INSTALLATION INSTRUCTIONS FOR *CVC9/95 & *MVC95 - TWO-STAGE GAS FURNACE
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements em-
bodied in theAmerican National Standard / Na-
®
tional Standard of CanadaANSI Z21.47·CSA-2.3
Gas Fired Central Furnaces.
C
US
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all
safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all
safety warnings. Often during installation or repair it is possible to place yourself in a position which is more
hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a
customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good
safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if
there is a direct conflict between existing practices and the content of this manual, the precautions listed here
take precedence.
*NOTE: Please contact your distributor or our
website for the applicable Specification
Sheet referred to in this manual.
5151 San Felipe Suite 500
Houston, TX 77056
www.goodmanmfg.com • www.amana-hac.com
IO-341E
12/10
© 2009-2010 Goodman Manufacturing Company, L.P.
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115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) ............................. 29
24 VOLT HUMIDIFIER ......................................................................................................................... 30
GAS SUPPLY AND PIPING ......................................................................................................................... 30
HIGH ALTITUDE DERATE ...................................................................................................................... 30
PROPANE GAS CONVERSION ................................................................................................................ 30
GAS VALVE ..................................................................................................................................... 31
GAS PIPING CONNECTIONS .................................................................................................................. 31
PROPANE GAS TANKS AND PIPING ......................................................................................................... 33
CIRCULATING AIR & FILTERS .................................................................................................................... 34
DUCT WORK -AIR FLOW ..................................................................................................................... 34
CHECKING DUCT STATIC ..................................................................................................................... 34
BOTTOM RETURN AIR OPENING [UPFLOW MODELS] .................................................................................. 35
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK ........................................... 35
UPRIGHT INSTALLATIONS ..................................................................................................................... 36
HORIZONTAL INSTALLATIONS ................................................................................................................ 36
STARTUP PROCEDURE & ADJUSTMENT ....................................................................................................... 36
HEAT ANTICIPATOR SETTING ................................................................................................................ 37
DRAIN TRAP PRIMING ........................................................................................................................ 37
FURNACE OPERATION ......................................................................................................................... 37
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. 37
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... 38
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................ 39
TEMPERATURE RISE ........................................................................................................................... 39
CIRCULATOR BLOWER SPEEDS ............................................................................................................. 40
BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................... 42
COMFORTNET™ SYSTEM ........................................................................................................................ 42
OVERVIEW ....................................................................................................................................... 42
AIRFLOW CONSIDERATIONS .................................................................................................................. 42
FOSSIL FUEL APPLICATIONS ................................................................................................................ 42
CTK01AA WIRING .......................................................................................................................... 43
COMFORTNET SYSTEM ADVANCED FEATURES .......................................................................................... 44
NETWORK TROUBLESHOOTING ................................................................................................................ 46
SYSTEM TROUBLESHOOTING ................................................................................................................. 47
NORMAL SEQUENCE OF OPERATION ........................................................................................................... 47
POWER UP ...................................................................................................................................... 47
HEATING MODE ................................................................................................................................. 47
COOLING MODE ................................................................................................................................ 48
FAN ONLY MODE .............................................................................................................................. 48
OPERATIONAL CHECKS ............................................................................................................................ 49
SAFETY CIRCUIT DESCRIPTION .................................................................................................................. 49
INTEGRATED CONTROL MODULE ............................................................................................................. 49
PRIMARY LIMIT ................................................................................................................................ 49
AUXILIARY LIMIT ............................................................................................................................... 49
ROLLOUT LIMIT ................................................................................................................................ 49
PRESSURE SWITCHES ......................................................................................................................... 49
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FLAME SENSOR ................................................................................................................................ 49
TROUBLESHOOTING ................................................................................................................................. 49
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... 49
DIAGNOSTIC CHART........................................................................................................................... 49
RESETTING FROM LOCKOUT ................................................................................................................ 50
MAINTENANCE ........................................................................................................................................ 50
ANNUAL INSPECTION ........................................................................................................................... 50
FILTERS .......................................................................................................................................... 50
BURNERS ......................................................................................................................................... 50
INDUCED DRAFT AND CIRCULATOR BLOWERS ............................................................................................ 50
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ........................................................... 51
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... 51
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ......................................................................................... 51
BEFORE LEAVING AN INSTALLATION ............................................................................................................ 51
REPAIR AND REPLACEMENT PARTS ............................................................................................................ 51
DIP SWITCHES ........................................................................................................................................ 52
TROUBLESHOOTING CHART ...................................................................................................................... 53
STATUS CODES ...................................................................................................................................... 58
*CVC9_AA, *MVC95_AA ................................................................................................................... 59
*CVC9_AB, *MVC95_AB .................................................................................................................. 60
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY
DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME
RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE
WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO
INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
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SAFETY PRECAUTIONS
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure
proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this
product.
WARNING
WARNING
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO
PROTECT THE ELECTRICAL COMPONENTS FROM WATER.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER.
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS:
DO NOT TRY TO LIGHT ANY APPLIANCE.
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE
IN YOUR BUILDING.
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
DEPARTMENT.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
CO can cause serious illness including permanent brain damage or death.
WARNING
-
B10259-216
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE,
ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE
BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT,
CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED,
MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING
MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT,
ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD
BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE
EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT
SOURCES SHOULD BE UTILIZED.
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PRODUCT DESCRIPTION & APPLICATION
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or new
controlstotheircontainersbeforetouchinganyungrounded
object.
SHIPPINGINSPECTION
All units are securely packed in shipping containers tested ac-
cording to International SafeTransitAssociation specifications.
Thecartonmustbecheckeduponarrivalforexternaldamage. If
damage is found, a request for inspection by carrier’s agent
must be made in writing immediately.
TOTHEINSTALLER
The furnace must be carefully inspected on arrival for damage
and bolts or screws which may have come loose in transit. In
the event of damage the consignee should:
1. Makeanotationondeliveryreceiptofanyvisibledamage
to shipment or container.
2. Notify carrier promptly and request an inspection.
3. Withconcealeddamage, carriermustbenotifiedassoon
as possible - preferably within five days.
4. Filetheclaimwiththefollowingsupportdocumentswithin
a nine month statute of limitations.
Before installing this unit, please read this manual thoroughly to
familiarize yourself with specific items which must be adhered to,
including but not limited to: unit maximum external static pres-
sure, gas pressures, BTU input rating, proper electrical connec-
tions, circulating air temperature rise, minimum or maximum CFM,
and motor speed connections.
IMPORTANTNOTETOTHEOWNERREGARDINGPRODUCTWAR-
RANTY
Your warranty certificate is supplied as a separate document with
the unit installed by your contractor. Read the limited warranty
certificate carefully to determine what is and is not covered and
keep the warranty certificate in a safe place. If you are unable to
locate the warranty certificate please contact your installing con-
tractor or contact customer service (877-254-4729) to obtain a
copy.
•
Original or certified copy of the Bill of Lading, or
indemnity bond.
•
•
Original paid freight bill or indemnity in lieu thereof.
Original or certified copy of the invoice, showing trade
and other discounts or reductions.
•
Copy of the inspection report issued by carrier’s
representativeatthetimedamageisreportedtocarrier.
ToreceivetheLifetimeHeatExchangerLimitedWarranty, goodfor
as long as you own your home, and the 10-year Parts Limited
Warranty, online registration must be completed within 60 days of
installation. Online registration is not required in California or Que-
bec.
The carrier is responsible for making prompt inspection of dam-
age and for a thorough investigation of each claim. The distribu-
tor or manufacturer will not accept claims from dealers for trans-
portation damage.
ToregisteryourGoodmanbrandunit, gotowww.goodmanmfg.com.
Click on the word “Warranty” located on the left side of the home
page. Next, click on the word “Product Registration” located on
the left side of the Warranty page and complete the forms in the
manner indicated on the Product Registration page.
ELECTROSTATICDISCHARGE(ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical com-
ponents.
Click on the word “Warranty” located on the top right of the home
page. Next, click on the word “Product Registration” located on
the left side of the Warranty page and complete the forms in the
manner indicated on the Product Registration page.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage.
By putting the furnace, the control, and the person at the same
electrostatic potential, these steps will help avoid exposing the
integrated control module to electrostatic discharge. This pro-
cedure is applicable to both installed and non-installed (un-
grounded)furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). Ifyoucomeincontactwithanungrounded
object, repeat step 2 before touching control or wires.
Product limited warranty certificates for models currently in pro-
hac.com. If your model is not currently in production or does not
appear on the website, please contact your installing contractor or
contact customer service at (877-254-4729) to obtain a copy of
your warranty certificate.
Each product overview page contains a Product Warranty link; by
clicking on it you will be able to view the limited warranty coverage
for that specific product.To view warranty registration information,
click on the Product Warranty text on the left navigation panel on
the home page of each website. The Online Product Registration
pages are located in this same section.
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PRODUCT DESCRIPTION & APPLICATION
Dual certification means that the combustion air inlet pipe is op-
tional and the furnace can be vented as a:
WARNING
Non-direct vent (single pipe) central forced air furnace in
which combustion air is taken from the installation area
or from air ducted from the outside or,
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECREATIONAL VEHICLE.
Direct vent (dual pipe) central forced air furnace in which
all combustion air supplied directly to the furnace burners
through a special air intake system outlined in these
instructions.
PRODUCT DESCRIPTION
FEATURES
This furnace may be used as a construction site heater ONLY if
all of the following conditions are met:
This furnace is a part of the ComfortNet™ family of products. The
CTK01 ComfortNet thermostat kit allows this furnace to be in-
stalledaspartofadigitallycommunicatingsystem. TheComfortNet
system provides automatic airflow configuration, enhanced setup
features, and enhanced diagnostics. It also reduces the number of
thermostat wires to a maximum of four. It may be also installed as
part of a “legacy” system using a standard 24 VAC thermostat.
•
The vent system is permanently installed per these
installation instructions.
•
A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating CANNOT be
used and can cause long term equipment damage.
Return air ducts are provided and sealed to the furnace.
A return air temperature range between 60ºF (16ºC) and
80ºF (27ºC) is maintained.
•
•
This product may also be installed with the ComfortNet thermostat
and a non-ComfortNet compatible single stage air conditioning
unit. However, this reduces the benefits of the ComfortNet system
as the enhancements will only apply to the furnace.
•
Airfiltersareinstalledinthesystemandmaintainedduring
constructionreplacedasappropriateduringconstruction,
and upon completion of construction.
PRODUCTAPPLICATION
•
•
Theinputrateandtemperaturerisearesetperthefurnace
rating plate.
100% outside air is provided for combustion air
requirementsduringconstruction.Temporaryductingcan
be used.
This furnace is primarily designed for residential home-heating ap-
plications. It is NOT designed or certified for use in mobile homes,
trailers or recreational vehicles. Neither is it designed or certified
for outdoor applications. The furnace must be installed indoors
(i.e., attic space, crawl space, or garage area provided the garage
area is enclosed with an operating door).
NOTE: Do not connect the temporary duct directly to the
furnace. Theductmustbesizedforadequatecombustion
and ventilation in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 or
CAN/CSA B149.1 Installation Codes.
This furnace can be used in the following non-industrial commer-
cial applications:
Schools,Officebuildings,Churches,Retailstores,
•
The furnace heat exchanger, components, duct system,
air filters and evaporator coils are thoroughly cleaned
following final construction clean up.
Nursinghomes,Hotels/motels,Commonorofficeareas
In such applications, the furnace must be installed with the follow-
ing stipulations:
•
All furnace operating conditions (including ignition, input
rate, temperature rise and venting) are verified according
to these installation instructions.
•
•
•
It must be installed per the installation instructions
provided and per local and national codes.
It must be installed indoors in a building constructed on
site.
It must be part of a ducted system and not used in a free
air delivery application.
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
•
Gas furnaces must be installed by a licensed plumber or
gas fitter.
•
•
It must not be used as a “make-up” air unit.
Itmustbeinstalledwithtwo-pipesystemsforcombustion
air, especially if VOC’s or other contaminants are present
in the conditioned space.
•
•
AT-handle gas cock must be used.
If the unit is to be installed in an attic, the passageway to
and the service area around the unit must have flooring.
To ensure proper furnace operation, install, operate and
maintain the furnace in accordance with these installation
and operation instructions, all local building codes and or-
dinances. In their absence, follow the latest edition of the Na-
tional Fuel Gas Code (NFPA54/ANSI Z223.1), and/or CAN/CSA
B149 Installation Codes, local plumbing or waste water codes,
and other applicable codes.
•
All other warranty exclusions and restrictions apply This
furnace is an ETL dual-certified appliance and is
appropriateforusewithnaturalorpropanegas(NOTE: If
using propane, a propane conversion kit is required).
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LOCATION REQUIREMENTS & CONSIDERATIONS
Acopy of the National Fuel Gas Code (NFPA54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
1430Broadway
•
•
•
Locate the furnace so condensate flows downwards to
the drain. Do not locate the furnace or its condensate
drainage system in any area subject to below freezing
temperatures without proper freeze protection. Refer to
Condensate Drain Lines and Trap for further details.
New York, NY 10018
Ensure adequate combustion air is available for the
furnace. Improper or insufficient combustion air can
expose building occupants to gas combustion products
that could include carbon monoxide. Refer to
Combustion and Ventilation Air Requirements.
Set the furnace on a level floor to enable proper
condensate drainage. If the floor becomes wet or damp
at times, place the furnace above the floor on a concrete
base sized approximately 1-1/2" larger than the base of
the furnace. Refer to the Horizontal Applications and
Considerations for leveling of horizontal furnaces.
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible material.
The only combustible material allowed is wood.
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material (including wood). Refer to subbase instructions
for installation details. (NOTE: A subbase will not be
required if an air conditioning coil is located beneath the
furnace between the supply air opening and the
combustible floor.
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH44131
Theratedheatingcapacityofthefurnaceshouldbegreaterthanor
equal to the total heat loss of the area to be heated. The total heat
loss should be calculated by an approved method or in accor-
dancewith“ASHRAEGuide”or“ManualJ-LoadCalculations”pub-
lished by theAir Conditioning Contractors ofAmerica.
•
•
A copy of the CAN/CSA B149 Installation Codes can also be
obtainedfrom:
CSA International
178RexdaleBoulevard
Etobicoke, Ontario, Canada M9W 1R3
LOCATION REQUIREMENTS &CONSIDERATIONS
Follow the instructions listed below and the guidelines provided in
the Combustion and Ventilation Air Requirements section when
selecting a furnace location.
•
Exposure to contaminated combustion air will result in
safety and performance-related problems. Do not install
the furnace where the combustion air is exposed to the
following substances:
permanentwavesolutions
chlorinated waxes or cleaners
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THIS UNIT.
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
WARNING
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
paintremovers
varnishes
hydrochloric acid
cements and glues
•
Centrally locate the furnace with respect to the proposed
or existing air distribution system.
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace is
heating.
•
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
Seal off a non-direct vent furnace if it is installed near an
area frequently contaminated by any of the above
substances. This protects the non-direct vent furnace
from airborne contaminants. To ensure that the
enclosednon-directvent furnacehasanadequatesupply
of combustion air, vent from a nearby uncontaminated
room or from outdoors. Refer to the Combustion and
Ventilation Air Requirements for details.
•
Provide provisions for venting combustion products
outdoors through a proper venting system. Special
consideration should be given to vent/flue pipe routing
and combustion air intake pipe when applicable. Refer
to Vent/Flue Pipe and CombustionAir Pipe -Termination
Locations for appropriate termination locations and to
determineifthepipingsystemfromfurnacetotermination
canbeaccomplishedwithintheguidelinesgiven. NOTE:
The length of flue and/or combustion air piping can be a
limiting factor in the location of the furnace.
•
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LOCATION REQUIREMENTS & CONSIDERATIONS
TOP
•
•
If the furnace is used in connection with a cooling coil
TOP
unit, install the furnace upstream or in parallel with the
cooling coil unit. Premature heat exchanger failure will
result if the cooling unit is placed ahead of the furnace.
If the furnace is installed in a residential garage, position
the furnace so that the burners and ignition source are
located not less than 18 inches (457 mm) above the
floor. Protect the furnace from physical damage by
vehicles.
SIDE
SIDE
SIDE
BOTTOM
Horizontal
BOTTO M
Upflow
Counterflow
•
If the furnace is installed horizontally, ensure the access
doorsarenotonthe“up/top”or“down/bottom”sideofthe
furnace.
Do not connect this furnace to a chimney flue that serves
a separate appliance designed to burn solid fuel.
OnCounterflowInstallations, theairconditioningcoilmust
bedownstreamonthesupply(positive)sideofthefurnace
heat exchanger.
Counterflow Installation over a noncombustible floor.
Beforesettingthefurnaceovertheplenumopening,ensure
the surface around the opening is smooth and level. A
tight seal should be made between the furnace base and
floor by using a silicone rubber caulking compound or
cement grout.
Counterflow Installation over a combustible floor. If
installation over a combustible floor becomes necessary,
use an accessory subbase (see Specification Sheet
applicableforyourmodelfordetails.) Aspecialaccessory
subbase must be used for upright counterflow unit
installationsoveranycombustiblematerialincludingwood.
Refertosubbaseinstructionsforinstallationdetails. Follow
the instructions with the subbase for proper installation.
Do not install the furnace directly on carpeting, tile, or
other combustible material other than wood flooring.
(NOTE: The subbase will not be required if an air
conditioning coil is installed between the supply air
opening on the furnace and the floor.)
A furnace installed in a confined space (i.e., a closet or utility
room) must have two ventilation openings with a total minimum
free area of 0.25 square inches per 1,000 BTU/hr of furnace input
rating. Refer to Specification Sheet applicable to your model for
minimum clearances to combustible surfaces. One of the ventila-
tion openings must be within 12 inches of the top; the other open-
ing must be within 12 inches of the bottom of the confined space.
In a typical construction, the clearance between the door and door
frame is usually adequate to satisfy this ventilation requirement.
•
•
•
FURNACESUSPENSION
If suspending the furnace from rafters or joists, use 3/8" threaded
rod and 2”x2”x1/8” angle iron as shown in the following diagram.
Thelengthofrodwilldependontheapplicationandtheclearances
necessary.
•
2"X2"X3/8" ANGLE IRON
(3 PLACES)
CLEARANCESANDACCESSIBILITY
Installations must adhere to the clearances to combustible mate-
rials to which this furnace has been design certified. The minimum
clearanceinformationforthisfurnaceisprovidedontheunit’sclear-
ance label. These clearances must be permanently maintained.
Clearances must also accommodate an installation’s gas, electri-
cal, and drain trap and drain line connections. If the alternate
combustion air intake or vent/flue connections are used additional
clearance must be provided to accommodate these connections.
RefertoVent/FluePipeandCombustionAirPipefordetails. NOTE:
In addition to the required clearances to combustible materials, a
minimum of 24 inches service clearance must be available in front
of the unit.
EXISTINGFURNACEREMOVAL
NOTE: When an existing furnace is removed from a venting sys-
tem serving other appliances, the venting system may be too large
to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from theAmerican
NationalStandard/NationalStandardofCanadaforGas-FiredCentral
FurnacesANSI Z21.4, CSA-2.3 latest edition Section 1.23.1.
The following steps shall be followed with each appliance connected to
the venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
1. Seal any unused openings in the venting system;
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COMBUSTION & VENTILATION AIR REQUIREMENTS
2. Inspect the venting system for proper size and horizontal
pitch, as required by the National Fuel Gas Code, ANSI
Z223.1 or the Natural Gas and Propane Installation Code,
CSA B149.1-05 and these instructions. Determine that there
is no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
•
Unconditioned areas behind the thermostat, such as
an outside wall.
Consult the instructions packaged with the thermostat for
mounting instructions and further precautions.
COMBUSTION & VENTILATION AIR REQUIREMENTS
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.
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF
FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE
SUPPLIED INTO THE FURNACE AREA.
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 shall operate at maxi-
mum speed. Do not operate a summer exhaust fan.
Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
heating/cooling costs but have created a problem supplying com-
bustion and ventilation air for gas fired and other fuel burning
appliances. Appliances that pull air out of the house (clothes
dryers, exhaust fans, fireplaces, etc.) increase the problem by
starving appliances for air.
6. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.
7. Test for spillage from draft hood appliances at the draft hood
relief opening after 5 minutes of main burner operation. Use
the flame of a match or candle.
Housedepressurizationcancausebackdraftingorimpropercom-
bustion of gas-fired appliances, thereby exposing building occu-
pants to gas combustion products that could include carbon mon-
oxide.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance
with the National Fuel Gas CodeANSI Z223.1/NFPA54 and/
or National Gas and Propane Installation Code CSA
B149.1-05.
If this furnace is to be installed in the same space with other gas
appliances, such as a water heater, ensure there is an adequate
supply of combustion and ventilation air for the other appliances.
Refer to the latest edition of the National Fuel Gas Code NFPA
54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or appli-
cable provisions of the local building codes for determining the
combustion air requirements for the appliances.
9. After it has been determined that each appliance connected
to the venting system properly vents when tested as out-
lined above, return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to their previ-
ous conditions of use.
Most homes will require outside air be supplied to the furnace
area by means of ventilation grilles or ducts connecting directly
to the outdoors or spaces open to the outdoors such as attics or
crawl spaces.
If resizing is required on any portion of the venting system, use
the appropriate table in Appendix G in the latest edition of the
National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05
Installation Codes.
INSTALLATION POSITIONS
This furnace may be installed in an upright position or horizontal
on either the left or right side panel. Do not install this furnace on
its back. For upright upflow furnaces, return air ductwork may be
attached to the side panel(s) and/or basepan. For horizontal
upflow furnaces, return air ductwork must be attached to the
basepan. For both upright or horizontal counterflow furnaces,
return ductwork must be attached to the basepan (top end of the
blower compartment). NOTE: Ductwork must never be attached
to the back of the furnace. Contact your distributor for proper
airflow requirements and number of required ductwork connec-
tions. Refer to “Recommended Installation Positions” figure for
appropriate installation positions, ductwork connections, and re-
sulting airflow arrangements.
THERMOSTATLOCATION
The thermostat should be placed approximately five feet from the
floor on a vibration-free, inside wall in an area having good air
circulation. Do not install the thermostat where it may be influ-
enced by any of the following:
•
Drafts, or dead spots behind doors, in corners, or under
cabinets.
•
•
•
•
•
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
10
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HORIZONTAL APPLICATIONS & CONSIDERATIONS
When using the horizontal alternate vent configuration, you must
use the RF000142 vent drain kit. See following illustration.
HORIZONTAL APPLICATIONS & CONSIDERATIONS
Horizontal applications, in particular, may dictate many of the
installation’s specifics such as airflow direction, ductwork connec-
tions, flue and combustion air pipe connections, etc. The basic
applicationofthisfurnaceasahorizontalfurnacediffersonlyslightly
from an upright installation. When installing a furnace horizontally,
VENT-DRAIN
“FIELD-SUPPLIED DRAIN
HOSE” FROM VENT-
DRAIN CONNECTED TO
CONDENSATE DRAIN
LINE WITH “FIELD-
SUPPLIED CONNECTOR”
additional consideration must be given to the following:
FURNACE MUST BE LEVEL
FROM END TO END
ALTERNATE VENT/FLUE
FURNACE MUST BE LEVEL
AND COMBUSTION AIR
OR SLIGHTLY TILTED FORWARD
INTAKE LOCATIONS
WITH THE DOORS 0" - 3/4"
BELOW THE BACK PANEL
NOTE: MAKE SMALL
LOOP IN HOSE TO
SERVE AS “P-TRAP”
4 3/4" MINIMUM
DRAIN TRAP
CLEARANCE
GAS LINE WITH
DRIP LEG (3" MINIMUM)
AlternateVent/FlueLocation
DRAIN LINE WITH 1/4" PER FOOT
DOWNWARD SLOPE
DRAIN PAN
36" MINIMUM SERVICE
CLEARANCE REQUIRED
FURNACE MUST BE SUPPORTED
AT BOTH ENDS AND MIDDLE
HorizontalFurnace
DRAINTRAPANDLINES
In horizontal applications the condensate drain trap is secured to
the furnace side panel, suspending it below the furnace. A mini-
mum clearance of 4 3/4 inches below the furnace must be pro-
vided for the drain trap. Additionally, the appropriate downward
piping slope must be maintained from the drain trap to the drain
location. Refer to Condensate Drain Trap and Lines for further de-
tails. If the drain trap and drain line will be exposed to temperatures
near or below freezing, adequate measures must be taken to pre-
vent condensate from freezing.
LEVELING
Leveling ensures proper condensate drainage from the heat ex-
changer and induced draft blower. For proper flue pipe drainage,
the furnace must be level lengthwise from end to end. The furnace
should also be level from back to front or have a slight tilt with the
access doors downhill (approximately 3/4 inches) from the back
panel. The slight tilt allows the heat exchanger condensate, gen-
erated in the recuperator coil, to flow forward to the recuperator coil
frontcover.
ALTERNATEVENT/FLUEANDCOMBUSTIONAIRCONNECTIONS
In horizontal installations provisions for alternate flue and combus-
tion air piping are available for upflow furnaces with left discharge
and counterflow furnaces with right air discharge. This configura-
tion allows the flue and combustion air piping to be run vertically
through the side of the furnace. Refer to the “Recommended In-
stallation Positions” figure for further detail. The standard piping
connections may also be used in these positions. Refer to Vent/
Flue Pipe and Combustion Air Pipe for details concerning the
conversion to the alternate vent/flue and combustion air connec-
tions.
RecommendedInstallationPositions
NOTE: Alternate “vertical” piping connections can not be used
when an upflow furnace is installed with supply air discharging to
the right, or when a counterflow furnace is installed with supply air
discharging to the left. In either case, use the standard flue and
combustion air piping connections.
11
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PROPANE GAS/HIGH ALTITUDE INSTALLATIONS
Contact the distributor for a tabular listing of appropriate
ALTERNATEELECTRICALANDGASLINECONNECTIONS
manufacturer’s kits for propane gas and/or high altitude installa-
tions. The indicated kits must be used to insure safe and proper
furnace operation. All conversions must be performed by a quali-
fied installer, or service agency.
Thisfurnacehasprovisionsallowingforelectricalandgaslinecon-
nections through either side panel. In horizontal applications the
connections can be made either through the “top” or “bottom” of
the furnace.
VENT/FLUE PIPE & COMBUSTION AIR PIPE
DRAINPAN
A drain pan must be provided if the furnace is installed above a
conditioned area. The drain pan must cover the entire area under
the furnace (and air conditioning coil if applicable).
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY
INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS
GIVEN IN THIS SECTION.
FREEZEPROTECTION
Refer to HorizontalApplications and Conditions - Drain Trap and
Lines.
WARNING
UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY
INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE
FURNACE TO ASSURE IT IS PROPERLY SEALED. LEAKS IN THE FLUE
SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO
EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.
FURNACESUSPENSION
If the furnace is installed in a crawl space it must be suspended
from the floor joist or supported by a concrete pad. Never install
the furnace on the ground or allow it to be exposed to water. Refer
to Location Requirements and Considerations - Furnace Suspen-
sion for further details.
A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
Because of the relatively low flue gas temperature and water con-
densation requirements, PVC pipe is used as venting material.
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS
WARNING
This furnace must not be connected to Type B, BW, or L vent or
vent connector, and must not be vented into any portion of a fac-
tory built or masonry chimney except when used as a pathway for
PVC as described later in this section. Never common vent this
appliance with another appliance or use a vent which is used by a
solid fuel appliance. Do not use commercially available “no hub
connectors” other than those shipped with this product.
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A
QUALIFIED INSTALLER OR SERVICE AGENCY.
This furnace is shipped from the factory configured for natural gas
at standard altitude. Propane gas installations require an orifice
and orifice change to compensate for the energy content differ-
ence between natural and propane gas.
It is the responsibility of the installer to follow the manufacturers’
recommendationsandtoverifythatallvent/fluepipingandconnec-
tors are compatible with furnace flue products. Additionally, it is
the responsibility of the installer to ensure that all piping and con-
nections possess adequate structural integrity and support to pre-
ventfluepipeseparation, shifting, orsaggingduringfurnaceopera-
tion.
High altitude installations may require both a pressure switch and
an orifice/spring change. These changes are necessary to com-
pensate for the natural reduction in the density of both the gas fuel
and the combustion air at higher altitude.
DUALCERTIFICATION:NON-DIRECT/DIRECTVENT
For installations above 7000 feet, please refer to your distributor
for required kit(s).
This furnace is dual certified and may be installed as a non-direct
vent (single pipe) or direct vent (dual pipe) appliance. Anon-direct
vent installation requires only a vent/flue pipe, while a direct vent
installation requires both a vent/flue pipe and a combustion air
intake pipe. Refer to the appropriate section for details concerning
piping size, length, number of elbows, furnace connections, and
terminations.
M anifold P ressure
P ressure
Switch
Change
Gas
Altitude
Kit
Orifice
High
Low
Stage
Stage
Natural
None
#43
#55
3.5" w.c.
1.9" w.c.
None
None
0-7000
LPM -05* 1
LPM -06* 2
Propane
10.0" w.c.
6.0" w.c.
1 LPM-05*supports White-Rodgers 2-stage valve only
2 LPM-06* supports both Honeywell and White-Rodgers 2-stage valves
NOTE: In Canada, gas furnaces are onlycertified to 4500 feet.
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
Piping must be adequately secured and supported to prohibit sag-
ging, joint separation, and/or detachment from the furnace. Hori-
zontalrunsofvent/fluepipingmustbesupportedeverythreetofive
feet and must maintain a 1/4 inch per foot downward slope, back
WARNING
TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS
MUST BE KEPT AWAY FROM ALL IGNITION SOURCES
(I.E., SPARKS, OPEN
towardsthefurnace, toproperlyreturncondensatetothefurnace’s
drain system. Allowances should be made for minor expansion
and contraction due to temperature variations. For this reason,
particular care must be taken to secure piping when a long run is
followed by a short offset of less than 40 inches.
FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS.
AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR
EYES.
Two- or three-inch nominal diameter PVC Schedule 40 pipe meet-
ing ASTM D1785, PVC primer meeting ASTM F656, and PVC
solventcementmeetingASTMD2564specificationsmustbeused.
Fittings must be DWV type fittings meeting ASTM D2665 and
ASTM D3311. Carefully follow the pipe manufacturer’s instruc-
tions for cutting, cleaning, and solvent cementing of PVC.
Precautions should be taken to prevent condensate from freezing
inside the vent/flue pipe and/or at the vent/flue pipe termination. All
vent/flue piping exposed to freezing temperatures below 35°F for
extended periods of time must be insulated with 1/2” thick closed
cell foam. Also all vent/flue piping exposed outdoors in excess of
the terminations shown in this manual (or in unheated areas) must
be insulated with 1/2” thick closed cell foam. Inspect piping for
leaks prior to installing insulation.
The use of Schedule 40 PVC Cellular Core (Foam Core) plastic
pipe is also acceptable as a flue/vent and intake pipe material.
PVC primer meetingASTM F656 and PVC solvent cement meet-
ing ASTM D2564 specifications must be used. Fittings must be
DWV type fittings meetingASTM D2665 andASTM D3311. Care-
fully follow the manufactures instructions for cutting, cleaning and
solvent cementing of PVC.
TERMINATIONLOCATIONS
NOTE: Refer to Location Requirements and Considerations for
combustion air contaminant restrictions.
The following bullets and diagram describe the restrictions con-
cerning the appropriate location of vent/flue pipe and combustion
airintakepipe(whenapplicable)terminations. RefertoNon-Direct
Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping lo-
cated in this section for specific details on termination construc-
tion.
MATERIALSANDJOININGMETHODS
As an alternative to PVC pipe, primer, solvent cement, and fittings,
ABS materials which are in compliance with the following specifi-
cations may be used. Two-or-three-inch ABS Schedule 40 pipe
must meet ASTM D1527 and, if used in Canada, must be CSA
listed. Solvent cement for ABS to ABS joints must meet ASTM
D2235 and, if used in Canada, must be CSA listed. The solvent
cementforthePVCtoABStransitionjointmustmeetASTMD3138.
Fittings must be DWV type fittings meeting ASTM D2661 and
ASTM D3311 and, if used in Canada, must be CSAlisted. Care-
fully follow the manufacturers’ instructions for cutting, cleaning,
and solvent cementing PVC and/orABS.
•
All terminations (flue and/or intake) must be located at
least12inchesabovegroundlevelortheanticipatedsnow
level.
•
Vent terminations (non-direct and direct vent) must
terminate at least 3 feet above any forced air inlet located
within 10 feet.
NOTE: This provision does not apply to the combustion
air intake termination of a direct vent application.
All 90° elbows must be medium radius (1/4 bend DWV) or long
radius (Long sweep 1/4 bend DWV) types conforming toASTM
D3311. Amedium radius (1/4 bend DWV) elbow measures 3 1/
16” minimum from the plane of one opening to the centerline of the
other opening for 2” diameter pipe, and 4 9/16” minimum for 3”
pipe.
•
•
•
Theventterminationofanon-directventapplicationmust
terminate at least 4 feet below, 4 feet horizontally from,
or 1 foot above any door, window, or gravity air inlet into
any building.
The vent termination of a direct vent application must
terminate at least 12 inches from any opening through
which flue gases may enter a building (door, window, or
gravity air inlet).
The vent termination of vent pipe run vertically through a
roof must terminate at least 12 inches above the roof line
(or the anticipated snow level) and be at least 12 inches
from any vertical wall (including any anticipated snow
buildup).
Aventterminationshallnotterminateoverpublicwalkways
or over an area where condensate or vapor could create
a nuisance or hazard or could be detrimental to the
operation of regulators, relief valves, or other equipment.
The combustion air intake termination of a direct vent
application should not terminate in an area which is
frequently dusty or dirty.
PROPERVENT/FLUEANDCOMBUSTIONAIRPIPINGPRACTICES
Adhere to these instructions to ensure safe and proper furnace
performance. The length, diameter, and number of elbows of the
vent/flue pipe and combustion air pipe (when applicable) affects
the performance of the furnace and must be carefully sized. All
piping must be installed in accordance with local codes and these
instructions.
•
•
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
Non-Direct Vent
vicing. CombustionAir and Vent piping should be routed in a man-
&
ner to avoid contact with refrigerant lines, metering devices, con-
densate drain lines, etc. If necessary, clearances may be in-
creased by utilizing two 45 deg. Long-Sweep Elbows and creat-
ing an “S” joint to provide additional space at connection loca-
tions. This joint can be rotated on the fitting to establish maxi-
mum clearance between refrigerant lines, metering devices, and
condensate drain lines, etc. This joint is the equivalent of one 90
deg. elbow when considering elbow count.
Direct Vent
Vent/Flue Terminations
Non-Direct Vent
Vent/Flue Termination
No Terminations
Above Walkway
<10'
4' min.
12"
3' min.
4'
min.
12"
min.
Grade or Highest
Anticipated
Snow Level
12" min.
Non-Direct Vent
Vent/Flue Termination
12" min.
Forced Air
Inlet
V
E
N
T
Direct Vent
Vent/Flue Termination
45 DEGREE
LONG-SWEEP
ELBOWS
Vent Termination Clearances
NOTE: InCanada,theCanadianFuelGasCodetakesprecedence
over the preceding termination restrictions.
CANADIANVENTINGREQUIREMENTS
In Canada, venting must conform to the requirements of the cur-
rent CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed,
ULC-S636complianttwo-orthree-inchdiameterPVCorABSpipe,
solventcement, andfittingsthroughout. Thecertifiedpipingshould
be clearly marked with the ULC Std “S636” on the pipe and fittings.
Carefully follow the pipe manufacturers’ instructions for cutting,
cleaning, and solvent cementing PVC and/orABS.
IncreasedClearanceConfiguration
NOTE: Do not use other commercially available “no hub connec-
tors” due to possible material conflicts. The vent/flue pipe can also
be secured using a PVC or ABS elbow or coupling using the
appropriate glue (see Materials and Joining Methods).
NOTE: For non-direct vent installations, a minimum of one 90°
elbow should be installed on the combustion air intake coupling to
guard against inadvertent blockage.
The vent can be run through an existing unused chimney provided
the space between the vent pipe and the chimney is insulated and
closed with a weather-tight, corrosion-resistant flashing.
COMBUSTION AIR PIPE
STANDARDFURNACECONNECTIONS
DIRECTVENT INSTALLATIONS
It is the responsibility of the installer to ensure that the piping
connections to the furnace are secure, airtight, and adequately
supported.
On upflow units secure the combustion air intake pipe directly to
the air intake coupling. On counterflow units secure the combus-
tion air intake pipe to the air intake coupling using the rubber cou-
plingandwormgearhoseclampsprovidedwiththeunit. Thecoun-
terflow rubber coupling allows service removal of air intake piping
internal to the furnace blower compartment. NOTE: Because of
probable material conflicts, do not use other commercially avail-
able “no hub connectors”. The combustion air intake pipe can
also be secured directly to the counterflow unit air intake pipe
coupling.
As shipped, attachment “couplings” for vent/flue and combustion
air intake pipe connections are provided on the furnace’s top cover
(upflow) or basepan (counterflow). To use the standard connec-
tions, field supplied vent/flue pipe and combustion air intake pipe
(when applicable) should be secured directly to the furnace at
these locations.
VENT/FLUEPIPE
NON-DIRECTVENT INSTALLATIONS
Vent/flue pipe can be secured to the vent/flue coupling using the
rubber coupling and worm gear hose clamps provided with this
furnace (see “Standard Connections” figure). The rubber coupling
allows separation of the vent/flue pipe from the furnace during ser-
A minimum of one 90° elbow should be installed on the combus-
tion air intake “coupling” to guard against inadvertent blockage.
14
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
COMBUSTION
AIR PIPE
VENT/FLUE
PIPE
COMBUSTION
AIR PIPE
4. Cut the vent/flue pipe 3.75 inches from the flanged end of
the pipe (see “Vent/Flue Pipe Cuts” figure).The section of
pipe attached to the coupling will reach through the side
panel to the induced draft blower. Discard remaining pipe
and elbows.
VENT/FLUE
PIPE
(DIRECT VENT ONLY)
(DIRECT VENT ONLY)
90 PVC
ELBOW
RUBBER
90 PVC
ELBOW
(NON-DIRECT VENT)
RUBBER
COUPLING
WITH WORM
GEAR CLAMPS
COUPLINGS
WITH WORM
GEAR CLAMPS
(NON-DIRECT VENT)
OR
OR
Counterflowunits.
Cut the vent/flue pipe 3.75 inches from the blower deck
coupling (see “Vent/Flue Pipe Cuts” figure).Save vent/flue
pipeattachedtoblowerdeckcouplingforuseinthealternate
location. Discard remaining pipe and elbows.
FLANGE
UPFLOW
COUNTERFLOW
3.75"
Standard Connections
CUT HERE
ALTERNATEFURNACECONNECTIONS
If the standard locations are undesirable for a specific installation,
alternate side panel locations are available for both combustion air
inlet and vent/flue pipe connections. These locations may be of
particular benefit to upright upflow installations requiring additional
access to an Acoil, or to upright counterflow installations requiring
additional access to a filter or electronic air cleaner, or to horizontal
installations desiring vent/flue (and combustion air intake) piping
run vertically from the side of the cabinet.
Vent/FluePipeCuts
5. Remove plastic plug from alternate vent/flue location.
Relocate and install plug in standard vent/flue location (top
cover).
NOTE: Standard and alternate locations can be combined (i.e.,
an installation may use the standard combustion air intake loca-
tionbutusethealternatevent/fluelocationorviceversa), ifneeded.
Counterflow units.
Remove plastic plug from alternate vent/flue location.
Relocate and install plug in standard vent/flue location
(basepan). Plug remaining hole in blower deck with plastic
plug included in the drain kit bag.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
6. Upflow andCounterflow units.
Insertcutsectionofvent/fluepipeandcouplingintoalternate
vent/flue location. Using a rubber coupling and worm gear
hose clamps from the drain kit bag, attach the vent/flue
pipe and coupling to the induced draft blower. Secure the
coupling to the cabinet using the screws removed in step 1
or with field-supplied 3/8” #8 self drilling screws.
ALTERNATEVENT/FLUELOCATION
The alternate vent/flue location is the large hole directly in line with
the induced draft blower outlet. To use the alternate vent/flue loca-
tion refer to the following steps and the “Alternate Vent/Flue Loca-
tion”figure.
WARNING
NOTE: Counterflow instructions follow the upflow instructions.
THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN THE
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,
EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD‐
SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS
CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES,
INCLUDING CARBON MONOXIDE
1. Remove and save the four screws securing the vent/flue
coupling to the furnace top panel.
Counterflow units.
Remove and save the four screws securing the vent/flue
coupling to the furnace basepan. Also remove the three
screws securing the furnace’s internal vent/flue piping to
the blower deck.
7. Upflow andCounterflow units.
2. Upflow andCounterflow units.
For upright installations, externally mount the rubber
elbow to the vent/flue coupling using a worm gear hose
clamp. Secure field supplied vent/flue piping to the rubber
elbow using a worm gear hose clamp. NOTE: Use of the
alternate vent/flue location for upright installations, requires
the drain trap be installed on the same side of the unit as
the flue pipe.
Loosen the worm gear hose clamps on the rubber elbow
and detach it from both the induced draft blower and the
vent/fluepipe.
3. Upflow andCounterflow units.
Remove the vent/flue pipe from the furnace.
15
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
8. Upflow andCounterflow units.
3. Remove plastic plug from alternate combustion air intake
location. Relocate and install plug in standard air intake
location (basepan). Plug the remaining hole in the blower
deck with the plastic plug included in the drain kit bag.
4. With the gasket facing the cabinet side panel, and the
flange’s flat spot facing forward, secure the combustion air
intake coupling to the cabinet using the screws removed in
step 1 or with field-supplied 3/8” #8 self -drilling screws.
For horizontal installations, externally secure the field-
suppliedvent/fluepipedirectlytothevent/fluecouplingusing
a PVC orABS coupling or elbow.
ALTERNATECOMBUSTIONAIRINTAKELOCATION
The alternate combustion air intake location consists of a large,
unobstructed hole (alternate vent connection is aligned with the
Induced Draft Blower). To use the alternate combustion air intake
location, refer to the following steps, and the “Alternate Combus-
tionAir Intake Location” figure.
CAUTION
BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS
WHEN REINSTALLING COUPLING AND SCREWS.
1. Removeandsavethefourscrewssecuringthecombustion
air intake coupling to the basepan. Remove an additional
three screws securing the furnace’s internal combustion
air intake pipe to the blower deck.
2. Remove the combustion air intake pipe from the furnace
andcutthepipeatthebasepancoupling. Savethebasepan
coupling and gasket from the blower deck coupling for use
in the alternate location. Discard the remaining pipe.
5. For non-direct vent installations installed horizontally, a
minimum of one 90° elbow should be installed on the
combustionairintake couplingtoguardagainst inadvertent
blockage. Noelbowisrequiredonthealternatecombustion
air intake of upright installations, however, a minimum
clearanceof2inchesisrequiredtoassureproperairsupply.
6. For direct vent installations, secure field-supplied
combustionairintakepipedirectlytotheairintakecoupling.
NOTE: APVCcouplingorelbowisrequiredoncounterflow
units.
3
3
REMOVE
PIPE
REMOVE
PIPE
1
REMOVE
3 SCREWS
5
5
REMOVE
REMOVE
AND RELOCATE
AND RELOCATE
2
2
DETACH RUBBER
ELBOW FROM
ID BLOWER AND
VENT/FLUE
PIPE
DETATCH RUBBER
ELBOW FROM
ID BLOWER AND
VENT/FLUE
PIPE
5
ADDITIONAL PLUG
FROM DRAIN KIT
6
SECURE TO
ID BLOWER WITH
6
RUBBER COUPLING
SECURE TO
AND HOSE
CABINET WITH
CLAMPS
7
EXTERNALLY
MOUNT
SCREWS
RUBBER ELBOW
6
SECURE TO
ID BLOWER WITH
RUBBER COUPLING
AND HOSE
CLAMPS
16
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
1) One 90° elbow should be secured to the combustion air intake connection.
NON-DIRECTVENT(SINGLEPIPE)PIPING
2) Minimum requirement for each vent pipe is five (5) feet in length and one
Non-direct ventinstallations require only a vent/flue pipe. The vent
pipe can be run horizontally with an exit through the side of the
building or run vertically with an exit through the roof of the building.
The vent can also be run through an existing unused chimney;
however, it must extend a minimum of 12 inches above the top of
the chimney. The space between the vent pipe and the chimney
must be closed with a weather-tight, corrosion-resistant flashing.
For details concerning connection of the vent/flue pipe to the fur-
nace, refer to Vent/Flue Pipe and Combustion Air - Standard Fur-
nace Connections or Alternate Furnace Connections for specific
details. Refer to the followingNon-Direct Vent (Single Pipe) Piping
- Vent/Flue Pipe Terminations for specific details on termination
construction.
elbow/tee.
3) Tee used in the vent/flue termination must be included when determining the
number of elbows in the piping system.
4) 2-1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
5) Increased Clearance Configurations using (2) 45 deg. Long Sweep el-
bows should be considered equivalent to one 90 deg. elbow.
VENT/FLUEPIPE TERMINATIONS
The vent/flue pipe may terminate vertically, as through a roof, or
horizontally, as through an outside wall.
Vertical vent/flue pipe terminations should be as shown in the fol-
lowing figure. Refer to Vent/Flue Pipe and Combustion Air Pipe -
Termination Locations for details concerning location restrictions.
The penetration of the vent through the roof must be sealed tight
with proper flashing such as is used with a plastic plumbing vent.
Although non-direct vent installations do not require a combustion
air intake pipe, a minimum of one 90° elbow should be attached to
the furnace’s combustion air intake if: an upright installation uses
the standard intake location, or a horizontal installation uses the
alternateairintakelocation. Thiselbowwillguardagainstinadvert-
ent blockage of the air intake.
Horizontal vent/flue pipe terminations should be as shown in the
following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe
- Termination Locations for details concerning location restrictions.
A 2 3/8” diameter wall penetration is required for 2” diameter pipe.
A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diam-
eter hole is required for 3” diameter pipe. To secure the pipe pass-
ing through the wall and prohibit damage to piping connections, a
coupling should be installed on either side of the wall and solvent
cemented to a length of pipe connecting the two couplings. The
length of pipe should be the wall thickness plus the depth of the
socket fittings to be installed on the inside and outside of the wall.
The wall penetration should be sealed with silicone caulking
material.
VENT/FLUE PIPE LENGTHS AND DIAMETERS
Refer to the following table for applicable length, elbows, and pipe
diameter for construction of the vent/flue pipe system of a non-
direct vent installation. In addition to the vent/flue pipe, a single 90°
elbow should be secured to the combustion air intake to prevent
inadvertent blockage. The tee used in the vent/flue termination
must be included when determining the number of elbows in the
piping system.
UPFLOW
Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)
Pipe (4)
Number of Elbows (3)(5)
Unit
Input
(Inch)
1
2
3
4
5
6
7
8
45,000 2 or 2 1/2 71
68 65 62 59 56 53 50
46 43 40 37 34 31 28
68 65 62 59 56 53 50
68 65 62 59 56 53 50
46 43 40 37 34 31 28
2 or 2 1/2 49
70,000
3
3
3
71
71
49
90,000
115,000
COUNTERFLOW
Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)
Pipe (4)
(Inch)
Number of Elbows (3)(5)
Unit
Input
1
2
3
4
5
6
7
8
2 or 2 1/2 61
58 55 52 49 46 43 40
68 65 62 59 56 53 50
58 55 52 49 46 43 40
68 65 62 59 56 53 50
68 65 62 59 56 53 50
70,000
3
71
2 or 2 1/2 61
90,000
3
3
71
71
115,000
17
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
In a basement installation, the vent/flue pipe can be run between
joist spaces. If the vent pipe must go below a joist and then up into
the last joist space to penetrate the header, two 45° elbows should
be used to reach the header rather than two 90° elbows.
TEE (OPTIONAL)
DIRECTVENT(DUALPIPE)PIPING
The inlet air screens provided in the installation instruction packet
are available for the installer to use in the inlet of the combustion air
pipe to prevent animals from building nests in the combustion air
pipe. Installation of screens, while strongly recommended, is not
required and will not affect performance of the unit.
12 " Min To Roof
Or Highest Anticipated
Snow Level
12 " Min To Roof
Or Highest Anticipated
Snow Level
Direct vent installations require both a combustion air intake and a
vent/flue pipe. The pipes may be run horizontally and exit through
the side of the building or run vertically and exit through the roof of
the building. The pipes may be run through an existing unused
chimney; however, they must extend a minimum of 12 inches
above the top of the chimney. The space between the pipes and
the chimney must be closed with a weather tight, corrosion resis-
tant flashing. Both the combustion air intake and a vent/flue pipe
terminations must be in the same atmospheric pressure zone.
Refer to Vent/Flue and Combustion Air Pipe - Termination Loca-
tions or Concentric Vent Termination for specific details on termi-
nation construction. For details concerning connection of pipes to
the furnace, refer to the Vent/Flue Pipe and Combustion Pipe -
StandardFurnaceConnectionsorAlternateFurnaceConnections.
Vertical Termination (Single Pipe)
90º
MEDIUM RADIUS
ELBOWS
12" MIN. TO ROOF
OR HIGHEST ANTICIPATED
SNOW LEVEL
VENT/FLUE &COMBUSTION AIR PIPE LENGTHS &DIAMETERS
Refer to the following table for applicable length, elbows, and pipe
diameterforconstructionofthevent/flueandcombustionairintake
pipe systems of a direct vent (dual pipe) installation. The number
of elbows tabulated represents the number of elbows and/or tees
in each (Vent/Flue & CombustionAir Intake) pipe. Elbows and/or
tees used in the terminations must be included when determining
the number of elbows in the piping systems.
Alternate Vertical Termination (Single Pipe)
If the combustion air intake pipe is to be installed above a finished
ceiling or other area where dripping of condensate will be objec-
tionable, insulation of the combustion air pipe may be required.
Use 1/2” thick closed cell foam insulation such as Armaflex™ or
Insultube™whererequired.
MIN.
12"
12" TO GROUND OR
FROM
WALL
HIGHEST ANTICIPATED
SNOW LEVEL
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS
HorizontalTermination(SinglePipe)
12" MIN.
Thevent/flueandcombustionairpipesmayterminatevertically, as
through a roof, or horizontally, as through an outside wall.
VENT/FLUE TEE
or
90° ELBOW TURNED
DOWN
12" MIN. ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
HorizontalTermination(SinglePipe)
AboveHighestAnticipatedSnowLevel
18
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
TEE (OPTIONAL)
UPFLOW
Direct Vent (Dual Pipe) Maximum Allowable Length*
of Vent/Flue & Combustion Air Intake Pipe(ft)
VENT/FLUE
Number of Elbows (1)(2)(3)(5)
COMBUSTION
AIR INTAKE
Pipe(4)
(inch)
Unit Input Termination
(Btu)
Style
1
2
3
4
5
6
7
8
12" MIN.
Standard 2 or 2 1/2 71 68 65 62
59 56 53 50
46 43 40 37
37 34 31 28
59 56 53 50
24 21 18 15
45 42 39 36
59 56 53 50
45 42 39 36
37 34 31 28
23 20 17 14
45,000
Alternate
2 or 2 1/2 58 55 52 49
2 or 2 1/2 49 46 43 40
SCREEN
Standard
3
71 68 65 62
70,000
2 or 2 1/2 36 33 30 27
Alternate
3
3
3
3
3
57 54 51 48
71 68 65 62
57 54 51 48
49 46 43 40
35 32 29 26
Standard
Alternate
Standard
Alternate
90,000
12" MIN. TO ROOF
OR HIGHEST ANTICIPATED
SNOW LEVEL
115,000
VENT/FLUE
*Maximum allowable limits listed are individual lengths for inlet & flue and NOT a combination.
COUNTERFLOW
Direct Vent (Dual Pipe) Maximum Allowable Length*
12" MIN.
of Vent/Flue & Combustion Air Intake Pipe(ft)
Number of Elbows (1)(2)(3)(5)
Pipe(4)
Unit Input Termination
SCREEN
(Btu)
Style
(inch)
2 or 2 1/2 49 46 43 40
71 68 65 62
2 or 2 1/2 36 33 30 27
57 54 51 48
2 or 2 1/2 61 58 55 52
71 68 65 62
2 or 2 1/2 48 45 42 39
1
2
3
4
5
6
7
8
37 34 31 28
59 56 53 50
24 21 18 15
45 42 39 36
49 46 43 40
59 56 53 50
36 33 30 27
45 42 39 36
Standard
3
70,000
Alternate
Standard
Alternate
12" MIN. TO ROOF
OR HIGHEST ANTICIPATED
SNOW LEVEL
3
3
Vertical Terminations (Dual Pipe)
90,000
Horizontal terminations should be as shown in the following figure.
Refer to Vent/Flue Pipe and Combustion Pipe - Termination Loca-
tion for location restrictions. A2 3/8” diameter wall penetration is
required for 2” diameter pipe. A3” diameter hole is required for a 2
1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter
pipe. To secure the pipe passing through the wall and prohibit
damage to piping connections, a coupling should be installed on
either side of the wall and solvent cemented to a pipe connecting
the two couplings. The pipe length should be the wall thickness
plus the depth of the socket fittings to be installed on the inside
and outside of the wall. The wall penetration should be sealed with
silicone caulking material.
3
57 54 51 48
Standard
Alternate
3
3
71 68 65 62
57 54 51 48
59 56 53 50
45 42 39 36
115,000
*Maximum allowable limits listed are individual lengths for inlet & flue and NOT a combination.
1) Elbows and/or tees used in terminations must be included when determin-
ing quantity of allowable elbows in the system.
2) Number of elbows tabulated are for each (Vent/Flue & Combustion Air
Intake) pipe.
3) Minimum requirements for each Vent/Flue & Combustion Air Intake pipe is
five (5) feet in length and one elbow/tee.
4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
12" MIN
5) Increased Clearance Configurations using (2) 45 deg. Long Sweep el-
bows should be considered equivalent to one 90 deg. elbow.
3" MIN
24" MAX
Vertical pipe terminations should be as shown in the following
figure. Refer to Vent/Flue Pipe and Combustion Pipe - Termina-
tion Locations for details concerning location restrictions. The
penetrations through the roof must be sealed tight with proper
flashing such as is used with a plastic plumbing vent.
3" MIN
24" MAX
90º
12" MIN. TO ROOF OR
HIGHEST ANTICIPATED
SNOW LEVEL
MEDIUM RADIUS
ELBOW
SCREEN
12" MIN. TO ROOF OR
HIGHEST ANTICIPATED
SNOW LEVEL
Standard Horizontal Terminations (Dual Pipe)
19
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
90º MEDIUM
RADIUS ELBOW
VENT/INTAKETERMINATIONSFORINSTALLATIONOFMULTIPLE
DIRECTVENTFURNACES
12” MIN
If more than one direct vent furnace is to be installed vertically
through a common roof top, maintain the same minimum clear-
ances between the exhaust vent and air intake terminations of
adjacent units as with the exhaust vent and air intake terminations
of a single unit.
MAX
MIN
2
AIR
INTAKE
If more than one direct vent furnace is to be installed horizontally
through a common side wall, maintain the clearances as in the
following figure. Always terminate all exhaust vent outlets at the
same elevation and always terminate all air intakes at the same
elevation.
12" MIN. TO ROOF OR
HIGHEST ANTICIPATED
SNOW LEVEL
SCREEN
AlternateHorizontalVentTermination(DualPipe)
12" MIN
Vents
90°
Medium
Radius
Elbows
3" MIN
24" MAX
SUPPORT
STRAPS
VENT/FLUE
TEE
3" Min.
24" Max.
3" Min.
24" Max.
3" Min.
24" Max.
COMBUSTION
AIR INTAKE
Air
Intakes
12" MIN. ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
Screen
SCREEN
12" Min.
12" MIN. ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
12" MIN. ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
90° MEDIUM
RADIUS ELBOWS
HorizontalVentingOfMultipleUnits
CONCENTRICVENTTERMINATION
RefertothedirectionsprovidedwiththeConcentricVentKit(DCVK)
for installation specifications.
StandardHorizontalTerminationsAboveAnticipatedSnow
Level(DualPipe)
SIDE WALL VENT KIT
This kit is to be used with 2” or 3” direct vent systems. The vent kit
must terminate outside the structure and may be installed with the
intake and exhaust pipes located side-by-side or with one pipe
above the other. This kit is NOT intended for use with single pipe
(indirect vent) installations.
SCREEN
Refer to the directions furnished with the Side Wall Vent Kit
(p/n0170K00000S) forinstallationspecifications.
12" MIN. TO ROOF OR
HIGHEST ANTICIPATED
SNOW LEVEL
AlternateVentTerminationAboveAnticipatedSnowLevel
(DualPipe)
In a basement installation, the pipes may be run between the joist
spaces. If the pipes must go below the joist and then up into the
last joist space to penetrate the header, two 45° elbows should be
used to reach the header rather than two 90° elbows.
20
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CONDENSATE DRAIN LINES & DRAIN TRAP
CONDENSATE DRAIN LINES & DRAIN TRAP
HOSE A
QTY: 1
A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
The condensate which is generated must be piped to an appropri-
ate drain location.
HOSE B
QTY: 1
DRAIN TRAP
QTY: 1
TUBE 1
QTY: 1
GREEN
HOSE CLAMPS
QTY: 3
TUBE 2
QTY: 2
In upright installations, the furnace’s drain hoses may exit either
the right or left side of the furnace. NOTE:If the alternate vent/flue
outlet is utilized in an upright installation, the drain trap and drain
connections must be located on the same side as the alternate
vent/flue outlet.
SILVER
HOSE CLAMP
QTY: 1
RED
HOSE CLAMP
QTY: 1
Hose and Tube Identification
In horizontal installations, the drain hoses will exit through the
bottom (down side) of the unit with the drain trap suspended be-
neath the furnace. The field-supplied drain system must be in
accordance with all local codes and the instructions in the follow-
ing sections.
Follow the bullets listed below when installing the drain system.
Refer to the following sections for specific details concerning fur-
nace drain trap installation and drain hose hook ups.
•
•
The drain trap supplied with the furnace must be used.
The drain line between furnace and drain location must
be constructed of 3/4” PVC.
•
•
The drain line between furnace and drain location must
maintain a 1/4 inch per foot downward slope toward the
drain.
Do not trap the drain line in any other location than at
the drain trap supplied with the furnace.
•
•
Do not route the drain line outside where it may freeze.
If the drain line is routed through an area which may
see temperatures near or below freezing, precautions
must be taken to prevent condensate from freezing
within the drain line.
•
If an air conditioning coil is installed with the furnace, a
common drain may be used. An open tee must be
installed in the drain line, near the cooling coil, to
relieve positive air pressure from the coil’s plenum.
This is necessary to prohibit any interference with the
function of the furnace’s drain trap.
STANDARDRIGHTORLEFTSIDEDRAINHOSECONNECTIONS
All installations positions require the use of the drain trap, hoses,
tubes, and clamps. The following quantity of hoses, tubes, and
hose clamps are provided with the unit.
21
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CONDENSATE DRAIN LINES & DRAIN TRAP
5. Cut 17 3/4 inches from the long end of Hose B and discard.
UPRIGHTINSTALLATIONS-TRAPONRIGHTSIDE
Secure the remaining hose to Tube 1 with a green hose
clamp. Route the other end of Hose B to front right side
panel grommet hole.
In a upright installation drain hoses are connected to drain ports on
therubberelbowandtherecuperatorcoilfrontcover.Thedrainlines
are then routed through the right side panel and into the drain trap
secured to the outside of the cabinet.
For details concerning mounting of the drain trap, refer toHorizontal
Drain Trap Mounting.
6. Insertshortendofeachoftube2throughsidepanelgrommet
holes. Secure tubes to hoses A and B with green hose
clamps. Ensurehosesandtubesmaintainadownwardslope
for proper drainage and that they are not kinked or binding.
NOTE: Refer to Alternate Vent/Flue Hose Connections for upright
installations using an alternate vent/flue outlet.
1. Remove the rubber plug from the right side of the front cover
drain port.
2. SecureHoseAtofrontcoverdrainportwitharedhoseclamp.
Route hose to rear side panel grommet hole.
3. Cutandremove1/4inchfromtheendofthedrainportonthe
rubberelbow.
4. Insert Tube 1 into rubber elbow drain port and secure with
silverhoseclamp. Angletubeoutwardtowardfrontoffurnace.
RIGHT SIDE
PANEL
RUBBER
ELBOW
RUBBER ELBOW
DRAIN PORT
SILVER HOSE CLAMP
TUBE 1
HOSE
SIDE PANEL
B
GROMMET
HOLES
TUBE(S) 2
DRAIN
TRAP
RED HOSE
CLAMP
HOSE
A
FRONT
COVER
DRAIN PORT
GREEN
HOSE
CLAMPS
(3 PLACES)
Upright“Standard”Connections-RightSide
(UpflowShown,CounterflowSimilar)
22
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CONDENSATE DRAIN LINES & DRAIN TRAP
ALTERNATEVENT/FLUEDRAINHOSECONNECTIONS
Upright installations using the alternate vent/flue outlet will require
“right-side only” drain hoses to be connected as follows. Refer to
Vent/Flue Pipe and Combustion Air Pipe for details on alternate
vent/flue pipe connection.
1. Remove the rubber plug/cap from the right-side drain port
on the front cover . Save for use in step 3.
7. Secure straight end of Hose B to exposed end of Tube 1
with a green hose clamp. Route hose toward right side
panel grommet holes.
8. Insert short end of one Tube 2 through rear right side panel
grommet drain hole. Secure tube to HoseA with a green
hose clamp.
2. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear right side panel grommet hole.
3. Removegrommetfromfrontright-sidepaneldrainhole. Seal
hole in grommet with large end of plug. Reinstall grommet
and plug into side panel drain hole.
9. InsertshortendofremainingTube2intoHoseBfromrubber
elbow and secure with green hose clamp. Ensure hoses
and tubes maintain a downward slope for proper drainage
and are not kinked or binding.
4. Cut 1/4 inch from the end of the drain port on the externally
mounted rubber elbow. Discard cut portion.
5. InsertTube1intorubberelbowdrainportandsecurewitha
silver hose clamp. Angle tube toward trap.
6. Cut 17 3/4 inches from the long end of Hose B and discard.
RUBBER ELBOW
(EXTERNALLY
MOUNTED)
RUBBER
ELBOW
FRONT
COVER
DRAIN
PORT
DRAIN PORT
HOSE B
SILVER HOSE CLAMP
TUBE 1
GREEN HOSE
CLAMPS
(3 PLACES)
HOSE A
TUBE(S) 2
RED HOSE
CLAMP
DRAIN TRAP
Upright“Alternate”Connections-RightSideOnly
(UpflowShown, CounterflowSimilar)
23
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CONDENSATE DRAIN LINES & DRAIN TRAP
5. Cut “X” inches from the long end of Hose B and discard.
UPRIGHTINSTALLATIONS-TRAPONLEFTSIDE
Refer to table for appropriate length to cut. Secure
remaining hose to Tube 1 with a green hose clamp. Route
other end of Hose B to front left side panel grommet hole.
NOTE: For left side trap installation, grommets must be moved
to the left side of the furnace and the plugs installed on the right
side of the furnace.
1. Remove the rubber plug/cap from the left side drain port
on the front cover.
NOTE: Long hose “B” must always be connected to Tube 1 and
the elbow and not on the front cover.
6. InsertshortendofeachTube2throughsidepanelgrommet
holes. Secure tubes to Hose A and Hose B with green
hose clamps. Ensure hoses and tubes maintain a
downward slope for proper drainage and that they are not
kinked or binding.
2. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear side panel grommet hole.
3. Cut and remove 1/4 inch from the end of the drain port on
the rubber elbow.
4. Insert Tube 1 into rubber elbow drain port and secure with
silver hose clamp. Angle tube outward toward front of
furnace.
LEFT
SIDE PANEL
FRONT COVER
DRAIN PORT
RUBBER
ELBOW
RED HOSE
CLAMP
RUBBER
ELBOW
DRAIN PORT
HOSE A
SILVER HOSE
CLAMP
SIDE PANEL
DRAIN
HOLES
TUBE 1
TUBE(S) 2
GREEN HOSE
CLAMP
DRAIN
TRAP
HOSE B
GREEN
HOSE CLAMP
Upright “Standard” Connections - Left Side
(UpflowShown,CounterflowSimilar)
"X" Length to Cut From Long
Cabinet Width
(inches)
Models
(kBTU_Tons)
End of Hose B
(inches)
17 1/2
21
45_30
70_40
7
3 1/2
090_50
115_50
24 1/2
None
24
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CONDENSATE DRAIN LINES & DRAIN TRAP
to appropriate length to minimize sagging. Plug left
(unused) pressure tap with plug removed from right side.
2. Secure Hose A to front cover drain tap with a red hose
clamp. Route hose to rear right (down) side panel grommet
holes.
UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)
1. Insert drain tubes into drain trap and position the drain
trap against the side panel. NOTE: Drain tubes must
reach the bottom of the drain trap.
2. Secure drain trap to side panel at the mounting holes
(dimples or crosshairs on counterflow models) located
below the grommet drain holes.
3. Cut 1/4 inch from the end of the drain port on the rubber
elbow and discard.
4. Insert Tube 1 into rubber elbow drain port and secure with
a silver hose clamp. Angle tube outward toward front of
furnace.
5. Cut 17 3/4 inches from the long end of Hose B and discard.
6. Secure remaining end of Hose B to exposed end of Tube
1 with a green hose clamp. Route hose to front right
3. Attach PVC drain line to drain trap outlet with either a 90°
elbow or coupling.
HORIZONTALINSTALLATIONS
RIGHT SIDE DOWN
down side panel grommet holes.
7. Cut 5 1/2 inches straight length from the long end of each
Tube 2 and discard the radius pieces.
Horizontal installations with the right side down require that the
drain hoses be connected to the right side front cover drain port
and the rubber elbow drain port.
8. Insert approximately one inch of each Tube 2 through the
right down side panel grommet holes. Secure tubes to
Hose A and Hose B using green hose clamps. Ensure
hoses and tubes maintain a downward slope for proper
drainage and are not kinked or bound.
NOTE: On counterflow models, relocation of the front cover
pressure switch hose is required.
Make connections as follows:
1. Remove the rubber plug/cap from right side of the front
cover drain port.
For details concerning mounting of the drain trap, refer to Con-
densateDrainLinesandDrainTrap-Horizontal DrainTrapMount-
ing.
Counterflow furnaces
Relocate the front cover pressure switch hose connection
from the left side pressure tap to the right (down) side tap.
The pressure switch hose must be connected to the down
side to guard against blocked drain conditions. Cut hose
FRONT COVER
DRAIN PORT
RED HOSE
CLAMP
HOSE A
FRONT
COVER
HOSE B
PRESSURE
RUBBER
ELBOW
TAP
RIGHT
SIDE
PANEL
TUBES 2
RUBBER ELBOW
DRAIN PORT
GREEN
HOSE
CLAMP
TUBE 1
SILVER HOSE
CLAMP
DRAIN TRAP
(3 PLACES)
HorizontalConnections-RightSideDown
(UpflowShown, CounterflowSimilar)
25
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CONDENSATE DRAIN LINES & DRAIN TRAP
6. Cut 5 1/2 inches straight length from the long end of each
LEFT SIDE DOWN
Tube 2 and discard radius ends.
Horizontal installations with the left side panel down will require
drain hoses to be connected to the left side front cover drain port
and the side drain port on the rubber elbow.
7. Insert approximately one inch of each Tube 2 through left
side panel grommet hole. Secure tubes to Hose A and
Hose B with a green hose clamps. NOTE: Tube must
reach bottom of trap. Ensure hoses and tubes maintain a
downward slope for proper drainage and that they are not
kinked or binding.
1. Removetherubberplug/capfromthefrontcoverleft(down)
side drain port.
2. Relocate the front cover pressure switch hose connection
from the right side (as shipped) pressure tap to the left
(down) side tap. The pressure switch hose must be
connected to the down side to guard against blocked drain
conditions. Cut hose to appropriate length to minimize
sagging. Plug right (unused) pressure tap with plug
removed from left side.
For details concerning mounting of the drain trap, refer to Con-
densateDrainLinesandDrainTrap-HorizontalDrainTrapMount-
ing.
HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE
PANEL)
1. Position the drain trap against side panel with drain tubes
inserted into trap. Note that the trap may be orientated
with the outlet facing either the furnace’s top cover or base
pan.
3. Secure Hose A to front cover drain port with a red hose
clamp. Route hose to rear left (down) side panel grommet
holes. NOTE: For left side drainage, grommets must be
relocated to left side panel.
2. Secure drain trap to side panel at the dimples or crosshairs
located on either side of the grommet drain holes.
3. Confirm that tubes reach bottom of drain trap and that all
hoses maintain a downward slope and are not kinked or
binding.
4. Remove the rubber cap from the side drain port on the
rubber elbow.
5. Secure the short end of Hose B to rubber elbow side drain
port using a green hose clamp. NOTE: For left side
drainage, route hose to far left (down) side panel grommet
holes. NOTE: Horizontal left side connections (when using
new side port drain elbow) does not require connecting a
hose to the induced draft blower housing.
4. Attach PVC drain line to drain trap outlet with either a 90°
elbow or coupling.
GREEN HOSE
CLAMP
HOSE B
HOSE A
FRONT
COVER
PRESSURE
TAP
GREEN HOSE
CLAMP
TUBE(S) 2
LEFT SIDE
PANEL
FRONT COVER
DRAIN PORT
DRAIN TRAP
RED HOSE CLAMP
SIDE PANEL
GROMMET
HOLES
Horizontal Connections - Left Side Down
(UpflowShown, CounterflowSimilar)
26
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ELECTRICAL CONNECTIONS
left side panel. The furnace is shipped configured for a right side
(left side for counterflows) electrical connection with the junction
box located inside the burner compartment. To make electrical
connections through the opposite side of the furnace, the junc-
tion box must be relocated to the other side of the burner com-
partment prior to making electrical connections. To relocate the
junction box, follow the steps shown below.
ELECTRICAL CONNECTIONS
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO
THE UNIT MUST BE POLARIZED AND GROUNDED.
NOTE: Wire routing must not to interfere with circulator blower
operation, filter removal, or routine maintenance.
WARNING
JUNCTIONBOXRELOCATION
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
CAUTION
WARNING
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,
DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS
UNIT.
WIRINGHARNESS
WARNING
The wiring harness is an integral part of this furnace. Field alter-
ation to comply with electrical codes should not be required.
Wires are color coded for identification purposes. Refer to the
wiring diagram for wire routings. If any of the original wire as
supplied with the furnace must be replaced, it must be replaced
with wiring material having a temperature rating of at least 105°
C. Any replacement wiring must be a copper conductor.
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
Line voltage connections can be made through either the right or
left side panel. The furnace is shipped configured for a right side
electrical connection. To make electrical connections through
the opposite side of the furnace, the junction box must be relo-
cated to the left side prior to making electrical connections. To
relocate the junction box, perform the following steps.
1. Remove the burner compartment door.
2. Remove and save the two screws securing the junction
box to the side panel.
3. Relocate junction box and associated plugs and grommets
to opposite side panel. Secure with screws removed in
step 2.
115VOLTLINECONNECTIONS
Before proceeding with electrical connections, ensure that the
supply voltage, frequency, and phase correspond to that speci-
fied on the unit rating plate. Power supply to the furnace must be
NEC Class 1, and must comply with all applicable codes. The
furnace must be electrically grounded in accordance with local
codes or, in their absence, with the latest edition ofThe National
Electric Code,ANSI NFPA70 and/orThe Canadian Electric Code
CSA C22.1.
Use a separate fused branch electrical circuit containing prop-
erly sized wire, and fuse or circuit breaker. The fuse or circuit
breaker must be sized in accordance with the maximum
overcurrent protection specified on the unit rating plate. An elec-
trical disconnect must be provided at the furnace location.
WARNING
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE
FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH
LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRICAL CODE.
Connect hot, neutral, and ground wires as shown in the wiring
diagram located on the unit’s blower door. For direct vent appli-
cations, the cabinet opening to the junction box must be sealed
air tight using either an UL approved bushing such as Heyco
Liquid Tight or by applying non-reactive UL approved sealant to
bushing.
To ensure proper unit grounding, the ground wire should run from
the furnace ground screw located inside the furnace junction box
all the way back to the electrical panel. NOTE: Do not use gas
piping as an electrical ground. To confirm proper unit grounding,
turn off the electrical power and perform the following check.
Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right or
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ELECTRICAL CONNECTIONS
1. Measureresistancebetweentheneutral(white)connection
and one of the burners.
2. Resistance should measure 10 ohms or less.
Thermostat
Single Stage Heating with
Single Stage Cooling
R
R
Furnace Integrated
Control Module
This furnace is equipped with a blower door interlock switch which
interruptsunitvoltagewhentheblowerdoorisopenedforservicing.
Do not defeat this switch.
NEU
Y
C
Dehumidistat
[Optional]
24VOLTTHERMOSTATWIRING
IMPORTANT NOTE
Remote
Condensing Unit
(Single-Stage Cooling)
Single Stage Heating with Single Stage Cooling
WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER
OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE.
NOTE: To apply a single-stage Heating Thermostat,
the thermostat selector switch on the
Integrated Control Module must be set on
single-stage.
A
REMOVABLE PLUG CONNECTOR IS PROVIDED WITH THE CONTROL TO
MAKE THERMOSTAT WIRE CONNECTIONS. THIS PLUG MAY BE REMOVED,
WIRE CONNECTIONS MADE TO THE PLUG, AND REPLACED. IT IS
STRONGLY RECOMMENDED THAT MULTIPLE WIRES INTO A SINGLE
TERMINAL BE TWISTED TOGETHER PRIOR TO INSERTING INTO THE PLUG
CONNECTOR. FAILURE TO DO SO MAY RESULT IN INTERMITTENT
OPERATION.
Thermostat
Two-Stage Heating
with
R
R
Single-Stage Cooling
Furnace Integrated
Control Module
Asatwo-stagenon-communicatingfurnace, thefurnaceintegrated
control module provides terminals for both “W1” and “W2”, and
“Y1” and “Y2” thermostat connections. This allows the furnace to
support the following system applications: ‘Two-Stage Heating
Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-
Stage Heating withTwo-Stage Cooling’. Refer to the following fig-
ures for proper connections to the integrated control module.
NEU
Y
C
Dehumidistat
[Optional]
Remote
Condensing Unit
(Single-Stage Cooling)
Two-Stage Heating with Single-Stage Cooling
Thermostat
Two-Stage Heating
Y2
W1 W2
with
Low voltage connections can be made through either the right or
left side panel. Thermostat wiring entrance holes are located in the
blowercompartment. Thefollowingfigureshowsconnectionsfora
“heat/cool system”.
( )
Two-Stage Cooling
Furnace Integrated
Control Module
Y2
Y2
W1 W2
This furnace is equipped with a 40 VAtransformer to facilitate use
with most cooling equipment. Consult the wiring diagram, located
on the blower compartment door, for further details of 115 Volt and
24 Volt wiring.
NEU
Dehumidistat
[Optional]
Remote
Condensing Unit
(Two-Stage Cooling)
NOTE: For single stage cooling applications, a jumper must be
located between Y1 and Y2 at the furnace control in order to
achieve the desired single stage cooling airflow. Use of ramping
profiles and dehumidification features require a jumper between
Y1 and O and Y1 and DEHUM, respectively.
Two-Stage Heating with Two-Stage Cooling
Thermostat Wiring Diagrams
SINGLE-STAGE HEATINGTHERMOSTATAPPLICATION
NOTE:Thermostat“R”requiredifoutdoorunitisequippedwitha
Comfort Alert™ module or if the out door unit is a part of the
ComfortNet family of equipment AND is wired as a legacy
system.
A single-stage thermostat with only one heating stage may be
used to control this furnace. The application of a single-stage
thermostat offers a timed transition from low to high fire. The
furnace will run on low stage for a fixed period of time before step-
ping up to high stage to satisfy the thermostat’s call for heat. The
delay period prior to stepping up can be set at either a fixed 5
minute time delay or a load based variable time between 1 and 12
minutes (AUTO mode). If theAUTO mode is selected, the control
averages the cycle times of the previous three cycles and uses
the average to determine the time to transition from low stage to
high stage.
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ELECTRICAL CONNECTIONS
temperature sensor to determine the most cost efficient means of
heating (heat pump or gas furnace).
To use a single-stage thermostat, turn off power to the furnace,
move the thermostat selection DIP switch to the OFF position.
Set the desired transition time by setting the transition delay DIP
switch to the desired ON/OFF position. Turn power back on. Refer
to the following figure.
A heat pump thermostat with three stages of heat is required to
properly use a two-stage furnace in conjunction with a heat pump.
Refer to the fossil fuel kit installation instructions for additional
thermostat requirements.
OFF
ON
Move to the ON position
to select two-stage
thermostat or OFF to
select single stage
thermostat
Heat OFF Delay
DIP Switches
Strictly follow the wiring guidelines in the fossil fuel kit installation
instructions. All furnace connections must be made to the furnace
two-stageintegratedcontrolmoduleandthe“FURNACE”terminal
strip on the fossil fuel control board.
3
4
Thermostat
Stage Delay
Move to the ON position
to select Auto transition
delay or OFF for 5 minute
transition delay
S1
115VOLTLINECONNECTIONOFACCESSORIES (HUMIDIFIERAND
ELECTRONICAIRCLEANER)
24VOLTDEHUMIDISTATWIRING
WARNING
The optional usage of a dehumidistat allows the furnace’s circula-
tor blower to operate at a slightly lower speed (85% of desired
speed) during a combined thermostat call for cooling and dehumi-
distat call for dehumidification. This can be done through an inde-
pendent dehumidistat or through a thermostat’s DEHUM terminal
(if available). This lower blower speed enhances dehumidification
of the conditioned air as it passes through theAC coil. For proper
function, a dehumidistat applied to this furnace must operate on
24 VAC and utilize a switch which opens on humidity rise. Refer
to the “Thermostat Wiring Diagrams” figure for additional wir-
ing details.
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
Thefurnaceintegratedcontrolmoduleisequippedwithlinevoltage
accessory terminals for controlling power to an optional field-sup-
plied humidifier and/or electronic air cleaner.
The accessory load specifications are as follows:
To install/connect a dehumidistat:
1. Turn OFF power to furnace.
Humidifier
Electronic Air Cleaner
1.0 Amp maximum at 120 VAC
1.0 Amp maximum at 120 VAC
2. Secure the dehumidistat neutral wire (typically the white
lead) to the terminal marked “DEHUM” on the furnace
integrated control module.
3. Secure the dehumidistat hot wire (typically the black lead)
to the terminal marked “R” on the furnace integrated control
module.
4. Secure the dehumidistat ground wire (typically the green
lead) to the ground screw on the furnace junction box.
NOTE: Ground wire may not be present on all
dehumidistats.
Turn OFF power to the furnace before installing any accessories.
Follow the humidifier or air cleaner manufacturers’ instructions for
locating, mounting, grounding, and controlling these accessories.
Accessory wiring connections are to be made through the 1/4"
quick connect terminals provided on the furnace integrated control
module. Thehumidifierandelectronicaircleanerhotterminalsare
identified as HUM and EAC. The humidifier and electronic air
cleaner neutral terminals are identified as NEUTRAL.All field wir-
ing must conform to applicable codes. Connections should be
made as shown.
5. Turn ON power to furnace.
To enable the dehumidify function on the integrated control mod-
ule, set the dehumidification ENABLE dipswitch from OFF to ON.
Once the switch is set, the dehumidify function is enabled during a
combinationcallforcooling(T-Stat)anddehumidification(DEHUM-
Stat).
ON
OFF
9
DEHUM
Unused
Move to the ON position
to enable dehumidification
10
S5
FOSSILFUELAPPLICATIONS
This furnace can be used in conjunction with a heat pump in a
fossil fuel application. Afossil fuel application refers to a combined
gas furnace and heat pump installation which uses an outdoor
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GAS SUPPLY AND PIPING
Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appli-
ances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must not
be exceeded to prevent unit overfiring.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
HIGHALTITUDEDERATE
When this furnace is installed at high altitude, the appropriate High
Altitude orifice kit must be applied. This is required due to the
natural reduction in the density of both the gas fuel and combus-
tion air as altitude increases. The kit will provide the proper design
certified input rate within the specified altitude range.
High altitude kits are purchased according to the installation alti-
tude and usage of either natural or propane gas. Contact your
distributor for a tabular listing of appropriate altitude ranges and
corresponding manufacturer’s high altitude (Natural, propane gas,
and/or Pressure Switch) kits.
Accessories Wiring
If it is necessary for the installer to supply additional line voltage
wiring to the inside of the furnace, the wiring must conform to all
local codes, and have a minimum temperature rating of 105°C. All
line voltage wire splices must be made inside the furnace junction
box.
Do not derate the furnace by adjusting the manifold pressure to a
lower pressure than specified on the furnace rating plate. The
combination of the lower air density and a lower manifold pressure
willprohibittheburnerorificefromdrawingtheproperamountofair
into the burner. This may cause incomplete combustion, flash-
back, and possible yellow tipping.
The integrated control module humidifier terminals (HUM) are en-
ergized with 115 volts whenever the induced draft blower is ener-
gized. The integrated control module electronic air cleaner termi-
nals (EAC) are energized with 115 volts whenever the circulator
blower is energized.
In some areas the gas supplier may artificially derate the gas in an
effort to compensate for the effects of altitude. If the gas is artifi-
cially derated, the appropriate orifice size must be determined
based upon the BTU/ft3 content of the derated gas and the alti-
tude. RefertotheNationalFuelGasCode, NFPA54/ANSIZ223.1,
andinformationprovidedbythegassuppliertodeterminetheproper
orifice size.
24VOLTHUMIDIFIER
A 5" long brown wire in the wire harness at the low fire pressure
switch provides 24 VAC humidifier control. This wire is powered
any time the pressure switch is closed. To connect 24 VAC HUM,
connect the 24 VAC line of the humidifier to the 5” brown wire. The
connection can be made by either stripping the wire and using a
wire nut or by using a field supplied quick connect terminal. The
wiring must conform to all local and national codes. Connect the
COM side of the humidifier to the C terminal on the furnace control
board (or to the COM side of the 24 VAC transformer). Do not
connect 115V humidifier to these terminals.
Adifferentpressureswitchmayberequiredathighaltituderegard-
less of the BTU/ft3 content of the fuel used. Contact your distribu-
tor for a tabular listing of appropriate altitude ranges and corre-
sponding manufacturer’s pressure switch kits.
PROPANEGASCONVERSION
GAS SUPPLY AND PIPING
WARNING
The furnace rating plate includes the approved furnace gas input
rating and gas types. The furnace must be equipped to operate on
the type of gas applied. This includes any conversion kits required
for alternate fuels and/or high altitude.
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A
QUALIFIED INSTALLER OR SERVICE AGENCY.
CAUTION
This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. Refer to the Propane Gas and/or High
Altitude Installations for details.
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
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GAS SUPPLY AND PIPING
Contact your distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude installa-
tions. The indicated kits must be used to insure safe and proper
furnace operation. All conversions must be performed by a quali-
fied installer, or service agency.
installer may also need to supply a transition piece from 1/2" pipe
to a larger pipe size.
The following stipulations apply when connecting gas piping. Re-
fer to Gas Piping Connections figure for typical gas line connec-
tions to the furnace.
GAS VALVE
•
Use black iron or steel pipe and fittings for building piping.
Where possible, use new pipe that is properly chamfered,
reamed, and free of burrs and chips. If old pipe is used, be
sure it is clean and free of rust, scale, burrs, chips, and old
pipe joint compound.
This unit is equipped with a 24 volt gas valve controlled during
furnace operation by the integrated control module. As shipped,
thevalveisconfiguredfornaturalgas. Thevalveisfieldconvertible
for use with propane gas by replacing the regulator spring with a
propane gas spring from an appropriate manufacturer’s propane
gas conversion kit. Taps for measuring the gas supply pressure
and manifold pressure are provided on the valve.
•
Use pipe joint compound on male threads ONLY. Always
use pipe joint compound (pipe dope) that is APPROVED
FORALLGASSES. DO NOTapply compound to the first
two threads.
The gas valve has a manual ON/OFF control located on the valve
itself. This control may be set only to the “ON” or “OFF” position.
Refer to the lighting instructions label or Startup Procedure &
Adjustment for use of this control during start up and shut down
periods.
•
•
Use ground joint unions.
Install a drip leg to trap dirt and moisture before it can enter
the gas valve. The drip leg must be a minimum of three
inches long.
•
•
Install a 1/8" NPT pipe plug fitting, accessible for test gage
connection, immediately upstream of the gas supply
connection to the furnace.
GASPIPINGCONNECTIONS
WARNING
Alwaysuseaback-upwrenchwhenmakingtheconnection
to the gas valve to keep it from turning. The orientation of
thegasvalveonthemanifoldmustbemaintainedasshipped
from the factory. Maximum torque for the gas valve
connection is 375 in-lbs; excessive over-tightening may
damagethegasvalve.
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT
DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE
OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM
THE METER/TANK TO THE FURNACE.
When sizing a trunk line, be sure to include all appliances which
will operate simultaneously when sizing a trunk line.
•
Install a manual shutoff valve between the gas meter and
unit within six feet of the unit. If a union is installed, the
union must be downstream of the manual shutoff valve,
between the shutoff valve and the furnace.
Thegaspipingsupplyingthefurnacemustbeproperlysizedbased
on the gas flow required, specific gravity of the gas, and length of
the run. The gas line installation must comply with local codes, or
in their absence, with the latest edition of the National Fuel Gas
Code, NFPA54/ANSI Z223.1.
•
•
Tighten all joints securely.
Connect the furnace to the building piping by one of the
followingmethods:
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
– Rigid metallic pipe and fittings.
Length of
Nominal Black Pipe Size
Pipe in Feet
1/2"
132
92
73
63
56
50
46
43
40
38
3/4"
1"
1 1/4"
1 1/2"
1600
1100
980
– Semi-rigid metallic tubing and metallic fittings.
10
20
30
40
50
60
70
80
90
100
278
190
152
130
115
105
96
520
350
285
245
215
195
180
170
160
150
1050
730
590
500
440
400
370
350
320
305
Aluminum alloy tubing must not be used in exterior
locations. In order to seal the grommet cabinet
penetration,rigidpipemustbeusedtoreachtheoutside
ofthecabinet. Asemi-rigidconnectortothegaspiping
may be used from there.
760
670
610
560
90
84
530
490
•
•
Use listed gas appliance connectors in accordance with
their instructions. Connectors must be fully in the same
room as the furnace.
79
460
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
Protect connectors and semirigid tubing against physical
and thermal damage when installed. Ensure aluminum-
alloy tubing and connectors are coated to protect against
external corrosion when in contact with masonry, plaster,
or insulation, or subjected to repeated wetting by liquids
such as water (except rain water), detergents, or sewage.
BTUH Furnace Input
CFH =
Heating Value of Gas (BTU/Cubic Foot)
To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases, the
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GAS SUPPLY AND PIPING
GAS VALVE
MANUAL
SHUT OFF VALVE
(UPSTREAM FROM
MANIFOLD
BURNERS
GAS LINE
PLUG IN
PIPE UNION)
PLUG IN
ALTERNATE
GAS LINE
HOLE
GAS LINE
HOLE
HEIGHT REQUIRED
BY LOCAL CODE
GROMMET
IN STANDARD
GAS LINE HOLE
GAS VALVE
PIPE UNION
DRIP LEG
DRIP LEG
BURNERS
MANUAL SHUT-OFF VALVE
(UPSTREAM FROM GROUND
JOINT PIPE UNION)
GROUND JOINT
PIPE UNION
DRIP LEG
GROMMET IN STANDARD
GAS LINE HOLE
GAS VALVE
GAS VALVE
BURNERS
BURNERS
DRAIN TRAP
DRAIN TRAP
MANIFOLD
PLUG IN ALTERNATE
GAS LINE HOLE
ALTERNATE GAS
LINE LOCATION
PLUG IN ALTERNATE
GAS LINE HOLE
MANIFOLD
ALTERNATE GAS
LINE LOCATION
HORIZONTAL[COUNTERFLOW]
HORIZONTAL [UPFLOW MODEL]
GasPipingConnections
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GAS SUPPLY AND PIPING
DIRECT/STANDARDINLETPIPING
PROPANEGASTANKSAND PIPING
WARNING
WARNING
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING
DEVICE IN CASE OF A GAS LEAK.
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
When gas piping enters directly to the gas valve through the stan-
dard inlet hole, the installer must supply straight pipe with a ground
joint union to reach the exterior of the furnace. The rigid pipe must
be long enough to reach the outside of the cabinet to seal the
grommet cabinet penetration. A semi-rigid connector to the gas
piping can be used outside the cabinet per local codes.
•
SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
•
PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
A gas detecting warning system is the only reliable way to detect
a propane gas leak. Rust can reduce the level of odorant in pro-
pane gas. Do not rely on your sense of smell. Contact a local
propane gas supplier about installing a gas detecting warning sys-
tem. If the presence of gas is suspected, follow the instructions
listed in the Safety Precautions section of this manual.
INDIRECT/ALTERNATEINLETPIPING
When gas piping enters indirectly to the gas valve through the
alternate gas inlet hole the following fittings (starting from the gas
valve) to reach the outside of the cabinet must be supplied:
•
•
•
•
•
Coupling.
All propane gas equipment must conform to the safety standards
of the National Board of Fire Underwriters, NBFU Manual 58.
90degreeelbow.
2 inch close nipple.
90degreeelbow.
For satisfactory operation, propane gas pressure must be 11 inch
WC at the furnace manifold with all gas appliances in operation.
Maintaining proper gas pressure depends on three main factors:
1. Vaporization rate, depending on temperature of the liquid,
and “wetted surface” area of the container or containers.
2. Proper pressure regulation. (Two-stage regulation is
recommended for both cost and efficiency).
Straight pipe, with a ground joint union, to reach the exterior
of the furnace. The rigid pipe must be long enough to reach
theoutsideofthecabinetsoastosealthegrommetcabinet
penetration. Asemi-rigid connector to the gas piping can
be used outside the cabinet per local codes.
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size will
dependonlengthofpiperunandtotalloadofallappliances.
GAS PIPING CHECKS
Before placing unit in operation, leak test the unit and gas connec-
tions.
Complete information regarding tank sizing for vaporization, rec-
ommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.
WARNING
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
OR OPEN FLAME TO TEST FOR LEAKS.
Since propane gas will quickly dissolve white lead and most stan-
dard commercial compounds, special pipe dope must be used.
Shellac-based compounds resistant to the actions of liquefied pe-
troleum gases such as Gasolac®, Stalactic®, Clyde’s® or John
Crane® are satisfactory.
Check for leaks using an approved chloride-free soap and water
solution, anelectroniccombustiblegasdetector, orotherapproved
testing methods.
Refer to the following illustration for typical propane gas installa-
tions and piping.
NOTE: Never exceed specified pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overfiring, resulting in heat exchanger failure.
5 to 15 PSIG
First Stage
(20 PSIG Max.)
Regulator
Disconnect this unit and shutoff valve from the gas supply piping
system before pressure testing the supply piping system with
pressures in excess of 1/2 psig (3.48 kPa).
Continuous
11" W.C.
200 PSIG
Maximum
Second Stage
Regulator
Isolate this unit from the gas supply piping system by closing its
external manual gas shutoff valve before pressure testing supply
piping system with test pressures equal to or less than 1/2 psig
(3.48 kPA).
PropaneGasInstallation(Typ.)
33
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GAS SUPPLY AND PIPING
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
ing, Warm Air Heating and Ventilating Systems. Pamphlets No.
90A and 90B.
Pipe or
A closed return duct system must be used, with the return duct
connected to the furnace. NOTE: Ductwork must never be at-
tached to the back of the furnace. For upflow installations requir-
ing 1800 CFM or more, use either two side returns or bottom
return or a combination of side /bottom. Flexible joints may be
used for supply and return connections to reduce noise transmis-
sion.To prevent the blower from interfering with combustion air or
draft when a central return is used, a connecting duct must be
installed between the unit and the utility room wall. Never use a
room, closet, or alcove as a return air chamber.
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
Tubing
Length
Feet
10
3/8"
730
500
400
370
330
300
260
220
200
190
170
160
1/2"
1,700
1,100
920
5/8"
3,200
220
3/4"
7/8"
1/2"
3/4"
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
7,500
4,200
4,000
3,700
3,400
3,100
2,600
2,300
2,100
1,900
1,700
1,500
20
30
2,000
1,700
1,500
1,300
1,200
1,000
900
40
850
50
770
60
700
80
610
100
125
150
175
200
540
490
430
830
830
400
780
770
380
730
720
CHECKING DUCT STATIC
To convert to capacities at 15 psig settings - multiply by 1.130
To convert to capacities at 5 psig settings - multiply by 0.879
Refer to your furnace rating plate for the maximum ESP (ex-
ternal duct static) rating.
Propane Gas Piping Chart I
Total external static refers to everything external to the fur-
nace cabinet. Cooling coils, filters, ducts, grilles, registers
must all be considered when reading your total external static
pressure. The supply duct pressure must be read between
the furnace and the cooling coil. This reading is usually taken
by removing the “A” shaped block off plate from the end on the
coil; drilling a test hole in it and reinstalling the block off plate.
Take a duct static reading at the test hole. Tape up the test
hole after your test is complete. The negative pressure must
be read between the filter and the furnace blower.
Sizing Between Second or Second Stage Regulator & Appliance*
Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting.
Capacities in 1,000 BTU/hour.
Pipe or
Nominal Pipe Size
Tubing Size, O.D. Type L
Tubing
Length
Feet
10
Schedule 40
3/8"
39
26
21
19
18
16
13
11
10
9
1/2"
92
62
50
41
37
35
29
26
24
21
19
17
5/8"
199
131
107
90
3/4"
329
216
181
145
131
7/8"
501
346
277
233
198
1/2"
275
189
152
129
114
103
89
3/4"
1"
1-1/4" 1-1/2"
567 1,071 2,205 3,307
20
393
315
267
237
217
185
162
146
132
112
100
732 1,496 2,299
590 1,212 1,858
504 1,039 1,559
30
40
50
79
448
409
346
307
275
252
209
185
913
834
724
630
567
511
439
390
1,417
1,275
1,066
976
60
72
1,211 187
80
62
104
90
81
72
66
60
155
138
122
109
100
93
100
125
150
200
250
55
78
Too much external static pressure will result in insufficient air
that can cause excessive temperature rise. This can cause
limit switch tripping and heat exchanger failure.
48
69
866
43
63
787
8
39
54
665
8
36
48
590
To determine total external duct static pressure, proceed as
follows;
*Data in accordance with NFPA pamphlet No. 54
Propane Gas Piping Chart II
1. With clean filters in the furnace, use a draft gauge (in-
clined manometer) to measure the static pressure of the
return duct at the inlet of the furnace. (Negative Pressure)
CIRCULATING AIR & FILTERS
2. Measure the static pressure of the supply duct. (Positive
Pressure)
DUCTWORK-AIRFLOW
3. The difference between the two numbers is .4” w.c.
Example:
WARNING
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR
SUPPLY.
static reading from return duct = -.1" w.c.
static reading from supply duct = .3" w.c.
total external static pressure on this system = .4" w.c.
Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace. Design
the ductwork in accordance with the recommended methods of
“Air Conditioning Contractors ofAmerica” Manual D.
NOTE: Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
Install the duct system in accordance with Standards of the Na-
tionalBoardofFireUnderwritersfortheInstallationofAirCondition-
34
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CIRCULATING AIR & FILTERS
4. Consult proper tables for the quantity of air.
CUT USING TIN SNIPS
If the total external static pressure exceeds the maximum
listed on the furnace rating plate, check for closed dampers,
registers, undersized and/or oversized poorly laid out duct work.
PRESS OUT BY HAND
CUT FOUR CORNERS
AFTER REMOVING SHEET
METAL
SCRIBE LINES OUTLINING
DUCT FLANGES
DuctFlangeCutOuts
When the furnace is used in connection with a cooling unit, the
furnace should be installed in parallel with or on the upstream side
of the cooling unit to avoid condensation in the heating element.
With a parallel flow arrangement, the dampers or other means
used to control the flow of air must be adequate to prevent chilled
air from entering the furnace and, if manually operated, must be
equipped with means to prevent operation of either unit unless the
damper is in the full heat or cool position.
When the furnace is installed without a cooling coil, it is recom-
mended that a removable access panel be provided in the outlet
air duct. 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 visual light inspection or such that a sampling probe
can be inserted into the airstream. The access panel must be
made to prevent air leaks when the furnace is in operation.
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
BOTTOMRETURNAIROPENING[UPFLOWMODELS]
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.
The bottom return air opening on upflow models utilizes a “lance
and cut” method to remove sheet metal from the duct opening in
the base pan. To remove, simply press out the lanced sections by
hand to expose the metal strips retaining the sheet metal over the
duct opening. Using tin snips, cut the metal strips and remove the
sheet metal covering the duct opening. In the corners of the open-
ing, cut the sheet metal along the scribe lines to free the duct
flanges. Using the scribe line along the duct flange as a guide,
unfoldtheductflangesaroundtheperimeteroftheopeningusinga
pair of seamer pliers or seamer tongs. NOTE:Airflow area will be
reduced by approximately 18% if duct flanges are not unfolded.
This could cause performance issues and noise issues.
FILTERS-READTHISSECTIONBEFOREINSTALLINGTHERETURN
AIRDUCTWORK
Filters must be used with this furnace. Discuss filter maintenance
with the building owner. Filters do not ship with this furnace, but
must be provided, sized and installed externally by the installer.
Filters must comply with UL900 or CAN/ULCS111 standards. If
the furnace is installed without filters, the warranty will be voided.
On upflow units, guide dimples locate the side return cutout loca-
tions. Use a straight edge to scribe lines connecting the dimples.
Cut out the opening on these lines. NOTE:An undersized open-
ing will cause reduced airflow.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR
OPENINGS.
RefertoMinimumFilterAreatablestodeterminefilterarearequire-
ments.
35
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STARTUP PROCEDURE & ADJUSTMENT
The following figure shows possible filter locations.
UPFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
AIR FLOW
600
376*
---
800
384
---
1000
480
627*
---
1200
576
1400 1600
2000
---
CENTRAL
RETURN
GRILLE
0453__XA
0704__XA
0905__XA
1155__XA
---
---
627*
836*
940*
672
768
---
SIDE RETURN
EXTERNAL FILTER
RACK KIT
---
---
836*
940*
836*
940*
960
960
(EITHER SIDE)
---
---
---
COUNTERFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600
---
800
---
1000
320*
---
1200
320*
427*
1400 1600
2000
---
0704__XA
0714__XA
0905__XA
336
384
---
---
427*
427*
480
0915__XA
*Minimum filter area dictated by heating airflow requirement.
Permanent Minimum Filter Area (sq. in)
PossibleUprightUpflow
[Based on a 600 ft/min filter face velocity]
FILTER
ACCESS
DOOR
UPFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600
800
384
---
1000 1200 1400 1600 2000
0453__XA 376*
480
564*
---
576
564*
752*
940*
---
---
---
RETURN
DUCT
CENTRAL
RETURN
GRILLE
0704__XA
0905__XA
1155__XA
---
---
---
672
752*
768
768
FILTER
SUPPORT
BRACKET
(Field Supplied)
---
960
960
---
---
940* 940*
COUNTERFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600
---
800
---
1000 1200 1400 1600 2000
0704__XA
0714__XA
0905__XA
0915__XA
641*
---
641*
854*
672
768
---
---
---
854* 854*
960
AIR FLOW
*Minimum filter area dictated by heating airflow requirement.
PossibleUprightCounterflow
FilterLocations
Disposable Minimum Filter area (sq. in)
[Based on 300 ft/min filter face velocity]
UPRIGHT INSTALLATIONS
Depending on the installation and/or customer preference, differ-
ing filter arrangements can be applied. Filters can be installed in
the central return register or a side panel external filter rack kit
(upflows). Asanalternativeamediaairfilterorelectronicaircleaner
can be used as the requested filter.
HORIZONTALINSTALLATIONS
Filters must be installed in either the central return register or in
the return air duct work.
STARTUP PROCEDURE &ADJUSTMENT
Furnace must have a 115 VAC power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. In addition to the following start-up and adjustment
items, refer to further information in Operational Checks section.
36
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STARTUP PROCEDURE & ADJUSTMENT
HEATANTICIPATORSETTING
GASSUPPLYPRESSUREMEASUREMENT
The heat anticipator in the room thermostat must be correctly
adjusted to obtain the proper number of cycles per hour and to
prevent “overshooting” of the setting. Set the heat anticipator set-
ting to 0.7 amps. Follow the thermostat manufacturer’s instruc-
tions on how to adjust the heat anticipator setting.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
DRAINTRAPPRIMING
The drain trap must be primed prior to furnace startup. To prime, fill
the drain trap with water. This ensures proper furnace drainage
upon startup and prohibits the possibility of flue gases escaping
through the drain system.
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured at
the gas valve inlet pressure boss or at a hose fitting installed in the
gas piping drip leg. The supply pressure must be measured with
the burners operating. To measure the gas supply pressure, use
thefollowingprocedure.
FURNACEOPERATION
Purge gas lines of air prior to startup. Be sure not purge lines into
an enclosed burner compartment.
Check for leaks using an approved chloride-free soap and water
solution, anelectroniccombustiblegasdetector, orotherapproved
method. Verify that all required kits (propane gas, high altitude,
etc.) have been appropriately installed.
INLET
OUTLET
FURNACESTARTUP
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
Gas Valve On/Off
Selector Switch
White-Rodgers Model 36G54 (Two-Stage)
NOTE: This furnace is equipped with an ignition device which
ter
anome
Hose
M
Open to
automatically lights the burner. Do not try to light the burner by
Atmosphere
hand.
5. Move the furnace gas valve manual control to the OFF
High Fire Regulator
Adjust
position.
Outlet
Pressure Boss
Regulator
Vent
6. Wait five minutes then smell for gas. Be sure check near
the floor as some types of gas are heavier than air.
7. If you smell gas after five minutes, immediately follow the
Safety Instructions on page 5 of this manual. If you do not
smell gas after five minutes, move the furnace gas valve
manual control to the ON position.
Low Fire
Regulator
Adjust
8. Replace the burner compartment door.
9. Open the manual gas shutoff valve external to the furnace.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room temperature.
12. After the burners are lit, set the thermostat to desired
temperature.
Inlet
Pressure
Boss
High Fire Coil
inal (HI)
Coaxial Coil
Manometer
Term
Switch
inal (M)
Term
Common
Terminal(C)
On/Off
White-Rodgers Model 36G54 Connected to Manometer
FURNACESHUTDOWN
High Fire
1. Set the thermostat to the lowest setting.
Regulator
Regulator
Adjust
Vent
Theintegratedcontrolwillclosethegasvalveandextinguish
flame. Followinga15seconddelay, theinduceddraftblower
will be de-energized. After a 120, 150, 180 or 210-second
delay period (field selectable delay OFF [90, 120, 150, 180]
plus 30-second ramp down), the circulator blower de-
energizes.
2. Removetheburnercompartmentdoorandmovethefurnace
gas valve manual control to the OFF position.
3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.
Gas Valve On/Off
Selector Switch
Low Fire
Regulator
Adjust
37
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STARTUP PROCEDURE & ADJUSTMENT
Honeywell Model VR9205 (Two-Stage)
Gas Line
Gas
Shutoff
Valve
Common
Terminal(C)
meter
Mano
en to
Op
Atmo
High Fire Coil
Terminal (HI)
e
Hos
sphere
Low Fire Coil
Terminal (LO)
Gas Line
To Furnace
i
Open To
Atmosphere
Inlet Pressure Tap
1/8 NPT
Drip Leg Cap
With Fitting
ter
Manome
Manometer Hose
Manometer
Outlet Pressure Tap
1/8 NPT
Measuring Inlet Gas Pressure (Alt. Method)
GASMANIFOLDPRESSUREMEASUREMENTANDADJUSTMENT
Honeywell Model VR9205 Connected to Manometer
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING
PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING
THE GAS VALVE PRESSURE REGULATOR.
2. Connect a calibrated water manometer (or appropriate gas
pressure gauge) at either the gas valve inlet pressure boss
orthegaspipingdripleg. SeeHoneywellVR9205gasvalve
figureorWhite-Rodgers36G54gasvalvefigureforlocation
of inlet pressure boss.
Only small variations in gas pressure should be made by adjusting
the gas valve pressure regulator. The manifold pressure must be
measured with the burners operating. To measure and adjust the
manifold pressure, use the following procedure.
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205gasvalve, afield-suppliedhosebarbfittingmustbeinstalled
prior to making the hose connection. If using the inlet pressure
boss on the White-Rodgers 36G54 gas valve, then use the 36G
Valve Pressure Check Kit, Goodman Part No. 0151K00000S.
3. Turn ON the gas supply and operate the furnace and all
other gas consuming appliances on the same gas supply
line.
4. Measure furnace gas supply pressure with burners firing.
Supply pressure must be within the range specified in the
Inlet Gas Supply Pressure table.
2. Turn off all electrical power to the system.
3. Outlet pressure tap connections:
a. Honeywell VR9205 valve: Remove the outlet pressure
boss plug. Install an 1/8" NPT hose barb fitting into the
outlet pressure tap.
b. White-Rodgers 36G54 valve: Back outlet pressure test
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure barb
fitting (Honeywell valve) or outlet pressure boss (White-
Rodgersvalve).
5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1” contacts
to provide a call for low stage heat.
7. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using theManifold Gas Pressure
table shown below.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
If supply pressure differs from table, make the necessary adjust-
ments to pressure regulator, gas piping size, etc., and/or consult
with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in step
3.
8. Remove regulator cover screw from the low (LO) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
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STARTUP PROCEDURE & ADJUSTMENT
9. Close thermostat “R” and “W2” contacts to provide a call
for high stage heat.
10. Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting or
outlet pressure boss.
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3
Input = 106,000 BTU/hr
Minor changes to the input rate may be accomplished through
manifold pressure adjustments at the gas valve. Refer to Startup
ProcedureandAdjustment-GasManifoldPressureMeasurement
and Adjustment section for details. NOTE: The final manifold
pressure cannot vary by more than ± 0.3” w.c. from the specified
setting. Consult your local gas supplier if additional input rate
adjustment is required.
13. Replace outlet pressure tap:
a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
14. Turn on electrical power and gas supply to the system.
15. Close thermostat contacts “R” and “W1/W2” to energize
thevalve.
5. Repeat steps 2 through 4 on high stage.
6. Turn ON gas to and relight all other appliances turned off in
step1. Becertainthatallappliancesarefunctioningproperly
and that all pilot burners are operating.
TEMPERATURERISE
Using a leak detection solution or soap suds, check for leaks at
outletpressurebossplug(Honeywellvalve)orscrew(White-Rodg-
ersvalve). Bubblesformingindicatealeak. SHUTOFFGASAND
REPAIRALLLEAKS IMMEDIATELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriateconversion.
Temperature rise must be within the range specified on the unit
rating plate.An incorrect temperature rise may result in condens-
ing in or overheating of the heat exchanger. An airflow and tem-
perature rise table is provided in the Specification Sheet applicable
to your model. Determine and adjust temperature rise as follows:
1. Operate furnace with burners firing for approximately ten
minutes. Ensureallregistersareopenandallductdampers
are in their final (fully or partially open) position.
Manifold Gas Pressure
2. Placethermometersinthereturnandsupplyductsasclose
to the furnace as possible. Thermometers must not be
influenced by radiant heat by being able to “see” the heat
exchanger.
Gas
Range
Nominal
1.9" w .c.
3.5" w .c.
6.0" w .c.
Natural
Low Stage 1.6 - 2.2" w .c.
High Stage 3.2 - 3.8" w .c.
Low Stage 5.7 - 6.3" w .c.
Propane
High Stage 9.7 - 10.3" w .c. 10.0" w .c.
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decreaseblowerspeedtoincreasetemperaturerise. Refer
to Startup Procedure and Adjustment -Circulator Blower
Speeds for speed changing details.
GASINPUTRATEMEASUREMENT(NATURALGASONLY)
The gas input rate to the furnace must never be greater than that
specified on the unit rating plate. To measure natural gas input
using the gas meter, use the following procedure.
1. TurnOFFthegassupplytoallothergas-burningappliances
except the furnace.
2. While the furnace is operating, time and record one
complete revolution of the smallest gas meter dial.
3. Calculate the number of seconds per cubic foot (sec/ft3) of
gas being delivered to the furnace. If the dial is a one cubic
foot dial, divide the number of seconds recorded in step 2
by one. If the dial is a two cubic foot dial, divide the number
of seconds recorded in step 2 by two.
4. CalculatethefurnaceinputinBTUsperhour(BTU/hr). Input
equals the sum of the installation’s gas heating value and a
conversionfactor(hourstoseconds)dividedbythenumber
of seconds per cubic foot. The measured input must not
be greater than the input indicated on the unit rating plate.
EXAMPLE:
39
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STARTUP PROCEDURE & ADJUSTMENT
HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
The cooling system manufacturer’s instructions must be checked
for required air flow. Any electronic air cleaners or other devices
may require specific air flows, consult installation instructions of
those devices for requirements.
3. Knowing the furnace model, locate the high stage cooling
air flow charts in the Specification Sheet applicable to your
model. Look up the cooling air flow determined in step 2
andfindtherequiredcoolingspeedandadjustmentsetting.
SUPPLY
AIR
TSUPPLY
RISE
=
Example: A *MVC95704CX furnace installed with a 2.5
ton air conditioning system. The air flow
TSUPPLY TRETURN
-
needed is 1000 CFM. Looking at the cooling
speed chart for *MVC95704CX, find the air
TRETURN
flow closest to 1000 CFM. A cooling airflow
of 990 CFM can be attained by setting the
cooling speed to “C” and the adjustment to “-
RETURN
AIR
” (minus).
4. Continuous fan speed is 30% of the furnace’s maximum
airflow capability.
Temperature Rise Measurement
CIRCULATORBLOWERSPEEDS
Example: If the furnace’s maximum airflow capability is
2000 CFM, the continuous fan speed will be
WARNING
0.30 x 2000 CFM = 600 CFM.
5. Locate the blower speed selection DIP switches on the
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropriately.
Select the desired “adjust” tap by positioning switches 3
and 4 appropriately. Refer to the following figure for switch
positionsandtheircorrespondingtaps. VerifyCFMbynoting
the number displayed on the dual 7-segment LED display.
6. Themulti-speedcirculatorbloweralsooffersseveralcustom
ON/OFF ramping profiles. These profiles may be used to
enhance cooling performance and increase comfort level.
The ramping profiles are selected using DIP switches 5
and 6. Refer to the following figure for switch positions and
their corresponding taps. Refer to the bullet points below
for a description of each ramping profile. Verify CFM by
noting the number displayed on the dual 7-segment LED
display.
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,
TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
This furnace is equipped with a multi-speed circulator blower. This
blower provides ease in adjusting blower speeds. The Specifica-
tionSheetapplicabletoyourmodelprovidesanairflowtable, show-
ingtherelationshipbetweenairflow(CFM)andexternalstaticpres-
sure(E.S.P.), fortheproperselectionofheatingandcoolingspeeds.
The heating blower speed is shipped set at “B”, and the cooling
blower speed is set at “D”. These blower speeds should be ad-
justed by the installer to match the installation requirements so as
to provide the correct heating temperature rise and correct cooling
CFM.
Use the dual 7-segment LED display adjacent to the dipswitches
to obtain the approximate airflow quantity. The airflow quantity is
displayed as a number on the display, rounded to the nearest 100
CFM. The display alternates airflow delivery indication and the
operating mode indication.
Sw itch Bank: S4
DIP Sw itch No.
Ramping
Profiles
5
6
A*
B
OFF
ON
OFF
OFF
ON
Example: The airflow being delivered is 1225 CFM. The display
indicates 12. If the airflow being delivered is 1275, the display
indicates 13.
1. Determine the tonnage of the cooling system installed with
the furnace. If the cooling capacity is in BTU/hr divide it by
12,000 to convert capacity to TONs.
C
OFF
ON
D
ON
(*Indicates factory setting)
•
Profile A provides only an OFF delay of one (1) minute at
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5Tons
100% of the cooling demand airflow.
2. Determine the proper air flow for the cooling system. Most
coolingsystemsaredesignedtoworkwithairflowsbetween
350and450CFMperton. Mostmanufacturersrecommend
an air flow of about 400 CFM per ton.
100% CFM
100% CFM
1 min
OFF
OFF
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
40
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STARTUP PROCEDURE & ADJUSTMENT
Low
Stage
Cool
High
Stage
Cool
Low
Stage
Heat
High
Stage
Heat
•
Profile B ramps up to full cooling demand airflow by first
stepping up to 50% of the full demand for 30 seconds. The
motor then ramps to 100% of the required airflow. Aone (1)
minuteOFFdelayat100%ofthecoolingairflowisprovided.
Model
Tap
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
390
520
650
780
390
520
715
929
550
770
1000
1250
520
715
910
1170
520
715
910
1170
390
520
715
929
360
520
780
960
520
715
910
1170
560
740
920
1190
508
690
906
1165
600
800
550
792
600
864
*MVC950453BX*
1000
1200
600
650
936
700
1008
1210
1325
1440
1555
1490
1570
1690
1780
1620
1721
1822
1922
1771
1822
1872
1922
1195
1318
1440
1562
1230
1350
1470
1600
1598
1706
1814
1922
1620
1760
1860
1970
1759
1791
1838
1878
100% CFM
100% CFM
1 min
50% CFM
1/2 min
840
OFF
OFF
800
920
*MVC950704CX*
*MVC950905CX*
*MVC950905DX*
*MVC951155DX*
*CVC90704CX*
*CVC950714CX*
*CVC90905DX*
*CVC950915DX*
1100
1429
810
1000
1080
1050
1120
1200
1250
1125
1195
1265
1335
1230
1265
1300
1335
830
•
ProfileCrampsupto85%ofthefullcoolingdemandairflow
and operates there for approximately 7 1/2 minutes. The
motor then steps up to the full demand airflow. Profile C
also has a one (1) minute 100% OFF delay.
1100
1470
1810
800
1000
1400
1800
800
100% CFM
OFF
OFF
1100
1400
1800
600
Sw itch Bank: S3
DIP Sw itch No.
Cooling Speed
Taps
1
2
800
915
A
B
OFF
ON
OFF
OFF
ON
1100
1429
660
1000
1085
870
C
OFF
ON
D*
ON
830
950
(*Indicates factory setting)
1130
1460
800
1040
1130
1110
1185
1260
1335
1120
1220
1280
1340
1214
1229
1296
1302
Switch Bank: S3
DIP Switch No.
Adjust Taps
1100
1400
1800
810
3
4
Normal*
10%
OFF
ON
OFF
ON
OFF
OFF
ON
ON
-10%
1110
1430
1860
783
Normal
(*Indicates factory setting)
•
Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow and
operates there for approximately 7 1/2 minutes. The motor
then steps up to the full demand airflow. Profile D has a 1/
2 minute at 50% airflow OFF delay.
1091
1406
1809
*CVC91155DX*
AirflowTable
OFF
OFF
41
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COMFORTNET™ SYSTEM
7. Select the heating speed for your model from the heating
speed chart in the Specification Sheet. The adjust setting
(already established by the cooling speed selection)
determineswhichsetofspeedsareavailable. Theselected
speedmustprovideatemperaturerisewithintheriserange
listed with the particular model.
COMFORTNET™ SYSTEM
OVERVIEW
The ComfortNet system (or CT™ system) is a system that in-
cludes a ComfortNet compatible furnace and air conditioner or
heat pump with a CTK01AAthermostat. Avalid ComfortNet sys-
tem could also be a compatible furnace, CTK01AA thermostat
and non-compatible, single stage air conditioner. Any other sys-
temconfigurationsareconsideredinvalidComfortNetsystemsand
must be connected as a traditional (or legacy) system (see Elec-
trical Connections for wiring connections). The table below com-
pares the valid CT systems.
Example: The *MVC950704CX is set for 990 CFM on
cooling, the“ADJUST”issetto“+”(plus). The
four heating speeds available are “A Plus”, “B
Plus”, “C Plus”, and “D Plus”. “A Plus” has a
rise of 46°F for both stages which is within
the30-60°Friserangeforthe*MVC950704CX.
This setting will keep electrical consumption
to a minimum. Set the “Heat” speed DIP
switches to “A”.
CT compatible
Furnace
CT compatible
Air Conditioner
Full CT system
benefits and features
Sw itch Bank: S4
CT compatible
Furnace
CT compatible
Heat Pump
Full CT system
benefits and features
DIP Sw itch No.
Heating Speed
Taps
7
8
Non-CT compatible
Single Stage
Air Conditioner
CT system
benefits and features
for furnace only
A
B*
C
OFF
ON
OFF
ON
OFF
OFF
ON
ON
CT compatible
Furnace
D
(*Indicates factory setting)
AComfortNetheating/airconditioningsystemdiffersfromalegacy/
traditional system in the manner in which the indoor unit, outdoor
unit and thermostat interact with one another. In a traditional sys-
tem, the thermostat sends commands to the indoor and outdoor
units via analog 24 VAC signals. It is a one-way communication
path in that the indoor and outdoor units typically do not return
information to the thermostat.
8. Select the desired “heating” speed tap by positioning
switches7and8appropriately. Refertofigureabove. Verify
CFMbynotingthenumberdisplayedonthedual7-segment
LED display.
In general lower heating speeds will: reduce electrical consump-
tion, lower operating sound levels of the blower, and increase the
outlet air temperature delivered to the home. The speeds avail-
able allow the blower performance to be optimized for the particu-
lar homeowner’s needs.
On the other hand, the indoor unit, outdoor unit, and thermostat
comprising a ComfortNet system “communicate” digitally with one
another. It is now a two-way communications path. The thermo-
stat still sends commands to the indoor and outdoor units. How-
ever, thethermostatmayalsorequestandreceiveinformationfrom
both the indoor and outdoor units. This information may be dis-
played on the CT thermostat. The indoor and outdoor units also
interact with one another. The outdoor unit may send commands
to or request information from the indoor unit. This two-way digital
communicationsbetweenthethermostatandsubsystems(indoor/
outdoor unit) and between subsystems is the key to unlocking the
benefits and features of the ComfortNet system.
BLOWERHEAT OFFDELAYTIMINGS
The integrated control module provides a selectable heat off delay
function. The heat off delay period may be set to 90, 120, 150, 180
seconds using the DIP switches or jumper provided on the control
module. The delay is factory shipped at 150 seconds but may be
changed to suit the installation requirements and/or homeowner
preference. Refer to the following figures for switch positions and
corresponding delay times.
Two-way digital communications is accomplished using only two
wires. The thermostat and subsystem controls are power with 24
VAC. Thus, a maximum of 4 wires between the equipment and
thermostat is all that is required to operate the system.
Switch Bank: S1
DIP Switch No.
Heat OFF Delay
1
2
90 seconds
120 seconds
150 seconds*
180 seconds
OFF
ON
OFF
ON
OFF
OFF
ON
ON
AIRFLOW CONSIDERATIONS
Airflow demands are managed differently in a fully commu-
nicating system than they are in a legacy wired system.
The system operating mode (as determined by the thermo-
stat) determines which unit calculates the system airflow
demand. If the indoor unit is responsible for determining
the airflow demand, it calculates the demand and sends it
to the ECM motor. If the outdoor unit or thermostat is
responsible for determining the demand, it calculates the
(*Indicates factory setting)
Heat Off Delay Dipswitches
42
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COMFORTNET™ SYSTEM
demand and transmits the demand along with a fan request
to the indoor unit. The indoor unit then sends the demand
to the ECM motor. The table below lists the various
ComfortNet™ systems, the operating mode, and airflow
demand source.
refers to a combined gas furnace and heat pump installation which
uses an outdoor temperature sensor to determine the most cost
efficient means of heating (heat pump or gas furnace). When
used with the CTK01AA thermostat, the furnace/heat pump
system is automically configured as a fossil fuel system. The
balance point temperature may be adjusted via the CTK01AA
thermostat advanced user menus (see CTK01AA instructions
for additional information).
System Operating
System
Airflow Demand Source
Air Conditioner
Furnace
Mode
Cooling
CTK01AAWIRING
Air Conditioner +
Furnace
Heating
NOTE: RefertoElectricalConnectionsfor115voltlineconnections
to the furnace.
Continuous Fan
Thermostat
NOTE: Aremovableplugconnectorisprovidedwiththecontrolto
make thermostat wire connections. This plug may be removed,
wire connections made to the plug, and replaced. It is strongly
recommended that multiple wires into a single terminal be twisted
together prior to inserting into the plug connector. Failure to do so
may result in intermittent operation.
Cooling
Heat Pump
Heat Pump
Furnace
Heat Pump Heating
Only
Heat Pump +
Furnace
Typical 18AWG thermostat wire may be used to wire the system
components. One hundred (100) feet is the maximum length of
wire between indoor unit and outdoor unit, or between indoor unit
and thermostat. Wire runs over (100) feet require larger gauge
wire.
Auxiliary Heating
Continuous Fan
Thermostat
Cooling
Heating
Furnace
Furnace
FOUR-WIREINDOOR AND OUTDOORWIRING
Furnace + Non-
Comm 1stg Air
Conditioner
Typical ComfortNet™ wiring will consist of four wires between the
indoor unit and outdoor unit and between the indoor unit and ther-
mostat. The required wires are: (a) data lines, 1 and 2; (b) thermo-
stat “R” (24 VAC hot) and “C” (24 VAC common).
Continuous Fan
Thermostat
For example, assume the system is an air conditioner
matched with a furnace. With a call for low stage cooling,
the air conditioner will calculate the system’s low stage
cooling airflow demand. The air conditioner will then send a
fan request along with the low stage cooling airflow demand
to the furnace. Once received, the furnace will send the low
stage cooling airflow demand to the ECM motor. The ECM
motor then delivers the low stage cooling airflow. See the
applicable ComfortNet™ air conditioner or heat pump
installation manual for the airflow delivered during cooling or
heat pump heating.
CTK01AA
Thermostat
1
1
2
2
R
R
C
C
CT™ Compatible Furnace
Integrated Control Module
CT™ Compatible AC/HP
Integrated Control Module
1
2
R
C
System Wiring using Four-Wires
TWO-WIREOUTDOOR,FOUR-WIRE INDOOR WIRING
Two wires can be utilized between the indoor and outdoor units.
For this wiring scheme, only the data lines, 1 and 2, are needed
between the indoor and outdoor units. A 40VA, 208/230 VAC to
24VAC transformer must be installed in the outdoor unit to provide
24VAC power to the outdoor unit’s electronic control. The trans-
former is included with the CTK01AA kit. See kit instructions for
mountingandwiringinstructions. Fourwiresarerequiredbetween
the indoor unit and thermostat.
In continuous fan mode, the CTK01AA thermostat provides
the airflow demand. The thermostat may be configured for
a low, medium, or high continuous fan speed. The low,
medium, and high fan speeds correspond to 25%, 50%,
and 75%, respectively, of the furnaces’ maximum airflow
capability. During continuous fan operation, the thermostat
sends a fan request along with the continuous fan demand
to the furnace. The furnace, in turn, sends the demand to
the ECM motor. The ECM motor delivers the requested
continuous fan airflow.
NOTE: Use of the CTK01AA transformer is recommended if
installing a dual fuel/fossil fuel system. Failure to use the
transformer in the outdoor unit could result in over loading of the
furnacetransformer.
FOSSILFUELAPPLICATIONS
This furnace can be used in conjunction with a CT™ compatible
heat pump in a fossil fuel application. A fossil fuel application
43
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COMFORTNET™ SYSTEM
•
Touch and hold the Installer Config key again for
approximately 3 seconds to enter theAdvanced Installer
Configurationmenu.
CTK01AA
Thermostat
1
1
2
2
R
R
C
C
CT™ Compatible
Furnace Integrated
Control Module
40VA Transformer (included in
CTK01AA kit)
CT™ Compatible
AC/HP Integrated
Control Module
R
C
1
2
24 VAC
208/230 VAC
Set Time
Run
Set
Installer
Config
Clean Display
Schedule
System Wiring using Two-Wires between Furnace and AC/HP and
Four-Wires between Furnace and Thermostat
Schedule
CT COMPATIBLE FURNACE WITH NON-CT COMPATIBLE SINGLE-
STAGEAIRCONDITIONER
Upon entering the advanced menus, theAdvanced Fault Menu is
displayed. The display will change to the Fault Screen and indi-
cate any faults that may be present in the indoor or outdoor
equipment. If a fault is present, the Fault Screen will show the
equipment and an error code with a description of the fault. Touch
Four wires are required between the furnace and thermostat. Two
wiresarerequiredbetweenthefurnacecontrolandsinglestageair
conditioner. For this system configuration, the “Y1” terminal on
the integrated furnace control becomes an output rather than an
input. The “Y1” connection to the outdoor unit is made using both
4-position thermostat connectors in the CTK01AA kit. Remove
the red keying tabs from the on-board connector block and posi-
tion both 4-position connector such that “1”, “2”, “R”, “C”, and “Y1”
positions are filled.
_
+
or
keys to view the fault status of any remaining equip-
ment. The text “NO FAULTS” will be scrolled if no errors are
present.
Call for Service
Call for Service
CTK01AA
Thermostat
4-Position Connectors
from CTK01AA
Advanced
Advanced
Thermostat Kit
Menu
Menu
1
2
R
C
Run
Run
Schedule
Schedule
CT™ Compatible
Furnace Integrated
Control Module
W1 W2 Y1 Y2
Touch the
or
to step through the list of installed equip-
O
1
2 R C G
ment, including the thermostat. Touch the Installer Config key
to enter the submenus for the equipment displayed. The text
“WORKING” will be displayed in the scrolling display area while
the data is being retrieved. The first sub-menu is then displayed.
See tables below for listing of furnace submenus.
Non-CT™ Compatible
Single Stage AC
C
Y
SystemWiringbetweenFurnaceandNon-CTCompatibleSingle
StageAirConditioner
Touch the
or to step through the list of submenus and view
_
+
settings. If a setting can be adjusted,
and
keys will ap-
COMFORTNETSYSTEMADVANCEDFEATURES
_
+
pear. Use the
or
keys to adjust the setting to the desired
The ComfortNet system permits access to additional system in-
formation, advanced setup features, and advanced diagnostic/
troubleshootingfeatures. Theseadvancedfeaturesareorganized
into a menu structure. The menus are accessed and navigated as
described in the following section.
value. Touch the
or to step to the next item. “WORK-
ING” will appear as the settings are being updated. “DONE” will
appear to indicate the change was accepted. If the change is not
accepted, the display will show “FAIL” then revert to the Fault
Screen.
ACCESSINGAND NAVIGATINGTHEADVANCEDFEATURESMENUS
Some parameters being displayed switch between the item name
and the item value. Touch the Hold key to momentarily stop the
display from switching.
TheadvancedsystemfeaturesareaccessedusingtheComfortNet
thermostat. These advanced features are accessed as follows:
•
On the CT thermostat Home Screen Display, touch the
Menu key to display additional key choices.
TouchandholdtheInstallerConfigkeyforapproximately
3secondstoentertheThermostatOptionsConfiguration
menu.
To exit an equipment submenu and revert back to the equipment
menus, touch the Menu key. Touch Menu again to revert back
to theThermostat Options Menu. Touch the Run Schedule key
to step out of all menus and back to the CT thermostat Home
Screen Display.
•
44
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COMFORTNET™ SYSTEM
FURNACE ADVANCED FEATURES MENUS
CONFIGURATION
Submenu Item
Indication (for Display Only; not User Modifiable)
Number of Heat Stages (HT STG)
Displays the number of furnace heating stages
Input Rate (BTU/HR)
Displays the furnace input rate in kBtu/hr
Motor HP (1/2, ¾, or 1 MTR HP)
Displays the furnace indoor blower motor horsepower
DIAGNOSTICS
Submenu Item
Fault 1 (FAULT #1)
Indication/User Modifiable Options
Most recent furnace fault
Comments
For display only
Fault 2 (FAULT #2)
Fault 3 (FAULT #3)
Fault 4 (FAULT #4)
Fault 5 (FAULT #5)
Fault 6 (FAULT #6)
Next most recent furnace fault
Next most recent furnace fault
Next most recent furnace fault
Next most recent furnace fault
Least recent furnace fault
For display only
For display only
For display only
For display only
For display only
Selecting “YES” clears the fault
history
Clear Fault History (CLEAR)
NO or YES
Consecutively repeated faults are shown a maximum of 3 times.
NOTE:
IDENTIFICATION
Submenu Item
Model Number (MOD NUM)
Indication (for Display Only; not User Modifiable)
Displays the furnace model number
Serial Number (SER NUM)
Software (SOFTWARE)
Displays the furnace serial number (Optional)
Displays the application software revision
SET-UP
Submenu Item
Heat Airflow Trim (HT TRM)
User Modifiable Options
-10% to +10% in 2% increments,
default is 0%
Comments
Trims the heating airflow by the selected
amount.
Heat ON Delay (HT ON
Heat OFF Delay (HT OFF)
Heat Airflow (HT ADJ)
5, 10, 15, 20, 25, or 30 seconds,
default is 30 seconds
30, 60, 90, 120, 150, or 180 seconds, Selects the indoor blower heat OFF delay
default is 150 seconds
Selects the indoor blower heat ON delay
1, 2, 3, or 4
Selects the nominal heating airflow (see
Startup Procedure and Adjustment –
Circulator Blower Speeds for additional
information)
STATUS
Submenu Item
Indication (for Display Only; not User Modifiable)
Mode (MODE)
CFM (CFM)
Displays the current furnace operating mode
Displays the airflow for the current operating mode
45
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COMFORTNET™ SYSTEM
NON-COMM (APPLIES ONLY TO A CT COMPATIBLE FURNACE MATCHED
WITH A NON-CT COMPATIBLE SINGLE STAGE AIR CONDITIONER)
Submenu Item
User Modifiable Options
Comments
Cool Airflow (CL CFM)
18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non-CT
is 18
compatible single stage AC unit
Cool Airflow Trim (CL TRM)
Cool Airflow Profile (CL PRFL)
Cool ON Delay (CL ON)
-10% to +10% in 2% increments,
default is 0%
A, B, C, or D, default is A
Selects the airflow trim amount for the non-
CT compatible single stage AC unit
Selects the airflow profile for the non-CT
compatible single stage AC unit
Selects the indoor blower ON delay for the
non-CT compatible single stage AC unit
5, 10, 20, or 30 seconds, default is
5 seconds
Cool OFF Delay (CL OFF)
30, 60, 90, or 120 seconds, default
is 30 seconds
Selects the indoor blower OFF delay for the
non-CT compatible single stage AC unit
THERMOSTAT MENU
The indoor control is equipped with a bank of three dipswitches
that provide biasing and termination functions for the communi-
cations transmission lines. The outdoor control in the CT™
compatible unit is equipped with a bank of two dipswitches that
provide termination functions for the communications transmis-
sion lines. Communications errors will result if these switches
are not correctly set. The table below indicates the switch posi-
tion for the bias and termination dipswitches along with the ex-
pected voltages. Note that the ON position is the correct posi-
tion for all bias and termination dipswitches.
If this furnace is installed with a CT compatible heat pump, the
system is recognized as a dual fuel system. The balance point
temperature should be set via the thermostat advanced menu.
Navigate to the THERMOSTAT menu. Press the INSTALLER
CONFIG key. Navigate to the SETUP menu and press the IN-
STALLER CONFIG button. Navigate to dF BAL PNT. Adjust
the dual fuel system balance point using the back/forward ar-
rows.
DIAGNOSTICS
OFF ON
Accessing the furnace’s diagnostics menu provides ready ac-
cess to the last six faults detected by the furnace. Faults are
stored most recent to least recent. Any consecutively repeated
fault is stored a maximum of three times. Example: A clogged
return air filter causes the furnace limit to trip repeatedly. The
control will only store this fault the first three consecutive times
the fault occurs. Navigate to the diagnostics menu as described
aboveinAccessingandNavigatingtheAdvancedFeaturesMenus.
1
BIAS
BIAS
2
3
TERM
Indoor Unit BIAS and TERMINATION Dipswitches
The ComfortNet system is a fully communicating system, and
thus, constitutes a network. Occasionally the need to trouble-
shoot the network may arise. The integrated furnace control has
some on-board tools that may be used to troubleshoot the net-
work. These tools are: red communications LED, green receive
(Rx) LED, and learn button.
NOTE: It is highly recommended that the fault history be cleared
when performing maintenance or servicing the furnace.
NETWORKTROUBLESHOOTING
•
•
•
Red communications LED – Indicates the status of the
network. The table below indicates the LED status and
the corresponding potential problem.
Green receive LED – Indicates network traffic. The table
below indicates the LED status and the corresponding
potential problem.
Communications is achieved by taking the difference between
two dc signals. The signals and transmission lines are referred
to as “data 1” and “data 2”. Each transmission line is biased to
approximately 2.5Vdc. During data reception/transmission, the
data lines vary between +5V and ground. (When data 1 is in-
creasing towards +5V, data 2 is decreasing towards ground and
when data 1 is decreasing towards ground, data 2 is increasing
towards +5V. Typically, the data 1 line is approximately 2.6Vdc
and the data 2 transmission line is approximately 2.3Vdc. The
voltage difference between data 1 and data 2 is typically 0.2 to
0.6 Vdc.
Learn button – Used to reset the network. Depress the
button for approximately 2 seconds to reset the network.
46
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NORMAL SEQUENCE OF OPERATION
LED
LED
Status
Off
Indication
Possible Causes
x None
x Communications
Failure
Corrective Action(s)
Notes & Cautions
x Normal condition
x Communications
Failure
x None
x None
1 Flash
x Depress Learn Button x Depress once
x Verify that bus BIAS
and TERM
dipswitches are in the
ON position.
quickly for a power-
up reset
x Depress and hold
for 2 seconds for
an out-of-box reset
x None
Red
Communications
LED
2 Flashes
Off
x Out-of-box reset
x Control power up
x Learn button
depressed
x No power to furnace
x Open fuse
x Communications error
x None
x No power
x Communications
error
x Check fuses and
circuit breakers;
replace/reset
x Turn power OFF
prior to repair
x Replace blown fuse
x Check for shorts in
low voltage wiring in
furnace/system
x Reset network by
depressing learn
button
x Check data 1/ data 2
voltages
1 Steady
Flash
x No network found
x Broken/ disconnected
data wire(s)
x Furnace is installed as
a legacy/ traditional
system
x Check
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
Green Receive
LED
terminal block
x Verify furnace
installation type
(legacy/ traditional or
communicating)
x Check data 1/ data 2
voltages
x Verify data1 and
data voltages as
described above
Rapid
Flashing
On Solid
x Normal network
traffic
x Data 1/ Data 2
miss-wire
x Control is “talking” on
network as expected
x Data 1 and data 2
wires reversed at
furnace, thermostat,
or CT™ compatible
outdoor AC/HP
x Short between data 1
and data 2 wires
x Short between data 1
or data 2 wires and R
(24VAC) or C (24VAC
common)
x None
x None
x Check
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
x Check data 1/ data 2
voltages
terminal block
x Verify data1 and
data voltages as
described above
SYSTEMTROUBLESHOOTING
•
•
•
115 VAC power applied to furnace.
Integrated control module performs internal checks.
NOTE: Refer to the instructions accompanying the CT compatible
outdoorAC/HPunit for troubleshooting information.
Integrated control module displays 88on dual 7-segment
display LED’s.
Refer to theTroubleshooting Chart in theAppendix for a listing of
possible furnace error codes, possible causes and corrective
actions.
•
•
Integrated control module monitors safety circuits
continuously.
Furnaceawaitscallfromthermostat. Dual7-segmentLED’s
display 0Pwhile awaiting call from thermostat.
NORMAL SEQUENCE OF OPERATION
HEATINGMODE
POWER UP
The normal operational sequence in heating mode is as follows:
The normal power up sequence is as follows:
•
R and W1 (or R and W1/W2) thermostat contacts close,
initiating a call for heat.
47
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OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
the balance of the heat off delay period (60, 90, 120 or 150
seconds).
•
•
Integrated control module performs safety circuit checks.
Induced draft blower is energized on high speed for a 15-
second prepurge. Humidifier terminal is energized with
induced draft blower.
•
•
Circulator blower and electronic air cleaner terminal is de-
energized.
CirculatorblowerrampsdowntoOFFduringthe30seconds
following the heat off delay period.
•
•
•
•
•
Induceddraftblowerstepstolowspeedfollowingprepurge.
Low stage pressure switch contacts are closed.
Igniter warm up begins upon step to low speed and
presence of closed low stage pressure switch contacts.
•
Furnace awaits next call from thermostat.
COOLINGMODE
Gasvalveopensatendofigniterwarmupperiod, delivering
gas to burners and establishing flame.
The normal operational sequence in cooling mode is as follows:
•
R and Y1/G or Y2/G thermostat contacts close, initiating a
call for cool.
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
•
•
Integrated control module performs safety circuit checks.
If the thermostat call is for low heat, gas valve and induced
draft blower will continue on low stage. If the call is for high
heat, the gas valve and induced draft blower will change to
high stage.
Outdoor fan and compressor are energized to their
appropriatespeed.
•
Circulatorblowerisenergizedontheappropriatecoolspeed
at the level and time determined by the selected ramping
profile. Electronic air cleaner terminal is energized with
circulator blower.
•
Circulator blower is energized on heat speed following a
thirty (30) second blower on delay. The circulator blower
requires thirty seconds to ramp up to full speed. Electronic
air cleaner terminal is energized with circulator blower.
•
•
Furnace circulator blower and outdoor cooling unit run their
appropriate speeds, integrated control module monitors
safety circuits continuously.
•
•
•
Furnace is now operating on the specified stage called for
by the two-stage thermostat.
Furnace runs, integrated control module monitors safety
circuits continuously.
R and Y1/G or Y2/G thermostat contacts open, completing
the call for cool.
If the two-stage thermostat changes the call from low heat
to high heat, the integrated control module will immediately
switch the induced draft blower, gas valve, and circulator
blower to their high stage settings.
•
•
Outdoor fan and compressor are de-energized.
Circulator blower continues running during a cool off delay
period. TheOFFdelaytimeandairflowlevelaredetermined
by the selected ramping profile.
Electronic air cleaner terminal and circulator blower are de-
energized.
•
•
If the two-stage thermostat changes the call from high heat
to low heat, the control will immediately switch the induced
draft blower and gas valve to their low stage settings. The
circulator blower will remain on high heating speed for thirty
(30) seconds before switching to the low heat circulating
•
•
Furnace awaits next call from thermostat.
FANONLYMODE
speed.
The normal operational sequence in fan only mode is as follows:
R and W1 (or R and W1/W2) thermostat contacts open,
completing the call for heat.
•
•
•
R and G thermostat contacts close, initiating a call for fan.
Integrated control module performs safety circuit checks.
•
•
Gas valve closes, extinguishing flame.
Circulatorblowerisenergizedoncontinuousfanspeed(30%
of the furnace’s maximum airflow capability) following a five
(5)seconddelay. Electronicaircleanerterminalisenergized.
Induceddraftblowerisde-energizedfollowingafifteensecond
post purge. Humidifier terminals are de-energized.
•
Circulator blower continues running for the selected heat
off delay period (90, 120, 150 or 180 seconds). The speed
runduringthisperioddependsonthelastheatcallprovided
by the thermostat.
Ifthelastcallforheatwasacallforlowheat, theaircirculator
motor will run on low heat speed for the duration of the heat
off delay period (90, 120, 150 or 180 seconds).
If the last call for heat was a call for high heat, the air
circulating motor will run on the high heating speed for thirty
(30) seconds and then switch to the low heating speed for
•
•
•
•
Circulator blower runs, integrated control module monitors
safety circuits continuously.
R and G thermostat contacts open, completing the call for
fan.
Circulator blower is de-energized. Electronic air cleaner
terminal is de-energized.
Furnace awaits next call from thermostat.
48
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TROUBLESHOOTING & MAINTENANCE
the coil front cover. These switches guard against insufficient air-
flow(combustionairandflueproducts)throughtheheatexchanger
and/or blocked condensate drain conditions.
OPERATIONAL CHECKS
The burner flames should be inspected with the burner compart-
ment door installed. Flames should be stable, quiet, soft, and
blue (dust may cause orange tips but they must not be yellow).
Flames should extend directly outward from the burners without
curling, floating, or lifting off. Flames must not impinge on the
sides of the heat exchanger firing tubes.
FLAMESENSOR
The flame sensor is a probe mounted to the burner/manifold as-
sembly which uses the principle of flame rectification to determine
the presence or absence of flame.
TROUBLESHOOTING
ELECTROSTATICDISCHARGE(ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
Use the following precautions during furnace installation and ser-
vicing to protect the integrated control module from damage. By
putting the furnace, the control, and the person at the same elec-
trostatic potential, these steps will help avoid exposing the inte-
grated control module to electrostatic discharge. This procedure
is applicable to both installed and uninstalled (ungrounded) fur-
naces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
controlprior todischargingyourbody’selectrostatic charge
toground.
Burner Flame
SAFETY CIRCUIT DESCRIPTION
Anumberofsafetycircuitsareemployedtoensuresafeandproper
furnace operation. These circuits serve to control any potential
safety hazards and serve as inputs in the monitoring and diagno-
sis of abnormal function. These circuits are continuously moni-
tored during furnace operation by the integrated control module.
2. Firmlytouchaclean, unpainted, metalsurfaceofthefurnace
away from the control. Any tools held in a person’s hand
during grounding will be discharged.
INTEGRATEDCONTROLMODULE
The integrated control module is an electronic device which, if a
potential safety concern is detected, will take the necessary pre-
cautions and provide diagnostic information through an LED.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution not
to recharge your body with static electricity; (i.e., do not
moveorshuffleyourfeet, donottouchungroundedobjects,
etc.). If you come in contact with an ungrounded object,
repeat step 2 before touching control or wires.
PRIMARY LIMIT
The primary limit control is located on the partition panel and moni-
tors heat exchanger compartment temperatures. It is a normally-
closed (electrically), automatic reset, temperature-activated sen-
sor. The limit guards against overheating as a result of insufficient
conditioned air passing over the heat exchanger.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or new
controlstotheircontainersbeforetouchinganyungrounded
object.
AUXILIARYLIMIT
The auxiliary limit controls are located on or near the circulator
blowerandmonitorsblowercompartmenttemperatures. Theyare
a normally-closed (electrically), manual-reset sensors. These lim-
its guard against overheating as a result of insufficient conditioned
air passing over the heat exchanger.
DIAGNOSTICCHART
WARNING
HIGH VOLTAGE !
ROLLOUT LIMIT
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
The rollout limit controls are mounted on the burner/manifold as-
sembly and monitor the burner flame. They are normally-closed
(electrically), manual-reset sensors. These limits guard against
burner flames not being properly drawn into the heat exchanger.
Refer to the Troubleshooting Chart in theAppendix for assistance
indeterminingthesourceofunitoperationalproblems. Thedual7-
segment LED display will display an error code that may contain a
letter and number.The error code may be used to assist in trouble-
shooting the unit.
PRESSURESWITCHES
The pressure switches are normally-open (closed during opera-
tion) negative air pressure-activated switches. They monitor the
airflow (combustion air and flue products) through the heat ex-
changer via pressure taps located on the induced draft blower and
49
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TROUBLESHOOTING & MAINTENANCE
RESETTINGFROMLOCKOUT
FILTERS
Furnace lockout results when a furnace is unable to achieve igni-
tion after three attempts during a single call for heat. It is charac-
terized by a non-functioning furnace and a E0code displayed on
the dual 7-segment display. If the furnace is in “lockout”, it will (or
can be) reset in any of the following ways.
CAUTION
TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES
GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR
SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
FILTERMAINTENANCE
Improper filter maintenance is the most common cause of inad-
equate heating or cooling performance. Filters should be cleaned
(permanent) or replaced (disposable) every two months or as re-
quired. When replacing a filter, it must be replaced with a filter of
the same type and size.
2. Manual power interruption. Interrupt 115 volt power to the
furnace.
3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 -20 seconds then
reset to previous setting.
FILTER REMOVAL
NOTE: If the condition which originally caused the lockout still
exists, thecontrolwillreturntolockout. RefertotheTroubleshooting
Chart for aid in determining the cause.
Depending on the installation, differing filter arrangements can be
applied. Filters can be installed in either the central return register
or a side panel external filter rack (upflow only). Amedia air filter or
electronic air cleaner can be used as an alternate filter. Follow the
filter sizes given in the Recommended Minimum Filter size table
to ensure proper unit performance.
MAINTENANCE
WARNING
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH,
DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY
MAINTENANCE. IF YOU MUST HANDLE THE IGNITER,
HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT
WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION
COULD DAMAGE THE IGNITER RESULTING IN PREMATURE
FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER
HANDLE THE IGNITER.
To remove filters from an external filter rack in an upright upflow
installation, follow the directions provided with external filter rack
kit.
HORIZONTAL UNIT FILTER REMOVAL
Filters in horizontal installations are located in the central return
register or the ductwork near the furnace.
Toremove:
ANNUALINSPECTION
1. Turn OFF electrical power to furnace.
2. Removefilter(s)fromthecentralreturnregisterorductwork.
3. Replace filter(s) by reversing the procedure for removal.
4. Turn ON electrical power to furnace.
The furnace should be inspected by a qualified installer, or service
agency at least once per year. This check should be performed at
the beginning of the heating season. This will ensure that all fur-
nace components are in proper working order and that the heating
system functions appropriately. Pay particular attention to the fol-
lowing items. Repair or service as necessary.
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL
Follow the manufacturer’s directions for service.
•
Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
BURNERS
Visually inspect the burner flames periodically during the heating
season. Turn on the furnace at the thermostat and allow several
minutes for flames to stabilize, since any dislodged dust will alter
the flames normal appearance. Flames should be stable, quiet,
soft, and blue (dust may cause orange tips but they must not be
yellow). They should extend directly outward from the burners
without curling, floating, or lifting off. Flames must not impinge on
the sides of the heat exchanger firing tubes.
•
•
•
•
•
Heatexchanger. Checkforcorrosionand/orbuildupwithin
the heat exchanger passageways.
Burners. Check for proper ignition, burner flame, and
flame sense.
Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.
Wiring. Check electrical connections for tightness and/
or corrosion. Check wires for damage.
Filters.
INDUCEDDRAFTANDCIRCULATORBLOWERS
The bearings in the induced draft blower and circulator blower mo-
tors are permanently lubricated by the manufacturer. No further
lubrication is required. Check motor windings for accumulation of
dust which may cause overheating. Clean as necessary.
50
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MISCELLANEOUS
CONDENSATETRAPANDDRAINSYSTEM(QUALIFIEDSERVICER
ONLY)
BEFORE LEAVING AN INSTALLATION
•
•
•
Cycle the furnace with the thermostat at least three times.
Verify cooling and fan only operation.
Annuallyinspectthedraintubes, draintrap, andfield-supplieddrain
line for proper condensate drainage. Check drain system for hose
connection tightness, blockage, and leaks. Clean or repair as
necessary.
Review the Owner’s Manual with the homeowner and
discuss proper furnace operation and maintenance.
Leave literature packet near furnace.
FLAMESENSOR(QUALIFIEDSERVICERONLY)
REPAIR AND REPLACEMENT PARTS
Under some conditions, the fuel or air supply can create a nearly
invisible coating on the flame sensor. This coating acts as an
insulator causing a drop in the flame sense signal. If the flame
sense signal drops too low the furnace will not sense flame and
will lock out. The flame sensor should be carefully cleaned by a
qualified servicer using emery cloth or steel wool. Following clean-
ing, the flame sense signal should be as indicated in the Specifica-
tions Sheet.
•
•
•
When ordering any of the listed functional parts, be sure to
provide the furnace model, manufacturing, and serial
numbers with the order.
Although only functional parts are shown in the parts list,
all sheet metal parts, doors, etc. may be ordered by
description.
Parts are available from your distributor.
FLUEPASSAGES(QUALIFIEDSERVICERONLY)
Functional Parts List-
Gas Valve
Blower Motor
The heat exchanger flue passageways should be inspected at the
beginning of each heating season. If necessary, clean the pas-
sageways as outlined below.
1. TurnOFFtheelectricalpowerandgassupplytothe furnace.
2. Disconnect the gas line and remove the burner/ manifold
assembly by removing the screws securing the assembly
to the partition panel.
3. Disconnect the flue pipe system from the induced draft
blower.
4. Remove the induced draft blower, drain and pressure tap
hoses from the recuperator coil front cover.
Gas Manifold
Blower Wheel
Natural Gas Orifice
Propane Gas Orifice
Igniter
Blower Mounting Bracket
BlowerCutoff
BlowerHousing
Inductor
Flame Sensor
Rollout Limit Switch
Primary Limit Switch
Auxiliary Limit Switch
Pressure Switch
InducedDraftBlower
Door Switch
Heat Exchanger with
RecuperatorCoil
CoilFrontCover
IntegratedControlModule
Transformer
5. Remove the recuperator coil front cover to expose the coil
tubes and turbulators.
6. Remove the recuperator coil turbulators individually by
slowly pulling each turbulator forward firmly.
7. Clean the recuperator coil tubes using a long handle wire
brush, such as a gun cleaning brush.
8. Clean the primary heat exchanger tubes using a wire brush
attached to a length of high grade stainless steel cable,
such as drain cleanout cable. Attach a variable speed
reversible drill to the other end of the cable. Slowly rotate
the cable with the drill and insert it into one of the heat
exchanger tubes. While reversing the drill, work the cable
inandoutseveraltimestoobtainsufficientcleaning. Repeat
for each tube.
9. Clean residue from furnace using a vacuum cleaner.
10. Replace the parts removed in the previous steps in reverse
order.
11. Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.
12. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in Startup
Procedure and Adjustments to reduce the chances of
repeatedfouling.
51
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DIP SWITCHES
DIP Sw itch No.
Sw itch
Purpose
Bank
Function
1
OFF
ON
OFF
ON
---
2
OFF
OFF
ON
ON
---
3
---
4
---
5
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
OFF
ON
---
---
---
---
---
---
6
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
OFF
ON
ON
---
---
---
---
---
---
7
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
OFF
ON
---
---
8
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
OFF
ON
ON
---
---
9
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
OFF
ON
10
---
90 seconds
120 seconds
150 seconds*
180 seconds
1-Stage T-stat
Heat OFF
Delay
---
---
---
---
---
---
---
---
---
S1
OFF
ON
---
---
---
Thermostat 2-Stage T-Stat
---
---
---
---
Setup
5-Min Delay
---
---
OFF
ON
---
---
Auto Delay
---
---
---
---
Bus BIAS
TERM
BIAS
ON*
---
ON*
---
---
---
S2
S3
Bus Termination
ON*
---
---
---
A
OFF
ON
OFF
ON
---
OFF
OFF
ON
ON
---
---
---
Cooling
B
---
---
---
Speed Tap
C
---
---
---
D*
---
---
---
Normal*
OFF
ON
OFF
ON
---
OFF
OFF
ON
ON
---
---
Adjust
Taps
10%
---
---
---
-10%
---
---
---
Normal
---
---
---
A*
---
---
---
Ramping
Profiles
B
---
---
---
---
---
C
---
---
---
---
---
D
---
---
---
---
---
S4
A
---
---
---
---
---
Heating
B*
C
---
---
---
---
---
Speed Tap
---
---
---
---
---
D
---
---
---
---
---
Disabled*
Enabled
---
---
---
---
Unused
Unused
DEHUM
S5
---
---
---
---
(*Indicates factory setting)
---
Not applicable
52
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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TROUBLESHOOTING CHART
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STATUS CODES
INTERNAL CONTROL FAULT/NO POWER
NORMAL OPERATION
O P
E 0
E 1
E 2
E 3
E 4
E 5
E 6
E 7
E 8
E 9
E A
d 0
d 4
b 0
b 1
b 2
b 3
b 4
b 5
b 6
b 7
b 9
C 1
C 2
LOCKOUT DUE TO EXCESSIVE RETRIES
LOW STAGE PRESSUE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
LOW STAGE PRSSURE SWITCH STUCK OPEN
OPEN HIGH LIMIT SWITCH
FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT
OPEN FUSE
LOW FLAME SIGNAL
IGNITER FAULT OR IMPROPER GROUNDING
HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
HIGH STAGE PRSSURE SWITCH STUCK OPEN
REVERSED 115 VAC POLARITY
DATA NOT YET ON NETWORK
INVALID MEMORY CARD DATA
BLOWER MOTOR NOT RUNNING
BLOWER COMMUNICATION ERROR
BLOWER HP MIS-MATCH
BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT
BLOWER MOTOR CURRENT TRIP OR LOST ROTOR
BLOWER MOTOR LOCKED ROTOR
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
INCOMPLETE PARAMETERS SENT TO MOTOR
LOW INDOOR AIRFLOW
LOW STAGE COOL
HIGH STAGE COOL
LOW STAGE HEAT
L 0
H I
F
HIGH STAGE HEAT
CONTINUOUS FAN
CFM/100; ALTERNATES WITH
,
,
,
,
H I
C 2 L O
F
1 2
C 1
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*CVC9_AA, *MVC95_AA
WIRING DIAGRAM
HIGH VOLTAGE!
Disconnect ALL power before servicing or installing this unit. Multiple
power sources may be present. Failure to do so may cause property
damage, personal injury or death.
TO
GND
115 VAC/ 1Ø /60 HZ
POWER SUPPLY WITH
OVERCURRENT
ID BLOWER TWO-STAGE PRESSURE
SWITCH ASSEMBLY
PROTECTION DEVICE
L
WARNING:DISCONNECT
POWER BEFORE
SERVICING. WIRING
TO UNIT MUST BE
PROPERLY POLARIZED
AND GROUNDED.
BK
24V HUM.
OR
HIGH FIRE
PRESSURE
SWITCH
HOT
SURFACE
IGNITER
LOW FIRE
PRESSURE
SWITCH
N
C
WH
C
NO
NO
DISCONNECT
2 CIRCUIT
2
1
CONNECTOR
TO 115VAC/ 1Ø /60 HZ POWER SUPPLY WITH
OVERCURRENT PROTECTION DEVICE
OR
3
HI
PU
GND
L
N
2
BR
C
FLAME
SENSOR
WARNING:
TWO STAGE
GAS VALVE
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
C
1
GY
PM
GY
NO
FRONT COVER
PRESSURE SWITCH
MUST BE PROPERLY
POLARIZED AND
GROUNDED.
DISCONNECT
MANUAL RESET ROLLOUT LIMIT
CONTROLS (SINGLE CONTROL ON
45 kBTU)
BL
PK
OR
DOOR
SWITCH
JUNCTION BOX
AUTO RESET PRIMARY
LIMIT CONTROL
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
PU
INDUCED
DRAFT
BLOWER
INDOOR
AIR
CIRCULATOR
BLWR
3
WH
2
RD
1
BK
GND
GND
BURNER COMPARTMENT
BLOWER COMPARTMENT
LINE
EAC
NEUTRAL
NEUTRAL
ELECTRONIC
AIR CLEANER
PU
MANUAL RESET
AUXILIARY
LIMIT CONTROL
YL
IND HI
NEUTRAL
ID
BLWR
IND LO
HUM
24 V THERMOSTAT CONNECTIONS
FUSE
24 V
3 A
NEUTRAL
NEUTRAL
HUMIDIFIER
IGN
FS
HOT SURFACE
IGNITER
BR
SEE
NOTE
DIAGNOSTIC
LED'S
5
3
6
2
1
4
OR
FLAME SENSOR
11 5 VAC
5
OR
OR
2ND STG DLY
T-STAT
NEUTRAL
LINE
9
7
8
HEAT OF F
DELAY
10
40 VA
TRANSFORMER
12
15
11
PK
GY
BR
FUSE 3A
TH (4)
UNU SED
DEHUM
R
13
14
24 VAC
MANU AL RESET AUXILIARY LIMIT
AUTO RESET PRIM ARY
LIMIT CON TROL
HEAT
CONTROLS
TO +VDC
PU
1
2
YL
HLO (10)
PSO (7)
Y1
DELAY
OR
GY
3
4
ADJUST
COOL
24
LOW FIRE
PRESS. SWITCH
C
VAC
24V HUM.
NO
W1
W2
PS1 (2)
115
VAC
BL
NO
LINE
PS2 (12)
40 VA
TRANSFORMER
TO
MICR O
1
2
3
4
5
C
BK
Y2
G
HIGH FIRE
PRESS. SWTICH
HLI (1)
MANUAL RESET ROLLOUT
LIMIT CONTROLS
FS
WH
O
NEUTRAL
WH
DEHUM
MVL (13)
NO
PM
C
FRONT COVER
PRESS. SWIT CH
MVH (14)
HI
RD
C
BL
MVC (8)
ECM MTR
HARNESS
WH
C
WH
GAS
VALVE
GND (5)
TR (11)
GY
BK
BK
BK
GND
BK
5
BK
TO
GND (4)
4
3
2
1
WH
R
GR
PK
+ VDC (1)
GND
BLOWER
INDOOR
AIR
RX (2)
TX (3)
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)
TO
MICRO
CIRCULATOR
BLWR
CIRCULATOR
BLOWER
INDUCTOR COIL
70kBTU,90kBTU,
115kBTU MODELS
ONLY
INTEGRATED CONTROL MODU LE
HUMIDIFIER
NOTES:
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.
EQUIPMENT GND
FIELD GND
LOW VOLTAGE (24V)
COLOR CODES:
PK PINK
BR BROWN
WH WHITE
BL BLUE
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE
USED WHEN SERVICING.
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED
WIRING MATERIAL HAVING A TEMPERATURE RATING OF
AT WITH LEAST 105°C. USE COPPER CONDUCTORS.
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
GY GRAY
RD RED
JUNCTION
TERMINAL
INTERNAL TO
4. UNIT MUST BE PERMANENTLY GROUNDEDAND CONFORM TO
N.E.C. AND LOCAL CODES.
YL YELLOW
OR ORANGE
PU PURPLE
GN GREEN
BK BLACK
5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS
IN STANDBY (NO THERMOSTAT INPUTS).
SWITCH (PRESS.)
INTEGRATED CONTROL
OVERCURRENT
PROT. DEVICE
PLUG CONNECTION
0140F00530 REV. B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
59
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WIRING DIAGRAM
*CVC9_AB, *MVC95_AB
HIGH VOLTAGE!
Disconnect ALL power before servicing or installing this unit. Multiple
power sources may be present. Failure to do so may cause property
damage, personal injury or death.
TO
GND
115VAC/1 Ø/60HZ
POWERSUPPLYWITH
OVERCURRENT
IDBLOWERTWO-STAGEPRESSURE
SWITCHASSEMBLY
PROTECTIONDEVICE
L
WARNING:DISCONNECT
POWERBEFORE
SERVICING.WIRING
TOUNITMUSTBE
PROPERLYPOLARIZED
ANDGROUNDED.
BK
24VHUM.
OR
HIGHFIRE
PRESSURE
SWITCH
HOT
SURFACE
IGNITER
LOWFIRE
PRESSUR
ESWITCH
N
C
WH
C
NO
NO
DISCONNECT
2CIRCUIT
2
1
CONNECTOR
TO115VAC/1 Ø/60HZPOWERSUPPLYWITH
OVERCURRENTPROTECTIONDEVICE
OR
2
HI
PU
GND
TWOSTAGE
GASVALVE
(HONEYWELL)
L
N
3
BR
C
FLAME
SENSOR
WARNING:
DISCONNECTPOWER
BEFORESERVICING.
WIRINGTOUNIT
C
1
GY
PM
GY
NO
FRONTCOVER
PRESSURESWITCH
MUSTBEPROPERLY
POLARIZEDAND
GROUNDED.
DISCONNECT
MANUALRESETROLLOUTLIMIT
CONTROLS(SINGLECONTROLON
45kBTU)
BL
PK
OR
DOOR
SWITCH
JUNCTIONBOX
AUTORESETPRIMARY
LIMITCONTROL
INDUCTORCOIL
70kBTU,90kBTU,
115kBTUMODELS
ONLY
PU
INDUCED
DRAFT
BLOWER
INDOOR
AIR
CIRCULATOR
BLWR
3
2
1
WH
RD
BK
GND
GND
BURNERCOMPARTMENT
BLOWERCOMPARTMENT
NEUTRAL
NEUTRAL
LINE
EAC
ELECTRONIC
AIRCLEANER
PU
YL
MANUALRESET
AUXILIARY
LIMITCONTROL
INDHI
NEUTRAL
ID
BLWR
INDLO
HUM
24VTHERMOSTATCONNECTIONS
FUSE
24V
3A
NEUTRAL
NEUTRAL
HUMIDIFIER
IGN
FS
HOTSURFACE
IGNITER
BR
SEE
NOTE5
DIAGNOSTIC
LED'S
3
6
2
5
1
4
OR
OR
OR
FLAMESENSOR
115VAC
2NDSTGDLY
T-STAT
NEUTRAL
LINE
9
7
8
HEATOFF
DELAY
10
40VA
TRANSFORMER
12
15
11
PK
GY
FUSE3A
TH(4)
UNUSED
DEHUM
R
13
14
24VAC
AUTORESETPRIMARY
MANUALRESETAUXILIARYLIMIT
CONTROLS
LIMITCONTROL
BR
HEAT
TO+VDC
PU
1
2
YL
HLO(10)
Y1
DELAY
OR
GY
3
4
PSO(7)
PS1(2)
ADJUST
COOL
24
LOWFIREPRESS.
SWITCH
C
VAC
24VHUM.
NO
W1
W2
115
VAC
BL
NO
LINE
PS2(12)
40VA
TRANSFORMER
TO
1
2
3
4
5
C
BK
MICRO
Y2
G
HIGHFIRE
PRESS.SWTICH
MANUALRESETROLLOUT
LIMITCONTROLS
FS
HLI(1)
WH
O
NEUTRAL
WH
DEHUM
MVL(13)
NO
PM
HI
C
FRONTCOVER
PRESS.SWITCH
C
MVH(14)
RD
C
BL
MVC(8)
ECMMTR
WH
HARNESS
WH
BK
GAS
VALVE
GND(5)
TR(11)
GY
BK
BK
GND
BK
5
BK
TO
GND(4)
+VDC(1)
4
3
2
WH
R
GR
PK
GND
1
BLOWER
INDOOR
AIR
CIRCULATOR
BLWR
RX(2)
TX(3)
COMPARTMENT
DOORSWITCH
(OPENWHEN
DOOROPEN)
TO
MICRO
CIRCULATOR
BLOWER
INDUCTORCOIL
70kBTU,90kBTU,
115kBTUMODELS
ONLY
INTEGRATEDCONTROLMODULE
HUMIDIFIER
NOTES:
EQUIPMENTGND
FIELDGND
LOWVOLTAGE(24V)
COLORCODES:
PKPINK
BRBROWN
WHWHITE
BLBLUE
1.SETHEATANTICIPATORONROOMTHERMOSTATAT0.7AMPS.
LOWVOLTAGEFIELD
HIVOLTAGE(115V)
HIVOLTAGEFIELD
2.MANUFACTURER'SSPECIFIEDREPLACEMENTPARTSMUSTBE
USEDWHENSERVICING.
3.IFANYOFTHEORIGINALWIREASSUPPLIEDWITHTHE
FURNACEMUSTBEREPLACED,ITMUSTBEREPLACEDWITH
WIRINGMATERIALHAVINGATEMPERATURERATINGOFAT
LEAST105°C.USECOPPERCONDUCTORSONLY.
4.UNITMUSTBEPERMANENTLYGROUNDEDANDCONFORMTO
N.E.C.ANDLOCALCODES.
FIELDSPLICE
SWITCH(TEMP.)
IGNITER
GYGRAY
RDRED
JUNCTION
YLYELLOW
ORORANGE
PU PURPLE
GNGREEN
BKBLACK
TERMINAL
5.TORECALLTHELAST6FAULTS,MOSTRECENTTOLEAST
RECENT,DEPRESSSWITCHFORMORETHAN2SECONDSWHILE
INSTANDBY(NOTHERMOSTATINPUTS)
SWITCH(PRESS.)
INTERNALTO
INTEGRATEDCONTROL
OVERCURRENT
PROT.DEVICE
PLUGCONNECTION
0140F00661
REV.B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
60
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