Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
Home
My WebLink
About
34585-Z
FORM NO. 4 TOWN OF SOUTHOLD BUILDING DEPARTMENT office of the Building Inspector Town Hall Southold, N.Y. CERTIFICATE OF OCCUPANCY No: Z-33741 Date: 05/27/09 T~IS CERTIFIES that the building GAS FURNACE Location of Property: 635 SOUNDVIEW AVE EXT SOUTHOLD (HOUSE NO.) (STREET) (HAMLET) County Tax ~ap No. 473889 Section 50 Block 2 Lot 7 Subdivision Filed Map No. __ Lot No. __ conforms substantially to the Application for Building Permit heretofore filed in this office dated APRIL 7, 2009 pursuant to which Building Permit No. 34585-Z dated APRIL 7, 2009 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is INSTALL GAS FURNACE IN AN EXISTING ONE FAMILY DWELLING AS APPLIED FOR. The certificate is issued to DARIA M CIAPUTA (OWNER) of the aforesaid building. S~3FFOL~K COUN~f DEPERT~qT OF }~L~L~{APPRO~-AL N/A ELEt-r~IC3%L C~RTIFICATE NO. 4028122 05/14/09 PLI~BERS CERTIFICATION DA'r~ N/A uthorized Signature Rev. 1/81 Form No. 6 TOWN OF SOUTBOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the. Building Department with the following: For new building or new use: 1. Final survey of property with accurate location of all buildings, pr~p~W Frees, streets, and unusual natural or topographic features. 2. Final Approval from Health Dept. of water supply and seaverage-disposal (S-9 form). 3. Approval of electrical installation fi-Om Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used ia system containsless than 2/10 of 1 °A lead. $. Commercial building, industrial building; multiple residences and similar buildings and installations, a cetlificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Boa~l Approval of completed site plan requirements. B. For existing'buildings (prior to April 9, 1957) non-conforming uses, or buddings and "pre-existing" land uses: 1. Accurate survey of property showing all property lines, streetg, building and.unnsual natural or topographic features. 2. A properly completed application and cOnsent to inspect signed by the applicant. If a Certificate of Occupancy is denied, the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees L Certificate of Occapancy - New dwetling $25.00, Additions to dwelllng $25.00, Alterations te dwelling $25.00, Swimming pool $25.00, Accessory building $25.00, Additions to accessory building $25.00, Businesses $50.00. 2. Certificate of Occupancy on Pre-existing Building - $100.00 3. Copy of Certificate ofOccupaney d $.25 4. Updated Certificate of Occupancy - $50.00 Temporary Certificate of Occupancy - Residential $15.00, Commercial $15.00 New Construction: ~ Location of Property: ~.~ House No. Owner or Owners of Property: Suffolk County Tax Map No 1000, Section Old or Pm-existing Building: (check one) Street Hamlet I/ Block ~ Lot Lot: Subdivision Filod Map. _ Permit No..~/--~'~>~' Date of Permit. Applicant: Health Dept. Approval: Underwriters Approval: Planning Board Approval: Request for: Temporary Certificate Fee Submitted: Finai Certificate: I/~ (check one) Applicant Signature BY THIS CERTIFICATE OF COMPLIANCE THE NEW YORK BOARD OF FIRE UNDERWRITERS BUREAU OF ELECTRICITY 40 FULTON STREET ~ NEW YORK, NY 10038 CERTIFIES THAT Upon the application of upon premises owned by MRS. STANLEY CIATUTA MRS. STANLEY ClATUTA 785 5TH AVE 785 5TH AVE NEW YORK, NY 10022 NEW YORK, NY 10022 Located at 635 SOUNDVIEW AVE EXT. SOUTHOLD, NY 11971 Application Number: 4028122 Certificate Number: 4028122 Section: Block: Lot: Building Permit:. BDC: ns11 Described as a Residential occupancy, wherein the premises electrical system consisting of electrical crevices and wiring, described below, located in/on the premises at: Basement, gas furnace, A visual inspection of the premises electrical system, limited to electrical devices and wiring to the extent detailed herein, was conducted in accordance with the requirements of the applicable code and/or standard promulgated by the State of New York, Department of State Code Enforcement and Administration, or other authority having jurisdiction, and found to be in compliance therewith on thdath Day of May, 2009. Name 9TY Rathe Rating Circuits Type Appliances and Accessories Fumace 1 0 Gas Wiring And Devices Switch 1 0 Gen, Purpose seal This certificate may not be altered in any way and is validated only by the presence of a raised seal at the location indicated. BY THIS CERTIFICATE OF COMPLIANCE THE NEW YORK BOARD OF FIRE UNDERWRITERS BUREAU OF ELECTRICITY 40 FULTON STREET ~ NEW YORK, NY 10038 CERTIFIES THAT Upon the application of upon premises owned by DOROSKI ELEC. INC STANLEY CIATUTA P,O, BOX 781 635 SOUNDVIEW EXT CUTCHOGUE, NY 11935, SOUTHOLD, NY 11971 Located at 635 SOUNDVlEW EXT SOUTHOLD, NY 11971 Application Number: 3009543 Certificate Number: 3009543 Section: Block: Lot: Building Permit: 0 BDC: ns11 Described as a Residential occupancy, wherein the premises electrical system consisting of electrical devices and wiring, described below, located in/on the premises at: Basement, service,Outside, A visual inspection of the premises electrical system, limited to electrical devices and wiring to the extent detailed herein, was conducted in accordance with the requirements of the applicable code and/or standard promulgated by the State of New York, Department of State Code Enforcement and Administration, or other authority having jurisdiction, and found to be in compliance therewith on the 14th Day of May, 2009. Name QTY Rate Rating Circuits Twe Service Service Disconnect: 1 200 cb ServicelPhase3w Service Rating200Amperes seal I of 1 This certificate may not be altered in any way and is validated only by the presence ota raised seal at the location indicated. FORM NO. 3 TOWN OF SOUTHOLD BUILDING DEPARTMENT Town Hall Southold, N.Y. BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) PERMIT NO. 34585 Z Date APRIL 7, 2009 Permission is hereby granted to: DARIA M CIAPUTA 203 WEST 90TH STREET NEW YORK,NY 10023 for : INSTALLATION OF A GAS FURNANCE PER MANUFACTURER SPECIFACATIONS AS APPLIED FOR. THIS BP # REPIJICES EXPIRED BP # 31500 at premises located at County Tax Map No. 473889 Section 050 pursuant to application dated APRIL Building Inspector to expire on OCTOBER 635 Block 7, 2009 SOUNDVIEW AVE EXT SOUTHOLD 0002 Lot No. 007 and approved by the 7, 2010. Fee $ 150.00 Authorized Signature ORIGINAL Rev. 5/8/02 FORM NO. 3 TOWN OF SOUTHOLD BUILDING DEPARTMENT Town Hall Southold, N.Y. (THIS BUILDING PERMIT PERMIT MUST BE KEPT ON THE PREMISES UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) PERMIT NO. 31500 Z Date OCTOBER 4, 2005 Permission is hereby granted to: ALEXANDER TRUSTEE CIAPUTA 785 5TH AVE APT 2E NEW YORK,NY 10022 for : INSTALLJ~TION OF A GAS FURNACE PER MANUFACTURER SPECIFICATIONS AS APPLIED FOR at premises located at 635 SOUNDVIEW AVE EXT SOUTHOLD County Tax Map No. 473889 Section 050 Block 0002 Lot No. 007 pursuant to application dated SEPTEMBER 29, 2005 and approved by the Building Inspector to expire on APRIL 4, 2007. Fee S 150.00 ~/~ % ~-~thorized Signature Rev. 5/8/02 ORIGINAL TOWN OF SOUTHOLD BUILDING DEPT. 765-1802 INSPECTION [ ] ROUGH PLBG. [ ] INSULATION [~FINAL [ ] FIRE SAFETY INSPECTION ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ]FOUNDATION 1ST [ ]FOUNDATION 2ND [ ]FRAMING / STRAPPING [ ]FIREPLACE & CHIMNEY REMARKS: INSPECTOR FIELD INSPE,CTION REPORT I DATE : COMMENTS FOUNDATION (1ST) FOUNDATION (2ND) ROUGH FRAMING & PLUMBING INSULATION PER N. Y. STATE ENERGY CODE TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL SOUTHOLD, NY 11971 TEL: (631) 765-1802 FAX: (631) 765-9502 www. northfork.net/Southold/ Examined Approved Disapproved a/c Expiration PERMIT NO. /'/ f20 F BUILDING PERMIT APPLICATION CHECKLIST Do you have or need the following, before applying'? Board of Health 4 sets of Building Plans Planning Board approval Survey Check Septic Form N.Y.S.D.E.C. Trustees Contact: Building Inspector Mail to: Phone: APPLICATION FOR BUILDING PERMIT Date INSTRUCTIONS a. This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets c;f plans, accurate plot plan to scale. Fee according to schedule. b. Plot plan showing location of lot and of buildings on premises, relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced before issuance of Building Permit. d. Upon approval of this application, the Building Inspector will issue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the work. e. No building shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f. Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has not been completed within 18 months from such date. If no zoning amendments or other regulations affecting the property have been enacted in the interim, the Building Inspector may authorize, in writing, the extension of the permit for an addition six months. Thereafter, a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of Southold, Suffolk County, New York, and other applicable Laws, Ordinances or Regulations, for the construction of buildings, additions, or alterations or for removal or demolition as herein described. The applicant agrees to comply with all applicable laws, ordinances, building code, housing code, and regulations, and to admit authorized inspectors on premises and in building for necessary inspections. (Signature of applicant or name, if a corporation) (Mailing address of applicant) State whether applicant is owner, lessee, agent, architect, engineer, general contractor, electrician, plumber or builder Name of owner ofpremises (As on the tax roll or latest deed) If appJ,ic~nI,~.,%elJrporation, signature of duly authorized officer ~N~ar~and title of corporate officer) Builders License No. Plumbers License No. _D, Electricians License No. Other Trade's License No. ? 1. Location of land on which proposed work will be done: House Number Street Hamlet/ County Tax Map No. 1000 Section 5~ C~ Block ~ Subdivision Filed Map No. (Name) Lot ~7 Lot 2. State existing use and occupancy of premises and intended use and occupancy of proposed construction: a. Existing use and occupancy b. Intended use and occupancy 3. Nature of work (check which applicable): New Building. Demolition 4. 5. Repair Removal Estimated Cost (.o O c~ c~ . c-~ c?) If dwelling, number of dwelling units If garage, number of cars Fee Addition Alteration Other Work &,-~.5 L',~,~ t~- (Description) (To be paid on filing this application) Number of dwelling units on each floor 6. If business, commercial or mixed occupancy, specify nature and extent of each type of use. 7. Dimensions of existing structures, if any: Front Rear Height Number of Stories Dimensions of same structure with alterations or additions: Front Depth Height Number of Stories .Depth Rear 8. Dimensions of entire new construction: Front Height Number of Stories Rear .Depth 9. Sizeoflot: Front 10. Date of Purchase ,,)~ 75/ Rear .Depth Name of Former Owner 11. Zone or use district in which premises are situated 12. Does proposed construction violate any zoning law, ordinance or regulation? YES NO__ 13. Will lot be re-graded? YES NO ,~ Will excess fill be removed from premises? YES__ NO 14. Names of Owner ofpremisesSr,~.--,~-¥ e-:~O~,'t~-,Address'~85- ~'Th ~v.~ PhoneNo.O/~7~8-SgtO Name of Architect Ad&ess ~'v ~v' Phone No" N~e of Contractor ~e~y ~vq~ Address ~ ~ ~v~ ~ ~o~ Phone No. ~ -~ ~ ~ - ~-~.~ 3 ~ 15 a. Is this prope~y within 100 feet of a tidal wetl~d or a ~eshwater wetl~d? *YES ~~ ~ * IF YES, SOUTHOLD TO~ TRUSTEES & D.E.C. PERMITS MAY BE REQUIRED. b. Is this prope~y wi~in 300 feet of a tidal wetland? * YES~ NO ~ * IF YES, D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distances to property lines. 17. If elevation at any point on property is at 10 feet or below, must provide topographical data on survey. STATE OF NEW YORK) SS: COUNTY OFa~.-Po=~ ~- f'c~, ~ ~r-c-....-~---"'~- being duly swom, deposes and says that (s)he is the applicant (Name of h'idividual signing contract) above named, (S)He is the C--c~r',arCCs-~Uc~ (Contractor, Agent, Corporate Officer, etc.) of said owner or owners, and is duly authorized to perform or have performed the said work and to make and file tiffs application; that all statements contained in tiffs application are tree to the best of his knowledge and belief; and that the work will be performed in the manner set forth in the application filed therewith. Sw0m to before me tiffs / 2 (z'2 day of~ 20 O~ · , ~ . ADREAN NORTHRIDGE * ' ~ ^ · · /~ I~ Notary Public, State of New York k._Jc l m r.u ,., [ / Notary ]~ublic "~ Qualified in Suffo k County r,/ Commission Exp res July 6 20 ~ / .$4~i~r e of"A~p fi'cant TOWN OF SOUTHOLD PROPERTY RECORD CARD LAND J IMP. AGE NEW NORMAL VL. TOTAL FARM DATE BUILDING CONDITION BELOW ABOVE Farm Acre Value Per Acre Value Tillo,ble 1 j Tillable 2 Tillable 3 Woodland Swampland Brushland House Plot~ ~` VILLAGE COMM. IND. REMARKS DISTRICT SUB. ACREAGE lq/,/ TYPE OF B~ CB. Tota I LOT ~ ILDING MISC. M. Bldg. Extension Extension Extension Garage O.B. Founda!!_on ~5~'~ d 4' ~asement , ? ?~ Ext. Walls Fire Place /:. ,: ~ ~E)rlveway Bath Floors Interior Finish Hea¢ Porch Attic Porch Rooms 1st Floor Rooms 2nd Floor NOTI~/~ BUILD/~-~ DE 765-1802 8AM TO 4PM FOR THE FOLLOWING INSPECTIONs: 1. FOUNDATION . TWo REQUIRED FOR POURED CONCRETE 2. ROUGH . FRAMING & PLUMBING 3. INSULATION 4. FINAL . CONSTRUCTION MUST BE COMPLETE FOR C,O. ALL CONSTRucTION SHALL MEET THE REQUIREMENTs OF THE CODEs OF NEW YORK STATE. NOT RESPONSIBLE FOR DESIGN OR CONSTRUCT/ON ERRORs. COHPLy WITH ALL CODES OF NE~' ' ~ ~,K STATE & TOWN CODES AS REQj,~RED,~,~ ~C~ND'TIONS OF OCCUPANCYOR USEIS UNLAWFUL WITHOUTCERTfFICATE OFOCCUPANCY ALL CONSTRUCTION SHALL MEET THE REQUIREMENTS OF THE CODES OF NEW YORK STATE, DOWNFLOW/HORIZONTAL/ UPFLOW GAS FURNACE USER: Please read all manuals and retain manuals for future reference. NOTE TO INSTALLER: This manual must be left with the equipment user. A01480 Do not use this furnace if any part has been under water. A flood-damaged furnace is extremely dangerous. Attempts to use the fur- nace can r~dt in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas contmis, control system parts, electrical parts that have been wet or the furnace if deemed necessary. /~, WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property d~rnage. Do not store or use gasoline or other flammable vapors and Hqulds in the vicinity of thin or any other appliance. WHAT TO DO IF YOU SlVIELL GAS · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · Leave the building immediately. · Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. · If you cannot reach your gas supplier, call the fire department. -- Installation and service must be performed by a qualified installer, service agency or the gas supplier. /~ WARNING: Carbon Monoxide is invisible, odorless, and toxic! Bryant recommends a carbon monoxide alarm in your home, even if you do not own a gas appliance. Locate the carbon monoxide alarm in the living area of your home and away from gas appliances and doorways to attached garages. Follow the alarm manufacturer's instruction included with the alarm. TABLE OF CONTENTS WELCOME TO TODAY'S GENERATION OF COMFORT ...................................... 2 FURNACE COMPONENTS ............................... 2 GENERAL FURNACE SAFETY ........................... 2 IMPORTANT FAC'I:S (DO'S AND DON'TS) ................. 3 SAFETY CONSIDERATIONS ............................. 3 BEFORE STARTING YOUR FURNACE ..................... 4 STARTING YOUR FURNACE ........................... 3,4 Steps for Starting Your Furnace ......................... 4 SHUTI'ING DOWNYOUR FURNACE .................... 5,6 PERFORMING RO~E MAINTENANCE ................. 6 Filtering Out Trouble ................................. 6 COMBUSTION AREA AND VENT SYSTEM ............... 6,7 BEFORE YOU REQUEST A SERVICE CALL .............. 7,8 REGULAR DEALER MAINTENANCE ...................... 8 INSTALLATION DATA .................................. 8 WELCOME TO TODAY'S GENERATION OF COMFORT Congratulations! Your new, higher efficiency gas furnace is a sound investment which will reward you and your family with years of warm memories winter after winter. Not only is your new furnace energy efficient, it is also ex- tremely reliable. Spend just a few minutes with this booklet to learn about the operation of your new furnace--and the small amount of maintenance it takes to keep it operating at peak efficiency. Years went into the development of your new furnace. Take a little time now to assure its most efficient operation for years to come. GENERAL FURNACE SAFETY 1. Combustible Materials, Gasoline Warning ................. 2. Furnace Must be Kept Free and Clear of Insulating Material Warning .................................... 3 3. Furnace Needs Air for Combustion and Ventilation Warning .................................. 7 4. Starting (Lighting) and Shutting Down the Furnace Warning .................................... 4,5 5. Draft Safegaard Switch Caution ......................... 8 6. Proper Furnace Shutdown Procedures .................... 5 7. Flood Damage Warning ............................... 1 8. Fire or Explosion Hazard Warning ....................... 1 9. Carbon Monoxide Warning ............................. 1 10. Service and Maintenance Electrical Hazard Warning ......... 6 11. Improper Vent Warning ................................ 6 12. Sharp Edges Caution .................................. 6 13. No Filter Caution .................................... 6 14. Filter Rod Modification Caution ......................... 6 15. Dirt, Rust, orAccumulation Caution .................... .7 FURNACE COMPONENTS (Furnace shown in upfiow position; may be used in downflow or horizontal orientation or applications. Vent Elbow may be turned to a different position, depending on type of installation) INDUCER MOTORASSEMBLY ~~VENTELBOW PRESSURE SWITCH DRAFT ~m SURFACE ~ ] II ~ ] ~ ~ BLOWER RATING PLATE NOT SHOWN (LOCATED ON BLOWER DOOR) A02259 Plus 80 and Model 310 INDUCER MOTOR ASSEMBLY VENT ELBOW MAIN LIMIT SWITCH (BEHIND GAS VALVE) PRESSURE SWITCH DRAFT FLUE SAFEGUARD COU. ECTOR SWITCH BOX FL~ME SENSOR A02260 2 Plus 80v and Plus 80t (Capacitor shown but not required for the Plus 80v) 2 IMPORTANT FACTS (DO's and DO NOT'S) · DO: READ AND UNDERSTAND THIS MANUAL. · DO: Have your furnace and vent sys- tem inspected aqnually by a qualified service technician. · DO: Inspect your filter monthly and clean or replace when needed. · DO: Provide adequate airflow to the furnace for efficient combustion and safe ventilation. · DO: Keep your fumace free and clear of insulating material. Some materials may be combustible. Examine the fur- nace area when the furnace is installed or when insulation is added. 3 · DO NOT: Enclose your furnace in an airtight room or seal it behind solid doors. · DO NOT: Keep combustible materi- als, gasoline, and other flammable liq- uids or vapors around your fumace. · DO NOT: Cover your furnace in any manner. · DO NOT: Store anything (including trash or debris) near your furnace. · DO NOT: In any way block or restrict airflow around your furnace. · DO NOT: In any way block or restrict airflow to your supply air and return air grills. · DO NOT: Use your furnace room as a broom closet or a place to store any kind of chemical or cleaner. · DO NOT: Contaminate the air used for combustion of your furnace with any kind of chemical or fumes. This could also cause heat exchangers, metal vent systems or components to deteriorate. NO'l'l::: These chemicals or fumes are present in many products around the home, such as: water softener salts, any type of household cleaning product, any type of laundry product, adhesives, paints, varnishes, paint strippers, waxes and plastics, etc. During remodeling be sure the com- bustion air is fresh and uncontami- nated, ff these compounds are burned in your furnace, the heat exchangers and metal vent system may deteriorate. NOTI=: The qualified installer or agency must use only factory- authorized re-placement parts, kits, and accessories when modifying or repairing this product. This furnace contains safety devices which must be manually reset. If the fur- nace is left unattended for an extended period of time, have it checked periodi- cally for proper operation. This precau- tion will prevent problems associated with no heat, such as frozen water pipes, etc. See "Before You Request a Service Call" section in this manual. SAFETY CONSIDERATIONS Installing and servicing heating equip- ment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform ba- sic maintenance functions such as cleaning or replacing air filters. All other operations must be performed by trained service personnel. Observe safety precautions in this manual, on tags, and on labels attached to the fur- nace and other safety precautions that may apply. Recognize safety information: 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 DAN- GER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identi- fies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability or operation. 3 Do not keep combustible male- rials, gasoline, and other flam- mable liquids or vapors around your furnace. Fire Hazardl Failure to keep in- sulation clear of furnace could result in fire, personal injury, or death. BEFORE STARTING YOUR FURNACE Examine the furnace installation to determine that: 1. All flue gas carrying areas external to the furnace (i.e. chimney, vent connector) are clear and free of obstructions. 2. The vent connector is in place, slopes upward and is physically sound without holes or excessive corrosion. 3. The return-air duct connection(s) is physically sound, is sealed to the furnace casing, and terminates outside the space containing the furnace. 4. The physical support of the fumace is sound without sagging cracks, gaps, etc. around the base. 5. There are no obvious signs of deterioration of the furnace. 6. The pilot and burner flames are in good adjustment (by comparison with pictorial sketches or drawings of the main burner flame and, if applicable, the pilot burner flame). STARTING YOUR FURNACE Your furnace uses an automatic hot sur- face ignition system to fight the bumers each time the thermostat signals the furnace to start. Follow these impor- tant safeguards: · Never attempt to manually light the bumers with a match or other source of flame. -' 4 · Read and follow the operating in- structions on the inside of main furnace door, especially the item that reads as follows: "Wait 5 minutes to clear out any gas. Then smell for gas, including near the floon If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step." · If a suspected malfunction occurs with your gas control system, such as the burners do not light when they should, refer to the shutdown proce- dures on the inside of main furnace door, or in the next section, to turn off your system, then call your dealer as soon as possible. Should the gas supply fail to shut off or if overheating oc- curs, shut off the gas valve to the furnace before shutting off the electrical supply. A failure to follow this warning could re- sult in a fire or explosion, and personal injury or death. · CHECKAIR FILTER: Before at- tempting to start your furnace, be sum the filter is clean and in place. (See the maintenance section of this manual.) Do not run the furnace without a filter in place. Then proceed as follows: 5 STEPS FOR STARTING YOUR FURNACE 1. Set your room thermostat to the lowest temperature setting. (See Fig. 5) 2. Close the external manual gas valve. (See Fig. 6) 3. Turn OFF electrical supply to fur- nace. (See Fig. 7) 6 7 4. Remove outer door by loosing the thumbscrew and pulling the door forward. (See Fig. 8) 5. Turn the control switch to OFF and wait 5 minutes to clear out any gas. (See Fig. 9) Then smell for gas, in- cluding near the floor. If you smell gas, STOP! Follow "B" on Furnace label. If you don't smell gas, go to next step. 6. After waiting 5 minutes, if you still smell gas, STOP! Follow the safety information on the cover of this 8 manual. If you do not smell gas, go to the next step. 7. Turn the control switch to ON. (See Fig. 10) 8. Replace the outer door and tighten the thumbscrew. (See Fig. 11) 9. Turn ON the electrical supply to the furnace. (See Fig. 12) 10. Open the external manual gas valve. (See Fig 13) 11. Set the room thermostat to a tem- perature slightly above the room temperature. This will automati- cally signal the furnace to start. The inducer motor will mit, and the hot surface igniter will have an orange glow. OR 10 11 12 12. After about 32 seconds, the gas valve permits gas to flow to the main burners where it is ignited. Hot flames begin to warm the fur- nace's heat exchanger. After a time delay of 25 sec, (45 sec for low stage on 2 stage furnaces) the fur- nace blower is switched on. 13 NOTE: If the main bumers fail to ig- nite, the fumace control system will go through 3 more ignition cycles. Then, if burners fail to ignite, the system will lockout. If lockout occurs, or the blower doesn't come on--shut down your furnace and call your dealer for service. 13. Set your thermostat to the tempera- ture that satisfies your comfort re- quirements. SUGGESTION: Setting the thermostat back a few degrees-~and compensating for the difference with warmer clothing-- can make a big difference in your fuel consumption on extremely cold days. The few degrees at the top of your thermostat "comfort level" are the most costly degrees to obtain. When the room temperature drops below the temperature selected on the thermostat, the furnace will be switched on automatically. When the room temperature reaches the degree selected on the thermostat, the furnace will be switched off automatically. Continuous Fan-Some thermostats have a "fan" mode with 2 selections: AUTO or ON. When set on AUTO, the furnace blower cycles on and off, con- trolled by the thermostat. In the ON position, the furnace blower runs con- tinuously except for a 42-62 sec delay at the "call for heat." Continuous fan keeps the temperature level in your home more evenly balanced. It also continuously filters the indoor air. FanOn PLUSh-On all bu~t the 310AAV or 310JAV, the blower speed can be increased or de- creased if desired due to change of seasons, large gatherings in your home, etc. Simply change your "FAN" switch from "on" to "off' (or "auto" depending on your ther- mostat), and then return to "on." The blower will switch to the next highest speed. There are at least 3 speeds to choose from. If the blower is running on its highest speed, a request to change will direct the blower to re- turn to its lowest speed. SHUTTING DOWN YOUR FURNACE Should you ever suspect a malfunction in your furnace, you will need to turn the furnace off. The following proce- dures must be followed: I. Set your room thermostat to the lowest temperature setting. (See Fig. 14.) 2. Close the external manual gas valve. (See Fig. 6 on page 4.) 3. Turn OFF the electrical supply to your fumaee. (See Fig. 15.) 4. Remove the outer door on your fur- nace. (See Fig. &) 5. Turn the control switch on the gas valve to the OFF position. (See Fig. 9. 14 15 16 6. Replace the outer door. (See Fig. ll.) 7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible. PERFORMING ROUTINE MAINTENANCE With the proper maintenance and care, your furnace will operate economically and dependably. Basic maintenance, which can easily be accomplished by someone who follows the directions, is found on this and the following pages. However, before beginning mainte- nance, follow these safety precautions: Turn off electrical power sup- ply to your furnace before re- moving the access doors to service or perform mainte- nance. A failure to follow this warning could result in per- sonal injury or death. Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reach- ing into the furnace.. FILTERING OUT TROUBLE. Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accumula- tion of dust and lint on internal parts of your furnace can cause a loss of efficiency. A dirty filter will cause excessive stress on the furnace blower motor and can cause it to overheat and automatically shut down. The furnace filter should be checked every 4 weeks or so and cleaned or replaced if necessary. If installed with factory specified dis- ix)sable media filter, check or replace filter before each heating and cooling season. Replace disposable media filter at least twice a year. If your furnace filter needs replacing, be sure to use the same size and type of fil- ter that was originally specified The air filter may be located in the filter cabinet attached to the side or bottom of the furnace. If air filter has been installed in another location, contact your dealer for instruc- tions. To inspect, clean, and/or replace the air filter(s), follow these steps: 1. Turn off electrical supply to fur- nace (See Fig. 7.) 2. Remove filter cabinet door (See Fig. 18 and 19.) NOT[[: It may be necessary to re- move 1 thumbscrew 3. Slide air filter out of filter cabinet. Keep dirty side up (if dirty) to avoid spilling dirt. (See Fig. 20 and 21.) 4. Inspect the filter, ff tom, replace it. NOT;: If a washable filter has been re- placed by: a) Factory specified disposable media filter - Do not clean. If dirty, replace only with media filter having the same part number and size. Install with airflow di- rection arrow pointing towards blower. b) Electronic air cleaner (EAC) - Re- fer to EAC Owner's Manual for mainte- nance information. 5. Wash filter (if dirty) in sink, bath- tub, or outside with a garden hose. Always use cold tap water. A mild liquid detergent may be used ff nec- essary. Spray water through filter in the opposite direction of airflow. Allow filter to dry. 6. Reinstall clean air filter. 7. Replace filter cabinet door. (See Fig. 22 and 23.) 8. Turn on electrical supply to furnace (See Fig. 12.) Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropri- ate protective clothing. Failure to follow this caution could re- sult in personal injury. COMBUSTION AREA AND VENT SYSTEM For proper and safe operation the furnace needs air for com- bustion and ventilation. Do not block or obstruct air openings on the furnace, air openings to the area in which the furnace is installed, and the space around the furnace. If holes are found--or if the vent pipe is obstructed or is not connected--toxic fumes can escape into your home. DO NOT OPERATE YOUR FUR- NACE. Call your dealer for ser- vice. A failure to follow this warning could result in per- sonal injury or death. Inspect the combustion area and vent system before each heating season. An accumulation of dirt, soot, or mst can mean a loss of efficiency and improper performance. Buildups on the main burners can cause faulty firing. This "delayed ignition" is characterized by au alarmingly loud sound. NOTE: If your furnace makes a loud noise when the main burners are ig- nited, shut down the fumaee---call your servicing dealer. Use your flashlight and follow these steps for inspecting the combustion area and vent system of your furnace: 1. Turn off the electrical supply to the furnace and remove the access door. (See Fig. 7 and 8.) 2. Carefully inspect the gas burner (See Fig. 17) for dirt, mst, or scale. Then inspect the elbow, flue connection area, and the vent pipe for mst. If dirt, rust, soot, or scale accu- mulations are found, call your servicing dealer. DO NOT OPERATE THE FURNACE. 3. Inspect the vent pipe for a sag, holes, or a disconnection. A hori- zontal vent pipe must slope upward away from furnace, ff rusty joints or seams, or signs of water leakages are found, call your dealer for service. 4. Restore electrical power to the fur- nace. (See Fig. 12.) 5. Start the furnace and observe its operation. If possible, watch the burner flames. Are they burning bright blue? If not (orifyou suspect some other malfunction), call your servicing dealer. 6. Replace access door. (See Fig. 11 .) 2O 2~ BEFORE YOU REQUEST A "SERVICE CALL" BEFORE YOU CALL FOR SERVICE, CHECK FOR SEVERAL EASILY SOLVED PROBLEMS: · Check for sufficient airflow. Check the air filter for dirt. Check for blocked return-air or supply-air grilles. Be sure they are open and unobstructed. If this isn't the case, call your servicing dealer. ff your furnace isn't operating at all, check the following list for easily solved problems: · Is your thermostat set above room temperature? Is the HEAT mode selected? · Is the electrical power supply switch ON? Is the blower access door firmly in place? Are any fuses blown? (There is a fuse on the furnace control board. Has a circuit breaker tripped? · Is the manual shutoff valve in the ga: supply pipe leading to the furnace open? Does the lever point in the same direction that the pipe runs (open)? Or is it at right angles (closed)? NOTE: Before proceeding with the next checks, turn OFF the electrical power supply to the furnace. Remove the access door. · Is the switch on the gas valve turned to the ON position? If this or the pre- ceding check shows an interruption in the gas supply, make sure the gas has not been shut off for safety reasons. It nothing else seems to be wrong, follow the startup procedures found on pages 4 and 5 of this booklet. 7 if for some reason the vent is blocked, the draft safeguard switch will shut off the fur- nace. (See page 2 for switch location.) The switch will au- tomatically reset after the fur- nace cools off. If the furnace fails to operate, contact a qualified service agency. · Check the manual-reset limit switches located on the ends of the burner enclosure (See Fig. 2). If the fur- nace has experienced a high-tempera- ture condition, due to inadequate combustion air, these switches will shut off the furnace. Reset the switches by pushing the button on the switch. If the switch trips a second time, torn off the furnace and call for service. · If your furnace still fails to operate, call your servicing dealer for trouble- shooting and repairs. Tell your dealer the model and serial numbers for your furnace. (You should have them re- corded on page 8 of this booklet.) By knowing exactly which furnace you have, the dealer may be able to offer suggestions over the phone, or save valuable time through knowledgeable preparation for the service call. REGULAR DEALER MAINTENANCE In addition to the type of routine main- tenance you might be willing to do, your furnace should be inspected regularly by a properly trained service technician. An annual inspection (or biennial inspection, at least) should include the following: 1. Inspection of all flue gas pas- sages including the burners, heat exchanger, inducer, elbow, and vent pipe. 2. Inspection of all combustion and ventilation air passages and openings. 3. Close check of all gas pipes leading to (and inside of) your furnace. 4. Inspection and cleaning of the blower motor and wheel. 5. Routine inspection and cleaning/ replacement of the air filter. 6. Inspection of all supply- and retorn-air ducts for obstructions, air leaks, and insulation. Any prob- lems found should be resolved at this time. 7. Inspection of furnace installation for proper support and any obvi- ous deterioration of the furnace. The support must be sound and without sags, gaps, cracks, etc., around the furnace base so as to provide an air seal between the retorn-air duct and furnace. 8. A check for loose connections atlaching individual components. Inspection of all electrical wiring and their connections. 9. Operational check of the fumaee itself to determine working condi- tion. Repair or adjustment should be made at this time. Ask your servicing dealer for further details about an economical service contract that covers seasonal inspections. INSTALLATION DATA Date Installed Dealer Name Address State/Province __ Telephone Zip/Postal Code FURNACE Product No. Model No. Serial No. AIR CONDITIONER OR HEAT PUMP OUTDOOR UNIT: Product No. Model No. Serial No. INDOOR COIL: Product No. Model No. Serial No. © 2002 Bryant Heating & Cooling Systems, 7310 W. Morris St. Indpls., IN 46231 Replaces OMO5-35 PRINTED IN U.S.A, Catalog No. 5331-008 OM05-41 11-02 8 Installation Instructions For Cased Coils Upflow-Downflow Heating-Cooling CK5A,CK5B CK5P FURNACE ~ OSUPPLY DOWNFLOW FURNACE A96244 Fig. l--Typical Coil Installation NOTE: Read the entire instruction manual before starting the installation. This symbol --* indicates a change since the last issue. SAFETY CONSIDERATIONS hnproper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause personal injuw or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations, Have fire extinguisher available. Read these instructions thoroughly and follow all warning or cautions attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements. It is important to recognize safety information. This is the safety alert symbol ~, When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operaUon. z~ WARNING: Before installing or servicing system, always turn off main power to system. There may be more than 1 disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death. ~ CAUTION: This coil contains Nitrogen precharge of 15 PSh Release of this pressure through the center of the rubbe, plugs is required before removing the plugs. Failure to follow this CAUTION could result in minor personal injury or product and property damage. IMPORTANT: Nitrogen can leak out through the hole that the needle pierced in the plugs. This does not indicate a leaking coil nor warrant tetra. of the coil. Form: IM-CKhA-07 Cancels: IM-CKfA-06 Printed in Mexico 07-03 Catalog No. 63CK-5A6 Table 1--CK5A/CK5B/CK5P Dimensions METERING DEVICE FITS NEXT SMALLER FURNACE FLUSH FIT SHELF WIDT~ MODEL NUMBER TONNAGE CK5A/B CK5P TO FURNACE (SEE FIG. 3, Eqt~al Overhang with Offset Piston NUMBER TXV NUMBER WIDTH (IN.) DIM A) Overhang Transition Left *CK5(A,P)XA018(0,T)l 4 1-1/2 52 EA36YDI24 14-3/16 -- -- *CKSBXA018014 * CK5(A,P)XA024(0,T) 14 *CKSBXA024014 2 59 EA36YDI24 14-3/16 12-7/8 -- -- * CKS(A,P)XA030(0,T} 14 *CKSBX030014 2-1/2 67 EA36YDI24 14-3/16 -- -- -- *CK5(A,P)XT036(0,T)I7 3 70 EA36YDI34 17-1/2 X -- *CK5BXT036017 CKS(A,P)XW024(0,T)I7 CKSBXW024017 2 59 EA36YD124 17-1/2 -- X X CK5(A,P)XW030(0,T)I7 2-1/2 67 EA36YDI24 17-I/2 16-3/I6 X X CKSBXW030017 *CKS(A,P)XA036(0,T)l 7 *CK5BXA036017 3 70 EA36YDI34 17-1/2 -- X X CKS(A,P)XE042(0,T)17 3-1/2 78 EA36YDI34 17-1/2 -- X X CK5BXE042017 *CK5(A,P)XT042 (0,T)21 3-1/2 78 EA36YD134 21 X -- -- *CKSBXT042021 *CKS(A,P)XT048(0,T)21 4 84 EA36YDI44 21 X -- *CKSBXT048021 CK5(A,P)XW036(0,T)21 3 70 EA36YDI34 21 19-5/8 -- X X CKSBXW036021 * CKS(A,P)XA042(0,T)21 3-1/2 78 EA36YDI34 21 X X *CKSBXA042021 * CKS(A,P)XA048(0,T)21 4 84 EA36YDI44 21 X X *CK5BXA048021 *CK5(A,P}XT060(0,T)24 5 90 EA36YD154 24-1/2 X -- -- *CK5BXT060024 CKS(A,P)XW048(0,T)24 4 84 EA36YDI44 24-1/2 -- X X CKSBXW048024 23-1/8 *CKS(A,P)XA060(0,T)24 5 90 EA36YD 154 24-1/2 X X *CKSBXA060024 CK5(A,P)XX060(0,T)24 5 90 EA36YDI54 24-I/2 -- X X CK5BXX060024 *In these models the coil can be removed from the casing and installed as an uncased coil w~ithout needing to field fabricate the coil enclosure to prevent air bypass. NOTE: For the 10th digit position in the model number, 0 = standard copper and T = tin-plated copper. INTRODUCTION Use this instraction manual to install indoor coils on upflow or downflow furnaces. (See Fig. 1.) Do not install coil in horizontal position. Model CK5A is enclosed in a painted casing while CK5B is available in an embossed casing; both of these coils come with pistons and both may be used with R-22 systems or Puron®. The CK5P coil is enclosed in a painted casing, however, it has a Puron TXV so it is only compatible with Puron systems. NOTE: Models with tin-plated copper coils ("T' in the 10th position of the model number) are installed the same as standard copper coils INSTALLATION PROCEDURE 'I--INSPECT EQUIPMENT File claim with shipper if equipment is damaged PROCEDURE 2--SELECT INSTALLATION PROCEDURE NOTE: Installing coils rotated 90 degrees from the front of the furnace, in upflow or downflow applications, can cause water blow-off or coil freeze-up due to the concentration of air on one slab of the coil or lack of air to a slab in the coil. It is recommended that on this type of application, a field-supplied adapter be placed between the coil and furnace to allow air to distribute properly between all slabs of the coil. For cased coils in upflow applications, follow A. See Table I for dimensions and overhang options. Note instructions for placement of coil casing For cased coils in downflow applications, follow B. For uncased coils in upflow applications, follow C. PROCEDURE 3--INSTALLATION OF FURNACE COILS A. Upflow Cased Coil Installation 1. Set coil in place on upflow furnace discharge air opening. (See Fig. 1.) 2. When coil front width matches furnace front width, the coil can be pIaced directly on furnace. NOTE: When model T036, T042, T048, or T060 is applied to same width furnace, remove block-offplates at casing base by removing 2 screws per plate from side of casing. (See Fig. 8.) SHELF ~/., 3" MIN. '~ ~/ ~ "B / ~ FURNACE ~ FIELD SUPPLIED A01482 Fig. 2--Transition Required for Overhang Fig. 3--Correct Orientation of Coil Support on FurnAa(~e483 Except for "T" Coils (See Fig. 7) 3. Ensure coil is level for proper condensate drainage. Do not tip coil toward condensate drain. Cod enclosure need not be fastened or screwed to furnace. 4. Following are instractions for alternative ways of overhanging coil on furnace: (See Fig. 7A, B, C.) T MODEL (6TH DIGIT) COILS APPLIED CENTERED OVER NARROW FURNACE 1. There is no transition required for this application. 2. Remove coil from packaging and place on top of furnace with 1-5/8 in. overhang on both sides. (See Fig. 7A.) 3. Continue with normal installation practices. (See Procedure 4.) A, W, OR X MODEL (6TH DIGIT) COIL APPLIED CENTERED OVER NARROW FURNACE WITH 2-1/4-1N. MINIMUM TRANSITION I. Prepare transition, following recommended transition drawing. (See Fig. 5.) Fabricate a 2-l/4-in. tall (minimum) transition. 2. Place transition on top of gas furnace. (See Fig. 7B.) Secure with sheet metal screws. Place coil on top of transition. Make sure coil rests evenly on top of transition and gas furnace. 3. Secure coil to transition using sheet metal screws. 4. Continue with normal installation practices. (See Procedure 4.) NOTE: If coil (cased or uncased) is n°t beinginstalled in the standard °rientati°n (fr°nt °f c°il matching fr°nt °f furnace) then c°il must be raised 2-1/4 in. above furnace. A, W, OR X MODEL (6TH DIGIT) COIL APPLIED DIRECTLY ON TOP AND OFFSET TO THE LEFT ON NARROW FURNACE 1. Notch support rail on underside of coil cabinet to provide clearances for gas famace flange. This rail is not visible from front of coil. To locate position of notch, place coil directly on top of gas furnace with overhanging portion entirely on left side as in Fig. 7C. Mark location of gas furnace flange on coil casing. Remove coil from top of furnace. Using tin snips, make a notch in rail large enough to allow clearance for gas flow furnace flange. 2. Place coil on top of gas furnace. Make sure coil is shifted completely to left side, and notch is sufficient so coil rests on top of furnace cabinet. 3. Prepare and install block-offplate. (See Fig. 7C.) Using field-supplied sheet metal, cut a block-off plate to be attached to bottom left side of coil casing. This plate prevents air leakage from overhanging portion of coil. Attach plate using sheet metal screws. 4. Continue with normal installation practices. (See Procedure 4.) B. Downflow Cased Coil Installation 1. Place N-coil on supply duct opening. 2. When coil width matches furnace width, furnace can be placed directly on the cased coil. NOTE: In downflow installation with a 4-way multipoise furnace, break off perforated duct flanges on furnace. (See Furnace Installation Instructions.) 3. Coils that underhang (narrower than furnace) must have a 2-1/4-in. long (minimum) field-fabricated transition between furnace and N-coil casing. 4. Coils that overhang (wider than furnace) do not require a transition in downflow application. However, a field-supplied furnace shelf sfiould be constructed to fit furnace to coil opening. 5. Place furnace on top of N-coil casing, or field-supplied furnace shelf. A CAUTION AIR CONDITIONING COIL BEHIND THIS PANEL. DO NOT DRILL OR CUT PANEL UNTIL COIL LOCATION HAS BEEN VERIFIED BY REMOVING ACCESS ?OVER. .~ Fig. 4---Plenum Caution Label Dimensions (In.) A B 12-3/4 17-1/2 A96359 A97232 Fig. 5---Recommended Transition NOTE: When removing a coil from its casing in the downflow position, support the coil enclosure with field supplied bracing. (See Fig. 6.) C. Upflow Uncased Coil Installation Only the coils marked with an asterisk (*) on Table I can be used as an uncased application. In these models the coil can be removed from the casing and installed as an uncased coil without need to field-fabricate a coil enclosure to prevent air bypass. 1. Field fabricate coil support shelf using dimensions given in Fig. 3. The coil support shelf is required to complete the uncased installation. 2. Locate and install the coil support shelf above furnace duct flanges, the coil support shelf is designed to accommodate upflow furnace opening flanges. 3. Set coil in place. 4. Place plenum enclosure on furnace. 5. lnsulate plenum enclosure. 6. Affix caution label to the right side of plenum enclosure. (See Fig. 4.) The caution label is stapled to the Installation Instructions. 7. Continue with normal installation practices. (See Procedure 4.) PROCEDURE 4--CONNECT REFRIGERANT PIPING Use accesso~ tubing package or field-supplied tubing of refrigerant grade. Suction tube must be insulated. Do not use damaged, dirty, or contaminated tubing because it may plug refrigerant flow-control device. ALWAYS evacuate the coil and field-supplied tubing before opening outdoor unit service valves. PROCEDURE 5---CONNECT REFRIGERANT LIQUID AND SUCTION LINES For matched and mismatched systems, use line sizes recommended in outdoor unit Installation Instructions. The coil can be connected to outdoor units using accessory tubing packages or field-supplied tubing of refrigerant grade. Always evacuate tubing and reclaim refrigerant when making connections or flaring tubing. Leak check connections before insulating entire suction line. SUCTION LINE FURNACE Fig. 6--Field Supplied Bracing A98391 FIELD ~ ALTERNATIVE ALTERNATIV~ B C Fig. 7~AIternative Coil Mounting Positions A97607 Suction line is designed for field sweat connection. Line is plugged to keep out moisture and dirt. Remove these plugs only when ready to make connection. LIQUID LINE Z~ CAUTION: To avoid damage to the refrigerant control device while brazing, wrap tubing or fittings with a heat-sinking material such as a wet cloth. Failure to follow this CAUTION could result in minor personal injury or product and property damage. A. The following section applies to only CK5A and CKSB coils: SYSTEM REFRIGERANT CONTROL z~ CAUTION: If unit is to be installed on system with a thermostatic expansion valve, removal of indoor coil piston is required. Failure to follow this CAUTION could result in minor personal injury or product and property damage. A refrigerant control device (bypass type piston) is factory supplied with coil. (See Table I.) The piston has a refrigerant metering hole through it, and is field replaceable. The piston shipped with the indoor coil may be different from the piston shipped with the outdoor condensing unit. If this is the case, you must replace the indoor piston. Always use the piston shipped with the outdoor condensing unit. If piston replacement is required: --5-- BLOCK-OFF PLATES A97629 Fig. 8---Block-Off Plate Removal I. Check the piston size stamped into side of brass hex nut. (See Fig. 9.) If this piston number does not match required piston shown on outdoor unit rating plate, replace indoor piston with piston shipped with outdoor unit. 2. When the piston is replaced, hand tighten the brass hex nut, then tighten with wrench 1/2 turn. 3. Remove rubber plug. 4. Liquid line is designed for sweat connection. ~ CAUTION: Remove Teflon seal during brazing. Replace when fitting has cooled, Failure to follow this CAUTION could result in minor personal injury or product and property damage. PROCEDURE 6--CONDENSATE DRAIN LINE CONNECTION The coil is designed to dispose of accumulated water through built-in condensate drain fittings. Two 3/4-in. female threaded pipe connections are provided in each coil condensate pan. Install a trap in condensate line for coil as close to coil as possible. Make trap at least 3 in. deep and no higher then the bottom of unit condensate drain opening. (See Fig. 11.) Pitch condensate line 1 in. for every i0 fi of length to an open drain or sump. NOTE: If unit is located in or above a living space, where damage may result from condensate overflow, a field-supplied, external condensate pan should be installed underneath entire unit, and a secondary condensate line (with appropriate trap) should be run from the unit into the pan. Any condensate in this external condensate pan should be drained to a noticeable place. As an alternative to using an external condensate pan, some localities may allow the farming of a separate 3/4-in. condensate line (with appropriate trap) per local code to a place where the condensate will be noticeable. The owner of the structure must be informed that when condensate flows from secondary drain or external condensate pan, the unit requires servicing or water damage will occur. NOIE: To avoid drainage problems, test the primary drain line by slowly pouring water into the pan. Check piping for leaks and proper condensate drainage. Using the secondary drain as explained in the above note provides future protection against overflow due to a clogged primary drain. PROCEDURE 7--HUMIDIFIER APPLICATION When installing a humidifier in a system which contains an N-Coil, consideration must be given to location of coil slabs. (See Fig. 12.) I. Care must be taken to prevent damage of N-coil when attaching humidifier to coil casing or plenum. 2. The models marked with an * in Table 1 are shipped with a label to be applied to plenum to indicate slab location. This is needed only in cases where the humidifier is not installed with original equipment. Label will alert future service and installation technicians about coil slab location. 3. Ensure that humidifier has adequate airflow. FOR GAS APPLIANCES INSTALLED IN THE STATE OF CALIFORNIA ff a gas appliance is not installed, operated, or main- rained in accordance with the manufacturer's insffuctlons, you could be exposed to substances found In gas or from of gas combustion which are known to the State of to cause cancer, birth defects, or other reproductive harm. Consult ~ur gas supplier in the State of California for more information. JTHIS BOOKLET CONTAINS MPORTANT INFORMATION Important Note: In the state of Massachusetts: · This product must be installed by a licensed Plumber or Gas Fitter. · When flexible connectors are used, the maximum length shall not exceed 36 inches. · When lever type gas shutoffs are used they shall be T-Handle Type INSTALLER: USE THE INFORMATION IN THIS BOOKLET TO INSTALL THE APPLIANCE AND AFFIX THIS BOOKLET ADJACENT TO THE APPLIANCE AFTER INSTALLATION. USER: KEEP THIS BOOKLET OF INFORMATION FOR FUTURE REFERENCE. SERVICER: USE THE INFORMATION IN THIS BOOKLET TO SERVICE THE APPLIANCE AND AFFIX THE BOOKLET ADJACENT TO THE APPLIANCE AFTER SERVICING. LITERATURE ASSEMBLY BOOKLET NO, 329983-701 IJllllllllllllllllllllll Cover Page P/N 329983-201 FORM NO. 11312A-45~ CATALOG NO. 5331-205 Bn/ant He~rflng & Cooling Systems 7310 W. Morfls Street Indianapolis, IN 46231 MODEL 31 2AAV/JAV Important Information Addendum to the Installation, Start-up, and Operating and Maintenance Instructions Series 120 or Series C 33 1/3" Mid-Efficiency Furnaces This furnace is equipped with the White-Rodgers Series G valve and a new igniter. This addendum sheet is to familiarize you with the new silicon nitride igniter and the Series G gas valve and to be used to check and adjust gas pressure for proper installation and start-up. This sheet will be used to complete the "Adjustments" section of the "Start-up Procedures" section and to replace igniter position figures in the "Cleaning Heat Exchanger" sections of the Installation, Start-up, Operating and Maintenance Instructions. See Fig. 1 for two-stage gas valve. This version of the G valve has standard 1/8" NPT inlet and outlet pressure taps that are removed with a 3/16" hex head wrench for connection to a manometers and Low Gas Pressure Switch (when used). For conversions to propane gas, refer to the iustmctions in the Natural to Propane Conversion Kit, KGANP3001ALL. Fig. 1-Two-Stage Gas Valve The major difference in the two-stage G valve, besides the compact design, is the location of the Low and High stage regulators. Both regulators are located on top of the valve and are marked "Lo" and "Hi" next to the regulator seal caps. Both regulator springs are adjusted with a standard 3/16" or smaller flat-tipped screwdriver. The other difference is the G series valve IS NOT a dual-fuel gas valve. Conversions to propane will require the replacement of BOTH regulator adjustment springs. The Low stage and High stage springs are identical to each other and the 2 springs are included in the Natural to Propane Conversion Kit, KGANP3001ALL. When referring to the "CLEANING HEAT EXCHANGER" section of the Installation. Start-up. Oneratine and Maintenance Instructions, or for disassembly and reassembly during service, maintenance, or cleaning, refer to Fig. 2 and 3 for the position of the new igniter. IMPORTANT: Fig. 2 - Igniter Position - side view Fig. 3 - Ign/ter Position - top view This sheet MUST be inserted into the Installation, Sta~-up, Operating and Maintenance Instructions and left with the furnace. IGVT- 1 SI 12-04 2-Stage Deluxe Induced-Combustion Cancels: II 312A-45-2 II 312A-45-3 12-02 Installation, Start-up, Operating, and Service and Maintenance Instructions Series 100lA NOTE: Read the entire mstrustion manual before starting the installation. This symbol --) indicates a change since the last issue. TABLE OF CONTENTS SAFETY CONSIDERATIONS ..................................................... 2 INTRODUCTION .......................................................................... 3 CODES AND STANDARDS ........................................................ 3 Safety ......................................................................................... 3 General Installation ................................................................... 3 Combustion and Ventilation Air ..............................................5 Duct Systems ............................................................................ 5 Acoustical Lining and Fibrous Glass Duct .............................. 5 Gas Piping and Gas Pipe Pressure Testing .............................. 5 Electrical Connections .............................................................. 5 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE ................................................................................ 5 LOCATION .................................................................................... 5 General ...................................................................................... 5 Location Relative to Cooling Equipment ................................ 6 AIR FOR COMBUSTION AND VENTILATION ...................... 6 Unconfined Space ..................................................................... 7 Confined Space ......................................................................... 7 INSTALLATION ........................................................................... 8 Upflow Installation ................................................................... 8 Bottom Return Air Inlet ...................................................... 8 Side Return Air Inlet ........................................................... 8 Leveling Legs (If Desired) .................................................. 8 Downflow Installation .............................................................. 9 Bottom Retain Air Inlet ...................................................... 9 Horizontal Installation .............................................................. 9 Suspended Unit Support ...................................................... 9 Platform Unit Support ....................................................... 10 Roll-Out Protection ............................................................ 10 Bottom Retm'n Air Inlet ....................................................10 Side Return Air Inlet ......................................................... 11 Filter Arrangement .................................................................. 11 Air Ducts ................................................................................. 11 General Requirements .......................................................11 Ductwusk Acoustical Treatment ....................................... 12 Supply Air Connections .................................................... 13 Return Air Connections .....................................................14 Gas Piping ............................................................................... 14 Electrical Connections ............................................................ 16 115-V Wiring ..................................................................... 16 .l-Box Relocation ............................................................... 16 Electxical Connection to J-Box ......................................... 16 REGISTERED QUALITY SYSTEM For Power Cord Installation .............................................. 16 For BX Cable Installation ................................................. 17 J-Box Cover Installation .................................................... 17 24-V Wiring ....................................................................... 17 Accessories ........................................................................ 18 V~nting .................................................................................... 18 General V~nting Reqtfirements .........................................18 Masonry Chimney Requirements ...................................... 21 Appliance Application Requirements ............................... 24 Additional Venfmg Requirements ..................................... 27 Sidewall Venting ............................................................... 27 START-UP, ADJUSTMENT, AND SAFETY CHECK ............ 27 General .................................................................................... 27 Start-Up Procedures ............................................................... 28 Adjustments ............................................................................. 28 Check Safety ConSols ............................................................ 33 Checklist .................................................................................. 33 SERVICE AND MAINTENANCE PROCEDURES .................. 34 Introduction ............................................................................. 34 General ............................................................................... 34 Elec~cal Controls and Wiring ......................................... 34 Care and Maintenance ............................................................ 37 Cleaning and/or Replacing Air Filter ............................... 37 Blower Motor and Wheel .................................................. 40 Cleaning Heat Exchanger .................................................. 41 Sequence of Operation ............................................................ 42 Wiring Diagrams ..................................................................... 45 Troubleshooting ...................................................................... 45 Manufacturer reserves the right to discontinue, or change at any time, specific, aeons or designs without ~olJc. and without incurring obligations. ~ PC 101 Catalog NO. See Cover Pdnted in U.S.A. Form 58CT-4S~ Pg 1 12~)2 Replaces: 58CT-2SI A D WIRE ENTRy NOTES: 1. Two additional 7/8-in. diameler ho~es are located in the top plate. 2. Minimum return-air openings al 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 of 14 112 x 12-in. rectangle. b. For 1200 CFM-20-in. round or 14 112 x 19 1/2-in. rectangle. c. For 1600 CFM-22qn. round or 14 1/2 x 22-in. rectangle. d. For airflow requiremenls above 1800 CFM, see Air DeliveP/table in Product Data Ii era ure for spec tic use of sin le side inlets. The use of both side inlets a combination of I side and the bottom or the bottom o~¢ w ensure adequate forum air oponings for a ~ow requiremenls above 1800 CFM --> Fig. 1--Dimensional Drawing SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, mainte- nance, or use can cause carbon monoxide poisoning, explo- sion, fire, elec~ical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distribu- tor or branch for information or assistance. The qualified installer or agency must use only factoD,-authorized and listed kits or accessories when modifying this product. Failure to follow tlfis warning could result in electrical shock, fire, personal injury, or death. Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause premature component failure. --> Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untxained 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 unit and other safety precautions that may apply. These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed .certain local codes and ordinances, especially those that may not have kept up with changing msiden- hal constrachon prachces. We require these instructions as a minimum for a safe installation. A02304 personal injury. Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls. This is the safety-alert symbol ~. When you see this symbol on the furnace and th instntctions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. 2. Install this furnace only in a location and position as specified in the "Location" section of these instructions. 3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air for Combustion and Ventilation" section. 4. Combustion products must be discharged outdoors. Conect this furnace to an approved vent system only, as specified in the "Venting" section of these instructions. 5. Never test for gas leaks with an open flame. Use a commer- cially available soap aolution made specifically for the detec- tion of leaks to check all connections, as specified in the "Gas Piping" section. Table 1--Dimensions (IN.) VENT UNIT SIZE A B C CONN.* SHIP W'l'. (LB) 045-081024045 14-3/16 12-9/16 12-11/16 4 116 045-12/036045 14-3/16 12-9/16 12-11716 4 117 075-08/024070 14-3/16 12-9/16 12-11/16 4 120 075-t2/036070 14-3/16 12-9/16 12-11/16 4 126 070-16/048070 17-1/2 15-7/8 16 4 135 090-14/042090 17-1/2 15-7/8 16 4 137 090-t6/048090 21 19-3/8 19-1/2 4 150 090-20/060090 21 19-3/8 19-1/2 4 155 115-12/036110 17-1/2 15-7/8 16 4 145 1t0-t6/048tt0 21 19-3/8 19-1/2 4 157 110-22/066110 21 19-3~8 19-1/2 4 162 135-1 6/048t 35 21 19-3/8 19-1/2 4 162 135-22/066135 24-1/2 22-7/8 23 4 174 155-20/060155 24-1/2 22-7/8 23 4 181 6. Always install furnace to operate within the furnace's intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as speci- fied in the "Start-Up, Adjustments, and Safety Check" section. See furnace rating plate. 7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See "Air Ducts" section. 8. A gas-fried furnace for installation in a residential garage must be installed as specified in the warning box in the "Location" section. 9. The furnace is not to be used for temporary heating of buildings or structures under construction. See page 5 for _~x 10. These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and C.G.A.) design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and CG.A.) listed gas conversion kit is required to convert furnace for use with propane gas. ~ 11. See Fig. 2 for required clearances to combustibles. -~> 12. Maintain a l-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 carpet- lng, 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. INTRODUCTION -->XThe Series 100/A 4-way multipoise Category I fan-assisted furnace is CSA (A.G.A. and C.G.A.) design-certified for natural and propane gas and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. A fan-assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed gas conversion kit is required to convert furnace for use with propane gas. This furnace is not approved for installation in mobile homes, recreational velfiules, or outdoors. This furnace is designed for nftmmum 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 85°F db. Failure to follow these return-air limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.) For accessory installation details, refer to the applicable instruction literature. NOTE: Remove all shipping brackets and materials before oper- ating the furnace. CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. In the United States and Canada, follow all codes and standards for the following: Step l---Safety US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSIfNFPA 90B CANADA: CAN/CGA-BI49.1 and .2-MOO National Standard of Canada. Natural Gas and Propane installation Codes (NSC- NGP1C) Step 2~General Installation US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire ProtectiOn Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC, contact thc American Gas Association, 400 N. Capitol, NW., Washington DC 20001 or www.NFPA.org. CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Tor- onto), Ontario, M9W IR3 Canada ~ INSTALLATION MINIMUM INCHES CLEARANCE TO COItIIBUST1BLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COI~BUSTIBLES ~is fc~:ed air ftxnace is eqUpped f~ use with ~s furnace is app[oved f~ UFf:LOW, DOv~XFLOW, and naturel gas at elfitudes 0-10,000 fl (0-3,050m). HOPJZONTAL inst,~laflons. An acoessory k~t, supplied by the Cette foumase est ap~ po~ rinstallatJon HO~ZONTALE manufactL~-er, shaJl be used to convert to propane et la c~culabon d'air VERS LE HAUT ~ VERS LE BAS. Qearance an~ws /1"~ Les fl~hes de d~ applications. PO nc{ chance with / ~ ne change~t pas avec 3~is fLrnace is for indoor installation in a furnaceode~taflm ~ ~ I'~entationdelafournase. btilding onnmnJcted on site. "..... ThisfumacemaybeinstelledmcombuslJble .~1~''~ , flo(xing in aton~ or close~ at mimmu'n c~ and may de ¥sr~ed in m ruth (~er gas- crmmses em~ o-a~om (0-~ 0,000 ~). lo fabric~qt, pour passer au gaz propone on pour , Cede fotrnaise est p~vue pour ~e '"'~ I! Celte fonmaise peub~e install~e s~ ~ D~ (po). un plancher CaT~bu~ble dens une alcove ou d'espace libre des rnat~aux combustil:~es, tel Vent Clearance to oombusflbles: qb'indiqu~ sor le d~agran3~. For Sin~e Wall ve~s 6 inches (6 po), Cede foon'~3~se peut ~a'e ulJlis~e avecm Fa' Type B-1 venHype I inoh (1 po). Pour conduit d'~raoJati~a ~ pami sirr~e 6 po (6 inches). au conduit onmmon d'aulzes apparelis a gaT_ F:~ur conduit d'~vacuaim de Ty~pe B-1 1 poll inchI. MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW For Installation on oombuslible flonnng only when installed on spedel base, Part No. KG~.SB0201ALL, 18 inches fTont deerance reqdred for elcow. Indicates supply or relt~-n sides when furnace is in the horizontel poeltion. Line cer~act only penT~ssible I:)e(ween lines fon'ned by intemec~ons o~ the Top ond two Sides of the funace jackel, ond building joisb, DI~6A6EMENT MINIMUM EN POUCES AVEC 15LISMENTS DE CONSTRUCTION COMBUSTIBLES PO~R LA POSITION COUI~IT DESCENUANT: Pour I'installalJon st~ on ~ combustible seulemont quand on ulJlise la base sp~dale, piece n° KGA,S~I.AJJ., I'ensemble sa'peri, n, piece n° CD5 ou CKS, ou le cater de sapenlin, piece n° KCAKC. Dans u'~e ~35ve, on deil melnlonir m d~3agemen~ ~ I'ava~ de 18 po (450 mm). La posiUon indiqu~e onnc~me le o5~ d'enlr~e ou de re{ou' quand la fou~aise esl dans la Le contacl n'est peri'his qu'entre les I~Jaes form~ per les intorsecliom du dessus e~ des 32759e-10t REV. B Fig. 2~learances to Combustibles 4 A02330 Fig. 3~Return Air Temperature MAX 85~F MIN60°F A02055 Step 3---Combustion and Ventilation Air US: Section 8.3 of the NFGC, Air for Combustion and Ventilation CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply for Appliances Step 4~Duct Systems US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Con- tractors National Association (SMACNA), or American Soci- ety of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34. Step ~ Acoustical Lining and Fibrous Glass Duct US and CANADA: current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 6--Gas Piping and Gas Pipe Pressure Testing US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing Codes CANADA: NSCNGPIC Part 3, 4, 5, A, B, E and H. Step 7--Electrical Connections US: National Electrical Code (NEC) ANSVNFPA 70-2002 CANADA: Canathan Electrical Code CSA C22.1 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE 2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person's hand during grounding will be satisfactorily discharged. 3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.). 4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the thmace again before touching control or wires. 5. Use this procedure for installed and uniustalled (ungrounded) fumaces. 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. LOCATION Step l~eneral This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Figure 4. NOTE: For high-altitude installations, the high-altitude conver- sion kit MUST be installed at or above 5500 fr 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 not be installed directly on any combustible material other than wood flooring (refer to INTRODUCTION). · be located as close to the chimney/vent and atlached to an air distribution system. Refer to Air Ducts section. · be provided ample space for servicurg and cleaning. Always comply with minimum fire protection clearances shown on the furnace cleamce to combustible label. Do not install furnace in a corrosive or contaminated atmo- sphere. Make sure all combustion and cireulafmg air require- ments are met, in addition to all local codes and ordinances. Electrostatic discharge can affect electrohic components. Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from person- nel and hand tools which are held dtmng the procedure. These precautions will help to avoid exposing the control to elec- trostatic discharge by pulling the furnace, the control, and the person at the same electrostatic potential. 1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DIS- CHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND. AIRFLOW THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND DISCHARGED DOWNWARD I ~o~ DISCHARGED TO THE RIGH*r Fig. 4~Multipoise Orientations A02097 This gas fuxnace may be used for construction heat provided that: -The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure. -The furnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure without thermostatic control. -Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components. -The temperature of the return air to the furnace is no less than 55 degrees F, with no evening setback or shutdown. The use of the furnace while the structure is under COUStTuction is deemed to be intermittent operation per our installation instructions. -The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value. -The tilters 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. Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control opera- tion will be adversely affected. Never connect return-air ducts to the back of the furnace. Failure to follow this warning could result in tire, personal injury, or death. (See Fig. 5.) BACK FRONT A02054 Fig. 5--Prohibit Installation on Back 6 Step 2--Location Relative to Cooling Equipment The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the fi:mace. 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 adcquate combustion and ventilation air must be provided in accordance with Section 8.3 of the NFGC, Air for Combustion and Ventilation, or applicable provisions of the local building codes. Canadian installations must be installed in accordance with NSC- NGPIC Part 7 and all authorities having jurisdiction. 18-1N. MINIMUM TO BURNERS A93044 Fig. 6---Installation in a Garage When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or NSCNGPIC. (See Fig. 6.) Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, deter- gents, bleaches, cleaning solvents, salts, air fresbenem, and other household products. All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-ak duct to prevent pulling air from the burner area and fi-om blocked vent safeguard opening. The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to Carbon Monoxide Hazard warning in venting section of these instruc- tions to determine amount of make-up air required. The requirements for combustion and ventilation air depend upon whether the furnace is located in an tmconfined or confined space. Step 1--Unconfined Space An unconfined space has a volume of at least 50 cu fi for each 1000 Btuh total input for all appliances (furnaces, clothes dry,rs, water heaters, etc.) in the space. For example: FURNACE MINIMUM WITH INPUT (BTUH) 7-1/2 FT CEILING (SQ. FT.) 44,000 294 66,000 441 88,000 587 110,000 734 132,000 881 154,000 1028 7 If the unconfined space is constructed unusually tight, air for combustion and ventilation must come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be equivalent to those used for a confined space (defined below). Return air must not be taken fi-om the room unless an equal or greater amount of air is supplied to the Step 2---Confined Space A confined space has a vohtme less than 50 cu fi- per 1000 Btoh of total input ratings of all appliances installed in that space. A confined space must have provisions for supplying air for com- bustion, ventilation, and dilution of flue gases using one of the following methods in Table 2 and Fig. 7 and 8. NOTE: When determining the free area of an opening, the blocking effect of louvers, grilles, and screens must be considered. If the free area of the louver or grille design is unknown, assume wood louvers have a 20 pement flee area and metal louvers or grilles have a 60 percent free area. Screens must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed. The opening size depends upon whether air comes from outside of the stxucture or an unconfmed space inside the structure. 1. Air from inside the structure reqff~ras 2 openings (for struc- tures not of unusually tight construction): a. Each opening must have a minimum free area of not less than 1 sq in per 1000 Bmh of total mpnt rating for all gas utilization equipment in the confined space, but not less than 100 sq in. The minimum dimension of air openings should be no smaller than 3 in. (See Table 2 and Fig. 7.) b. If building construction is unusually tight, a permanent opening directly commtmicating with the outdoors shall be provided. (See next section). c. If the furnace is installed on a raised platform m provide a return-air plenum, and return air is taken directly from the hallway or space adjacent to furnace, all air for combustion must come from outdoors. 2. Air from outside the structure requires I of the following: a. If combustion air is taken from outdoors through 2 vertical ducts, the opomngs and ducts must have at least I sq in. of free area per 4000 Btuh of total input for all equipment within the confined space. (See Fig. 8 and Table 2.) b. If combustion air is taken from outdoors through 2 hod- zontal ducts, the openings and ducts must have at least 1 sq in. of free area per 2000 Btah of total input for all eqfftpment within the confined space. (See Fig. 8 and Table 2.) c. If combustion air is taken from the outdoors through a single opening or duct (horizontal or vertical) commencing within 12 in. of the top of the confined space, the opening and duct must have at least I sq in. of free area per 3000 AIR DUCTS INTERIOR HEATED SPACE VENT THROUGH ROOF PER 1000 BTUH* IN DOOR ~ OR WALL z ~T~ SPAcEUNCONFINED6, MIN (FRONT) t 1 SQ IN. PER 1000 BTUH* IN DOOR _------ OR WALL ~12" MAX AIR DUCTS * Minimum opening size is 100 sq in. with minimum dimensions of 3 in. t Minimum of 3 in. when type-B1 vent is used. A02038 Fig. 7~onfined Space: Air for Combustion and Ventilation from an Unconfined Indoor Space Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space. Equipment clearances to the structure shall be at least I in. from the sides and back and 6 in. from the front of the appliances. (See Table 2 and Fig. 8.) When duels are used, they must be of the same cross sectional area as the free area of the opeffmgs to which they connect. The minimum dimension of ducts must not be less than 3 in. INSTALLATION Step l--Upflow Installation BOTTOM RETURN AIR INLET These fumaces 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: I. 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 rem-air opening. This panel MUST be in place when only side return air is used. 1Z' MAX I SQIN. BTUH* AIR DUCTS DUCTS TO OUTDOORS F~R 2000 BIDH' 12"k ISQIN. PER 40O0 BTUH* O 1 SO IN. PER 4OOO BTUH' 1Z' AIR DUCTS 1SQtN. TO PER 4000 OUTEX3ORS BTUH* *Minimum dimensions of 3 in. NOTE: Use any of the following combinations of openings: A&B C&D D&E F&G A02165 Fig. 8-..~onflned Space: Air for Combustion and Ventilation from Outdoors NOTE: Side return-air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return-air openings in DOX,VNFLOW configuration. LEVELING LEGS (IF DESIRED) In up/iow 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 Step 1 To install leveling legs: 1. Position furnace on its back. Locate and drill a hole in each bottom corner of fi]mace. (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. Table 2-Minimum Free Area of Combustion Air Opening* AIR FROM INDOOR OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH FURNACE UNCONFINED SPACE VERTICAL DUCTS HORIZONTAL DUCTS SINGLE DUCT INPUT Free Area Free Area of Free Area of Free Area of Round Pipe Round Pipe Opening and Duct Round Pipe (BTUH) of Opening Opening and Duct (in. Dia) (in. Dia) Opening and Duct (In. Dia) (Sq In.) (Sq. In.) (sq In.) (Sq In.) 44,000 100 11 4 22 6 14.7 5 66,000 100 16.5 5 33 7 22.0 6 88,000 1 O0 22.0 6 44.0 8 29.3 7 110,000 110 27.5 6 55 9 36.7 7 132,000 132 33 7 66 10 44.0 8 t54,000 154 38.5 7 77 10 51.3 8 * Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances in the space require combustion air. BO'FrOM FILLER ~ PANEL PANEL ~ A02098 Fig. ~ Removing Bottom Closure Panel IH ~16~ Fig. lO--Leveling Legs A02071 Step 2--Downflow Installation NOTE: For downflow applications, this furnace is approved for use on combustible flooring when any one of the 3 accessories are used: · Special Base, KGASB · Cased Coil Assembly Part No. CD$ or CK5 Coil Box Part No. KCAKC 1. Determine application being installed from Table 3. 2. Construct hole in floor per Table 3 and Fig. 11. 3. Construct plenum to dimensions specified in Table 3 and Fig. 11. 4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 13. NOTE: It is recommended that the perforated supply-air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory-supplied cased coil or coil box. To remove the supply-air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.) 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 ah' is used. To remove bottom closure panel, perform the following: 1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.) 2. Rotate bottom filler panel downward to release holding tabs. 3. Remove bottom closure panel. 4. Reinstall bottom filler panel and screws. Step 3~Horizontal Installation Do not install the furnace on its back or hang furnace with control compartment facing dow'award. Safety control opera- tion will be adversely affected. Never connect return-air ducts to the back of the furnace. Failure to follow this warning could result in fire, personal injury, or death. 9 The furnace can be installed horizontally in an attic or crawl space on either the let,-hand (LH) or right-hand {RI-I) side. The furnace can be hung from floor joists, rafters or trusses or installed on a platform, non-combustible blocks, bricks or pad. SUSPENDED UNIT SUPPORT The furnace may be supported under each end with threaded rod, angle iron or metal plumber's strap as shown. (See Fig. 15 and 16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber's straps) may be used to suspend the unit from each bottom comer. To prevent screws from pulling out, use 2 # 8 x %-in. screw into the side and 2 # 8 x %-in. screw in the bottom of the fimaace casing for each strap. (See Fig. 15 and 16.) · A96283 Fig. 11--Floor and Plenum Opening Dimensmns FURNACE (OR COIL CASING WHEN USED) -- COMBUSTIBLE ~ FLOORING A96285 Fig. 12--Furnace, Plenum, and Subbase Installed on a Combustible Floor FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL SOX COMBUSTIBLE FLOORING SHEET METAL PLENUM -- FLOOR -- OPENING Fig. 13~Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor PLATFORM UNIT SUPPORT Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For fin-naces with l-in. clearance requirement on side, set unit on non-combustible blocks, bricks or angle iron. For crawlspaee installations, if the unit is not suspended from the floor joists, the ground underneath unit must be level and the umt set on blecks or bricks. ROLL-OUT PROTECTION Provide a minimum 17 3/4" X 22' piece of sheet metal for roll-out protection in front of burner area for traits closer than 12 inches above the combustible deck or suspended units closer than 12-in. to joists. The sheet metal MUST extend underneath the fia'nace casing by 1 in. with the door removed. The bottom closure pan on fizrnaces of widths 17 1/2 in. and larger may be used for roll-out protection when bottom of fin'nace is used for return air connection. See Fig. 17 for proper orientation of roll-out shield. BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, peO'orm the following: 1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.) 2. Rotate bottom filler pane] downward to release holding tabs. 10 Table 3--Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B C D Upflow Applications on Combustible or Noncombustible 12-11/16 21-5/8 13-5/16 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Floodng 12-9/16 19 13-3/16 19-5/8 (KGASB subbase not required) 14-3116 Downflow applications on combustible flooring (KGASB 11-13/16 t 9 13-7/16 2{3-5/8 subbase required) Downflow Applications on Combustible Ftoorin9 with CD5 or CK5 Coil Assembly or KCAKC coil box (KGASB subbase 12-5/16 19 13-5/16 20 not required) Upflow Applications on Combustible or Noncombustible 16 21-5/8 16-5/8 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Floodng 15-7/8 19 16-1/2 19-5/8 (KGASB subbase not required) 17-112 Downflow applications on combustible flooring (KGASB 15-1/8 19 16-3/4 20-5/8 subbass required) Downflow Applications on Combustible FIoorin9 with CD5 or CK5 Coil Assembly or KCAKC coil box (KGASB subbase 15-1/2 19 16-1/2 20 not required) Upflow Applications on Combustible or Noncombustible 19-1/2 21-5/8 20-1/8 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 19-3/8 19 20 19-5/8 (KGASB subbase not required) 21 Downflow applications on combustible floodng (KGASB 18-5/8 19 20-1/4 20-5/8 anbbass required) Downflow Applications on Combustible Floodng with CD5 or CK5 Coil Assembly = KCAKC coil box (KGASB subbase 19 19 20 20 not required) Upflow Applications on Combustible or Noncombustible Floodng (KGASB subbase not required) 23 21-1/8 23-5/8 22-1/4 Downflow Applications on Noncombustible Flooring 22-7/8 19 23-1/2 19-5~8 (KGASB subbase not required) 24-112 Downflow applications on Combustible floodng (KGASB 22-1/8 19 23-3/4 20-5/8 subhass required) Downflow Applications on Combustible Floodng with CD5 or CK5 Coil Assembly or KCAKC coil box (KGASB subbase 22-1/2 19 23-1/2 20 not required) 3. Remove bottom closure panel. 4. Reinstall boUam filler panel and screws. SIDE RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return-air opening. This panel MUST be in place when only one side return air is used. Not all horizontal furnaces are approved for side return air connections (See Fig. 20.) Step 4--Filter Arrangement 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 MexYm Filter Cabinet. The Media Filter Cabinet uses either a factory-supplied standard I inch filter or 4 inch wide Media Filter which can be purchased separately. Refer to the instructions supplied with MecY~a Cabinet for assembly and installation options. 11 Step 5--Air Ducts GENERAL REQUIREMENTS The duct system should be designed and sized according to accepted national standards such ar those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioffmg Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guide- lines reference tables available f~om your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. Installation tip: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insu- lated to enhance system performance. When ah' conditioning is used, a vapor barrier is recommended. UPFLOW DOWNFLOW HORIZONTAL PREFERRED PREFERRED Fig. 14--Duct Flanges '14" THREADED ROD A02329 8" MIN FOR DOOR SECURE ANGLE IRON TO BO~FOM OF FURNACE WITH 3 #8 x ~14" SCREWS TYPICAL FOR 2 SUPPORTS 1" SQUARE. 1 I," x 1 I," x I," ANGLE IRON OR UNI-STRUT MAY BE USED ~2~ HEX NUTS. (2) WASHERS & (2) LOCK WASHERS O PER ROD Fig. 15~Horizontal Unit Suspension Maintain a l-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. 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 A02345 DUCTWORK ACOUSTICAL TREATMENT Installation tip: Metal duct systems that do not have a 90 degree elbow and 10 fi of main duct to the first branch take-off may require internal acoustical lmmg. As an alternative, fibrous duct- work may be used if constructed and installed m accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts. 12 PENING Fig. 16--Horizontal Suspension with Straps INE CONTACT ONLY PERMISSIBLE BETWEEN A02014 173/4' OVER ALL 43/4' UNDER DOOR UNDER FURNACE EXTEND OUT 12" OUT FROM FACE OF DOOR K AREA * WHEN USED WITH SINGLE WALL VENT CONNECTIONS GAS VALVE SEDIMENT TRAP Fig. 17--Typical Attic Installation A02164 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 duet to flange on furnace supply-air outlet. Bend flange upward to 90° with wide duct pliers. The supply-air duct attachment must ONLY be connected to furnace supply- outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be con- nected external to furnace main casing. Installation tip: For horizontal applications, the top-most flange may be bent past 90 degrees to allow the evaporator coil to hang on the flange temporanly while the remaining attachment and sealing of the coil are performed. Downflow Furnaces Connect supply-air duct to supply-air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace 13 supply/outlet or air conditioning coil casing (when used). When installed on combustible material, supply-air duct aUachment must ONLY be connected to the accessory subbase, KGASB, or factory approved air conditioning coil casing. DO NOT cut main furnace casing tx) attach supply side air duct, humidifier, or other accesso- ries. All accessories MUST be connected external to furnace casing. RETURN AIR CONNECTIONS If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appli- ance. Black iron pipe shall be installed at the gas valve and extend a minimum of 2 in. outside the furnace. Never connect return-air ducts to the back of the furnace. A failure to follow this warning can cause a fire, personal injury, or death. Downflow Furnaces The return-air duct must be connected to return-air opening (bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Fig. 19.) Upflow and Horizontal Furnaces The retum-air duct must be connected to bottom, sides (le~ or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifter may be attacbed into unused side return air portion of the furnace casing. (See Fig. 18, and 20.) Not all horizontal furnaces are approved for side return air connec6ous. (See Fig. 20.) Step 6--Gas Piping Table 4 Maximum Capacity of Pipe* NOMINAL IRON INTERNAL LENGTH OF PIPE iFT) PIPE DIAMETER SIZE (IN.) 10 20 30 40 50 0N.) 1/2 0.622 175 120 97 82 73 314 0.824 360 250 200 170 151 I 1.049 680 465 375 320 285 1-114 1.380 1400 950 770 660 580 1-112 1.610 2100 1460 1180 990 900 * Cubic ft of gas per hr for gas pressures of 0.5 psig (14~n wc or less and a pressure drop of 0.5-in wc (based on a 0.60 spebl~c gray ty gas. Ref: Table 12.2 NFPA 54-2002. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A failure to follow this warning could result in fire, explosion, personal injury, or death. Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S. and the NSCNGPIC in Canada. Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line nmning directly from meter to furnace. Refer to Table 4 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 f~. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas. --'> An accessible manual shutoffvalve MUST be installed external to furnace casing and within 6 ft of fmnace. A 1/8-in. NFl' plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve. -~> NOTE: The gas valve inlet pressure tap connection ~s suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. we) stated on gas control valve. (See Fig. 50.) --'> Some installations require gas entry on right side of furnace (as viewed in upflow). (See Fig. 2la.) Install a sediment trap in riser leading to furnace as shown in Fig 2lb. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and exterior manual equip- ment gas shutoff valve. ---> Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada, local, and national plumbing and gas codes before the furnace has been connected. Atter all connections have been made, purge lines and check for leakage at furnace prio[ to operating furnace. -->x If pressure exceeds 0.5 psig (14-in. we), gas supply p~pe must be disconnected from furnace and capped before prqssure test. If test pressure is equal to or less than 0.5 psig (14-in. we), turn off electric shutoff switch located on furnace gas control valve and accessible manual shutoff valve before test. After all connections have been made, purge lines and check for leakage. ~'>The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF. 14 UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR CONNECTION 1 CONNECTION 2 ONLY ONLY RETURN AIR RETURN AIR | *20 MODELS ALL O~IER MODELS YES YES Fig, 18---Upflow Return Air Configurations and Restrictions Fig. 19--Downflow Return Air Configurations and Restrictions Fig. 20---Horizontal Return Air Configurations and Restrictions A02075 A02163 A02162 FACTORY INSTALLED LOCATION TWO ALTERNATE FIELD LOCATION A02099 Fig, ACCESSORIES 1. Electronic Air Cleaner (EAC) Connect an accessory Electxonic Air ~ (if used) using l/4-in female quick connect terminals to o male l/4-in quick-connect terminals on the control board and EAC-2. The terminals are rated for [.0 amps maximum and are energized during blower motor 2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp (if used) to the l/4-in male quick-connect HUM terminal CoM-24V screw terminal on the control boan The HUM terminal is energized when gas valve is energized. NOTI=: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation. DO NOT connect furnace control HUM terminal to (humidifier) terminal on Thermidistat, Zone similiar device. See Thermidistaff~ stat, or controller manufacturer's instructions proper Step 8--Venting The fLu-nace shall be connected to or vent complying with a recognized standard, · or concrete chimney lined with a lining material having jurisdiction. Venting into an concrete chimney is prohibited. When an existing furnace ' a venting ~ sized to vent the attached appliances. An sized Category I venting vent, leakage of condensate and combustion products, and spillage of combustion products into the living space, etc. CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death~ The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1. Seal any unused openings in venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Deter- mine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition. 3. As far as practical all building doors and windows the space in which the appliance(s) connected to are located and other spaces of the dampers. 4. Close 5. Tuam on c the system. Turn on any exhaust fans, such as and bathroom exhausts, so they are operating )perate a summer exhaust fan. instmcfious. Place the appliance being into operation. Adjust the thermostat so appli- race 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. 8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance wit the National Fuel Gas Code, ANSI Z223.1/NFPA 54 9.1, Natural Gas and Propane Installation it has been determined that each appliance connected venting system properly vents when tested as return doors, windows, exhaust fans, other gas-fired burning appli- Vent system other appliances system or connector determined using NGPIC. may need to be resized. For any vent systems or vent connectors, sized to approach minimum size as found in the NFGC or NSC- 18 Follow all safety codes for requirements, including local Gas Code (NFGC) 10 nithel Gas and Propane Installation Code Section 7 and Appendix C in Canada. sizing and installation the National Fuel Parts 7 and Natural CSA-B 149.1-00, These furnaces are design-certified as Category I furnaces in accordance with ANSI Z21.47aJCSA 2.3a-2001 and operate with a non-positive vent static pressure to mimmize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in thc venting system. These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSC- NGPIC. Furnace control must be grounded for proper operation or control will lock out, Control is grounded through green/yellow wire routed to gas valve and manifold bracket 2" Nipple Street Elbow Gas Valve A02327 ~ Fig. 2la--Right Side Gas Entry Example GAS-- '-- --' SUPPLY MANU^L ../ II SHUTOFF VALVE (REQUIRED/~"'& SEDIMENT -- TRAP ~ UNION'-' A02035 Fig. 21b~Typical Gas Pipe Arrangement Step 7--Electrical Connections Sec Fig, 22 for field wiring diagram showing typical field 115-v wiring. Check all factory and field electrical connections for tightness. --) Field-supplied winng shall conform with the limitations of 63°F (33°C) rise. Thc cabinet MUST have an uninterrupted or unbroken ground accordmg to NEC ANSI/NFPA 70-2002 ami Canadian Elec- b'ical 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 gage. Do not usc gas piping as an electrical ground. Failure te follow this warning could result in electrical shock, fire, or death, 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 uflity is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 5 for eqmpment electrical specifications. Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2002 and any local codes or ordinances that might apply. For Canadian instal- lations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or authorities having juris- diction. Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 5 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace. NO?re: Proper polarity must be maintained for l15-v wiring. If polarity ts incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate. J-BOX RELOCATION NOTF: If factory locatron of J-Box ~s acceptable, go to next section (J-Box Cover Installation). NOT£: On 14" wide casing models, the J-Box shall not be relocated to other side of furnace casing when the vent pipe is muted within the casing. 1. Remove screws holding auxiliary J-box. (See Fig. 23.) 2. Cut wire tie on loop in wires te J-box. 3. Locate box to desired location. 4. Fasten J-Box to casing with screw. 5. Route J-box wires within furnace away from sharp edges and hot surfaces. ELECTRICAL CONNECTION TO J-BOX electrical or gas components. 16 I Attach electrical box to J-Box bracket. 2. Route wires through hole in electrical box and J-Box bracket. 3. Secure ground wire to green screw on J-Box bracket. 4. Connect line voltage leads as shown in Fig.22. FOR POWER CORD INSTALLATION Power cords must be able to handle the electrical requirements listed in Table 5. Refer to power cord manufacturer's listings. 1. Route listed power cord through hole in J-Box. 2. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used. 3. Secure ground wire to green screw on J-Box bracket. 115-VOLT FIELD- SUPPLIED FUSED DISCONNECT .... FIELD 24-VOLT WIRING .... FIELD 115-, 208/230-, 460-VOLT WIRING -- FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 , ,1-STAGE THERMOSTAT WIRE ~ ' ~ ~ ~ ~ ONLY '~' ~ ' ~ __oj_ j ...... BOX [~ ............... 24-VOLT TERMINAL BLOCK FURNACE FIELD-SUPPLIED FUSED DISCONNECT CONDENSING UNIT 208/230-OR 2081230- VOLT SINGLE PHASE NOTES: 1. Connect Y/Y2-terminal as shown for proper operation. 2. Some thermostats require a "C" terminal connection as shown. 3. If any of the odginal wire, as supplied, must be replaced, use same type or equivalent wire. A95236 Fig. 22--Field Wiring Diagram Table 5--Electrical Data VOLTS- OPERATING MAXIMUM UNIT SIZE HERTZ- VOLTAGE RANGE MAXIMUM UNIT MAXIMUM MINIMUM UNIT AMPS AMPACITY# WIRE LENGTH (FT).I: FUSE OR CKT BKR WIRE GAGE PHASE Maximum* Vlinimum* AMPSt' 045-08/024045 115-60-1 127 104 5.4 7.52 50 15 14 045-12/036045 115-60-1 127 104 7.1 9.67 39 15 14 070-06/0240?0 115-60-1 127 104 5.2 7.22 52 15 14 070-12/036070 115-60-1 127 104 7.3 9.91 38 15 14 070-16/048070'* 115-60-1 127 104 9.8 13,42 29 15 14 090-1~._~._~_n90 115-60-1 127 104 8.2 10.84 35 15 14 090-16/048090 115-60-1 127 104 9.9 13.0 29 15 14 090-201060090- 115-60-1 127 104 12.9 16.70 35 20 12 110-12/036110 115-60-1 127 104 8.3 10.76 35 15 14 110-16/048110 115-60-1 127 104 10.2 13.19 28 15 14 110-22/066110 115-60-1 127 104 13.8 17.60 33 20 12 135-16/048135 115-60-1 127 104 10.0 13.13 29 15 14 130-22/066135 115-60-1 127 104 14.3 18.56 32 20 12 155-20/060155 115-60-1 127 104 15.0 19.34 30 20 12 · Pe~nssbe mits of the voltage range at which the unit c 3e~ates satisfactorily. # Unit ampaclty = 125 percent of largest operating component's full load amps p us 100 percent of all other potential operating components' (EAC, humidifier, etc.) full load amps. t Time<~elay type m r~commended. ~: Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. 4. Connect line voltage leads as shown in Fig. 22. FOR BX CABLE INSTALLATION 1. Route BX cable to hole in J-Box. 2. Secure BX cable to J-Box bracket with connectors approved for the type of cable used. 3. Secure ground wire to green screw on J-Box bracket. 4. Connect line voltage leads as shown in Fig. 24. J-BOX COVER INSTALLATION 1. Remove J-Box cover from blower access door on furnace and reinstall blower access door screw. 2. Fold tab on J-Box bracket with pliers. 3. Insert tab of J-Box cover into slot of J-Box bracket. 4. Secure J-Box cover to bracket with screw provided. 5. Remove U-shaped cut-out fi-om outer door to clear J-box. 24-V WLRING Make field 24-v connections at the 24-v terminal strip. (See Fig. 31.) Connect terminal Y/Y2 as shown in Fig. 22 or Fig. 24-30 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. 17 FACTORY INSTALLED TWO ALTERNATE FIELD LOCATION A02099 Fig. 23--Relocating J-Box ACCESSORIES 1. Electxomc Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using l/4-in female quick connect terminals to the two male l/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. 2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp maximum humidif~r (if used) to the 1/4-in male quick-connect HUM terminal and COM-24V screw terminal on the control board thermostat strip. The HUM terminal is energized when gas valve is energized. NO?F: A field-supplied, l15-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation. DO NOT connect furnace control HUM t~aninal to HUM (humidifier) terminal on Thermidistat, Zone Controller or simi]iar device. See TbermidistatTM, Zone Controller, thermo- stat, or controller manufacturer's instructions for proper Step 8---Venting ----> The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction. Venting into an unlined masonry chimney or concrete chimney is prohibited. .~x When an existing furnace is removed or replaced in a venting system, the venting system may not be properly sized to vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space, etc. CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1. Seal any unused openings in venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Deter- mine that there is no blockage or resthction, 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 appli- ance is operating continuously. 7. Test for spillage fi.om 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 wit the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B 149.1, Natural Gas and Propane Installation Codes. 9. Afl.er it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appli- ance to their previous conditions of use. Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table fotmd in the NFGC or NSC- NGPIC. 18 GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code (NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and 10 in the United States or the National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA-B 149.1-00, Section 7 and Appendix C in Canada. These furnaces are designq:ertified as Category I furnaces in accordance with ANSI Z21.47aJCSA 2.3a-2001 and operate with a non-positive vent static pressure to minimize the potential for vent gas leakage. Category I fttrnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSC- NGPIC. THERMIDISTAT HEAT STAGE 2 ~ COOL STAGE 1 ~ _ HEAT STAGE 1 ~[ - COOL STAGE 2 ~. _ HUMIDIFY OUT.OR ~-[~- TWO-STAGE TWC~SPEED FURNACE AIR CONDITIONER HUMIDIFIER (24 VAC) A00276 Fig. 24-~Two-Stage Furnace with Two-Speed Air Conditioner THERMIDISTAT TWO-STAGE SINGLE-SPEED FURNACE HEAT PUMP RVS COOLING HEAT STAGE 3 (FURNACE HI) HUMIDIFIER (24 VAC) Fig. 2~Two-Stage Furnace with Single-Spe~2~7 Heat Pump (Dual Fuel) THERMIDISTAT RVS COOLING ~. HUMIDIFY (24 VAC) OUTDOOR ........ SENSOR Fig. 26--Two-Stage Furnace with Two-Speed Heat Pump (Dual Fuel) A0027B ]9 DU~J. FUEL THERMOSTAT TW(~STAGE SINGLE~PEED TWO-STAGE TWO-STAGE TWO-SPEED FURNACE HEAT PUMP THERMOSTAT FURNACE AIR CONDITIONER 24 VAC COMM RVS SENSING Fig. 27--Dual Fuel Thermostat with Two-Stag~°279 Furnace and Single-Speed Heat Pump RVS COOLING 24 VAC COMM RVS SENSING Fig. 28--Dual Fuel Thermostat with Two-Stage Furnace and Two-Speed Heat Pump __ NOTE Fig. 29 Two-Stage Thermostat with Two-Sta~°~28~ Furnace and Two-Speed Air Conditioner SINGLE-STAGE TWO-STAGE TWO-SPEED THERMOSTAT FURNACE AIR CONDITIONER A00282 Fig. 30---Single-Stage Thermostat with Two-Stage Furnace and Two-Speed Air Conditioner 20 NOTES for Fig. 24-30 1. Heat pump MUST have a high pressure switch for dual fuel applications. 2. Refer to outdoor equipment Iustallation Instructions for additional information and setup procedure. 3. Select the "ZONE" position on the two-speed heat pump control. 4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications. 5. Dip switch No. I on Thermidistat should be set in OFF position for air conditioner installations. This is factory default. 6. Dip switch No. I on Thermidistat should be set inON position for heat pmnp installations. 7. Dip switch No. 2 on Thermidistat should be set in OFF position for single-speed compressor operation. This is factory default. 8. Dip switch No. 2 on Thermidistat should be set in ON position for two-speed compressor operation. 9. Configuration Option No. 10 "Dual Fuel Selection" must be tumedON in all dual fuel applications. 10. NO connection should be made to the furnace HUM terminal when using a Thermidistat. 11. Optional connection: If wire is connected, dip switch No. I on furnace control should be set in ON position to allow Thermidistat?rhermostat to control furnace staging. 12. Optional connection: If wire is connected, ACRD$ jumper on furnace control should be removed to allow ThermidistatYThermostat to control outdoor unit staging. 13. 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. 14. The RVS Sensing terminal "L' should not be connected. This is internally used to sense defrost operation. 15. DO NOT SELECT the "FURNACE INTERFACE" or "BALANCE POINT" option on the two-speed heat pump control beard. This is controlled internally by the Thermidistat/Dual Fuel Thermostat. 16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single-speed compressor operation. This is factory default. 17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation. The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC. Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected. Failure to follow this warning could result in a build-up of carbon monoxide and lead to personal injury or death. 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 thc furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the minimum vent connector capacity is lower than the low fire rate of the furnace and the maximum vent connector capacity is high*r than the furnace high fire rate. 3. Do not connect this appliance to a single wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors. 4. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system opomting under positive pressure. 5. In the US: Do not vent this appliance with any solid fuel burning appliance, la Canada, check with the authority having jurisdiction for approval on use with solid fuel burning appliance. ~x 6. Category I fttmaces must be vented vertically or nearly vertically unless eqmpped with a listed power ventor. --> 7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 32. MASONRY CHIMNEY REQUIREMENTS These furnaces are CSA design-certified for use in exterior tile-lined masonry chimneys with a factory accessory Chim- ney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit numbers marked on the furnace mtfug plate. Ifa clay tile-lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relinmg might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Soild Fuel Burning Appliances ANS1/NFPA 211-2000 in the United States and to a Provincial or Territorial Building Code in Canada (in its absence, the National Building Code of Canada) and must be in good condition. U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type-B vent, or a listed alternative venting design. NOTE: See the NFGC, 13.2.20 regarding alternative venting design and the Exception, which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACA02015FC, which are listed for use with these furnaces. The Chimney Adapter Kit is listed alternative venting system for these furnaces. See the kit instructions for complete details. 21 SETUP SWITCHES LOW-HEAT ONLY AND BLOWER OFF-DELAy 24-V-THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) -- 3-AMP FUSE/ LED OPERATION &/ TWINNING AND/OR COMPONENT TEST TERMINAL / ACRDJ - AIR CONDITIONING ///'RELAY DISABLE JUMPER DIAGNOSTIC LIGHT 115-VAC (L2) NEUTRAL~ TRANSFORMER 24-VAC CONNECTIONS PL1 - LOW VOLTAGE MAIN HARNESS CONNECTOR PL3 SELECTION TERMINALS ~ / ~ MOTOR CONNECTOR Fig. 31--2-Stage Furnace ControI-PSC Blower Motor Canada-This furnace is permitted to be vented into a clay tile-lined masonry chinmey that is e[pesed to the outdoors below the roof line, provided: 1. Vent connector is Type-B double-wall, and 2. This fu~ace is common vented with at least I dra~ hood- equipped appliance, and 3. The combined appliance input rating is less than the maximum capacity given in Table A, and A02017 4. The input rating of each space heating appliance is greater than the minimum input rating given in Table B for the local winter design tc~nperature. Chimneys having interna] areas greater than 38 square inches require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table B, and 5. The authority having jurisdiction approves. If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with a furnace listed for use with the kit, a listed chimney-lining system, or a Type-B common vent. 22 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI 7_223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian installation Codes CSA-B149.1 in Canada. Yes No No Yes Rebuild Repair liner or top seal Reline or reline chimney as necessary. in cleanout? Mortar Mortar, tile, metal vent or tile Remove mortar fuel oil residue? debds? and tile debds or liner, Clay tile misal No Condensate drainage at bottom of chimney? No Chimney expossd to outdoors below roof line? No Chimne sized, listed liner or Not SuitaUe Install chimney adapter per instructions. Line chimney with property sized, listed flexible metal liner or Type-B vent per NFGC or NSCNGPIC Vent Sizing Tables and liner or vent manufacturer's Not Suilabte Ins[allation instructions. Part C of a single furnace? app4ication Suitable Install chimney adapte~ per instructions. Fig. 32--Chimney Inspection Chart A02101 23 Exterior Masonry Chimney FAN + NAT Installations with Type-B Double-Wall Vent Connectors Table A-Combined Appliance Maximum Input rating in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY VENT (SQ. IN.) HEIGHT(F-r) 12 19 28 38 6 74 119 178 257 8 80 130 193 279 10 84 138 207 299 15 NR 152 233 334 20 NR NR 250 368 30 NR NR NR 404 Table B-Minimum Allowable Input Rating of Space-Heating Appliance in Thousands of BTU per Hour 12 INTERNAL AREA OF CHIMNEY VENT (SQ. IN,) HEIGHT (FT) I 19 I 28 I 38 Local gg% Winter Design Tern ~rature: 17 to 26 degrees 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 degrees F* 6 NR 78 121 166 u. 8 NR 94 135 182 ~ 10 NR 111 149 198 .o 15 NR NR 193 247 20 NR NR NR 293 30 NR NR NR 377 Local 99% Winter Design Temperature: -10 to 4 degrees F* 6 NR NR 145 196 u. 8 NR NR 159 213 ~ 10 NR NR 175 231 .o 15 NR NR NR 283 ~ 20 NR NR NR 333 30 NR NR NR NR Local 99% Winter Design Temperature: -11 degrees F or lower' Not recommended for any vent configuration *The 99% Winter Design D~y-Bulb (db) tempemfores are found in the 1993 ASHRAE Fundamentals Handbook. Chapter 24, Table 1 United States) and 2 (Canada). or use lhe 996% heating db tempemfores found in the 1997 or 2001 ASHRAE Fundamentals Handbook. Climatic Design Information chap- ter. Table lA (United States) and 2A (Canada). Inspections before the sale and at the time of installation will determine the acceptability of the chinmey or the need for repair and/or (re)lining. Refer to the Fig. 32 to perform a chimney inspection. If the inspection of a previously used tile-lined chim- ney: a. Shows signs of vent gas condensation, the chinmey should be relined in accordance with local codes and the authority 24 having jurisdiction. The chimney should be relined with a listed metal liner, Type-B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFGC, Section 7.9 for additional information on condensate drains. b. Indicates the chimney exceeds the 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 file liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed (ULC listed in Canada) metal liner or UL listed Type-B vent. Relining with a listed metal liner or Type-B vent is considered to be a vent-in-a-chase. Ifa metal liner or Type-B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner. APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer fi.om condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes. The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Condi- tioning Conlmctors of America (Manual J); American Society of Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering methods. Excessive ovcrsizing of the fur- nace could cause the furnace and/or vent to fail prematurely. When a metal vent or metal tinct is used, the vent must be in good condition and be installed in accordance with the vent maunfac- turer's instructions. To prevent condensation in the furnace and vent system, the following precautions must be observed: 1. The return-air temperature must be at least 60°F db except for brief periods of time during warm-up fi.om setback at no lower than 55°F db or during initial start-up from a standby condition. 2~ Adjust the gas input rate per the installation insm~ctions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. D~rating is permitted only for altitudes above 20~0 ft. 3. Adjust the air temperature rise range to the midpoint or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems. 4. Set the thermostat heat anticipator or cycle rate to reduce short cycling. Air for combustion must not be contaminated by halogen com- pounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air fi-eshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combusfibn-air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion. Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace. SEE NOTES: 1.2.4.7.8,9 A02058 Fig, 33--Upflow Application-Vent Elbow Up SEE NOTES: 1,2,3,4,7,8.9 A02059 Fig, 34---Upflow Application-Vent Elbow Right SEE NOTES: 1.2.4.5,7.8.9 A02061 Fig. 3~---Downflow Application-Vent Elbow Up SEE NOTES: 1.2,4,5.6,7.8,9 A02062 Fig. 37--Downflow Application-Vent Elbow LeE then Up SEE NOTES:I,2,3.4,5,7.8.9 A02060 Fig. 3~Downflow Application-Vent Elbow Up then Left See Venting Notes on Page 27 25 SEE NOTES: 1.2.3.4.5.7.8.9 A02297 Fig. 38~Downflow Application-Vent Elbow Up then Right SEE NOTES: 1,2,4,7,8,9 A02064 Fig. 3~Hofizontal Left Application-Vent Elbow Left SEE NOTES: 1,2,4.5,7,8,9 A02065 Fig. 40~Horizontal Left Application-Vent Elbow Right then Up SEE NOTES: 1 ~,4,5,7,8,9 A02066 Fig. 41--Horizontsl Left Application-Vent Elbow Up SEE NOTES: 1,2,4,5,7,8,9 A02067 Fig. 42~orizontal Left Application-Vent Elbow Right SEE NOTES: 1,2,4,5,7,8,9 A02068 Fig. 43~Horizontal Right Application-Vent Elbow Left See Venting Notes on Page 27 Cauttonll For the following applications, use the minimum vertical heights as specified below For all other applicatipns, follow exclusivel the National Fuel Gas Code FURNACE ORJENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR) MINIMUM VENT DIAMETER (IN.)* MINIMUM VER~ICAL VENT HEIGHT {F'r)" Downflow Vent elbow left, then up 154,000 132,000 5 12 Fig. 37 110,000(036/-12 only) Vent elbow dght, Hor~.ontst Left then up 154,000 Fig. 4O t 32,000 5 7 Hodzontel Left Vent Elbow up 154,000 Fig. 41 132,000 5 7 Horl~ontel Left vent elbow ~ght Fig. 42 154,000 5 ? Dovmflow Vent elbow up then left I t0,000 Fig. 35 (036/-12 only) 5 10 Downffl3w Vent elbow up, then right 110.000 Fig. 38 (036/-12 only) $ 10 NOTE: All vent cenr~urstlons must also meet Nationel Fuel Gas Code venting requirements NFGC. '4 in. inside casing or vent guard **Including 4 in. vent section(s) 26 SEE NOTES: 1,2,4.7,8,9 A02069 Fig. 44~Horizontal Right Application-Vent Elbow Right SEE NCRES: t~,4,5,7,8,9 A02070 Fig. 45~Horizontal Right Application-Vent Elbow Left then Up Venting Notes for Fig. 33-45 l. For common vent, vent connector sizing and vent material: United States, latest edition of the National Fuel Gas Code (NFGC), ANSI Z223.1/NFPA .54. In Canada, latest edition of the National Standards of Canada, Natural Gas and Propane Installation Code (NSCNGPIC), CSA B149.1-00. 2. Immediately increase to 5-inch vent connector outside furnace casing when 5-inch vent connector required, refer to Note I above. 3. Side outlet vent for upflow and downftow installations must use Type B vent immediately after exiting the furnace, cxcept whoa KGAVG0101DFG is used m the downflow position. 4~ Type B vent wherc required, refer to Notc I above. 5.4" single wall (26 ga~ min.) vent must be used insidc furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace, 6. Accessory Downflow Vent Guard Kit, KGAVGOIO1DFG reqalred in downflow installations with bottom vent configuration. 7. Chimney Adapter Kit required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC and KGACA02015FC for sizing and complete application details. 8. Secure vent conncctor to furnace elbow with (2) ¢orrusinn-raskqant sheet metul screws, spaced approximately 180° apart. 9. Secure all other single wail vent connector joints with (3) corrosion resistant screws spaced approximately 120° apart. Secure Type B vent connectors per vent connector manufacturer's recommendations, ADDITIONAL VENTING REQUIREMBNTS A 4" round vent elbow is supplied with the furnace. A 5 inch or 6 inch vent connector maybe required for some model furnaces. A field-supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal increaser fitting is required when 5 inch or 6 inch vent connector is used. See Fig. 33-45 Venting Orientation for approved vent configurations. NOT~: Vent connector length for connector sizing starts at furnace vent elbow. The 4 inch vent elbow is shipped for upflow configunstion and may be wtated 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 docs NOT count as part of the number of vent connector elbows. The vent connector can exit the door fltrongh one of 5 locations on the door. L Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two fiuld-supplied, corrosinn-resistnnt, sheet metal screws located 180° apa~c 2. Vent the furnace with the appropriate connector as shown in Fig. 33-45. 3. Oricnt the door to determine the correct location of the door cutout to be removcd. 4. Use aviatinn-typc tin snips to remove the correct U-shaped cnt-out on door. An accessory Vent Guard Kit, KGAVGO101DFG is REQUIRED for downflow applications fur use where the vent exits throngh the lower portion of the furnace casing door. Rcfur to thc Vent Guard Kit Instructions for complete details. The horizontal portion of the venting system shall maintain a minimum of l/4-in, upward slope per linear ff and it shall be rigidly supported every 5 R or less with metal hangers or straps to ensure there is no movument after installation. SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting without the use of an ~ld-on power venter. In the U.S.: Per the NFGC, any listed power vnnter may be used, when approved by the authority having jurisdiction. In Cnnada: Only power venters approved by the appliance manufacturer and where allowed by the authority having jurisdic- finn may be used for sidewall venting. The only approved power venter is the Field Controls SWG4D and SWG-SD sidewall power renter. Select the power renter to match the btuh input of the appliance being vented. Follow all nnusufectu~r's installation requirements for venting and tem~ina. tion included with the power vcoter. START-UP, ADJUSTMENT, AND $AFETY CHECK 8rep ¶---Oen~ral This furnace is equipped with manual reset limit switches in the gas control mv, a. The switches open and shut offpower to thc gas valve if a flume rollout or overbearing condition occum in the gas control area. DO NOT bypass the swi~has. Correct inadequate combustion air supply problem a~d reset the switches. Failure to follow this warning can cause fire, explosion, personal injury, or death. Personal injmy can result form sharp metal edges, etc, Be cmeful when removing parts, Gloves and safety glasses should be worn when sarviong equipment, 27 1. Maintain llS-v wiring and ground. Improper polarity will result in rapid flushing LED and no fomaen operation. Table 6-Altitude Derate Multipler for U.S.A. ALTITUDE PERCENT (FT) OF DERATE 0-2000 0 2001-3000 8-12 3001-4000 12-16 4001-5000 16-20 5001-6000 20-24 6001-7000 24--28 7001-8000 26-32 8001-9000 32-36 9001-10,000 36-40 * Derate multiplier factors are based on mk DERATE MULTIPLIER FACTOR* 1.00 0.90 0.86 0.82 0.78 0.74 0.70 0.66 0.62 ~oint altitude tot altitude range. 2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 22.) 3. Gas supply pressure to the furnace must greater than 4.5-in. wc (0.16 psig ) but not exceed 14-in. wc (0.5 psig ). 4. Check all manual-reset switch 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 2 Stage Furnace control board, See Fig 31 and 46. 7. Setup switch descriptions - See Table 7. Step 2---Start-Up Procedures Never purge a gas line into a combustion chamber. Neve~ usc matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning can cause fire, explosion, personal injuw, or death. 1. Purge gas lines after all connections have been made. 2. Check gas lines for leaks. Blower access door switch opens l 15-v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death. 3. To Begin Component Self-Test: Remove blower access door. Disconnect the thermostat R lead fi-om fi-om furnace control board. Manually close blower door switch. Short (jumper) for approximately 2 sec. the COM-24v terminal on control to the TEST/TWIN 3/16-inch quick- connect t~rrninat on control until the LED goes out. Remover jumper fi-om terminals. (See Fig. 31.) NOTE: The furnace control allows all components, except the gas valve, to be nm for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control. Component test sequence is as follows for 2-stage fttmace: Refer to service label attached to furnace or See Fig. 50. a. LED will display previous status code 4 times. b. Inducer motor starts on high-speed and continues to nm tmtil Step 7 of component test sequence. c. Hot surface ignitor is energized for 15 sec., then off. d. Blower motor operates on LO-HEAT speed for 10 sec. e. Blower motor operates on HI-HEAT speed for 10 sec. fi Blower motor operates on COOL speed for 10 sec. g. Inducer motor goes to low-speed for 10 sec., then stops. h. Reconnect R lead to furnace control board, remove tape fi-om 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 sethng above room temperature. Step 3~Adjustments DO NOT reckill orifices. Improper drilling (burrs, out-of- round holes, etc.) can cause excessive bomer noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig. 48.) 28 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be within ±2 percent of furnace rating plate input. ha the U.S.A., the input rating for altitudes above 2,000 ft. must be reduced by 4 percent for each 1,000 ft. above sea level. In Canada, input rating must be reduced by 10 percent for altitudes of 2,000 ft. to 4,500 t~. above sea level. For altitudes above 5500 ft., a field-supplied high altitude pressure switch is required. 1. Determine the correct gas input rate. In the U.S.: For installations below 2000 ft., refer to the unit rating plate. For installations above 2000 ft., multiply the input on the rating plate by the de-rate multiplier in Table 6 for the correct input rate. In Canada: At installation altitudes from 2000 to 4500 t~, this furnace must be derated 10 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example and use 0.90 as derate multiplier factor. EXAMPLE: 88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. Derate Furnace input Rate Furnace Input Rate X Multiplier at Installation at Sea Level Factor Altitude 88,000 X 0.90 79,200 2. Determine the correct orifice and manifold pressure adjust- ment. All models in all positions except Low NOx models in downflow and horizontal positions use Table I I (22,000 BTUH per burner). Table 7--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 thennostat. SW-1 Adaptive Heat Mode OFF Turn ON when using 2 stage thermostat to allow Low Heat opera- tion when R to W/W1 closes and High Heat operation when R to W/~V1 and W2 close. Control blower OFF delay time. Used in conjunction with SW-3 SW-2 Blower OFF delay ON or OFF See Table 10. Control blower OFF delay time. Used in conjunction with SW-2 SW-3 Blower OFF delay ON or OFF See Table 10. Low NOx models in downflow or horizontal positions MUST use Table 12 (21,000 BTUH per burner). See input listed on rating plate. a. Obtain average yearly gas heat value (at installed altitude) fi.om local gas supplier. b. Obtain average yearly gas specific gravity from local gas supplier. c. Find installation altitude in Table 11 or 12. d. Find closest natural gas heat value and specific gravity in Table 11 or 12. e. Follow heat value and specific gravity lines to point of intersection to find orifice size and low-and high-heat manifold pressure settings for proper operation. f. Check and verify burner orifice size in fm-nace. NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY. g. Replace orifice with correct size if required by Table 11 or 12. Use only factory-supplied orifices. See EXAMPLE 2. 22,000 BTUH/bumer application-use Table 11. EXAMPLE 2:(0-2000 f~ altitude) Heating value = 1000 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7-in. wc for high-heat 1.6-in. wc for low-heat * Furnace is shiPPed with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate. 3. Adjust manifold pressure to obtain low fire input rate. 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 2 stage furnace control to ON position. (See Fig. 31 or Table 7) to lock furnace in low-heat operation. f. Manually close blower door switch. g. Jumper R and W/W1 thermostat connections on control to start fitmace. (See Fig. 31.) h. Remove regulator adjustment cap from low-heat gus valve pressure regulators. (See Fig. 47) and turn low-heat adjust- ing screw (5/64 hex Allen wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate. 29 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 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. NOTfi: If orifice hole appears damaged or it is suspected to have be~n redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics; 4. Verify natural gas low-heat input rate by clocking meter. NOT;: Gas valve regulator adjustment caps must be in place for proper input to be clocked. a. Turn off all other gas appliances and pilots. b. Run for 3 minutes in low-heat operation. c. Measure time (in sec) for gas meter to complete 1 revolu- tion. And note reading. d. Refer to Table 9 for cubic ft of gas per hr. e. Multiply gas rate cu fffhr by heating value (Btu/cu fl) to obtain input. NOI£: Using the 2 cu. t~. or 5 cu. fl. gas meter dial provides greater accuracy in verifying gas input rate. If clocked rate does not match required input fi.om Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low fire input is achieved. Re-install low-fire 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 tempera- ture rise ranges specified on umt rating plate for high-and low-heat. Determine the temperature rise as follows: NOT£: Blower access door must be installed when taking t~rn- perature rise reading. Leaving blower access door offwitl result in incorrect temperature measurements. 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 fi.om 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 fi.om 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. .... F~ELD CONIROL ~NG (24VAC) COND~JCTOR ON CONTEOL PCB ~ ~ PLUG R~CEPTACLE ~L5 PL4 Fig. 46--Wiring Diagram A02159 ON/OFF LOW*FIRE ~ ~'~ (UNDER CAP) PRESSURE TAP A00158 Fig. 47--Redundant Automatic Gas Control Valve ORIFICE Fig. 48--Orifice Hole A93059 20 Derate for altitude if applicable. 3.) Return and supply ducts for excessive restrictions bausing static pressures greater than 0.50-in. we. c. Adjust air temperature risc by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For low beat, speed selection can be low (factory setting), reed-low, or reed (5-speed blowers only). d. Remove thermostat jumpers and release Blower Access Door Switch. e. To change motor speed selection for low heat, remove blower motor lead fi.om contxol LO-HEAT terminal. (See Fig. 31 and Table 8.) Select desired blower motor speed lead from I of the other terminals and relocate it to the LO-HEAT terminal. (See Table 8 for lead color identifica- tion). Reconnect original lead to SPARE terminal. f. Repeat step a and b. 31 Table 8 --Speed Selection COLOR SPEED AS SHIPPED While Common BLW Black High COOL Ye#ow Med-High SPARE Oranget Med SPARE Blue Med-Low HI-HEAT Low* LO HEAT Red ~eed-as shipped default Not all models equipped with 5 speed motors g. When correct low fire input rate and temperature rise is achieved, proceed to Step 6. 6. Adjust Manifold Pressure to Obtain High Fire Rate a. Remove high fire regulator adjustment cap ftom gas valve pressure regulator. b. Manually close blower access door switch. c. Jumper R, W/Wl and W2 thermostat connections on control to run furnace in high fire. (See Fig. 31.) d. Turn high-heat adjusting screw (5/64 hex Allen wrench) counterclockwise (out) to decrease input rote or clockwise (in) to increase rate. e. Re-install high-fire adjustment caps. f. Leave manifold or similar device connected and proceed to Step 7. NOTE: DO NOT set high-heat manifold pressure less than 3.2-in. wc or more than 3.8-m wc for natural gas. If manifold pressure is outside this range, change main burner orifices. 7. Verify natural gas high heat input rate by clocking meter. NOTE: Gas valve regulator adjustment caps must be in place for proper input to be clocked. a. Turn off all other gas appliances and pilots. b. Run for 3 minutes in high-heat operation. c. Measure time (in sec) for gas meter to complete I revolu- tion and note reading. d. Refer to Table 9 for cubic ft of gas per hr. e. Multiply gas rate cu fi/hr by heating value (Btu/cu ft) to obtain input. NOTE: Using the 2 cu. ft. or 5 cu. t~. gas meter dial provides greater accuracy in verifying gas input rate. 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 tempera- ture rise. Do not exceed temperature rise ranges specified on unit rating plate for high fire. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Determine the air temperature as follows: TABLE 9-GAS RATE (CU FTIHR) SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DiAL FOR 1 I 2 5 FOR t I 2 5 REVOLUTION Cu Ft Cu Fl Cu FI REVOLUTION Cu Ft Cu Ft Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1536 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 21 171 343 957 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 5~0 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 74 164 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 50 150 49 73 147 367 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 fire, speed selection can be med-high, med (5-speed blowers only), or med-low (factory sei~ing). d. Remove thermostat jumpers and release blower access door switch. e. To change motor speed selection for high heat, remove blower motor lead from control HI-HEAT terminal. (See Fig. 31 and Table 8.) 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 8 for lead color identification). Reconnect original lead to SPARE terminal. f. Repeat steps a thru c. g. When correct High tim input rate and temperature rise is achieved, turn gas valve ON/OFF switch to OFF. h. Release Blower Access Door switch. i. Remove manometer or similar device from gas valve. j. Re-install manifold pressure tap plug in gas valve. (See Fig 47.) k. Remove thermostat jumper wire from furnace control board. 1. Turn LHT switch OFF. m. Turn gas valve ON/OFF switch to ON. n. Proceed to Step 9, "Set Blower OffDelay" before installing blower access door. NOTE: Blower access door must be installed when taking tem- perature rise reading. Leaving blower access door offwill result in incorrect temperature measurements. a. Verify the unit is operating in high fire 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-mn ducts. b. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise. NOTE: If the temperature risc is outside this range, first check: 1.) Gas input for low-end high-fire opeation. 2.) Derate for altitude if applicable. 3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.50-in. we. 4.) Dirty filter. point of rise range or above. 32 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 10 and Fig 31.) 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/Wi circuit. Accurate amp draw readings can be obtained' at the wires normally connected to thermostat subhase terminals, R end 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. 49 across the R and W terminals or R and W wires. Table 10~2 Stage Furnace Blower OFF Delay Setup iwitch DESIRED HEATING MODE SETUP SWITCH SETUP SWITCH BLOWER OFF DELAY (SEC.) SW-2 SW-3 90 OFF OFF OFF ON 120 150 ON OFF 180 ON ON (4.) Record amp draw across terminals when furnace is in low heat and after blower starts. (5.) Set heat anticapator 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 br. Step 4 Check Safety Controls The flame sensor, gas valve, and pressure switch were all checked in the Start-up procedure section as part of normal operation. 1. Check Main Limit Switches This control shuts off combustion control system and ener- gizes air-circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted return-air supply or motor failure. If limit control does not ftmction 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. Unbloek return air to permit normal circulation. d. Burners will re-light when furnace cools down. 2. Check draft safeguard switch. The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions. a. Verify vent pipe is cool to the touch. b. Disconnect power to furnace and remove vent connector from furnace vent elbow. c. Restore power to furnace and set room thermostat above room temperature. d. After normal start-up, allow furnace to operate for 2 minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal. e. Furnace should cycle off within 2 minutes. f. Remove blockage and reconnect vent pipe to furnace vent elbow. g. Switch will auto-reset when it cools. h. Re-install vent pipe. NOTF: If switch is open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To reset furnace control board, turn thermostat above room temperature or from HEAT to OFF and tam 115 v power OFF, then back ON~ 3. Check Pressure Switch(es) This conh'ol proves operation of the draft inducer blower. a. Turn off l15-v power to furnace. b. Disconnect inducer motor lead wires from wire harness. c. Turn on l15-v power to furnace. 33 THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) HOOK-AROUND --7 AMMETER / / EXAMPLE: 50 AMPS ON AMMETER = 05 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SE~rlNG A96316 Fig. 49~Amp Draw Check With Ammeter d. Set thermostat to "call for heat" and wait 1 minute. When pressure switch is functioning properly, hot surface igniter should NOT glow and contel 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 l15-v power to furnace. g. Reconnect inducer motor wires, replace outer door, and ntrn on llS-v power. h. Blower will run for 90 seconds before beginning the call for heat again. i. Furnace should ignite normally. Step 5--Checklist 1. Put away tools and instruments. Clean up debris. 2. Check that switches for LHT and OFF-DELAY are blower OFF-DELAY are selected as desired. 3. Verify that blower and burner access doors are properly installed. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer's instruc- tions. 6. Review User's Guide with owner. 7. Attach literature packet to furnace. LED CODE STATUS F~CH OF ~ FCLLOC~NG ~TATU~ CC~S IS ^ P¢~ DIC4T t~M~R ~,~m 11~ FIRST [~G~T ~D ~ ~ ~ ~ ~ ~S ~ ~ 23 PR ~ES'W1TCH DID NOTOPEN Chec~fo~: -~}bSl~U~e~J pressuretubi. COMPONENT TEST Fig. 50~2-Stage Service Label A02026 SERVICE AND MAINTENANCE PROCEDURER furnace can be installed in any oftbe 4 positions shown in Fig. 4, The ability to properly pedorm maintenance on this equip- ment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended m the User's Manual. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS PERSONAL INJURY, OR DEATH. ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety wamings exactly, could result in dangerous operation, serious injury, death or property dam- age. ImFropor servicing could result in dangerous operation, serious injury, death or property damage. -Before servicing, disconnect all electrical power to fmnace. -When servicing controls, label all wires prior to disconnect- ing. Reconnect wkes correctly. -Verify proper operation after servicing. Step l--4ntroduction 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 you must revise your orientation to component location accord- ingly. ELECTRICAL CONTROLS AND WIRING 34 The electrical ground and polarity for ll5-v wiring must be properly maintained. Refer to Fig. 22 for field wiring information and to Fig. 46 for furnace wiring information. NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and time-sensing electrode. The 24-v circuit contains an automotive-type, 3-amp fuse located on the control. (See Fig. 31.) Any sho~s 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 instnnnentafion 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. 50, and the troubleshooting guide at the end of this procedure. For Controls with an Amber LED The stored status codes will NOT be erased fi-om 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: TABLE 11-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 Percent For Each 1000 Ft Above Sea Level) ALTITUDE RANGE (FT) 2000 ALTITUDE RANGE (FT) U.S.A. Altitudes 2001 3000 Canada Altitudes 2001 4500 AVG GAS HEAT VALUE (BTUICU FT) 900 925 95O 975 1000 1025 1050 1075 1100 AVG GAS HEAT VALUE (BTU/CU FT) 8O0 825 850 875 900 925 950 975 1000 ALTITUDE AVG GAS RANGE HEAT VALUE (FT) (BTU/GU IT) 775 8O0 3001 U,S.A, Only to 4OO0 825 850 875 9O0 925 95O ALTITUDE AVG GAS RANGE HEAT VALUE (FT) (BTU/GU IT) 75O 775 4001 to 5000 · Orifice numbers 43 are factory installed 80O 825 850 875 900 925 SPECIFIC GRAVITY OF NATURAL GAS 0.58 Odfice Manifold no. Pressure 41 3.5/1.5 42 3.3/1.4 43 3.8/1.7 43 3,6/1.6 43 3,5/1.5 43 3,3/1,4 3.6/1.6 3,4/1.5 3,3/1.4 0.58 Orifice Manifold no. Pressure 42 3.2/1.4 43 3.7/1.6 43 3.5/1.5 43 3.3/1.4 3.5/1.5 3.4/1.5 3.2/1.4 3.7/1.6 0.60 Odfice Manifold no. Pressure 42 3.6/1.6 42 3,4/1,5 42 3.3/1.4 43 3.8/1.6 43 3.6/1.6 43 3,4/1.5 43 3.2/1,4 44 3.5/1.5 44 3.4/1.5 SPECIFIC Orifice 0'CMManifoid no. Pressure 41 / 3.5/1.5 42 I 3.7/1.6 42 3.5/1.5 42 3.3/1.4 43 3.8/1.7 43 3.6/1.6 43 3.5/1.5 43 3.3/1.4 43 3.2/1.4 Odflce 0'C~Manifold no. Pressure 0.62 Orifice Manifold no, Pressure 41 3.7/1.6 42 3.5/1.5 42 3.4/1.5 42 3.2/1.4 43 3.7/1.6 43 3.8/1.5 43 3.4/1.5 3.2/1.4 3.5/1.5 GRAVITY OF NATURAL GAS 0.60 Orifice i'62 Manifold Manifold Pressure no. Pressure 42 43 43 43 45 3.5/1.5 I 41 3.6/1.6 3.3/1.4 42 3.4/1.5 3.8/1.6 42 3.2/1.4 3.6/1.6 43 3.7/1.6 3.4/1.5 43 3.5/1.5 3.2/1.4 43 3.3/1.4 3.5/1.5 3.6/1.6 3.3/1.4 3.4/1.5 3.8/1.7 3.2/1.4 SPECIFIC GRAVITY OF NATURAL GAS 3.7/1.6 3.5/1.5 3.3/1.4 3.8/1.7 3.6/1,6 3,4/1.5 3.2/1.4 3.5/1,5 3,4/1.5 0.58 0.60 Odflce Manifold Orifice Manifold no. Pressure no. Pressure 3.2/1.4 3.3/1.4 3.6/1.6 3.8/1.6 3.4/1.5 3.5/1.5 3.2/1.4 3.3/1.4 3.5/1.5 3.6/1.6 3.3/1.4 3.4/1.5 3.8/1.6 3.2/1.4 3.8/1.6 3.7/1.6 SPECIFIC 0.62 Orifice Manifold no. Pressure 41 3.4/1.5 42 3.2/1.4 43 3.7/1.6 43 3.4/1.5 3.3/1.4 3.5/1.5 3.3/1.5 45 3.8/1.7 GRAVITY OF NATURAL GAS Odfice ].64 Manifold no. Pressure 41 3.5/1.5 42 3.3/1.4 43 3.8/1.6 43 3.611.5 43 3.4/1.5 43 3.2/1.4 3.411.5 3.3/1.4 0.58 Orifice Manifold no. Pressure 4i I 3.6/1.6 43 3.4/1.5 3.2/1.4 3.4/1.5 3.211.4 45 I 3.7/1.6 46 3.7/1.6 46 3.5/1.5 0.60 Orifice I Manifold no. Pressure 43 3.8/1.6 43 3.5/1.5 43 3.3/1.4 44 3.6/1.5 44 3.4/1.5 45 3.8/1.7 46 3.8/1.7 46 3.6/1.6 Orifice i'62 Orifice i'64 Manifold Manifold no. Pressure no. Pressure 43 3.6/1.6 43 3.8/1.6 43 3.4/1.5 43 3.5/1.5 3.2/1.4 43 3.3/1.4 3.5/1.5 3.6/1.6 3.3/1.4 3.4/1.5 I 45 I 3.7/1.6 3.211.4 46 3,7/1.6 I 46 3.8/1.7 NOTE: NO thermostat signal may be present at control, and all blower-OFF delays must be completed. a. Leave llS-v power to furnace mined on. b. Remove outer access door. 35 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. TABLE 11-(Tabulated Data Based On 22,000 Btuh High-HeatJ14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTUICU FT) 725 750 775 5001 to 800 6000 825 850 875 900 Odfice No. 43 43 46 46 47 47 0.58 Manifold Pressure 3.4/1.5 3.2/1.4 3.4/1.5 3.2/1,4 3.8/1~7 3.6/1.6 3.8/1.7 3.6/1.6 SPECIFIC GRAVITY OF NATURAL GAS Orifice No. 43 43 45 46 46 47 0.60 Manifold Pressure 3,5/1.5 3.3/1.4 3.5/1.5 3.3/1.4 3.8/1.6 3.7/1.6 3.5/1.5 3.8/1.6 Orifice No. 43 43 43 46 46 46 0.62 Manifold Pressure 3.6/1.6 3.4/1.5 3.2/1.4 3.4/1.5 3.2/1.4 3.8/1.7 3.6/1.6 3.4/1.5 Odflce No, 43 43 43 44 44 45 46 46 Manifold Pressure 3.7/1.6 3.5/1,5 3.3/1.4 3.5/1.5 3.3/1.4 3.8/1.6 3.7/1,6 - 3.5/1.5 ALTITUDE RANGE (F'r) 6001 to 7000 7001 to 8000 ALTITUDE RANGE (FT) ALTITUDE RANGE (FT) AVG GAS SPECIFIC HEAT VALUE 0,58 AT ALTITUDE Orifice Manifold Orifice (BTU/CU FT) No. Pressure No. GRAVITY OF NATURAL GAS 0.64 Orifice No. Manifold Pressure 675 43 3.4/1.5 43 3.7/1.6 ?00 44 3.6/1.6 43 3.5/1.5 725 44 3.4/1.5 43 3.2/1.4 750 45 3.8/1.7 44 3.5/1.5 775 46 3.7/1.6 44 3.2/1.4 800 46 3.5/1.5 45 3.7/1.6 825 47 3.7/1.6 46 3.6/1.6 850 47 3.5/1 ~5 46 3.4/1.5 AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) 650 675 700 725 750 775 800 825 0.60 0.62 Manifold Odfice Manifold Pressure No. Pressure 43 3.5/1.5 43 3.6/1.6 43 3.3/1.4 43 3.4/1.5 44 3.5/1.5 44 3.6/1.6 44 3,3/1.4 44 3.4/1.5 45 3.7/1,6 45 3.8/1.7 46 3.6/1.6 46 3.8/1.6 46 3.4/1.5 46 3.5/1.5 47 3.6/1.6 47 3.8/1.6 SPECIFIC GRAVITY OF NATURAL GAS Odfice No. 45 46 46 47 47 48 0.58 0.60 0.62 0.64 Mainifo~d Orifice Pressure No. 3,6/1.6 3.3/1.5 3.8/1.6 3.7/1.6 3.4/1.5 3.6/1.6 3.4/1.5 3.7/1.6 43 46 46 47 47 48 Manifold Pressure 3.2/1.4 3.5/1.5 3.2/1.4 3.8/1.7 3.6/1.5 3.8/1.6 3.5/1.5 3.8/1.6 Odfice No. 43 45 46 46 47 47 Manifold Pressure 3.4/1.5 3.6/1.6 3.3/1.4 3.7/1.6 3.7/1.6 3.4/1.5 3.7/1.6 3.4/1.5 Odfice No. I 0.60 Manifold Manifold Pressure No. Pressure Odfice No. 47 47 SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.62 0.64 Orifice Odfice No. Manifold Pressure 3.6/1.6 AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) 3.3/1.5 3.5/1.5 Odfice No. 43 625 Manifold Pressure 3.5/1.5 3.2/1.4 3,4/1.5 3.2/1.4 3.8/1.6 3.6/1.5 3.8/1.6 3.6/1.5 Manifold Pressure 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 8001 675 46 3.6/1.6 46 3,8/1,6 45 3.7/1.6 45 3.8/1.7 to 700 47 3.8/1.7 46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 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 · Orifice numbers 43 are factor/installed ALTITUDE HEAT VALUE RANGE AT ALTITUDE (FT) (BTUICU FT) 60O 'E 625 0 ~ to 650 ~, IO,OO0 675 ~ 700 725 TABLE 11-(Tabulated Data Based On 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS 0.58 SPECIFIC GRAVITY OF NATURAL GAS 0,60 0.62 0.64 Odfice Manifold Od§ce Manifold Orifice Manifold Odflce Manifold No. Pressure No. Pressure No. Pressure No, Pressure · Orifice numbers 43 are facto~ installed 46 3.6/1.6 46 47 3.8/1,6 46 47 3.5/1.5 47 48 3,7/1.6 48 3.5/1.5 3.8/1.7 3.4/1.5 3.7/1.6 3.8/1.6 3.4/1.5 3.7/1.6 3.6/1.6 3.4/1,5 3,8/1,7 3.6/1.6 3.6/1.6 3,8/1.7 44 3,3/1.4 44 46 3.8/1.7 45 46 3.6/1.5 46 47 3,7/1.6 46 47 3.5/1.5 47 48 3.7/1.6 48 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~are and Maintenance 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 cleamng com- pounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids. 3. Paint thinners and other painting compounds, paper bags, or other paper products. A failure to follow this warning could result in corrosion of the heat exchanger, fire, personal injury, or death. For continuing high performance and to minimize possible eqinp- meat failure, periodic maintenance must be performed on this equipment. Consult your local dealer about proper frequency of maintenance and the availability of a mainmnance contract. 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. A failure to follow this warning could result in personal injury. personal injury, or death. The minimum maintenance on this equipment is as follows: 1. Check and clean air filter each month or more frequently if required. Replace if torn. 2. Check blower motor and wheel for cleanliness each heating and coolmg season. Clean as necessary. 3. Check electhcal connections for tightness and controls for proper operation each heating season. Service as necessary. 4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have fumace and bumer serviced by a qualified professional. 5. 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 professional. 6. 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 acces- sory instructions. CLEANING AND/OR REPLACING AIR FILTER The air filter arrangement may vary depending on the application. NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower. Personal injury can result from shanp metal edges, etc. Be careful when removing parts. Gloves and safety glasses should be worn when servicing equipment 37 Media cabinet filter procedures: NOTE: Media Cabinet is included with two-stagu furnace. 1. Turn off electrical supply to furnace before removing filter 2. Remove filter cabinet door. 3. Slide filter out of cabinet. 4. If equipped with permanent, washable filter, clean filter by spraying cold tap water through filter in opposite direction of TABLE 12-Orifice Size and Manifold Pressure for Gas Input Rate(Tabulated Data Based On 21,000 Btuh High-HeatJ14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) ALTITUDE RANGE (FT) 2000 AVG GAS HEAT VALUE (BTU/CU FT) U.S.A. .N6tudes 'o 2001 o 3000 Canada Altitudes 2001 4500 9O0 925 950 975 1000 1025 1050 1075 1100 ALTITUOE AVG GAS RANGE HEAT VALUE (FT) (BTU/GU FT) 800 825 85O 875 900 925 950 975 1000 ALTITUDE AVG GAS RANGE HEAT VALUE (Fl') (BTU/CU Fl') 775 8OO 3001 U.S,A, Only to 4000 4001 1o 5000 825 850 875 900 925 950 ALTITUDE AVG GAS RANGE HEAT VALUE (FT) (BTU/GU FT) 750 775 SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 Odfice Manifold Odfice Manifold no. Pressure no. Pressure 42 I 3.2/1.5 3.3/1.6 43 I 3.7/1.8 3.8/1.8 43 I 3.5/1.7 3.6/1.7 43 I 3.3/1.6 3.4/1.6 44 I 3.6/1.7 3.3/1.6 44 I 3.4/1.6 3.6/1.7 44 I 3.3/1.6 3.4/1.6 45 3.8/1.8 3.2/1.5 46 J 3.8/1.8 3.7/1.8 SPECIFIC GRAVITY OF NATURAL GAS 0.58 Odfice 0.62 Odflce Manifold Odflce Manifold no. Pressure no. no. Pressure · Orifice numbers 43 are factory installed 0.60 Manifold Pressure ~ 43 I 3.5/1.7 43 3.7/1.7 43 I 3,3/1,6 43 3.5/1.6 43 I 3.2/1.5 3.3/1,6 44 I' 3.4/1.6 3.5/1.7 44 I 3.2/1.5 3.3/1.6 45 I 3.7/1.8 45 ~ 3.8/1,8 46 3.7/1.8 46 I 3.8/1.8 46 3.5/1.7 46 3.6/1.7 SPECIFIC 0.62 Odfice Manifold no. Pressure 41 3.4/1.6 42 3.2/1.5 43 3.7/1.8 43 3.5/1.7 43 3.4/1.6 3.2/1.5 3~5/1.7 3.3/1.6 44 3.2/1.5 0.64 Orifice Manifold no. Pressure 42 3.5/1.7 42 3.3/1.6 43 3.8/1.8 43 3.7/1.7 43 3.5/I .7 43 3,3/1.6 43 3.2/1.5 44 3.4/1.6 44 3.3/1.6 Odflce rio. 43 43 43 /45/ 46 0.64 Manifold Pressure 3.3/1,6 42 3.4/1.6 3.8/1.8 42 3.2/1.5 3,6/1.7 43 3.7/1.8 3.4/1.6 i43 3.5/1.7 3.2/1.5 43 3.3/1.6 3,5/1.6 3.6/1.7 3.3/1.6 3.4/1.6 3.8/1.8 3.2/1.5 3.8/1.8 3.7/1.8 GRAVITY OF NATURAL GAS 0.58 0.60 Odfi~eiManifold Orifice Manifold no.IPressure no. Pressure 4! 3.5/1.7 4i 3.7/1.7 3.3/1.6 43 3.4/1.6 3.6/1.7 3.2/1.5 3,4/1.6 3.5/1.7 45 I 3.8/1.8 / 3.3/1.6 46 3.8/1.8 45 3.8/1,8 46 3.6/1.7 46 3.7/1.8 46 3~4/1.6 46 3.5/1.7 0.62 0.64 Odfice Manifold Odfice Manifold no. Pressure no. Pressure 43 3.5/1.7 43 3.7/1.7 43 3.3/1.6 43 3.4/1.6 3.6/1.7 3.2/1.5 3.4/1.6 3~5/1.7 3.2/1.5 3.3/1.6 3.7/1.0 I 45 I 3,8/1,6 46 3.7/1,7 46 3.8/1.8 SPECIFIC GRAVITY OF NATURAL GAS 0.58 Orifice 0'6~Aanifold Od~ice t Manifold no. Pressure no, Pressure 00o 850 46 875 46 900 47 925 3.3/1.6 43 3.4/1.6 3.6/1.7 43 3,2/1.5 3.3/1.6 4~ ' 3.4/1.6 3.8/1.8 3.2/1.5 3.5/1.7 46 3.7/1.7 3.8/1.8 46 3.5/1.7 3.6/1.7 3.7/1.8 0.62 Odfice Manifold 46 40 0.64 Odfice Manifold no. Pressure 3.5/1.7 43 3.6/1.7 3.3/1.6 43 3.4/1.6 3.6/1.7 43 3.2/1.5 3.4/1.6 44 3.5/1.6 3.8/1,8 44 3.3/1.6 3.8/1.8 45 3.7/1.8 3.6/1.7 46 3.7/1.8 3.8/1.8 46 3.5/1.7 airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended. See Table 13 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 38 with accessory KGAFR0301ALL external filter Table 13. 6. Slide filter into cabinet. 7. Replace filter cabinet door. 8. Turn on electrical supply to furnace. rack, Sec TABLE 12-(Tabulated Data Based On 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS ALTITUDE HEAT VALUE RANGE AT ALTITUDE (FT) (BTU/CU FT) 725 750 = 775 O 5001 ~ to 800 ~ 6000 825 :~ 850 875 9OO AVG GAS ALTITUDE HEAT VALUE RANGE (FT) AT ALTITUDE (BTU/CU FT) 675 70O _>, r: 725 0 6001 ~.' to 750 ~. 7000 775 ~ 800 825 850 AVG GAS ALTITUDE HEAT VALUE RANGE AT ALTITUDE (FT) (BTU/CU FT) 650 675 = 700 O 7001 <.' to 725 ~. 8000 750 ~ 775 8OO 825 AVG GAS ALTITUDE HEAT VALUE RANGE AT ALTITUDE (FT) (BTU/CU FT) _>, 650 O 8001 675 ~ 700 ~.' 9 0 725 750 775 Orifice No. SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.64 Manifold Pressure Orifice No. Odfice No. Manifold Pressure 44 3.5/1.7 43 43 3.411.6 44 3.3/1.6 44 43 3.2/1.5 45 3.7/1.8 44 44 3.4/1.6 46 3.7/1.8 46 44 3.2/1.5 46 3.5/1.7 46 46 3.8/1.8 47 3.7/1.8 47 46 3.6/1.7 47 3.5/1.7 47 48 3.8/1.8 47 SPECIFIC 0.58 Manifold Pressure Orifice NO, 3.5/1.7 44 3.3/1.6 45 3.7/1.8 46 3.6/1.7 46 3.4/1.6 47 3.6/1.7 47 3.4/1.6 48 3.7/1.7 Orifice No. 0.58 Manifold Pressure 44 3.3/1.6 45 3.7/1.8 46 3.6/1.7 47 3.8/1.8 47 3.5/1.7 48 3.8/1.8 3.6/1.7 48 48 0.58 Orifice NO. 46 47 47 46 48 0.60 0.62 Manifold Orifice Manifold Pressure No. Pressure 3.2/1.5 43 3.3/1.6 3.4/1.6 44 3.5/1.7 3.2/1.5 44 3.3/1.6 3.8/1.8 45 3.8/1.8 3.6/1.7 46 3.7/1.8 3.8/1.8 46 3,5/1.7 3.6/1.7 47 3.7/1.8 3.4/I .6 47 3.5/1.7 GRAVITY OF NATURAL GAS 3.3/1.6 46 3.4/1.6 3.7/1.7 I 47 Manifold Pressure 3.7/1.8 3.6/1.7 3.8/1.8 3.5/1.7 3.7/1.8 3.5/1.7 3.8/1.8 0.60 0.62 I Orifice I Manifold ~ Pressure 46 46 47 SPECIFIC GRAVITY OF NATURAL GAS Orifice Manifold No. Pressure 43 3.2/1.5 44 3.4/1.6 45 3.8/1.8 46 3.8/1.8 46 3.5/1.7 47 3.8/1.8 47 3.5/1.7 48 3.8/1.8 0.64 Orifice Manifold No. Pressure 3.3/1.6 43 3.4/1.6 3.5/1.7 43 3.2/1.5 3.3/1.6 44 3.4/1.6 3.7/1.8 45 3.8/1.8 3.611.7 46 3.8/1.8 3.4/1.6 46 3.5/1.7 3.6/1.7 47 3.8/1.8 3.4/1.6 47 3.5/1.7 0.60 Orifice Manifold NO. Pressure 44 3.4/1.6 45 3.8/1.8 46 3.7/1.8 46 3.5/1.7 47 3.7/1.8 47 I 3.4/1.6 48 I 3.711.8 48 I 3.5/1.6 0.62 Orifice { Manifold ~ Pressure 46 47 47 48 0,64 Orifice Manifold No. Pressure 3.5/1.7 43 3.2/1.5 3.311.6 44 3.4/1.6 3.8/1.8 45 3.8/1.8 3.8/1.8 46 3.5/1.6 3.6/1.7 47 3.7/1.7 3.8/1.8 47 3.4/1.6 3.6/1.7 3.7/1.8 SPECIFIC GRAVITY OF NATURAL GAS 0.60 0.62 0.64 Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No, Pressure No. Pressure 58 3.8/1.8 44 3.311.6 44 3.4/1.6 46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 46 3.4/1.6 46 3.5/1.7 46 3.7/1.7 47 3.6/1.7 47 3.7/1.8 46 3.4/1.6 48 3.8/1.8 47 3.5/1.7 47 3.6/1.7 48 3.6/1.7 48 3.7/1.8 48 3.8/1.8 3.4/1.6 48 3.5/1.7 48 3.6/1.7 39 TABLE 12-(Tabulated Data Based On 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) ALTITUDE RANGE (FT) O 9001 <.' to ~ 10,000 AVG GAS HEAT VALUE AT ALTITUDE (BTUICU FT) 600 0.58 SPECIFIC GRAVITY OF NATURAL GAS 0.60 0.62 Orifice No. 46 Odflce Manifold No. Pressure 46 3~6/1.7 47 3.7/1.8 47 3.4/1.6 48 3.6/1.7 48 3.4/1.6 49 i 3.7/1.8 625 47 650 47 675 48 700 725 48 49 Manifold Odfice Manifold Pressure No. Pressure 3.7/1.8 46 3.8/1.8 3.8/1.8 46 3.5/1.7 3.6/1.7 47 3.7/1.8 3.8/1.8 47 3.4/1.6 3.5/1.7 48 3.6/1.7 3.8/1.8 48 3.4/1.6 Odflce No. 45 Manifold Pressure 3.7/1.8 46 3.6/1,7 47 3,8/1.8 47 3.5/1.7 48 48 3.7/1,8 3.5/1.7 * Orifice numbers 43 are factory installed Table 13---FILTER SIZE INFORMATION (IN.) FURNACE FILTER SIZE FILTER CASING WIDTH Side Return Bottom Return TYPE 14-1/2 16 x 25 X I 14 X 25 x 1 Cleanable* 21 16 X 25 X I 20 X 25 X 1 Cleanable* 24 16 X 25 X I 24 X 25 X 1 Cleanable* * Recommended BLOWER MOTOR AND WHEEL Blower access door switch opens 115-v power to control. No component operation can occur tmless switch is closed. Caution mast be taken when manually closing this switch for service purposes. Failure to follow this warning could result in personal injm7 or death. The following steps should be performed by a qualified service technician. To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually. The inducer and blower motors are pre-lubricated and require no additional lubrication. 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 offelectrical 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. Notice wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing. 6. Remove 2 screws from control box to blower shelf. T Hang control box from front of fm'nace 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 (clipk) on blower wheel blades. 10. Vacuum any loose dust from blower housing, wheel and motor. 11. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degteaser. To remove wheel: NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each ann is positioned at the same location during reassembly. a. Disconnect capacitor wires (if equipped) and ground wke attached to blower homing. b. Remove screws securing cutoff plate and remove cutoff plate from homing. c. Loosen set screw holding blower wheel on motor shaft. d. Remove bolts holding motor to blower housing and slide motor out of wheel. e. Remove blower wheel from housing. f. Clean wheel and housing. 12. Reassemble motor and blower by reversing steps 11 e, through I la. 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 reposifion if necessary. Spin the blower wheel by hand to verify that the wheel does not rub on the housing. Reinstall blower assembly in furnace. Reinstall control box assembly in furnace. 14. 15. 16. 40 Heating fan speed(s) MUST be adjusted to provid~ proper air t~aporatu~ rise as specified on the rating plate. Failure to adjust thc heating speed(s) may shorten heat exchanger life. Rec~tmuended operation is at the midl~int of thc risc range or slightly above. Refer to #SET TEMPERATURE RISE' under START-UP, ADJUSTMENT, and SAFETY CHECK. NO~E: Refer to Table 8 for motor spead lead relocation if leads were not id~mtiflad b~fore disconnection, 17. R~.onnect blower leads to furnace control. Refer to furnace wirln~: diagram, and connect thermostat leads ff previously disconnected. 18. To check blower for proper rotation: ~ Turn on electrical supply. Blower access door synch opens llS-v power to furnace cont~L No eomponent operation can occur. Caution mast be taken when manually closing this switch for service pta~osas. Failoro to follow this warning ~add result in electrical shock, personal inju~, or death. b. Manually close blower acceas door switch. NOT~: If thcnnostet terminals are jumpered at the time blower access door switoh is clusad, blower will nm for 90 s~c before be~itmlng a hceting or cooling cycle. c. Perform component self-test as shown at the bottom of the SERVICE label, located on the front of blower nocess door, d. Verhey blower is rota~ng in the corr~t direction. 19. If f~muce is operating properly, RELEASE BLOWER AC- CESS DOOR SWITCH, then replace blower access &~or. Remove any jumpers or reconnect any discormucted thermo- 20. l~wnflow or horizontal fornacos with vent pipe tiuongh funmce only: a. Install and connect short piocc of vent pipe insidc f~rnace to existing vent. b. Cnnnoct vent connector to vent elbow. 21. Turn on gas supply and cyclc furnace through one complete heath~ smd cooling cycle. Verify the onit t~nperature risc as below ?O°F, tm~ off ch~uit breaker to outdoor unit before mnni~s furnace in the conting c~le. Turn outdoor circuit broak~ on ~ c~pleting cooling cycin. CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service teehnklan: NOT~: If the heat exehansers get a heavy aceumui~finn of soot them thoronghly. 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, ioconent size or damaged manifold orifice(s), improper gas, or a restrinted beat exchanger. Action must be t~-en to correct rite problem. If it become~ necessary to clean the heat exchangers because of dust or corrosion, proceed as follows: L Tmn OFF gas and electrical power to fum~e. 41 7/8" t A02151 Fig. 5~l--4%sition of Ignl~r to Burner 2. R~nove outer access door, 3. Discmmoct vent coonector from furnace vent elbow, 4. For downflow or harizontal fomuce having an internal vent pipe, remove internal vent pipe within the casing. 5. Disconocct wkus to the following components. ~ wi~'s to aid in recormuction of: b. Inducer motor. c. Pr~sra~ switches. d. Limit overtemperature switch. ¢. Gas valve. f. Hot surfa~ igniter. g. Flame-sensing electrode 6. Remove screws that fasten the cellector box assembly to the cell panel. Be careful not to damag~ the enllcetor box. Inducer sss~ably and elbow need not be removed float cell~etor box. 7, Disconn~;t gas line flora gas manifold. 8. Rgmove the 5 scr~vs that attach thc burner aas~nbly to the cell paneL Th~ ~,s valve and individual burners n~d not be removed from support as~mbly. Remove NOx baffie~ if iustallad. NOT~: Be very earefol whan t~moving burner assembly to aa)id b~aking igniter. Se~ Fig. 51 and 52 for corr~.'t igniter location. 9. Using fiald-provided 25w. alihar rifle cloning blush, I/4' dismater steel ~,,i.g cable, 36 in. Ion~:, a variable sp~d, reversible electric drill, and vacuton clcener, ¢1~ cells ~s follows: a. R~move metal scow fitting fi,om wir~ brush to allow insertion into cable. b. insort the twisted wire nnd of brush into eixl of spring cebl~, and crimp tight with ~,i,,,pin~ tool or o'imp by sttiking with ball-p~n hammer. TIGHTNESS IS VERY IMPORTANT. NOTE: The materials m~lad in item 9 can usually be purchased (I.) Attach vmable-sf~l, reversible drill to tho end of spring cable (~1 oppusito brush). (2.) ~ brush end of cable into the outlet opting of cell and slowly rotate with drill. DO NOT fno.'e cable. Gradually insert cable into upper pass of cell. (See Fig. 53.) 9/32" '-- Fl1~2" A02150 Fig, 52--Position of Igniter to Burner Ag1252 Fig. 53---Cleaning Heat Exchanger Cell 14. Reinstall inte~al vent pipe, if a~plicablc. 1S. Re'install writ connector on furnace vent clbow. Secm-ely fasten vent c, otmec~ to v~at elbow wi~ 2 ficld-suppli~i, corto~ion-resiaUmt, sheet meal sc, rows located 180~ apart. 16. P,.eplac~ blower ~ door only. 17. Se~ th~rmoalat abov~ mom te~nperature ami check furnace for tn,ri, er operation. 18. V~ify blowcr airflow ami speed chang~ Inn~v~cn I~ating and 19. Check fu~ gas l~aks, Ne',nsf uae a match or other ogen tlame to chock for ~as le~s. Usc a soap-and-wnt~ solution. A failm~ to follow w~,,&,g could ~tlt in fire, personal injury, or 42 20. R~pla~e out, x* acc~a~ door, Step a---aequen~ of Operation NOTE: F~I m~ ~~ ~1 ~11 ~ ~l b ~ ~ ~ ~ Us~ ~ ~c ~,, ~ F~. ~, ~l~w ~ ~ of ~ ~ ~ ~t ~. R~ ~ ~lbw ~e ~ ~ ~ ~lly. ~! ~ W~l~ ~ ~l ~ ~ b~ ~ ~e ~ b~ off~y ~ ~ ~ ~ ~w~ ~ ~ly. ~ blo~ ~ ~k ~ ~ ~ ~ ~1 CPU, ~ T~, ~ ~ ID~ blo~ ~ ~ ~ ~ ~ ON, (~ i~ 2. ~) ~ ~ c~ ~ of ~ ~ of ~e low-~ ~ly ~E ~~a~~e~as~ thermostat because the furnace control CPU includes a pro- grammed 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 fttrnace 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 switch- ing 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 thc 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 operation the inducer motor IDM comes up to speed, the low-heat pressure switch LPS closes, and the furnace control CPU begins a 15-second prepttrge period. After the low-heat pressure switch re-cluses the fur- nace control CPU will begin a 15-second prepurge period, and continue to nm the inducer motor 1DM at high-speed. (2.) If the furnace control CPU selects high-beat 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 pres- sure 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 presstne switch closes for a maximum of 2 minutes after ignition. b. Igniter Warm-Up-At the end of the prepurge period, the HS1 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 burners where it is ignited. After 5 seconds, the igniter HSI is de-energized and a 2-second 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 [[DM 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 Ignirinn- Lockout. Lockout will be reset automatically after three hours, by momentarily inteiTuptiug 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/WI, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM 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 GV-M is energized the blower motor (BLWM) is energized at LO HEAT speed. High-Heat-25 seconds after the GV-M is energized the BLWM is energized at HI HEAT speed. Simultaneously, the electronic air cleaner (EAC-I) terminal is energized and remains energized as long as the BLWM is energized. f. Switching from Low-to High-Heat-If the furnace control CPU switches from low-heat to high-heat, the fttmace 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. Thc 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 single- stage thermostat. h. Blower-OFF Delay-When the thermostat is satisfied, the R to W circuit is opened, de-energizthg the gas valve GV-M, stopping gas flow to the bttmers, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5-second post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized for 90, 120, 150, or 180 seconds (depend- lng on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second blower-OFF delay. 2. Two-Stage Thermostat and Two-Stage Heating (See Fig. 29 for thermostat connections) I~lOTl:: In this mode the LHT must be ON to select the low-heat only operation mode in response to closing the thermostat R-to-WI circuit. Closing the thermostat R-to-WI-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 WI and-W2 circuits for high-beat. The furnace consol 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. 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 switcharg from low- to high-Heat and vice versa. a. Switching from Low- to High-Heat-If the thermostat R to WI 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. 43 b. Switching from High- to Low-Heat-If the thermostat R to W2 circuit opens, and the R to 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 thc 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 a~er the R to W2 circuit opens. 3. Cooling Mode-Thc thermostat "calls for cooling" closing the R-to-G-and-Y circuits a. Single-Speed Cooling- (See Fig. 22 for thermostat connections) The tbermostat 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 tenninal 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. 31.) b. Single-Stage Thermostat and Two-Speed Cooling (Adaptive Mode) (See Fig. 30 for thermostat connections) This furnace can operate a two-speed cooling unit with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high-cooling op- eration. This selection is based upon the stored history of thc length of previous coohng period of the single-stage thermostat. NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable thc adaptive cooling mode in response to a call for cooling. (See Fig. 31 .) When in place the furnace control CPU can ttun 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", chis~ng thc 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). 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 Yl-and-Y2 circuits switch the outdoor unit to high-cooling speed, and the R to G-and-Yl-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 nm at low-cool speed (same speed as LO-HEAT) until the outdoor unit compressor comes hack on at high speed. The electronic air cleaner terminal EAC-I 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. 31.) c. Two-Stage Thermostat and Two-Speed Cooling (See Fig. 29 for thermostat connections) NOTE: The ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging. (See Fig. 31.) The thermostat closes thc R to G and-Y1 circuits for Iow-cooling or closes the R to G and-Yl-and-Y2 circuits for high-cooling The R to YI circuit starts the outdoor unit on low-cooling speed, and the R to G-and-Y1 circuit starts the furnace blower motor BL~,VM on low-cool speed (same speed as LO HEAT). The R to Yl-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R to G-and- Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The elect~odic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the P~ to G-and-Y1 or R to G-and-Yl-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. 31.) 4. Thermidistat Mode (See Fig. 24-26 for Thermidistat coimectiuns) The dehumidification output, DHUM on the Thermithstat 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. Thc cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are listed below: a. When the R-to-G-and-Y1 circuit is closed and there is a demand for dehumidification,the furnace blower motor BLWM will continue running at hiw-cool speed (same speed as LO HEAT). b. When the R-to-G-and Y/Y2 circuit is closed and there is a demand for dehumidification,the furnace blower motor BLWM .will drop the blower speed from COOL to HI HEAT for a maXmaum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidifi- cation 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. When the "call for cooling" is satisfied and there is a demand for dehumidification, the cooling blower-off delay is decreased from 90 seconds to 5 seconds. 5. 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 EAC-I 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 delay period at LO HEAT or HI HEAT speed respechvely. 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 addittonal 90 seconds on Iow-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 ther- mostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous-blower speed. When the R to G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation. Continuous Blower Speed Selection from Thermostat -To select different continuous-blower speeds fi.om the room thermostat, momentarily turn off the FAN switch or push- button on the room thermostat for t -3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous-blower speed fi.om the factory setting of LO HEAT to HI HEAT speed. Momentarily turning off the FAN switch again at the thermostat will shift the continuous-blower speed from HI HEAT to COOL. Repeating the procedure will shift the continuous-blower speed fi.om 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 follow- ing a power interruption. 6. Heat Pump (See Fig. 27 and 28 for tbermostat connections) When installed with a heat pump, the furnace control auto- mafically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R to W/WI-and-Y1 or R to W/Wl-and-Yl-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 pest-purge period and the blower remains running at LO HEAT speed. If the R to W/Wl-and-Yl-and-G signals disappea~ at the same time, the blower motor BLWM will remain on for the selected blower- OFF delay period. If the R to W/WI-and-Y1 signals disap- pear, leaving the G signal, the blower motor BLWM will remain on for the selected blower-OFF delay period then switch to continuous-blower speed. When the R to W/WI-and-Y/Y2, R to W/Wl-and-Y/Y2- and-G, R to W/Wl-and-Yl-and-Y/Y2, or R to W/Wl-and- Yl-and-Y/Y2-and-G circuits are energized the furnace control CPU will switch to or tom 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 pest-purge period and the blower switches to COOL speed after a 3 second delay. If the R to W/Wl-and-Y/Y2-and-G or R to W/WI-and-Yl-and- Y/Y2-and-G signals disappear at the same hme, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the R to W/WI-and-Y/Y2 or R to W/WI-and- Yl-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 diagrams. Step 5~Troubleshooting See pages 46 and 47. Refer to the service label. (See Fig. 50~Service Label.) The Troubleshooting Guide can be a useful tool in isolating furnace operation problems. Beginning with the word "Start," answer each question and follow thc appropriate arrow to the next item. Thc Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence. 45 START LED status on? light YES ,~FYES I Replace furnace control. Is LED status light blinking raph:ily J without a pause? YES . I Checkforcorrectlinevoltagepoladty if units are twinned, check ~or probe~ Iow- J~'~ voltage (24V) b'ansformer phasing. I Replace d°°r switch' I · ~ Replace transth~mer. Is LED status light blinking ON/OFF slowty ~ NO · with a comb nat on of short and long flashes? Determine ststus code. The status ccde is a To recall status code briefly remove and reconnect one RED wire from the draft safeguard switch to display stored status code. On RED LED control do not remove power or blower access panel before initiating status code recall You can also recall the previous status code by momentarily shorting the TEST/TWIN terminal to Com24V terminal until the LED goes out. LED will flash the status code of the previous fault o~ status code #11 (1 short and 1 long flash) if thera was no previous fault. After the control repeats the code 4 times, the control will go through a brief component lest sequence. The inducer will start and run for the entire component test. The HSL motor LO HEAT speed, HI HEAT speed, and COOL speed will run Cot 10 - 1 fl seconds each. Gas valve and humidhqer will not be turned on. NO Does the control respond to W/W1, W2, YI, NO Run system through a Iow-heat, high-heat, o~ cooling cyCe to check operation. Status codes are erased after 72 hours. On RED LED boards stored status codes can also be Rep!ace furnace ~ YES control. TNO Is 24V present at W/W1, W2, Y1, YP(2 or G thermostat terminals ~ the furnace control? YES Disconnect all the thermostat wires from the furnace control. jumper wire? ,i~N° A02107a _~12 BLOWER ON AFTER POV~ER UP - (115v OR 24V) - N~'mal operation, Blower runs f~' the selected blower off- LIMIT CIRCUIT LOCKOUT - Lockcut occurs ~f ~h~ limit, draft safeguard, flame ._~23 PRESSURE SWITCH DID NOT OPEN Check for: - Obstructed pressure tube. Pressure switch bluck dosed. __~2 SECONDARY VOLTAGE FUSE IS ~ OPEN Checkfor: - Short blrcuil in seccndary va#age (24V) widng including therm~tat leads. Discc~nscl t h~rmostst lea ds _~31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED - Check fo~: 32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - ff of)eh - L(3w inducer vbltage (115V) - Low inlel gas pressu~ (if LGPS useo'). 34 IGNITION PROVING FAILURE - ff flame is no~ sensed during the tdal fo~ ignition NO YES * Blod4ed vent switch used in Chimney Adapter Kit 43 LOW-HEAT PRESS URE SWITCH OFE N WHILE HIGH-HEAT PRESSURE SWITCH IS CLOSED - Check fo~: 45 CONTROL CIRCUITRY LOC KOUT Aut~ reset after 1 hour Iockoul due to: - Ftsme circuil failure - Gas val'~ relay stuck open. control ~f c~de repeats. NO Replace furnace control. ~S ~ Chsck fr~ conlJnuity in the harness and ignder I I J ~'1 Replace defective component J I NO IDoes gas vblve open and allow gas to flow? ~NO ,1~YES IDo the main bumem s~ay on? ~ YES ~J C~ean flame sensor with fine s~eel wool and I I 1~YES IWill main burners ignite and stey ,i~YES Allow blower to ccme on and repeat test to I / I NO ~1 Redlace furnace control I A02107b Copyright 2002 Canier Corporatio~ 58ct4si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without !ncurring obitgafions. PC 101 Catalog No. See Cover Printed in U.S.A. Form 58CT-fSI P§ 48 12-02 Replaces: 58CT*2Sl INDUCED-COMBUSTION GAS FURNACE CASING GROUP Outer door Blower door Top filler plate Bottom filler plate Bottom enclosure INDUCER GROUP Housing assembly Vent elbow assembly Pressure switch assembly Inducer motor Inducer wheel Draft safeguard switch FILTER GROUP Filter(s) - washable (1 -in.) Retainer rod Media Filter (4-in.) PARTS REPLACEMENT INFORMATION GUIDE HEAT EXCHANGER GROUP Cell Panel Heat exchanger ceil Low NOx baffle (California models only) BLOWER GROUP Blower housing Blower cutoff Blower motor Blower wheel Capacitor Capacitor strap Grommet ELECTRICAL GROUP Control bracket Junction box Limit switch(es) Circuit board Door switch Transformer Wiring harness 115v Wiring harness 24v GAS CONTROL GROUP Manifold Burner assembly Orifice Flame sensor Hot surface ignitor Gas valve Manual reset limit switches Burner support assembly TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the "Heating Equipment" or "Air Conditioning Contractors and Systems" headings for dealer listing by brand name, or contact: Bryant Heating & Cooling Systems Consumer Relations Department P.O. Box 4952 Syracuse, New York 13221 1-800-428-4326 Have ava[lable the 16-digit Product No. end Seda[ No. located on the unit rating plate to ensure c(xrect replacement part. Example of Product Number ELECTRICAL COOLING HEATING SUPPLY CONTROL SIZE SIZE VARIATION MODEL CODE CODE {'Xl000 BTUH~ ('X 1000 BTUH~ CODE 310A A V 036 070 A-Common unit HEAT MINOR EXCHANGER SERIES CODE A JA WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory-authorized replacement parts, kits, or accessories when modifying this product. © 2002 er/ant Heating & Cooling Systems 7310 w. Morris St. indianapolis, IN 46231 pi0425 P~)4-25