issue 0527 Page 3 of 28 BLOWER MOTOR SPECIFICATIONS AND AIRFLOW ADJUSTING DATA Adjusting Airflow ADJUST HEAT and COOL Taps on Integrated Ignition Blower Control Board 0000424 HEAT SETTING
6. FLASHES LOCKOUT TO TOO MANY FLAME DROPOUTS 9 FLASHES INCORRECT LINE VOLTAGE PHASING A GREEN LED IS PROVIDED INDICATE HIGH HEAT STATE LED OFF DEMAND FOR HIGH HEAT LEQ ON HIGH HEAT DEMAND OPERATING NORMALLY LED FLASHING HIGH HEAT DEMAND HIGH PRESSURE SWITCH CLOSED A AMBER LEO IS PROVIDED TO INDICATE BLOWER MOTOR CFM BEING DELIVERED COUNT THE NUMBER OF TIMES THE LED FLASHES AND MULTIPLY BY 100 EACH FLASH STGNIFIES 100 0000444 20571201 Issue 0527 PL PRESSURE SWITCH LOW PH PRESSURE SWITCH HIGH ROLL OUT SWITCH Ha FACTORY WIRING CONDENSING UNIT MANUAL RESET AL AUXILIARY LIMIT TRANSFORMER Fl LOW VOLT FUSE 1 IN LINE CONNECTION TBS INDUCER GLOVER SWITCH 0000444 LINE FIELD WIRING mY FIELD CONNECTION O RM YELLOW NOTES 1 FIELD POWER SUPPLY CONNECTIONS BLACK AND WHITE WIRES CAPPED WITH ORANGE WIRE NUTS 2 WARNING UNIT MUST BE GROUNDED WIRING MUST CONFROM N E C AND CODES t 3 TF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE F REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 AND BE A MINIMUM OF 16 GA AWG COPPER STRAND WIRE 4 SET THE HEAT ANTICIPATOR ON THE THERMOSTAT AT 0 60 AMPS 5 LOW VOLT FUSE 3 OR 5 AMP AUTOMOTIVE TYPE LITTLEFUSE 25700 3 5 OR BUSS AT 3 5 F0000444A Page 5 of 28 AWARNING The fu
7. flooring on wood flooring in the upflow or horizontal positions however it must not be installed directly on carpeting tile or any other combustible material In the downflow position it must be installed combustible flooring on the special base listed on the rating label OR on a cased In a horizontal position line contact with combustibles is only permissible between lines formed by the intersection of the furnace top the front and back sides and building joists studs or framing See Figure 1 Figure 1 HORIZONTAL LINE CONTACT LINE CONTACT ONLY PERMISSIBLE BETWEEN TOP CORNERS OF FURNACE AND BUILDING JOISTS STUDS OR FRAMING KEEP ALL INSULATING MATERIAL CLEAR OF FURNACE INSULATING MATERIALS MAY BE COMBUSTIBLE 0000035 Furnace must not lean back It must be level or tilt up to 2 to the front See Figure 1 A clearance of at least 30 should be provided at the front of the unit for servicing For attic installations the passageway and servicing area adjacent to the furnace should be floored Page 7 of 28 If the furnace is to be installed in a crawl space consult local codes Use of a concrete pad 1 to 2 thick is recommended If the furnace is to be suspended from the ceiling it will be necessary to use steel pipe straps around each end of the furnace These straps should be attached to the furnace with sheet metal screws and to the rafters with bolts The furnace may also be su
8. lined masonry chimney provided 1 The chimney is currently serving at least one drafthood equipped appliance 2 The vent connectors and chimney are sized in accordance with the applicable sections of the U S National Fuel Gas Code ANSI 7223 1 54 and or CSA _ B149 1 Natural Gas Propane Installation Codes This furnace must NOT vented ALONE into an existing masonry chimney either tile lined or unlined unless the chimney is also lined with either a type B vent system or a listed single wall metal lining system Both of these systems must be sized in accordance with the applicable sections of the U S National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas and Propane Installation Codes Before venting this furnace into a chimney check the chimney for deterioration and repair if necessary This furnace must not be vented into a chimney serving a separate appliance designed to burn solid fuel Type B vent connectors must be used on all installations and it must be sized per the applicable sections of the U S National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas and Propane Installation Codes Type B Vent The furnace is also approved for use with a B vent that terminates through the roof Refer to the applicable sections of the U S National Fuel Gas Code ANSI 2223 1 54 and or CSA 149 1 Natural Gas and Propane Installation Codes for proper sizing and
9. only by a qualified service agency Figure 18 Issue 0527 BLOWER REMOVAL AND REPLACEMENT BLOWER RETAINING SCREWS Foo00042_ Page 25 of 28 TROUBLE SHOOTING With LED Indicator Assistance Troubleshooting Make the following visual checks before toubleshooting 1 Check to see that the power to the furnace and the integrated ignition blower control board is ON 2 The manual shutoff valves in the gas line to the furnace must be open 3 Make sure all wiring connections are secure 4 Review the Sequence of Operation see page 23 Start the system by setting thermostat above room temperature Observe system response Then use the information provided in this section to check the system operation The furnace has a built in self diagnostic capability If a system problem occurs a fault code is shown by a red LED on the control board The control continuously monitors its own operation and the operation of the system If failure occurs the LED will indicate the failure code The flash codes are presented in Table 9 Fault Code History Button The control stores the last five fault codes in memory A pushbutton switch fault code history switch is located on the control see Page 5 When the pushbutton switch is pressed and released the control flashes the stored fault codes The most recent fault code is flashed first the oldest fault code is flashed last To clear the fault code history press and ho
10. serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 20571201 Issue 0527 A WARNING The furnace and its individual shutoff valve must be disconnected from the supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG 3 5kPa or 14 w c The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 PSIG 3 5kPa or 14 w c Failure to follow the above procedures could lead to a hazardous condition and bodily harm Figure 12 A GAS CONTROL PIPING WHEN FLANGE IS NOT USED APPLY WRENCH y L NSS S 59 5 Sy CONTROL TO H EITHER SHADED N AREAS Figure 12 B TYPICAL GAS SERVICE CONNECTION FIELD SUPPLIED MAIN N MANUAL SHUT OFF i F0000269 Page 16 of 28 This furnace is manufactured for use with Natural gas and must be converted using the proper LP conversion kit for use with LP Propane gas For LP Propane gas a tank regulator is required to reduce supply pressure to 12 13 w c For manifold pressu
11. vent cap and turn ON gas AWARNING At higher altitudes and varying heating valves manifold pressure or orifice changes maybe required Consult Tables 7 and 8 for appropriate values Failure to follow this warning could lead to a hazardous furnace operating condition and result in serious bodily injury or loss of life Determining Furnace Input Natural Gas Only NOTE All access doors must be in place when checking gas input 1 Turn OFF all other gas appliances except for pilot burners served by the same gas meter 2 With furnace operating in full heat cycle note how many seconds it takes for one full revolution of the smallest dial on the meter Typically this will be a 1 2 or 1 cubic foot test dial 3 Using the number of seconds for one revolution and the size of the meter dial determine the cubic foot per hour of gas flow by using the formula provided below or Table 5 Number of Dial Revolutions x Cubic Foot Revolution 3600 ubic E Time in seconds Required for Number of Timed Revolutions 20571201 Issue 0527 TABLE 5 Gas Rate Cubic Feet per Hour TEST DIAL TEST DIAL Seconds 1 2 Seconds 1 2 One Cubic Canis Cubic Revolution Feet Feet Revolution Feet Feet 36 50 2 EJ A 8 200 408 2180 360 ii
12. with a listed mechanical venter in accordance with horizontal venting instructions It must not be connected to any portion of a mechanical draft system operating under positive pressure The 3 in to 4 in vent adaptor coupling supplied with unit MUST BE USED t must be connected directly to the outlet of the combustion blower using field supplied corrosion resistant sheet metal screw See Figure 8 20571201 Issue 0527 Figure 8 VENT ADAPTOR MOUNTING F REDUCER SUPPLIED WITH UNIT SCREW X FIELD SUPPLIED 0000260 Pre Installation Vent System Inspection Before this furnace is installed it is highly recommended that any existing vent system be completely inspected For a chimney or B vent this should include the following 1 Inspection for any deterioration in the chimney Page 12 of 28 vent If deterioration is discovered the chimney must be repaired or the B vent must be replaced 2 Inspection to ascertain that the vent system is clear and free of obstructions Any blockage must be cleared before installing this furnace 3 Cleaning the chimney or B vent if previously used for venting a solid fuel burning appliance or fireplace 4 Confirming that all unused chimney or B vent connections are properly sealed 5 Verification that the chimney is properly lined and sized per the applicable codes Masonry Chimney This furnace can be common vented into an existing tile
13. 18 of 28 STARTUP AND OPERATIONAL CHECKOUT AWARNING It is not recommended that this furnace be used as a construction heater during any phase of construction Very low return air temperatures harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit The unit may only be used for heating of buildings or structures under construction if the conditions listed on page 6 the Introduction section of these instructions are met The automatic gas valve controls the flow of gas to the main burners The control circuit built into the automatic valve body has 2 positions OFF and ON Figure 13 To shut off gas manually Switch from ON to OFF position When in OFF position the main burners are extinguished This furnace is equipped with an automatic hot surface ignition control and does not require the manual lighting for furnace operation Figure 13 GAS CONTROL DIAGRAM BARBED VENT STAGE REGULATOR HIGH STAGE FITTING _ ADJUSTMENT UNDER VENT REGULATOR ADJUSTMENT UNDER VENT 28 WIRING CAP TERMINALS 3 INLET l PRESSURE lt m OUTLET MANIFOLD INLET VR8205 TWO STAGE PRESSURE TAP 0000427 2 GAS CONTROL KNOB AWARNING Do not attempt to manually light the burners
14. AFFIX LABEL HERE INSTALLATION AND SERVICING INSTRUCTIONS UPFLOW DOWNFLOW OR HORIZONTAL TWO STAGE HEAT VARIABLE SPEED GAS FIRED NON CONDENSING WARM AIR FURNACE Issue 0527 TABLE OF CONTENTS Safety sts heer Oe a pee ee te eas led 2 Gas Connections ees ee 16 Furnace Specifications 3 Control Board amp Variable Speed Motor Features 17 Furnace Wiring Specifications 5 Unit Sequence of Operation 18 Introduction ah eee eae Ee 6 Start Up Operation amp Checkout 19 7 Sequence of Operation 23 Air for Combustion amp Ventilation 8 Servicing The Furnace 24 DUCHNG 5 11 Control System Diagnostics 26 VENTING bi hace Maa aad he 12 Wiring Diagram 2 Sate ee ee OER ee 27 AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Installation and service must be performed by
15. DJUST FLAY 16 4 1 44 EH 20 0 T CM 3 s P6 Q 2 7 9 Tae m pos ig 4 a PG B PB 14 L 09 NRI 06 15 FAN P6 lt _ LOGIC 1 5 Pg 2 HEAT 6 13 INTERFACE THERMOSTAT R FLSE P i 24 VAL 120 VAC gt 5 g lt H b a AND STAGE HEAT eS STAGE HEAT a EUTRAL RLL ROLIT HIHO SWITCH p o_o 05 oe 4 4 x J EUTRAL 5 BLOWER MOTOR 2 LOW PRESSURE WITH aa 2 2 FARK a ee P 5 6 HIGH PRESSURE SWITCH 2 HN HIGH GAS VALVE 6 7 KA p 5 Pe GAS VALVE 8 re J INOUCER MOTOR P2 p FL AWE CINE HS IGNI TOR ELECTRODE 1170 20 l HOT BI 20 VAC LINE 0000443 20571201 Issue 0527 Page 27 of 28 NOTES 20571201 Issue 0527 Page 28 of 28
16. ERATION LOW HEAT CIRCULATING AIR FAN ON AFTER DELAY 30 SECONDS FLAME SENSE LOST THERMOSTAT CALL FOR HEAT ENDS MAIN VALVE CLOSES COMBUSTION AIR BLOWER OFF AFTER POST PURGE 15 SECONDS CIRCULATING AIR FAN OFF AFTER DELAY WAIT FOR NEXT CALL FOR HEAT Issue 0527 1 HOUR AUTO LOCKOUT RESET DELAY FLASH 6 7 OR 8 CIRCULATING AIR FAN OFF AFTER DELAY COMBUSTION AIR BLOWER OFF AFTER POST PURGE 0000426 23 28 SERVICING THE FURNACE A CAUTION ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury death or property damage e Before servicing disconnect all electrical power to furnace Wehn servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing AWARNING The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools If you are at all uncertain contact your dealer for qualified maintenance and service since improper service could lead to furnace shutdown or a hazardous condition which could lead to an unsafe condition and bodily harm Reattach all wiring and piping as per the wiring diagram and installation instructions Turn on utilities and check for leaks using soapy w
17. S COOL SETTINGS MOTOR BLOWER HEATING CFM 50 STATIC COOL CFM 50 STATIC MODEL HP WHEEL SETTING SETTING SETTING SETTING COOLING SETTING SETTING SETTING SETTING ADJUSTMENT o 1200 1000 600 25 325 625 1380 1150 690 1020 850 510 1200 1000 600 AV075B3 640 540 840 1380 1150 690 1020 850 510 1600 1400 1000 AV100B4 1150 1350 1800 1610 1150 1360 1190 850 2000 1800 1400 AV125B5 1550 1750 2200 2070 1610 1700 1530 1190 THE UNIT AS SHIPPED IS FACTORY SET AT SETTING A TO RUN AT THE MIDDLE OF THE HEATING RISE RANGE SHOWN ON THE UNIT RATING LABEL A WARNING When operating the furnace in the heating mode the static pressure and the temperature rise supply air temperature minus return air temperature must be within those limits specified on the rating label Failure to follow this warning could lead to severe furnace damage A WARNING Turn OFF all gas and electrical power to furnace before performing any maintenance or service on unit Unless specific test requires gas and electrical supplies Failure to take this precaution may result in personal injury due to electrical shock or uncontrolled gas leakage 20571201 Issue 0527 Page 4 of 28 FURNACE WIRING SPECIFICATIONS
18. a qualified installer service agency or the gas supplier Installation by an unqualified person may lead to equipment damage and or a hazardous condition which may cause bodily injury and harm and as such at the sole discretion of the manufacturer the entire warranty may be voided and be of no further force and effect 20571201 Issue 0527 Electric Shock Hazard Turn Off All Power Before Servicing WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Extinguish any open flame Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone supplier s instructions If you cannot reach your gas supplier call the fire department Follow the gas Page 1 of 28 SAFETY The following is a list of safety precautions and their locations in this manual These safety rules and precautions must be followed when installing this furnace 20571201 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate Install this furnace only in a location and position as specified The Location Placement Section on page 7 of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section on page 8 of these instructions Combustion products must be discharged outdoors Connect this furnace to an approved vent syst
19. ater and a brush A visual check of the main burner should be made at the beginning of each heating season Check the input rate and adjust if necessary Perform a safety check of the limit control and pressure switch Check the air filter clean and or replace as necessary Replace the appropriate access panels or door AWARNING Never use an open flame when testing for gas leaks Use of an open flame could lead to a fire or explosion ACAUTION Many soaps used for leak testing are corrosive to certain metals Piping must be rinsed thoroughly with clean water after leak check has been completed Manifold or Burner Manifold Removal Replacement 1 Make sure that all utilities gas and electricity are turned off upstream of the furnace 2 Remove the louvered access door by sliding the door Combustion Component Check straight up swinging the bottom of the door away The heat exchanger gas burners and venting system from the furnace and pulling the door down and out must be checked each year prior to the heating season of the furnace See Figure 17 by a qualified dealer serviceman 3 Disconnect the gas line from the gas valve Be sure The following procedures should be performed that a wiring diagram is available or be ready to mark any wires that are disconnected Unplug the 1 Remove the burner manifold assembly from the three connectors from the gas valve furnace follow the instruction
20. be used for this purpose A WARNING When supply ducts carry air circulated by the furnace to areas outside the spaces containing the furnace the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space containing the furnace Incorrect ductwork termination and sealing will create a hazardous condition that could lead to bodily harm ACAUTION Air openings intake and outlet pipes return air grilles and warm air registers must not be obstructed To Convert to Downflow Position 1 Convert the combustion blower to side flue exit as outlined on page 14 2 Install proper special base per Table 2 for installation on combustible flooring follow instructions supplied with special base 3 Itis recommended that the return air be connected to the bottom panel of the furnace when it is installed in the downflow position NOTE SPECIAL SUB BASE NOT REQUIRED WHEN FURNACE IS MOUNTED ON A METAL CASED EVAPORATOR COIL Table 2 SPECIAL BASE INSTALLATION SPECIAL BASE MODEL NUMBER CAT NO AV050B3 AV075B3 20066501 68L77 AV100B4 20066502 68L78 AV125B5 20066503 68L79 NOTE Installation on combustible flooring only when installed on one of the above listed special bases or as identified on the furnace model and rating label Page 11 of 28 Filters Air filters must be used in every installation For side return installations air filters must be installed externa
21. be checked and cleared Failure to do so may result in serious bodily harm or nuisance furnace shutdown and or a hazardous condition that may lead to property damage personal injury or death Page 22 of 28 CALL FOR HIGH HEAT AIR PROVING SWITCH PROVED CLOSED WITHIN 30 SECONDS YES HIGH STAGE MAIN VALVE OPENS CIRCULATING AIR FAN TO HIGH HEAT SPEED HIGH HEAT CALL ENDS LOW HEAT DEMAND REMAINS HIGH STAGE MAIN VALVE AND CALL FOR HIGH HEAT CIRCULATING AIR FAN DE ENERGIZED 20571201 HIGH STAGE MAIN VALVE DE ENERGIZED FIVE MINUTE WAIT FOR SEQUENCE OF OPERATION DIRECT IGNITION SYSTEM CONTROL APPLY POWER TO APPLIANCE THERMOSTAT CALLS FOR HEAT AIR PROVING SWITCH PROVED OPEN amp WAIT FOR AIR PROVING SWITCH WAIT FOR LIMIT CIRCUIT LIMIT CIRCUIT CLOSED TO OPEN FLASH 3 TO CLOSE ANDIOR RESET OF FLAME ROLLOUT FLASH 4 FIVE MINUTE WAIT PERIOD COMBUSTION AIR BLOWER OFF COMBUSTION AIR BLOWER ON AIR PROVING SWITCH PROVED CLOSED WITHIN 60 SECONDS PREPURGE 15 SECONDS HSI ENERGIZED 7 SECONDS 15 SECONDS ON RE TRIES 30 SECONDS BETWEEN TRIAL PURGE MAIN VALVE OPENS HSI DE ENERGIZED MAIN BURNER LIGHTS AND IS SENSED DURING TRIAL FOR IGNITION MAIN VALVE CLOSES FAILED TRIALS FOR IGNITION LESS THAN FIVE DURING THIS IGNITION SEQUENCE MAIN VALVE CLOSES FLAME SENSE LOST MORE THAN FIVE TIMES IN THIS CALL FOR HEAT OR OTHER ABNORMAL OP
22. ce from inside the building structure two permanent openings to an additional room of sufficient volume as to combine the volumes of the spaces to meet the criteria for an Unconfined Space must be created Each opening must have a free area of not less than one square inch per 1000 Btu per hour of total input of all appliances within the Confined Space but not less than 100 square inches These openings must be located 12 inches from the top and bottom of the furnace area respectively and must be at least 3 inches long on the smaller side of the opening See Figure 2 Neither opening can be blocked at any time Figure 2 CONFINED SPACE INDOOR AIR TOTAL INPUT FREE AREA ROUND DUCT Btuh Sq In Dia In FURNACE OPENINGS TO ADDITIONAL ROOMS L 2 150 1000 BTUH pag OF TOTAL INPUT EXAMPLE 50 000 Btuh Furnace amp 10 000 Btuh Water E 12 MAX Heater 60 000 Btuh Total Input 12 X 04 Dia Round Duct __ WATER HEATER 0000264 If ventilation and or combustion air must be supplied to the Confined Space from outside the building structure two permanent openings to the outdoors must be created Each opening must have a free area of not less than one square inch per 4000 Btu per hour of total input of all appliances within the Confined Space These openings must be located 12 inches from the top and b
23. e Figure 13 outlet pressure tap and install a pressure tap and connect it to a manometer Turn on the gas and electrical supplies Page 19 of 28 The gas control Figure 13 has two separate pressure regulator adjustment screws one for 1 stage marked LO the second one for 27 stage marked The adjusting screws are positioned on either side of the barbed fitting The pressure regulator adjustment is sensitive one turn of the adjusting screw will result in a relatively large change in manifold pressure Turn regulator adjusting screws clockwise to increase pressure OUT counterclockwise to decrease presure Set the unit on high fire and adjust the 274 stage high fire pressure regulator to the required setting Disconnect the violet wire from the HI terminal on the gas control and the burners will drop down to the 1 stage low fire then adjust the 1 stage pressure regulator setting as required Gas input must never exceed the value shown on the furnace rating label These units are equipped for rated input at manifold pressures of 2 3 w c 1 stage and 3 5 w c 274 stage for natural gas When these furnaces have been converted for use with LP propane gas the manifold pressures 6 4 w c 1 stage and 10 0 w c 27 stage After proper adjustments reconnect violet wire and furnace should go up to 274 stage high fire Turn OFF gas replace manifold pressure tap pipe plug regulator adjustment
24. e Speed Features The furnace is equipped with a variable speed circulation air blower motor that will deliver a constant airflow within a wide range of external static pressures Other features of this variable speed motor include Soft Start The variable speed motor will slowly ramp up to normal operating speed This minimizes noise and increases comfort by eliminating the initial blasts of air encountered with standard motors Soft Stop At the end of a cooling or heating cycle the variable speed motor will slowly ramp down after a short blower off delay If continuous blower operation has been selected the variable speed motor will slowly ramp down until it reaches the airflow for that mode Circulating Airflow Adjustments Heating Mode The unit as shipped is factory set setting A to run at the middle of the heating rise range as shown on the unit rating plate Adjustments can be made to the heating airflow by repositioning the jumper plug marked HEAT A B C D see AirFlow Adjustment Table on page 4 based on the information found in the table Heating rise must always be within the rise range shown on the rating plate Page 17 of 28 Cooling Mode The units are factory set for the highest airflow for each model Adjustments can be made to the cooling airflow by repositioning the jumper plug marked COOL A B C D see AirFlow Adjustment Table on page 4 based on the information found in the table By mo
25. e furnace The manifold pipe must be supported during this step or it could fall and damage the furnace or cause bodily injury b Slide the burner manifold assembly forward out of the furnace until the assembly is clear of the manifold retention pins c Rotate the assembly slightly in order for the legs to clear the sides of the cabinet and remove through the front of the furnace To reinstall the manifold pipe or burner manifold assembly reverse the above steps Blower Removal Replacement Removal 1 2 3 20571201 Turn OFF all electrical power to the furnace Remove the control box access panel and blower access panel Unplug wires from the blower assembly to the control box Remove the four 4 screws securing the control box in the unit two 2 in the cabinet at the sides of the blower door opening and two 2 at the top rear of the control box Be sure to support the control box so that it does not fall Rotate the control box out of the cabinet and support it so that no strain is placed on any wiring It may be necessary to disconnect the electrical supply and thermostat wiring from the control board Remove the blower retaining screws from the front of each blower leg See Figure 18 These are the two 2 screws located in the blower compartment that secure the blower legs to the blower partition panel Slide the blower forward about two 2 inches This will disengage the rear of the blower legs from
26. een the furnace and adjacent construction TABLE 1 MINIMUM INSTALLATION CLEARANCES UPFLOW POSITION DOWNFLOW POSITION HORIZONTAL POSITION Suitable for alcove or closet Suitable for alcove or closet installationt on non Suitable for attic alcove or closet installationt on installationt on combustible combustible flooring at minimum clearance from flooring at minimum clearance from adjacent construction not less than the following for proper special base Top Sides Back Front 2 combustible flooring at minimum clearance from adjacent construction not less than the following adjacent construction not less than the following Installation on combustible flooring only when installed on special base see model amp rating label formed by intersection of the top and two sides of Line contact only permissible between lines the furnace jacket and building joist studs or framing Vent t For closet installation see Air for Combustion and Ventilation AWARNING Failure to comply with all of the clearances will create a fire hazard INSTALLATION POSITIONS AIRFLOW a 4 UPFLOW gt 4 HORIZONTAL HORIZONTAL LEFT RIGHT AIRFLOW AIRFLOW AIRFLOW 0000404 The furnace should also be located as near to the center of the air distribution system as possible and should be installed level This furnace may be installed on non combustible 20571201 Issue 0527
27. em only as specified in Venting on page 12 of these instructions 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 Connection section on page 16 of these instructions 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 Furnace Specifications on page 3 of these instructions See furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See page 11 for Ducting gas fired furnace for installation in a residential garage must be installed as specified in The Location Placement section on page 7 of these instructions Itis not recommended that this furnace be used as a construction heater during any phase of construction Very low return air temperatures harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit The unit may only be used for heating of buildings or structures under construction if the conditions listed on page 6 in the Introduction section of these instructions are met
28. emovers varnishes etc e Hydrochloric acid e Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials e Unrefined gases AWARNING Contaminated combustion air may cause premature failure of the heat exchanger that may lead to a hazardous condition and or bodily harm or loss of life Adequate Ventilation and Combustion Air This section is provided to give guidelines for the introduction of air for ventilation and combustion air The total quantity of air provided to the installation area must equal the requirements of all gas appliances in the area Adequate facilities for providing air for combustion 20571201 Issue 0527 and ventilation must be provided in accordance with the latest edition of the National Fuel Gas Code ANSI 2223 1 54 or CSA 149 1 Natural Gas and Propane Installation Codes or applicable provisions of the local building codes The furnace shall be installed in a location in which the facilities for ventilation permits satisfactory combustion of gas proper venting and maintenance of ambient temperature at safe limits under normal conditions of use The furnace shall be located so as not to interfere with proper circulation of air In addition to air needed for combustion ventilation in the form of process air must be provided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilution safety exhaus
29. ermined 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 ELECTRICAL CONNECTIONS When installed the furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the U S National Electrical Codes ANSI NFPA 70 or CSA Standard 22 1 Part 1 Canadian Electrical Code For proper installation refer to furnace rating label for electrical ratings and for the field rating and wire size Use copper wire only for 115V supply service to unit When replacing any original internal wiring use only 105 C 16 AWG copper wire Thermostat wiring of this unit refer to furnace wiring specifications on page 5 or alternately from the wiring diagram on page 27 In all instances other than wiring for the thermostat the wiring to be done and any replacement of wire shall conform with the temperature limitation for Type T wire 63 F rise 35 The electrical connections and the thermostat connections are made at the openings on either side panel of the unit in the control box area Either side may be used as convenient but the provided hole plugs must be inserted in the unused holes The control system depends on the correct polarity of the power supply Connect Hot H wire and Ground G wire as shown in
30. f life GAS CONNECTIONS Gas piping shall be of such size and so installed as to provide a supply of gas sufficient to meet maximum demands without undue loss of pressure between the gas meter and the furnace It is recommended that the gas line to the furnace shall be a separate line direct from the meter unless the existing gas line is of ample capacity Refer to gas pipe capacity table in the National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas and Propane Installation Codes If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do no use a connector which has previously serviced another gas appliance Use a joint compound pipe dope that is resistant to the action of liquefied petroleum gases or any other chemical constituents of the gases to be conducted through the piping For proper furnace operation the maximum gas supply pressure is 14 w c and the minimum gas supply pressure is 4 5 w c Natural 11 w c LP as shown on rating label Before any system of gas piping is finally put into service it should be carefully tested to determine if it is gas tight Check all piping for leaks using soapy water and a brush The piping must stand a pressure of six 6 inches of mercury 3 PSIG for a period of ten 10 minutes or as required by local authority A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in
31. furnace wiring specification on wiring diagram Use reference Table on page 3 Furnace Specifications for over current protection max unit amp 20571201 Issue 0527 Instructions for wiring the thermostat are packed in the thermostat field supplied box Make the thermostat connections as shown in furnace wiring specifications at the 24 volt terminal board located in the control box Single Stage Thermostat Operation The automatic heat staging option allows a single stage thermostat to be used with a two stage furnace To activate this option move the jumper pin See Figure 11 to desired setting 5 minutes or 10 minutes The furnace will start on first 157 stage heat and stay at first 1 stage heat for the duration of the selected time before switching to 274 stage heat Page 15 of 28 Figure 11 AUTOMATIC HEAT STAGING JUMPER 60 a 10 0000425 When installing optional accessories to this appliance follow the manufacturer s installation instructions included with the accessory AWARNING The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur This may consist of electrical wire or approved conduit when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning can result in an electrical shock fire bodily harm or loss o
32. gas on low fire for the first 15 seconds of steady heat and ignores any 274 stage demand After the 15 second period the control switches the inducer to low speed After a 30 seconds blower on delay the control energizes the low heat circulating air blower The blower runs at reduced CFM approximately 400 for 30 seconds then ramps up to 1 stage heat speed If 1 stage heating operation is not sufficient to satisfy the heating demand the room thermostat initiates a call for 2 stage heat W1 and W2 The control changes the inducer from low to high speed and confirms the high fire pressure switch contacts are closed and the gas valve energizes on 2 stage heat The circulating air blower then ramps up to 2 stage heat speed When the 274 stage call for heat is satisfied the control shuts off the gas valve and runs the combustion air blower for a post purge period of 5 seconds The circulating air blower continues to run for approximately 3 minutes before ramping down If the thermostat W2 call ends and W1 remains the control de energizes the high gas output changes the inducer speed from high to low and the gas valve drops back to 1 stage heat After approximately 2 minutes the circulating air blower ramps down to 1 stage heat speed 20571201 Issue 0527 In the event the unit loses ignition the control will attempt to recycle up to five times before it goes into a 1 hour lockout Lockout may be manually reset by remo
33. iances connected to the venting system are not in operation 1 Seal any unused openings in the venting system Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI 2223 1 54 or the CSA B149 1 Natural Propane Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Close fireplace dampers Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas and Propane Installation Codes After it has been det
34. iate manifold pressures based the elevation and the heating value can be found in Table 7 20571201 Issue 0527 TABLE 7 High Altitude Manifold Pressure Derate with standard 42 orifice Natural 54 orifice LP sizes Heating Value of Natural Gas PENE BTU FT3 ae ee 1650 3500 3000 3999 Heating Value based on atmospheric pressure of 30 inhg and 60 F temperature If local codes require an orifices change the appropriate orifice size based on the elevation and the heating value can be found in Table 8 Sizing of the orifice must be based on the previously mentioned 4 derate for each 1 000 feet for installations at or above 2 000 feet rule and the orifices must be drilled in such a way as to assure concentricity Hand drilling of orifices is unacceptable TABLE 8 High Altitude Orifice Size Derate Heating Value of Natural Gas Altitude BTU FT3 Feet ae Heating Value based on atmospheric pressure of 30 inhg and 60 F temperature AWARNING Hand drilling of orifices is never acceptable since it could lead to delayed ignition overfiring improper combustion flashback and flame rollout All these conditions could lead to a fire hazard and bodily harm or loss of life Blower Adjustment Checkout This furnace is equipped with a variable speed circulation air blower motor that will deliver a constant airlfow within a wide range of external static pressures The
35. installed with combustion air drawn from a heated space which includes exhaust fans fireplaces or other devices that may produce a negative pressure should be considered confined space installations Page 10 of 28 DUCTING The proper sizing of warm air ducts is necessary to insure satisfactory heating operation Ductwork should be in accordance with the latest editions of U S NFPA 90A Air Conditioning Systems and NFPA 90B Warm Air Heating and Air Conditioning Systems or Canadian equivalent Ductwork Recommendation The supply duct work should be attached to the flanged opening provided at the discharge end of the furnace See page Furnace Specificatons for the dimensions of this opening A left right or bottom return air opening must be used as determined by the layout of the installation The back must not be cut out for return connections An externally mounted air filter is required This furnace has a two piece bottom panel For bottom or end duct return remove the back portion of the bottom panel by removing the four 4 screws two 2 on each side toward the back of the furnace See Figure 7 Tilt furnace toward the front the back portion of the panel will drop down Then the back portion can be removed by pulling toward the back of the furnace Figure 7 BOTTOM PANEL REMOVAL FRONT FRONT REMOVE SCREWS 2 EACH SIDE 0000024 Knockouts are provided on both sides of
36. l to the furnace casing An external filter rack kit with filter parts 20069901 or Cat No 68175 12 157 25 sizes and 20069902 Cat No 68L76 for 157 19 x 25 sizes is available as an optional accessory For bottom end return installations the above optional external rack may be used if the unit was not provided with a internal filter Minimum filter size and suggested filter materials are shown in Table 3 If different type filter is used it must be an equivalent high airflow capacity Table 3 EXTERNAL FILTER RACK SIZE SIDE BOTTOM END RETURN RETURN 050 3 15 X25 12 X 25 100 4 15 X25 125 5 15 X25 15 X25 19 X 25 This furnace may use either a disposable filter permanent filter electronic or high efficiency media air cleaner Consult filter cleaner manufacturers for maintience service and static pressure drop for air moving requirements When installing the furnace with cooling equipment for year round operation the following recommendations must be followed for series or parallel air flow 1 In series flow applications the evaporator coil is mounted after the furnace in an enclosure in the supply air stream The furnace blower is used for both heating and cooling airflow 2 In parallel flow installation dampers must be provided to direct air over the furnace heat exchanger when heat is desired and over the cooling when cooling is desired At no time may the evapora
37. ld the pushbutton switch in for more than 5 seconds before releasing High Heat State LED On these models a green LED is provided on the control board to indicate high heat state see Table 10 CFM LED An amber LED is provided on the control board to display CFM To determine what CFM the motor is delivering at any time count the number of times the amber LED flashes Each flash signifies 100 CFM count the flashes and multiply by 100 to determine the actual CFM delivered for example 10 flashes x 100 1000 CFM 20571201 Issue 0527 Table 9 Failure Codes Red LED LED Fault Description LED Off No power to control or control hardware fault detected LED On Normal operation 1 Flash Flame present with gas valve off 2 Flashes Pressure switch closed with inducer off Incorrect polarity and phasing Table 10 High Heat State Green LED LED LED Off No demand for high heat LED On High heat demand operating normally LED Flashing demand high pressure switch not Page 26 of 28 WIRING DIAGRAM 6 12 i PRT 6 9 FE Id 6 16 COOL HEAT A
38. mine the cause of the rollout correct the condition that caused it and reset the flame rollout switch AWARNING The furnace should be allowed to cool off before attempting to reset the switch Failure to follow these instructions could result in injury due to burns The switches are located behind the front access door Remove front access door from the furnace and reset by pushing in the button in the middle of the switch between the two wire connections See Figure 16 Very little force is required to push the reset button and a click should be heard when the switch resets Figure 16 FLAME ROLLOUT SWITCH ROLLOUT SWITCH LOCATIONS RESET BUTTONS F0000270 20571201 Issue 0527 Pressure Switch Check To check the operation of the pressure switch vent safety control remove the vent adaptor from the combustion blower Place the furnace into operation for high fire Gradually cover up the blower outlet the furnace should first drop to low fire and with further restriction of the opening the main burners should shut OFF Remove the restriction and the unit should relight Replace the vent adaptor and reseal the opened joints as required The operational checkout is now complete Be sure to adjust the thermostat to the desired setting and inform the homeowner how to operate the furnace system before leaving the job site AWARNING If the pressure switch activates to shut the furnace down the vent system must
39. nace to the vent terminal 6 All runs of pipe should be as short as possible with as few turns as possible 7 Seams should be tightly joined and checked for leaks 8 The flue pipe must not extend into the chimney but be flush with the inside wall 9 The chimney or vent pipe must extend at least three 3 feet above the highest point where it passes through a roof of a building and at least two 2 feet higher than any portion of building within a horizontal distance of ten 10 feet It shall also extend at least five 5 feet above highest connected equipment flue collar Figure 9 VENT EXIT OPTIONS HORIZONTAL RIGHT AIR FLOW DOWNFLOW HORIZONTAL LEFT UPFLOW F0000261 AIR FLOW 10 The 3 to 4 vent adaptor coupling must be used to connect to the combustion blower outlet It must be installed directly to the combustion blower outlet See Figure 8 To Convert to Side Flue Exit 1 Remove the louver door from the furnace Be sure the side vent exit knock out is removed from the right side panel of the cabinet See Figure 9 2 Disconnect the pressure switch tubing from the combustion blower 20571201 Issue 0527 3 Remove the four 4 screws that secure the combustion blower adaptor plate to the flue collector box taking care to support the blower assembly so that it does not fall 4 Rotate the blower 90 degrees clockwise so that the outlet of the blower is pointing toward
40. old Press Orifice Heating Value Specific Gravity Size Btu per Cu Ft Drill Natural Manifold Press 3 5 w c 800 0 6 900 0 6 1000 0 6 1100 0 6 Propane Manifold Press 10 w c 2500 1 53 54 After securing the manifold assembly replace all other components and or wiring being sure that all connections and screws are tightened properly Altitude Derating The following information is provided as guidelines for altitude derating and is not meant to supersede any state or local codes Local codes have priority over any others and in some case might limit your options in dealing with an altitude derate situation NOTE In Canada for altitudes up to 4500 ft 1372 m see the rating label on this furnace for proper manifold pressure and orifice size Certification for installations at altitudes over 4500 ft 1372 m is the jurisdiction of local authorities Check with your local gas company to find out if the gas supply in your area is derated Gas deration negates the necessity of performing any adjustment on the furnace If your gas supply is not derated regardless of the type of gas used installation of this furnace at elevations above 2 000 ft requires an input reduction at the rate of four percent 4 for each 1 000 ft above sea level Unless an orifice change is specified by an applicable code the recommended method of altitude derating this furnace is to appropriately lower your manifold pressure The appropr
41. ombustion air intake of another appliance 6 Vent terminal should be located at least four 4 feet above any electric or gas meters regulators and relief equipment General Venting Requirements This furnace may be common vented only with other Category appliances Common venting is allowed as permitted by National and or local codes Refer to the applicable sections of the U S National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas and Propane Installation Codes for proper sizing and set up The vent must be terminated with a listed vent cap This venting must be installed in accordance with the vent manufacturer s instructions and be in accordance with all local codes and or National Codes Follow Figure 9 for vent exit options The following requirements are provided for a proper venting system Be sure that the chimney flue is clear of any dirt or debris 2 Be sure that the chimney is not servicing an open fireplace 3 Never reduce the pipe size below the outlet size of the furnace without checking the applicable sections of the U S National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas Propane Installation Codes Page 13 of 28 4 All pipe should be supported using the proper clamps and or straps These supports should be at least every four 4 feet 5 All horizontal runs of pipe should have at least a 1 4 in per foot of upward slope from the fur
42. ottom of the furnace area respectively See Figures 3 4 and 5 Neither opening can be blocked at any time Figure 3 CONFINED SPACE OUTDOOR AIR TOTAL INPUT FREE AREA ROUND DUCT Btuh Sq In Dia In 10 15 40 000 Z 60 000 12 MAX 80 000 4 4 100 000 120 000 OPENINGS 140 000 OUTDOORS T 160 000 150 IN 4000 BTUH OF TOTAL INPUT oo EXAMPLE 12 MAX 50 000 Btuh Furnace amp 10 000 Btuh Water me Heater 60 000 Btuh Total Input 5 Dia ____ WATER HEATER Round Duct 20571201 Issue 0527 Page 9 of 28 Figure 4 CONFINED SPACE OUTDOOR AIR FROM ATTIC TOP AIR OPENING 1 SQ IN 4000 BTUH TOTAL INPUT ATTIC 7 2 SS INSULATION MUST EXTEND ABOVE ATTIC 21 4 5555555 L INSULATION BOTTOM AIR OPENING 21 1 SQ IN 4000 BTUH FURNACE i OF TOTAL INPUT m0 oo 12 MAX M N WATER HEATER 0000266 Figure 5 CONFINED SPACE OUTDOOR AIR FROM ATTIC amp CRAWL SPACE gt VENTILATION LOUVERS _____ TOP AIR OPENING 25 1 SQ IN 4 000 BTUH N OF TOTAL INPUT
43. re see Table 6 A main manual shut off valve must be used in the gas piping The shut off type and location must follow local codes and should always be in an accessible but protected location In the absence of local codes the recommended methods for installing the gas piping to the furnace are shown in Figures 12 A and 12 B The gas valve contains two threaded ports for a 1 8 NPT tap in order to test incoming gas pressure and outgoing manifold pressure See Figure 13 ACAUTION Many soaps used for leak testing are corrosive to certain metals Piping must be rinsed thoroughly with clean water after leak check has been completed AWARNING Never use an open flame when testing for gas leaks Use of an open flame could lead to a fire or explosion CONTROL BOARD amp VARIABLE SPEED MOTOR FEATURES Humidifier Connections Terminals are provided on the blower control board for connections to a 120 volt optional humidifier The HUM terminal is energized whenever the thermostat calls for heat Refer to furnace wiring diagram for specific connection information Electronic Air Cleaner Connections Terminals are provided on the blower control board for connection of a 120 volt optional electronic air cleaner The EAC terminal is energized whenever the thermostat calls for heat cooling or continuous blower Refer to the furnace wiring diagram for specific connection information Continuous Blower Operation The comfor
44. replaced upon construction completion input rate and temperature rise must be set per the furnace rating plate One hundred percent 100 outdoor air must be provided for combustion air requirements during construction Temporary ducting may supply outdoor air to the furnace Do not connect combustion air duct directly to the furnace Size the temporary duct following these instructions in the section Air for Combustion amp Ventilation for air in a confined space with air from outside furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly cleaned following final construction clean up furnace operating conditions including ignition input rate temperature rise and venting must be verified according to these installation instructions These instructions are written for individual residential installation only For multi unit installation or commercial applications please contact manufacturer for recommendations 20571201 Issue 0527 Page 6 of 28 LOCATION PLACEMENT Site Selection This furnace may be located in an attic closet basement crawl space alcove or suspended from the ceiling of a utility room or basement Select a location that will meet all requirements for safety clearances ventilation and combustion air ductwork design gas piping electrical wiring and venting Clearances The following minimum clearances or greater must be provided betw
45. rnace cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur The unit must also be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of the U S National Electrical Code ANSI NFPA_ 70 or CSA Standard C22 1 Part 1 Canadian Electrical Code if an external electrical source is utilized DO NOT use gas piping as an electrical ground INTRODUCTION This furnace is design certified by CSA International as a Category furnace using air from inside the structure for combustion It is shipped as a packaged unit complete with burners and controls and requires a line voltage 115V connection to the junction box a thermostat hook up as per the wiring diagram and a gas line connection ducting and flue piping This furnace can be installed in either upflow downflow or horizontal airflow positions at no time should this unit be operated on its back The design of this furnace is NOT CSA Certified for installation in recreation vehicles in manufactured mobil homes outdoors or as a construction heater This furnace has been designed to interface with split system cooling equipment approved by a nationally recognized testing laboratory so as to provide year round air conditioning The blower has been sized for both heating and cooling and the furnace controls include a cooling fan relay The furnace installa
46. s found on this page 2 Place the burner manifold assembly on a flat work Figure 17 area and vacuum the burners It might be necessary FURNACE PANEL REMOVAL to use a soft bristly brush to remove dirt and then vacuum 3 Disconnect wiring to combustion blower 4 Disconnect wiring to pressure switches and remove pressure switches supe FRONT 5 Remove the burner opening inlet plate and the flue UP DOOR iw collector box with the combustion blower attached Ny This will expose both the burner and flue openings of CONTROL A the primary heat exchangers ACCESS DOOR t 6 Vacuum the length of each heat exchanger tube using a straight attachment into the burner openings REMOVE N and the flue openings SOREWS 7 Replace the flue collector box burner opening inlet REMOVE plate and burner manifold assembly Insure that all SCREWS gaskets are properly positioned and that no leaks BLOWER exist DOOR 0000271 20571201 Issue 0527 Page 24 of 28 Disconnect wires from rollout switch Remove manifold or burner manifold assembly Manifold ONLY a Remove the No 10 screws that secure the manifold pipe to both legs of the manifold assembly The manifold pipe must be supported during this step or it could fall and damage the furnace or cause bodily injury b Slide the manifold pipe with valve and orifice forward out of the furnace Burner Manifold Assembly a Remove the No 10 screws that secure the burner manifold assembly legs to th
47. set up of this furnace with B vent for a dedicated vent system or a common vented system Horizontal Venting This furnace is design certified by CSA International for horizontal venting through an outside wall by use of one of the following auxiliary draft inducer kits 20571201 Issue 0527 Table 4 AUXILIARY DRAFT INDUCERS Field Controls Co 50000 75000 100000 or 50000 75000 100000 or 551 SS1C 125000 GPAK J 50000 75000 or 100000 100000 or 125000 Tjernlund Products Inc GPAK 1 See rating label on this furnace for input Vent Length Max 60 ft Min 12 ft Vent Diameter 4 in Follow instructions included with venting kit for proper installation and setup Location Requirements for Horizontal Venting Locate the vent terminal adhering to the following minimum clearances and as specified in the auxiliary draft inducer vent kit 1 Vent terminal must be located at least one 1 foot above the grade or at least one 1 foot above the normal expected snowfall 2 Avoid installing vent terminal above public walkways If this is not possible install the terminal at least seven 7 feet above the walkway 3 Vent terminal should be at least four 4 feet to the side of and at least one 1 foot above doors and windows 4 Vent terminal should be at least three 3 feet above any forced air inlet located within ten 107 feet 5 Vent terminal should be located at least six 6 feet from the c
48. spended by using an angle iron frame bolted to the rafters See Table on page 3 for size and weight of furnace Care must be taken to allow for service access If a furnace is to be installed in a residential garage it must be installed so the burners and the ignition source are located not less than 18 above the floor and the furnace must be located or protected to avoid physical damage by vehicles AWARNING Do not place combustible material on the furnace jacket Failure to comply with this warning will create a fire hazard AWARNING This furnace is not watertight and is not designed for outdoor installation This furnace shall be installed in such a manner as to protect the electrical components from water Outdoor installation would lead to a hazardous electrical condition and to premature furnace failure AIR FOR COMBUSTION AND VENTILATION Contaminated Combustion Air This furnace is not to be installed in a structure defined as having contaminated combustion air Allowing exposure to substances containing chlorine or fluoride could harm the furnace and void the warranty Substances to avoid include but are not limited to e Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals e De icing salts or chemical e Carbon tetrachloride e Halogen type refrigerants e Cleaning solvents such as perchloroethylene e Printing inks paint r
49. t and odor control Air must be supplied for ventilation including all air required for comfort and proper working conditions for personnel For purposes of this instruction the following definitions apply Confined Space A space whose volume is less than 50 cubic feet per 1000 of the aggregate input rating of all appliances installed in that space A space whose volume is less than 50 cubic feet per 1000 Btu hr of the aggregate input rating of all appliances installed that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered of the unconfined space Unconfined Space Page 8 of 28 If the installation area meets the definition of Unconfined Space and does not have additional air AWARNING requirements as described the furnace may be installed Do not block the combustion or ventilation air without making special provisions for combustion and openings in the furnace Any blockage will result in ventilation air improper combustion and may result in a fire hazard or unsafe condition ACAUTION Whenever this furnace is installed in an area along with one or more gas appliances the total Btu hr input of all appliances must be included when determining the free area requirements for combustion and ventilation air openings If ventilation and or combustion air must be supplied to the Confined Spa
50. t level of the living space can be enhanced when using this feature by allowing continuous circulation of air between calls for cooling or heating The circulation of air occurs at half the full cooling airflow rate To engage the continuous blower operation place the fan switch on the thermostat into the ON position A call for fan from the thermostat closes R to G on the ignition control board The control waits for a 1 second thermostat debounce delay before responding to the call for fan by ramping the circulating blower up to 50 of the cooling speed but not less than 425 cfm s When the call for continuous fan is satisfied the control immediately de energizes the circulating blower Dehumidification For situations where humidity control is a problem a dehumidification feature has been built into the variable speed motor At the start of each cooling cycle the variable speed motor will run at 82 of the rated airflow for 7 5 minutes After 7 5 minutes has elapsed the motor will increase to 100 of the rated airflow Additional dehumidification be achieved by connecting a humidistat to the DEHUM and R terminals on the integrated ignition blower control board In this 20571201 Issue 0527 setup the variable speed motor will operate at a 10 reduction in the normal cooling airflow rate when there is a call for dehumidification Both dehumidification methods described above can be utilized on the same furnace Variabl
51. the blower partition Rotate the front of the blower down to clear the control box mounting tabs on the underside of the blower partition and continue sliding the blower forward until it is out of the unit Take care to clear the control box mounting tabs If necessary disconnect the auxiliary limit leads on the sides of the blower housing Replacement 1 2 3 Place the blower in the blower opening of the unit and reconnect the auxiliary limit leads Slide the blower back into the unit taking care to clear the control box mounting tabs When the blower is about halfway into the cabinet rotate the rear of the blower UP so that the rear of the blower legs engage the side rails in the blower partition Continue sliding the blower into the unit until the front of the blower housing is behind the control box mounting tabs Rotate the front of the blower UP until the legs lie flat against the bottom of the blower partition then slide blower fully into position The rear of the blower should be against the stop in the partition and the rear of the blower legs should be under the partition Reattach the two 2 blower securing screws the control box any disconnected wiring the blower access panel and the control box access panel Lubricating Motors Direct drive motor and blower assemblies are factory lubricated and normally do not require oiling If oiling is required lubrication of the blower motor is to be preformed
52. the furnace to facilitate the cutout required to the return air ductwork Furnace cutouts must be the full size specified by the corner markers Undersized cutouts will adversely affect the airflow capability of the furnace and could cause overheating of the heat exchanger The following recommendations should be followed when installing the ductwork 1 Install locking type dampers in all branches of the individual ducts to balance out the system Dampers should be adjusted to impose the proper static at the outlet of the furnace 2 Noncombustible flexible duct connectors recommended to connect both the supply and return ducts to the furnace 3 cases where the return air grille is located close to the blower inlet there should be at least one 90 air turn between blower and return grille Further reduction in sound can be accomplished by installing acoustical air turning vanes and or lining the inside of the duct with acoustical material 4 Itis recommended that the supply duct be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall 20571201 Issue 0527 be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted by sampling the air stream The access panel shall be designed so as to prevent leaks when locked in position If an air conditioning coil is installed the access panel to the coil can
53. the right side panel of the furnace 5 Insure that the gasket is in place between the blower adaptor plate and the flue collector box Reattach the blower assembly to the flue collector box using the four 4 screws removed in step 3 Be sure that the screws are properly tightened and that the gasket seals the plate to the box 6 Reconnect the pressure switch tubing to the combustion blower 7 Optional Install vent pipe guard Kit Number 20284801 Figure 10 VENT PIPE GUARD KIT 0000263 For Horizontal Positions It is not necessary to reposition any of the components of the furnace in order to install it in either horizontal position As outlined above it is permissible to use the side vent exit for the horizontal left position if desired Checking For Vent Oversizing If this furnace is replacing a furnace that is attached to a venting system serving other appliances the venting system is likely to be too large to properly vent all of the attached appliances An improperly sized venting system can lead to condensation leakage or spillage Page 14 of 28 A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appl
54. tion must conform with local building codes or in the absence of local codes with the latest edition of the U S National Fuel Gas Code ANSI 2223 1 54 or Canadian Natural Gas and Propane Installation Codes CSA B149 1 For complete information on installation standards consult the U S National Fuel Gas Code obtainable from the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or the American Gas Association 1515 Wilson Boulevard Arlington VA 22209 or the Canadian installation codes obtainable from Canadian Standards Association 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 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 must not exceed a maximum continuous temperature of 85 F dB The furnace may be used for heating of buildings or structures under construction if the following conditions are met e vent system must be permanently installed per these instructions Aroom thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed return air duct must be provided and sealed to the furnace e Return air temperature range between 60 F and 80 F must be maintained e filters must be installed in the system and must be maintained during construction e Air filters must be
55. tor coil be located on the return air side of the heat exchanger IMPORTANT The dampers should be adequate to prevent cooled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either the cooling unit or furnace unless the damper is in the full cool or full heat position AWARNING The coil MUST be installed on the air discharge side of the furnace Under no circumstances should the air flow be such that cooled conditioned air can pass over the furnace heat exchanger This will cause condensation in the heat exchanger and possible failure of the heat exchanger that could lead to a fire hazard and or hazardous conditions that may lead to bodily harm Heat exchanger failure due to improper installation will not be covered by warranty VENTING Venting for this category furnace must be to the outside in accordance with local codes requirements of the local utility In the absence of local codes venting must conform to the applicable sections of the latest edition of U S National Fuel Gas Code ANSI 2223 1 54 and or CSA B149 1 Natural Gas Propane _ Installation Codes and the vent manufacturers instructions This furnace is CSA International certified as a Category forced air appliance and can not be vented into vent system with any Category Il Ill or IV appliance It must be vented vertically or nearly vertically unless installed
56. unit as shipped is factory set to run at the middle of the heating rise range as shown on the unit rating plate For low heat to high heat transition the control changes the blower speed from low heat speed to high heat speed Check the temperature rise between the return and supply plenums to make sure it is within the rise range shown on the rating plate Heat blower off delay is a fixed 180 second delay After the 180 second delay the motor will slowly ramp down to a soft stop NO adjustments need to be made in the heating mode Page 21 of 28 Limit Control Checkout After the furnace has been in operation for at least 15 minutes restrict the return air supply by blocking the filters or closing the return registers and allow the furnace to shut down on high limit The main burners will shut OFF and the main blower and combustion blower should continue to run Remove the restriction and the burners should come back on in a few minutes Flame Rollout Switch This unit is equipped with two 2 manual reset flame rollout switches that protects against improper venting of the flue gases from the heat exchanger due to blockage causing heat or flames to rollout into the burner box from the heat exchangers either safety device will activate and shut off power to the automatic gas valve before there is damage to the furnace The loss of power to the gas valve will shut off the gas burners Should this occur it will be necessary to deter
57. ving power from the control for more than 1 second or removing the thermostat call for heat for more than 3 seconds If during a heating cycle the limit control senses an abnormally high temperature and opens the ignition control de energizes the gas valve and the combustion blower while the circulating blower ramps up to 2 stage heat speed The circulating blower remains energized until the limits are closed AWARNING Should overheating occur or the gas supply fail to shut OFF turn OFF the manual gas valve to the appliance BEFORE turning OFF the electrical supply A failure to adhere to this warning can result in a fire or explosion and bodily harm Fan ON A call for continuous fan from the thermostat closes R to G on the control board The control waits for a 1 second debounce delay before responding by energizing the circulating air blower at 50 of the cooling speed When the call for fan is turned off the control de energizes the circulating blower Cooling A call for cooling from the thermostat closes R to Y and R to G on the blower control board The control waits for a 1 second thermostat debounce delay before energizing the circulating air blower to 82 of the cooling speed After 7 5 minutes the circulating blower automatically ramps up to 100 of the cooling speed When a call for cooling is satisfied the circulating blower ramps back down to 82 of the cooling speed for 60 seconds then shuts off Page
58. ving the ADJUST jumper plug see Table on page 4 from the NORM position to the or position will also cause the cooling airflow setting to be raised or lowered by 15 The TEST position on the ADJUST tap is not used To determine what CFM the motor is delivering at any time count the number of times the amber LED on the control board flashes Each flash signifies 100 CFM count the flashes and multiply by 100 to determine the actual CFM delivered for example 10 flashes x 100 1000 CFM UNIT SEQUENCE OF OPERATION Here s How Your Heating System Works Standby Mode When the control is in standby mode it continually monitors thermostat input rollout switch and flame sense Call For Heat On call for 1 stage heat W1 from the room thermostat the ignition control performs a 1 second self check The control verifies the limit switch is closed and both low and high pressure switches are open The control always starts on low fire and ignores 2 stage call for heat until low heat is established and heat blower on delay is complete The induced draft blower is energized to high speed and waits for the low pressure switch to close before starting a 15 second pre purge period Upon completion of the pre purge the hot surface igniter is energized for a period of 7 seconds 15 seconds on retries before the gas valve is energized 15 stage and main burners ignite The induced draft blower remains on high speed with the
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