DCS9 Installation Instructions

AMS9/ACS9/DMS9/DCS9 GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS
Installer: Affix all manuals adjacent to the unit.
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47CSA-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 product data book referred to in this manual.
www.amana-hac.com
is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved. 2004-2006 Goodman Company, L.P.
IO-254E
2/06
Table of Contents
I. Component Identification ............................................................................................................................................... 5 II. Safety ............................................................................................................................................................................... 6 III. Product Application ....................................................................................................................................................... 6 IV. Location Requirements & Considerations ................................................................................................................. 7
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 6
GENERAL ......................................................................................................................................................... 7 CLEARANCES AND ACCESSIBILITY ......................................................................................................................... 8 FURNACE SUSPENSION ....................................................................................................................................... 8 EXISTING FURNACE REMOVAL .............................................................................................................................. 8 THERMOSTAT LOCATION ...................................................................................................................................... 9
V. Combustion & Ventilation Air Requirements ................................................................................................................ 9 VI. Installation Positions .................................................................................................................................................. 11 VII. Horizontal Applications & Considerations ............................................................................................................... 11
GENERAL ....................................................................................................................................................... 11 DRAIN TRAP AND LINES .................................................................................................................................... 11 LEVELING ....................................................................................................................................................... 11 ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS ................................................................................. 11 ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS .......................................................................................... 12 DRAIN PAN ..................................................................................................................................................... 12 FREEZE PROTECTION ........................................................................................................................................ 12 FURNACE SUSPENSION ..................................................................................................................................... 12
VIII. Propane Gas /High Altitude Installations ................................................................................................................ 12 IX. Vent/Flue Pipe & Combustion Air Pipe ...................................................................................................................... 12
GENERAL ....................................................................................................................................................... 12 DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT ................................................................................................ 12 MATERIALS AND JOINING METHODS .................................................................................................................... 13 PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ............................................................................... 13 TERMINATION LOCATIONS .................................................................................................................................. 13 CANADIAN VENTING REQUIREMENTS ................................................................................................................... 14 STANDARD FURNACE CONNECTIONS .................................................................................................................... 14 ALTERNATE FURNACE CONNECTIONS ................................................................................................................... 14 NON-DIRECT VENT (SINGLE PIPE) PIPING ........................................................................................................... 16 DIRECT VENT (DUAL PIPE) PIPING ..................................................................................................................... 17 VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES ............................................. 18 CONCENTRIC VENT TERMINATION ........................................................................................................................ 18
X. Condensate Drain Lines & Drain Trap ........................................................................................................................ 18
GENERAL ....................................................................................................................................................... 18 UPRIGHT INSTALLATIONS ................................................................................................................................... 19 HORIZONTAL INSTALLATIONS .............................................................................................................................. 20

XI. Electrical Connections ................................................................................................................................................ 21
WIRING HARNESS ............................................................................................................................................ 21 115 VOLT LINE CONNECTIONS ........................................................................................................................... 21 24 VOLT THERMOSTAT WIRING .......................................................................................................................... 22 115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) .................................... 22 24 VOLT HUMIDIFIER ........................................................................................................................................ 22
XII. Gas Supply and Piping .............................................................................................................................................. 22
GENERAL ....................................................................................................................................................... 22 GAS PIPING CONNECTIONS ................................................................................................................................ 23 PROPANE GAS TANKS AND PIPING ..................................................................................................................... 24 DUCTWORK - AIR FLOW .................................................................................................................................... 25 FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK .................................................... 25 UPRIGHT INSTALLATIONS ................................................................................................................................... 26 HORIZONTAL INSTALLATIONS .............................................................................................................................. 26
XIII. Circulating Air & Filters ............................................................................................................................................ 25
Table of Contents
XIV. Startup Procedure & Adjustment ............................................................................................................................. 26
HEAT ANTICIPATOR SETTING .............................................................................................................................. 26 DRAIN TRAP PRIMING ....................................................................................................................................... 26 FURNACE OPERATION ........................................................................................................................................ 26 GAS SUPPLY PRESSURE MEASUREMENT ............................................................................................................. 27 GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ................................................................................. 28 GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ....................................................................................... 28 TEMPERATURE RISE ......................................................................................................................................... 29 CIRCULATOR BLOWER SPEEDS .......................................................................................................................... 29 POWER UP ..................................................................................................................................................... 29 HEATING MODE ............................................................................................................................................... 29 COOLING MODE .............................................................................................................................................. 30 FAN ONLY MODE ............................................................................................................................................. 30 BURNER FLAME ............................................................................................................................................... 30 PRIMARY LIMIT ................................................................................................................................................ 30
XV. Normal Sequence of Operation ................................................................................................................................. 29
XVI. Operational Checks .................................................................................................................................................. 30
XVII. Safety Circuit Description ....................................................................................................................................... 30
GENERAL ....................................................................................................................................................... 30 INTEGRATED CONTROL MODULE ......................................................................................................................... 30 PRIMARY LIMIT ................................................................................................................................................ 30 AUXILIARY LIMIT .............................................................................................................................................. 30 ROLLOUT LIMIT ............................................................................................................................................... 30 PRESSURE SWITCHES ....................................................................................................................................... 30 FLAME SENSOR ............................................................................................................................................... 31
XVIII. Troubleshooting ...................................................................................................................................................... 31
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ............................................................................................... 31 DIAGNOSTIC CHART ......................................................................................................................................... 31 RESETTING FROM LOCKOUT .............................................................................................................................. 31 ANNUAL INSPECTION ......................................................................................................................................... 31 FILTERS .......................................................................................................................................................... 31 BURNERS ....................................................................................................................................................... 32 INDUCED DRAFT AND CIRCULATOR BLOWERS ....................................................................................................... 32 CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ..................................................................... 32 FLAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 32 FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 32
XIX. Maintenance .............................................................................................................................................................. 31
XXI. Before Leaving an Installation ................................................................................................................................. 32 XXII. Repair & Replacement Parts ................................................................................................................................... 33
APPENDIX
Troubleshooting Chart ..................................................................................................................................................... 34 AMS9/ACS9 Wiring Diagram ............................................................................................................................................ 36 DMS9/DCS9 Wiring Diagram ............................................................................................................................................ 37
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.
TO THE OWNER
It is important that you fill out the owners registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date. Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference. If additional information or operating instructions are required, contact the dealer where the purchase was made. Homeowner Notice: If the residence is left unattended for an extended period of time (i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances beyond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.
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 NEIGHBORS PHONE.
FOLLOW THE GAS SUPPLIERS INSTRUCTIONS.
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT. INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
TO THE INSTALLER
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 pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.
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.
TRANSPORTATION DAMAGE
All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carriers agent must be made in writing immediately. 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. Make a notation on delivery receipt of any visible damage to shipment or container. 2. Notify carrier promptly and request an inspection. 3. With concealed damage, carrier must be notified as soon as possible - preferably within five days. 4. File the claim with the following support documents within a nine month statute of limitations.
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
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.
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.
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.

B10259-216
Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.
Keep this literature in a safe place for future reference.
I. CO MPO NENT ID ENTIFI CATI ON COMPO MPONENT IDENTIFI ENTIFIC TIO
5
BURNER COMPARTMENT
9 10 11 3 13 14 16 12
5 33
27
28
10 11
BLOWER COMPARTMENT BURNER COMPARTMENT
4 3
* * * * * * *
2 1 31 32 30 20 19
26
25 24
29 3
BLOWER COMPARTMENT
21
CF M 87 S4 4 321 OF F ON 87 4 321 S3 CU T FO R DE HU M
29
28
Upflow/Horizontal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Gas Valve Gas Line Entrance (Alternate) Pressure Switch Gas Manifold Combustion Air Intake Connection / Coupling Hot Surface Igniter Rollout Limit Burners Flame Sensor Flue Pipe Connection / Coupling Flue Pipe (Internal) Combustion Air Intake (Alternate) Primary Limit Gas Line Entrance Flue Pipe Connection (Alternate) Rubber Elbow Induced Draft Blower Electrical Connection Inlets (Alternate) Coil Front Cover Pressure Tap Coil Front Cover Drain Port Drain Line Penetrations 22 23 24 25 26 27 28 29 30 31 32 33
*
10 7 4 1 11 8 5 2 12 9 6 3
15 17 18 19 20 21 22 23 24 26
23 18
3 32
16 30 12
15 17 31
19 21 14
Intell-Ignition
TW O TS TA T SI NG LE ON S1 C US
20
19 20
WR
3 2 1 OF F
21
13 9 8 7 6 4
2 22 7 1
27
25
Counterflow/Horizontal
Drain Trap Blower Door Interlock Switch Capacitor Integrated Control Module (with fuse and diagnostic LED) 24-Volt Thermostat Connections Transformer (40 VA) Circulator Blower Auxiliary Limit Junction Box Electrical Connection Inlets Coil Front Cover Combustion Air Inlet Pipe
II. SAFET Y SAFETY Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL.
If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 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 controls to their containers before touching any ungrounded object. III. PR ODUC T APPLI C ATI ON PRO DUCT APPLIC TIO
This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnace must be installed indoors WARNING (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH This furnace can be used in the following non-industrial commercial MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE applications: STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER Schools, Office buildings, Churches, Retail stores REPRODUCTIVE HARM. Nursing homes, Hotels/motels, Common or office areas In such applications , the furnace must be installed with the followWARNING ing stipulations: It must be installed per the installation instructions provided TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH and per local and national codes. DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT It must be installed indoors in a building constructed on THE ELECTRICAL COMPONENTS FROM WATER. site. It must be part of a ducted system and not used in a free air delivery application. It must not be used as a make-up air unit. WARNING It must be installed with two-pipe systems for combustion air, especially if VOCs or other contaminants are present HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, in the conditioned space. INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILIDNG IN WHICH ANY All other warranty exclusions and restrictions apply This SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE furnace is an ETL dual-certified appliance and is EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES appropriate for use with natural or propane gas ( NOTE: If AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE using propane, a propane conversion kit is required). BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE Dual certification means that the combustion air inlet pipe is opCLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING tional and the furnace can be vented as a: TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD Non-direct vent (single pipe) central forced air furnace in BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES which combustion air is taken from the installation area or SHOULD BE UTILIZED. from air ducted from the outside or, Direct vent (dual pipe) central forced air furnace in which ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS all combustion air supplied directly to the furnace burners through a special air intake system outlined in these NOTE: Discharge static electricity accumulated in the body before instructions. touching the unit. An electrostatic discharge can adversely affect This furnace may be used as a construction site heater ONLY if the electrical components. following conditions are met: Use the following precautions during furnace installation and ser The vent system is permanently installed per these vicing to protect the integrated control module from damage. By installation instructions. putting the furnace, the control, and the person at the same electro A room thermostat is used to control the furnace. Fixed static potential, these steps will help avoid exposing the integrated jumpers that provide continuous heating CANNOT be used. control module to electrostatic discharge. This procedure is appli Return air ducts are provided and sealed to the furnace. cable to both installed and non-installed (ungrounded) furnaces. A return air temperature range between 60F (16C) and 1. Disconnect all power to the furnace. Do not touch the 80F (27C) is maintained. integrated control module or any wire connected to the control Air filters are installed in the system and maintained during prior to discharging your bodys electrostatic charge to construction, replaced as appropriate during construction, ground. and upon completion of construction are replaced. 2. Firmly touch a clean, unpainted, metal surface of the furnaces The input rate and temperature rise are set per the furnace near the control. Any tools held in a persons hand during rating plate. grounding will be discharged. 100% outside air is provided for combustion air 3. Service integrated control module or connecting wiring requirements during construction. Temporary ducting can following the discharge process in step 2. Use caution not to be used. recharge your body with static electricity; (i.e., do not move NOTE: Do not connect the temporary duct directly to the or shuffle your feet, do not touch ungrounded objects, etc.). furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation
QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A
Air Requirements, Section 5.3.3. The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up. All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.
IV . LOC ATI ON REQUIREMENTS & CO NSID ERA TI ONS IV. LOCA TIO CONSID NSIDERA ERATI TIO
GENERAL
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED
WHEN INSTALLING THE UNIT. NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met: Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V, Combus Gas furnaces must be installed by a licensed plumber or tion and Ventilation Air Requirements. gas fitter. Centrally locate the furnace with respect to the proposed A T-handle gas cock must be used. or existing air distribution system. If the unit is to be installed in an attic, the passageway to Ensure the temperature of the return air entering the and the service area around the unit must have flooring. furnace is between 55F and 100F when the furnace is To ensure proper installation and operation, thoroughly read this heating. manual for specifics pertaining to the installation and application of Provide provisions for venting combustion products this product. outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and WARNING combustion air intake pipe when applicable. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, Termination Locations for appropriate termination locations EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON and to determine if the piping system from furnace to MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, termination can be accomplished within the guidelines OR MAINTENANCE OF THIS PRODUCT. given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace. Locate the furnace so condensate flows downwards to the WARNING drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, without proper freeze protection. Refer to Section X, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL Condensate Drain Lines and Trap for further details. VEHICLE. Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose To ensure proper furnace operation, install, operate and maintain building occupants to gas combustion products that could the furnace in accordance with these installation and operation ininclude carbon monoxide. Refer to Section V, Combustion structions, all local building codes and ordinances. In their absence, and Ventilation Air Requirements. follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, Set the furnace on a level floor to enable proper condensate local plumbing or waste water codes, and other applicable codes. drainage. If the floor becomes wet or damp at times, place A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can the furnace above the floor on a concrete base sized be obtained from any of the following: approximately 1-1/2" larger than the base of the furnace. American National Standards Institute Refer to the Section VII, Horizontal Applications and 1430 Broadway Considerations for leveling of horizontal furnaces. New York, NY 10018 Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. National Fire Protection Association The only combustible material allowed is wood. 1 Batterymarch Park A special accessory subbase must be used for upright Quincy, MA 02269 counterflow unit installations over any combustible material CSA International (including wood). Refer to subbase instructions for 8501 East Pleasant Valley installation details. (NOTE: A subbase will not be required Cleveland, OH 44131 if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor. A copy of the CAN/CSA B149 Installation Codes can also be obtained from: Exposure to contaminated combustion air will result in CSA International safety and performance-related problems. Do not install 178 Rexdale Boulevard the furnace where the combustion air is exposed to the Etobicoke, Ontario, Canada M9W 1R3 following substances: The rated heating capacity of the furnace should be greater than or chlorinated waxes or cleaners equal to the total heat loss of the area to be heated. The total heat chlorine-based swimming pool chemicals loss should be calculated by an approved method or in accordance water softening chemicals with ASHRAE Guide or Manual J-Load Calculations published deicing salts or chemicals by the Air Conditioning Contractors of America. carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks
paint removers varnishes hydrochloric acid cements and glues 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 enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Section V, Combustion and Ventilation Air Requirements for details. If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling 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. If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the up/top or down/bottom side of the furnace.
FURNACE SUSPENSION
If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2x2x1/8 angle iron as shown below. The length of rod will depend on the application and the clearances necessary.
PROVIDE 8" MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL
3/8" DIAMETER THREADED ROD (6 PLACES) ASSURE FURNACE IS LEVEL FROM END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 0"-3/4" BELOW THE BACK OF THE FURNACE HOLD DOWN NUTS SUPPORT NUTS
2"X 2" X1/8" ANGLE IRON (3 PLACES) POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMVOAL TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL
Suspended Furnace
EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system 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 the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47b-2002, CSA-2.3b-2002 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: a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition; c. In so 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. 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 maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers; d. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously; e. Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;
CLEARANCES AND ACCESSIBILITY

Installations must adhere to the clearances to combustible materials which this furnace has been design certified to. The minimum clearance information for this furnace is provided on the units clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installations gas, electrical, 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. Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for details. 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.
TOP TOP S ID E S ID E S ID E B O T TO M BOTTO M U p flo w C o u nte rflo w H o rizon ta l
A furnace installed in a confined space (i.e., a closet or utility room) f. After it has been determined that each appliance connected to the must have two ventilation openings with a total minimum free area venting system properly vents when tested as outlined above, reof 0.25 square inches per 1,000 BTU/hr of furnace input rating. Return doors, windows, exhaust fans, fireplace dampers and any other fer to the Product Data Book applicable to your model* for minimum gas burning appliance to their previous conditions of use; clearances to combustible surfaces. One of the ventilation openg. If improper venting is observed during any of the above tests, the ings must be within 12 inches of the top; the other opening must be common venting system must be corrected. within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usu- Corrections must be in accordance with the latest edition of the Naally adequate to satisfy this ventilation requirement. tional Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 In-
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual. 8
stallation Codes. 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 Installation Codes.
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 (Section 5.3), or CSA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building THERMOSTAT LOCATION codes for determining the combustion air requirements for the apThe thermostst should be placed approximately five feet from the pliances. floor on a vibration-free, inside wall in an area having good air circu- Most homes will require outside air be supplied to the furnace area lation. Do not install the thermostat where it may be influenced by by means of ventilation grilles or ducts connecting directly to the any of the following: outdoors or spaces open to the outdoors such as attics or crawl spaces. Drafts, or dead spots behind doors, in corners, or under The following information on air for combustion and ventilation is reprocabinets. duced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section Hot or cold air from registers. 5.3. 5.3.1 General: Radiant heat from the sun.
Light fixtures or other appliances. Radiant heat from a fireplace. Concealed hot or cold water pipes, or chimneys. Unconditioned areas behind the thermostat, such as an outside wall.
(a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases. (b) Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced. (c) In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors. (d) In addition to air needed for combustion, air shall be supplied for ventilation, including all air required for comfort and proper working conditions for personnel. (e) While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.
DRAFTS O R DEAD SPOTS -BEHIN D DO ORS -IN CO RNERS -U NDER CABIN ETS
Thermostat Influences Consult the instructions packaged with the thermostat for mounting instructions and further precautions. ON & VENTIL ATI ON AIR REQUIREMENTS V. CO MBUSTI VENTILA TIO COMBUSTI MBUSTIO
WARNING
POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF
(f) Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER determining the adequacy of a space to provide combustion air reCOMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE quirements. OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA. 5.3.2 Equipment Located in Unconfined Spaces: Improved construction and additional insulation in buildings have In unconfined spaces (see definition below) in buildings, infiltration may reduced heat loss by reducing air infiltration and escape around be adequate to provide air for combustion ventilation and dilution of doors and windows. These changes have helped in reducing heatflue gases. However, in buildings of tight construction (for example, ing/cooling costs but have created a problem supplying combustion weather stripping, heavily insulated, caulked, vapor barrier, etc.), addiand ventilation air for gas fired and other fuel burning appliances. tional air may need to be provided using the methods described in 5.3.3Appliances that pull air out of the house (clothes dryers, exhaust b or 5.3.4. fans, fireplaces, etc.) increase the problem by starving appliances Space, Unconfined. for air. For purposes of this Code, a space whose volume is not less than 50 House depressurization can cause back drafting or improper comcubic feet per 1,000 BTU per hour of the aggregate input rating of all bustion of gas-fired appliances, thereby exposing building occupants appliances installed in that space. Rooms communicating directly with to gas combustion products that could include carbon monoxide. the space in which the appliances are installed through openings not 1. Headaches-Nausea-Dizziness, Flu-Like Symptoms. furnished with doors, are considered a part of the unconfined space. 2. Excessive humidity-heavily frosted windows or a moist clammy feeling in the home. 5.3.3 Equipment Located in Confined Spaces: 3. Smoke from a fireplace will not draw up the chimney. (a) All Air from Inside the Building: The confined space shall be pro4. Flue gases that will not draw up the appliance vent pipe. vided with two permanent openings communicating directly with If this furnace is to be installed in the same space with other gas an additional room(s) of sufficient volume so that the combined 9
volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.
Chimney or Gas Vent
Chimney or Gas Vent Ventilation louvers (each end o f attic)
NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
Outlet Air Water Heater
NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not less than 100 square inches.
Furnace
Inlet air duct [ends 1 ft (300 mm) above floor]
Opening
Equipment Located in Confined Spaces; All Air from Outdoors Through Ventilated Attic. See 5.3.3-b.
Furnace
Water Heater
Opening
3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Equipment Located in Confined Spaces; All Air from Inside Building. See 5.3.3-a.
(b) All Air from Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. 1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent Ventilation louvers (each end of attic)
Furnace
Outlet air duct
NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*.
Water Heater Inlet air duct
NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
Outlet Air Water Heater
*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.
Equipment Located in Confined Spaces; All Air from Outdoors. See 5.3.3-b.
4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.
NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.
Chimney or Gas Vent
Furnace Alternate air inlet
Inlet Air
Ventilation louvers for unheated crawl space
Equipment Located in Confined Spaces; All Air from OutdoorsInlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic. See 5.3.3-b
Opening
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.
Furnace
Water Heater
Alternate Opening Location
Equipment Located in Confined Spaces; All Air from Outdoors Single Air Opening. See 5.3.3-b.
10
5. When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure. 5.3.4 Specially Engineered Installations: The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases. 5.3.5 Louvers and Grilles: In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 6075 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation. 5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces: Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a. VI. INST ALL ATI ON POSITI ONS INSTALL ALLA TIO POSITIO 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 connections. Refer to Recommended Installation Positions figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.
FURNACE MUST BE LEVEL ALTERNATE VENT/FLUE AND COMBUSTION AIR INTAKE LOCATIONS FROM END TO END FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0" - 3/4" BELOW THE BACK PANEL
4 3/4" MINIMUM DRAIN TRAP GAS LINE WITH DRIP LEG (3" MINIMUM) CLEARANCE
DRAIN PAN
DRAIN LINE WITH 1/4" PER FOOT DOWNWARD SLOPE
FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE
36" MINIMUM SERVICE CLEARANCE REQUIRED
Horizontal Furnace
DRAIN TRAP AND LINES

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4 inches below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Section X, Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.
LEVELING
Leveling ensures proper condensate drainage from the heat exchanger 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, generated in the recuperator coil, to flow forward to the recuperator coil front cover.
ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS
In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge NSID ERA TI ONS and counterflow furnaces with right air discharge. This configuraRIZO NT AL APPLI CATI ONS & CO VII. HO NSIDERA ERATI TIO RIZONT NTAL APPLIC TIO CONSID HORIZO tion allows the flue and combustion air piping to be run vertically GENERAL through the side of the furnace. Refer to the Recommended InstalHorizontal applications, in particular, may dictate many of the lation Positions figure for further detail. The standard piping coninstallations specifics such as airflow direction, ductwork connec- nections may also be used in these positions. Refer to Section IX, tions, flue and combustion air pipe connections, etc. The basic ap- Vent/Flue Pipe and Combustion Air Pipe for details concerning the plication of this furnace as a horizontal furnace differs only slightly conversion to the alternate vent/flue and combustion air connecfrom an upright installation. When installing a furnace horizontally, tions. additional consideration must be given to the following:
11
AIR DISCHARGE
ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS
Bottom Return Duct Connection
Side Return Duct Connection
Side Return Duct Connection
AIR DISCHARGE
UPFLOW UPRIGHT
COUNTERFLOW UPRIGHT
This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas. High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. For installations above 7000 feet, please refer to your distributor for required kit(s).
HIGH ALTITUDE GAS ORIFICE CHART Altitude Gas Natural Kit None LPT-00A Orifice #43 #55 Manifold Pressure 3.5" w.c. None Propane 10.0" w.c. Pressure Switch
AIR DISCHARGE
AIR DISCHARGE
0-7000
UPFLOW HORIZONTAL LEFT AIR DISCHARGE
COUNTERFLOW HORIZONTAL RIGHT AIR DISCHARGE
NOTE: In Canada, gas furnaces are certified to 4500 feet.

AIR DISCHARGE
AIR DISCHARGE
UPFLOW HORIZONTAL RIGHT AIR DISCHARGE
COUNTERFLOW HORIZONTAL LEFT AIR DISCHARGE
Contact the distributor for a tabular listing of appropriate manufacturers kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency. ON AIR PIPE IX. VENT/FL UE PIPE & CO MBUSTI VENT/FLUE COMBUSTI MBUSTIO
Recommended Installation Positions 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.
GENERAL
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS
SECTION.
ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the top or bottom of the furnace.
WARNING
UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE
ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED.
DRAIN PAN
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).
LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS
PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.
A condensing gas furnace achieves its high level of efficiency by Refer to Section VII, Horizontal Applications and Conditions - Drain extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. BeTrap and Lines. cause of the relatively low flue gas temperature and water condenFURNACE SUSPENSION sation requirements, PVC pipe is used as venting material. If the furnace is installed in a crawl space it must be suspended This furnace must not be connected to Type B, BW, or L vent or vent from the floor joist or supported by a concrete pad. Never install the connector, and must not be vented into any portion of a factory built furnace on the ground or allow it to be exposed to water. Refer to or masonry chimney except when used as a pathway for PVC as Section IV, Location Requirements and Considerations - Furnace described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel Suspension for further details. appliance. Do not use commercially available no hub connectors OPANE GA S /HI GH AL TITUD E INST ALL ATI ONS other than those shipped with this product. VIII. PR GAS /HIGH ALTITUD TITUDE INSTALL ALLA TIO PRO It is the responsibility of the installer to follow the manufacturers recommendations and to verify that all vent/flue piping and connecWARNING tors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connecPOSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF tions possess adequate structural integrity and support to prevent THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS flue pipe separation, shifting, or sagging during furnace operation. MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL
CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
FREEZE PROTECTION
DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT
This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct 12
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.
TERMINATION LOCATIONS
NOTES: Refer to Section IV, Location Requirements and Considerations for combustion air contaminant restrictions. The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on termination construction. All terminations (flue and/or intake) must be located at least 12 inches above ground level or the anticipated snow 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. The vent termination of a non-direct vent application must 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 build up). A vent termination shall not terminate over public walkways 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.
Non-Direct Vent & Direct Vent Vent/Flue Terminations Non-Direct Vent Vent/Flue Termination
MATERIALS AND JOINING METHODS

WARNING
TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE
KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.
AVOID BREATHING
Two- or three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturers instructions for cutting, cleaning, and solvent cementing of PVC. As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications 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 cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. All 90 elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium 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.
PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

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. Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnaces 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. 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 35F 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.
No Terminations Above Walkway
<10' 3' min.
12"
4' min.
12" min.
4' min.
Grade or Highest Anticipated Snow Level Forced Air Inlet
12" min. 12" min.

Direct Vent Vent/Flue Termination Non-Direct Vent Vent/Flue Termination
Vent Termination Clearances NOTE: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.
13
CANADIAN VENTING REQUIREMENTS

In Canada, venting must conform to the requirements of the current CAN/CSA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the pipe manufacturers instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. 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

DIRECT VENT INSTALLATIONS On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow 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 available no hub connectors. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling. NON-DIRECT VENT INSTALLATIONS A minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage.
COMBUSTION AIR PIPE (DIRECT VENT ONLY)
90 PVC ELBOW (NON-DIRECT VENT)
STANDARD FURNACE CONNECTIONS

It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported. As shipped, attachment couplings for vent/flue and combustion air intake pipe connections are provided on the furnaces top cover (upflow) or basepan (counterflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.
VENT/FLUE PIPE
COMBUSTION AIR PIPE (DIRECT VENT ONLY)
VENT/FLUE PIPE
RUBBER COUPLING WITH W ORM GEAR CLAMPS
90 PVC ELBOW (NON-DIRECT VENT)
RUBBER COUPLINGS WITH WORM GEAR CLAMPS
OR
OR
VENT/FLUE PIPE
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 servicing. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by utilizing two 45 deg. Long-Sweep Elbows and creating an S joint to provide additional space at connection locations. This joint can be rotated on the fitting to establish maximum 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.
UPFLOW
COUNTERFLOW
STANDARD CONNECTIONS
ALTERNATE FURNACE CONNECTIONS

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 A coil, 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. NOTE: Standard and alternate locations can be combined (i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS.
ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps, the Vent/Flue Pipe Cuts figure, and the Alternate Vent/Flue Location figure. NOTE: Counterflow instructions follow the upflow instructions. 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 furnaces internal vent/flue piping to the blower deck.
Increased Clearance Configuration NOTE: Do not use other commercially available no hub connectors 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 Section IX, 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.
14
2. Upflow and Counterflow units. Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent/ flue pipe. 3. Upflow and Counterflow units. Remove the vent/flue pipe from the furnace. 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. Counterflow units. Cut the vent/flue pipe 3.75 inches from the blower deck coupling. See Vent/Flue Pipe Cuts figure. Save vent/flue pipe attached to blower deck coupling for use in the alternate location. Discard remaining pipe and elbows.
FLANGE
3.75"
3 REMOVE PIPE
1 REMOVE 4 SCREWS
1. REMOVE 4 SCREWS
3 REMOVE PIPE
1 REMOVE 3 SCREWS
5 REMOVE AND RELOCATE

2 DETACH RUBBER ELBOW FROM ID BLOWER AND VENT/FLUE PIPE
5 REMOVE AND RELOCATE 2 DETATCH RUBBER ELBOW FROM ID BLOWER AND VENT/FLUE PIPE
UPFLOW
COUNTERFLOW
5 ADDITIONAL PLUG FROM DRAIN KIT 7 EXTERNALLY MOUNT RUBBER ELBOW 6 SECURE TO ID BLOWER WITH RUBBER COUPLING AND HOSE CLAMPS
CUT HERE
COUNTERFLOW/UPRIGHT (UPFLOW SIMILAR)
Vent/Flue Pipe Cuts

5. Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover). 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. 6. Upflow and Counterflow units. Insert cut section of vent/flue pipe and coupling into alternate 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.
6 SECURE TO ID BLOWER WITH RUBBER COUPLING AND HOSE CLAMPS
6 SECURE TO CABINET WITH SCREWS
UPFLOW/HORIZONTAL (COUNTERFLOW SIMILAR)
Alternate Vent/Flue Location
ALTERNATE COMBUSTION AIR INTAKE LOCATION

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 Combustion Air Intake Location figure. NOTE: Counterflow unit instructions follow the upflow instructions. 1. Remove and save the four screws securing the combustion air intake coupling to the furnaces top panel (upflow). Counterflow units. Remove and save the four screws securing the combustion air intake coupling to the basepan. Remove an additional three screws securing the furnaces internal combustion air intake pipe to the blower deck. 2. Remove the combustion air intake coupling and gasket from the top panel. Counterflow units. Remove the combustion air intake pipe from the furnace and cut the pipe at the basepan coupling. Save the basepan coupling and gasket from the blower deck coupling for use in the alternate location. Discard the remaining pipe. 3. Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (top cover).
WARNING
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.
7. Upflow and Counterflow 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. 8. Upflow and Counterflow units. For horizontal installations, externally secure the fieldsupplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.
15
Counterflow units. 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. Upflow and Counterflow units. With the gasket facing the cabinet side panel, and the flanges 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.
(Single Pipe) Piping - Vent/Flue Pipe Terminations for specific details on termination construction. Although non-direct vent installations do not require a combustion air intake pipe, a minimum of one 90 elbow should be attached to the furnaces combustion air intake if: an upright installation uses the standard intake location, or a horizontal installation uses the alternate air intake location. This elbow will guard against inadvertent blockage of the air intake.
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 nondirect 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.
Non-Direct Vent (Single Pipe) Maximum Allowable Length of Vent/Flue Pipe (ft) Unit Input (BTU) 45,000 70,000 90,000 115,000 Pipe (4) Size (inc.) 2 2 2 2 3 Number of Elbows 2 68 68 60 25 58 3 65 65 57 22 55 4 62 62 55 20 52 5 59 59 52 17 49 6 56 56 50 15 46
(1) (2)
CAUTION
BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN
REINSTALLING COUPLING AND SCREWS.
5. Upflow and Counterflow units. For non-direct vent installations installed horizontally, a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. No elbow is required on the alternate combustion air intake of upright installations, however, a minimum clearance of 2 inches is required to assure proper air supply. 6. Upflow and Counterflow units. For direct vent installations , secure field-supplied combustion air intake pipe directly to the air intake coupling. NOTE: A PVC coupling or elbow is required on counterflow units.
1 REMOVE 4 SCREWS 2 REMOVE 2 REMOVE AND CUT 1 3 REMOVE REMOVE 3 SCREWS AND 3 RELOCATE ADDITIONAL PLUG FROM DRAIN KIT 1 REMOVE 4 SCREWS 5 2" CLEARANCE REQUIRED (NON-DIRECT VENT)
(3)(5)
7 53 53 47 12 43
8 50 50 45 10 40
1) One 90 elbow should be secured to the combustion air intake connection. 2) Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee. 3) Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system. 4) 3 diameter pipe can be used in place of 2 diameter pipe. 5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.
3 . REMOVE AND RELOCATE COUNTERFLOW
VENT/FLUE PIPE 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 following figure. Refer to Section IX, 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. Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Section IX, 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 while 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 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. 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.
UPFLOW 4 SECURE TO CABINET 5
UPFLOW/HORIZONTAL SHOWN (COUNTERFLOW SIMILAR)
Alternate Combustion Air Intake Location
NON-DIRECT VENT (SINGLE PIPE) PIPING

Non-direct vent installations 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 furnace, refer to Section IX, Vent/Flue Pipe and Combustion Air - Standard Furnace Connections or Alternate Furnace Connections for specific details. Refer to the following Non-Direct Vent
16
TEE
12 " Min To Roof Or Highest Anticipated Snow Level
tion construction. For details concerning connection of pipes to the furnace, refer to the Section IX, Vent/Flue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections.
VENT/FLUE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake 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 & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems. If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2 thick closed cell foam insulation such as Armaflex or Insultube where required.
Dire ct Ve nt (Dual Pipe) Maximum Allowable Length of Vent/Flue & Combustion Air Intak e Pipe (ft) Unit Input (Btu) Vent/Flue/Air Intake Termination Standard Alternate Standard Alternate Standard Alternate Standard Alternate Standard Alternate Pipe Size 2 2 2 2 2 2 2 2 3 3
(4)
Vertical Termination (Single Pipe)

90 MEDIUM RADIUS ELBOWS
12" MIN. TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL
Num ber of Elbows 2 68 55 68 55 55 42 26 7 88 74 3 65 52 65 52 52 39 23 10 87 70 4 62 49 62 49 5 59 46 59 46
(1)(2)(3)(5)
(in.)
6 56 43 56 43
7 53 40 53 40
8 50 37 50 37
Alternate Vertical Termination (Single Pipe)

WALL INSIDE OUTSIDE TEE or 90ELBOW TURNED DOWN COUPLING ELBOW OR COUPLING
MIN. 12" FROM WALL
12" TO GROUND OR HIGHEST ANTICIPATED SNOW LEVEL
45,000 70,000 90,000 115,000 115,000
49 46 43 40 37 36 33 30 27 24 20 Not Recom mended Not Recomm ended 80 66 76 62 72 58 68 54 64 50
Horizontal Termination (Single Pipe)

12" MIN.
VENT/FLUE TEE or 90 ELBOW TURNED DOWN
1) One 90 elbow should be secured to the combustion air intake connection. 2) Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee. 3) Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system. 4) 3 diameter pipe can be used in place of 2 diameter pipe. 5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.
12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS

The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe Termination 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.
TEE
Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level
DIRECT VENT (DUAL PIPE) PIPING
VENT/FLUE The inlet air screens provided in the installation instruction packet 90 COMBUSTION MEDIUM RADIUS ELBOWS are available for the installer to use in the inlet of the combustion air AIR INTAKE 12" MIN. 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. Direct vent installations require both a combustion air intake and a 12" MIN. TO ROOF OR SCREEN HIGHEST vent/flue pipe. The pipes may be run horizontally and exit through ANTICIPATED SNOW LEVEL 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 24" MAX. 3" MIN. 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 resistant flashVertical Terminations (Dual Pipe) ing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Horizontal terminations should be as shown in the following figure. Section IX, Vent/Flue and Combustion Air Pipe - Termination Loca- Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termitions or Concentric Vent Termination for specific details on termina- nation Location for location restrictions. A 2 3/8 inch diameter wall
17
penetration is required for 2 diameter pipe while a 3 1/2 inch 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.
12" MIN 3" MIN 24" MAX
3" MIN 24" MAX
Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) 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.
Standard Horizontal Terminations (Dual Pipe)
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES

If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit. 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.
90 Medium Radius Elbows Vents
90 MEDIUM RADIUS ELBOW
24" MAX
24" MAX 3" MIN
AIR INTAKE
Alternate Horizontal Vent Termination (Dual Pipe)

3" Min. 24" Max. 24" Max. 3" Min. 24" Max. 3" Min.
12" M IN
3" MIN. 24" MAX.
12" MIN.
Screen
SUPPORT STRAPS
VENT/FLUE TEE
Horizontal Venting Of Multiple Units

COMBUSTION AIR INTAKE.
SCREEN 90 MEDIUM RADIUS ELBOWS
12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL
CONCENTRIC VENT TERMINATION

Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications. X. CO ND ENSA TE DRAIN LINES & DRAIN TRAP COND NDENSA ENSATE
GENERAL
Standard Horizontal Terminations Above Anticipated Snow Level (Dual Pipe) 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 appropriate drain location. In upright installations, the furnaces 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. In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended beneath the furnace. The field-supplied drain system must be in accordance with all local codes and the instructions in the following sections. 18
WARNING
IN UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX. THIS WILL
REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION. DUE TO ELECTRICAL SHOCK.
RIGHT SIDE PANEL RUBBER ELBOW RUBBER ELBOW DRAIN PORT RED HOSE CLAMP TUBE 1 HOSE SIDE PANEL B GROMMET HOLES TUBE(S) 2 FRONT COVER DRAIN PORT RED HOSE CLAMP HOSE A GREEN HOSE CLAMPS (3 PLACES) DRAIN TRAP
FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH
Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace 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 or CPVC. 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 coils plenum. This is necessary to prohibit any interference with the function of the furnaces drain trap.
Upright Standard Connections - Right Side (Upflow Shown, Counterflow Similar)

LEFT SIDE PANEL FRONT COVER DRAIN PORT RED HOSE CLAMP HOSE A SIDE PANEL DRAIN HOLES TUBE(S) 2 DRAIN TRAP RUBBER ELBOW RUBBER ELBOW DRAIN PORT RED HOSE CLAMP TUBE 1 GREEN HOSE CLAMPS (3 PLACES) HOSE B
UPRIGHT INSTALLATIONS
In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet. NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap - Alternate Vent/Flue Hose Connections for upright installations using an alternate vent/flue outlet.
STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS

Upright installations using the standard vent/flue outlet require drain hoses to be connected as follows. The following quantity of hoses, tubes, and hose clamps are provided with the unit.
HOSE A QTY: 1 HOSE B TUBE 1 QTY: 1 TUBE 2 QTY: 2 GREEN HOSE CLAMPS QTY: 3 RED HOSE CLAMPS QTY: 2 QTY: 1
Upright Standard Connections - Left Side (Upflow Shown, Counterflow Similar) 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 red hose clamp. Angle tube outward toward front of furnace. 5. Right side drains Cut 17 3/4 inches from the long end of Hose B and discard. 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. Left side drains Cut X inches from the long end of Hose B and discard. 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.
Cabinet Width Models (inches) (kBTU_Tons) 17 1/2 45__30 21 70__40 090__50 24 1/2 115__50
"X" Length to Cut From Long End of Hose B 7 inches 3 1/2 inches None
Hose and Tube Identification 1. Remove the rubber plug from the front cover drain port (right or left side, depending on the intended drain trap mounting). 2. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear side panel grommet hole. NOTE: For left side drainage, grommets will have to be relocated to left side panel. 19
6. Insert short end of each Tube 2 through side panel grommet 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. For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS

Upright installations using the alternate vent/flue outlet will require right-side only drain hoses to be connected as follows. Refer to
Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection. 1. Remove the rubber plug from the front cover right-side drain port. Save for use in step 3. 2. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear right side panel grommet hole.
RUBBER ELBOW (EXTERNALLY MOUNTED) FRONT COVER DRAIN PORT RUBBER ELBOW DRAIN PORT
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 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.
FRONT COVER DRAIN PORT RED HOSE CLAMP FRONT COVER PRESSURE TAP
HOSE A
RED HOSE CLAMP TUBE 1 HOSE B GREEN HOSE CLAMPS (3 PLACES)
HOSE B SIDE PANEL GROMMET HOLES
RUBBER ELBOW RIGHT SIDE PANEL
RED HOSE CLAMP
HOSE A TUBE(S) 2
SIDE PANEL GROMMET HOLES DRAIN TRAP
TUBES 2 GREEN HOSE TUBE 1 CLAMP (3 PLACES)
DRAIN TRAP
Upright Alternate Connections - Right Side Only (Upflow Shown, Counterflow Similar) 3. Remove grommet from front right-side panel drain hole. Seal hole in grommet with large end of plug. Reinstall grommet and plug into side panel drain hole. 4. Cut 1/4 inch from the end of the drain port on the externally mounted rubber elbow. Discard cut portion. 5. Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp. Angle tube outward toward front of furnace. 6. Cut 17 7/8 inches from the long end of Hose B and discard. 7. Secure remaining 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 Hose A with a green hose clamp. 9. Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp. Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding. For details concerning mounting of the drain trap, refer to the following section.
RUBBER ELBOW DRAIN PORT RED HOSE CLAMP
Horizontal Connections - Right Side Down (Upflow Shown, Counterflow Similar) 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 red 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 down side panel grommet holes. 7. Cut 5 1/2 inches straight length from the long end of each Tube 2. 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. For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
LEFT SIDE DOWN

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. 1. Remove the rubber plug from the coil front cover left (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. 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.
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. Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling.
HORIZONTAL INSTALLATIONS
RIGHT SIDE DOWN
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. NOTE: On counterflow models, relocation of the front cover pressure switch hose is required. Make connections as follows: 1. Remove the rubber plug from the coil front cover drain port. Counterflow furnaces Relocate the front cover pressure switch hose connection from the left side pressure tap to the right (down) side tap. 20
INDUCED DRAFT BLOWER DRAIN PORT HOSE B FRONT COVER PRESSURE TAP HOSE A
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
WIRING HARNESS
GREEN HOSE CLAMPS (3 PLACES) TUBE(S) 2
LEFT SIDE PANEL
FRONT COVER DRAIN PORT RED HOSE CLAMP SIDE PANEL GROMMET HOLES
DRAIN TRAP
The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color and number 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 105C. Any replacement wiring must be copper conductor.
115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. 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 of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. Use a separate fused branch electrical circuit containing properly 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 electrical disconnect must be provided at the furnace location. NOTE: Line polarity must be observed when making field connections.
Horizontal Connections - Left Side Down (Upflow Shown, Counterflow Similar) 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. 6. Cut 5 1/2 inches straight length from the long end of each Tube 2. 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. For details concerning mounting of the drain trap, refer to Section X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
WARNING
IN UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX. THIS WILL
REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION.
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 furnaces top cover or base pan. 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. Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling. XI. ELEC TRI CAL CO NNEC TI ONS ELECTRI TRIC CONNEC NNECTI TIO
Connect hot, neutral, and ground wires as shown in the wiring diagram located on the units blower door. For direct vent applications, the cabinet opening to the junction box must be sealed air tight using either a UL approved bushing such as Heyco Liquid Tight or by applying a UL approved non-reactive sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side (right side for counterflows) electrical connection with the junction box located inside the blower compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the blower compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below. NOTE: Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance.
WARNING
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
POLARIZED AND GROUNDED.
CAUTION
WARNING
TO AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A

PRECAUTION WHEN REMOVING HOLE PLUGS.
1. Remove the burner compartment door. 2. Remove and save the two screws securing the junction box to the side panel. 21
3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2.
The furnaces integrated control module is equipped with line voltage accessory terminals for controlling power to an optional fieldsupplied humidifier and/or electronic air cleaner. The accessory load specifications are as follows:
Humidifier Electronic Air Cleaner

* * * * *
1.0 Amp maximum at 120 VAC 1.0 Amp maximum at 120 VAC
STANDARD JUNCTION BOX LOCATION
ALTERNATE JUNCTION BOX LOCATION
Junction Box Relocation
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. The humidifier and electronic air cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown below.
OPTIONAL ACCESSORIES
ELECTRONIC AIR CLEANER HUMIDIFIER
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
To ensure proper unit grounding, the ground wire should run from HUM-N 120 VAC EAC-N the furnace ground screw located inside the furnace junction box all HOT AND PARK the way back to the electrical panel. NOTE: Do not use gas piping TERMINALS as an electrical ground. To confirm proper unit grounding, turn off INTEGRATED 120 VAC NEUTRAL CONTROL the electrical power and perform the following check. TERMINALS MODULE 1. Measure resistance between the neutral (white) connection 12 PIN and one of the burners. CONNECTOR 2. Resistance should measure 10 ohms or less. Accessories Wiring This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. If it is necessary for the installer to supply additional line voltage Do not defeat this switch. wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105C. All 24 VOLT THERMOSTAT WIRING line voltage wire splices must be made inside the furnace junction NOTE: Wire routing must not interfere with circulator blower box. operation, filter removal, or routine maintenance. The integrated control module humidifier terminals (HUM) are enerLow voltage connections can be made through either the right or left gized with 115 volts whenever the induced draft blower is energized. side panel. Thermostat wiring entrance holes are located adjacent The integrated control module electronic air cleaner terminals (EAC) to the junction box locations in the blower compartment. Wire rout- are energized with 115 volts whenever the circulator blower is enering must not to interfere with circulator blower operation, filter re- gized. moval, or routine maintenance. Refer to the following figure for thermostat connections to the integrated control module terminal strip. 24 VOLT HUMIDIFIER A 1/4 piggy back quick connect terminal on the pressure switch Y Y provides 24VAC humidifier control. This terminal is powered any W W Y Y W W time the pressure switch closes. To connect 24VAC HUM, connect R R the 24VAC line of the humidifier to the piggyback on the pressure C R R G G G switch and the COM line of the humidifier to C on the control board C C terminal strip (or to the COM side of the 24VAC transformer). Do HEATING not connect 115V humidifier to these terminals. HEATING AND REMOTE ROOM
THERMOSTAT FURNACE COOLING ROOM THERMOSTAT FURNACE CONDENSING UNIT
Thermostat Diagram This furnace is equipped with a 40 VA transformer 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.
XII. GA S SUPPL Y AND PIPIN G GAS SUPPLY PIPING
GENERAL
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.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND E LECTRONIC AIR CLEANER)
WARNING
TO AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
HUM-H
EAC-H
CODE.
* *
WARNING
NATIONAL ELECTRIC
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.
22
Inlet gas supply pressures must be maintained within the ranges GAS PIPING specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The GENERAL minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.
CONNECTIONS
CAUTION
Natural Gas Propane Gas
Inlet Gas Supply Pressure Minimum:5.0" W.C. Maximum :10.0" W.C. Minimum:11.0" W.C. Maximum :13.0" W.C.
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE

DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.
HIGH ALTITUDE DERATE

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 combustion 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 altitude and usage of either natural or propane gas. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturers high altitude (Natural, Propane Gas, and/or Pressure Switch) kits. 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 will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping. 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 artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturers pressure switch kits.
When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line. The gas piping supplying the furnace must be properly sized based 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, NFPA 54/ANSI Z223.1.
Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size Pipe in Feet 1/2" 3/4" 1" 1 1/4" 10 132 278 520 1050 20 92 190 350 730 30 73 152 285 590 40 63 130 245 500 50 56 115 215 440 60 50 105 195 400 70 46 96 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific Gravity Gas) CFH = BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)
1 1/2" 1600 1100 980 760 670 610 560 530 490 460
PROPANE GAS CONVERSION
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL
CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
To connect the furnace to the buildings 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 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. Refer to Gas Piping Connections figure for typical gas line connections to the furnace.
This unit is configured for natural gas. The appropriate manufacturers propane gas conversion kit, must be applied for propane gas installations. Refer to the Section VIII, Propane Gas / High Altitude Installations section for details.
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. Use pipe joint compound on male threads ONLY. Always use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads. 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. Always use a back-up wrench when making the connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped
GAS VALVE
This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturers propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. 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 Section XIV, Startup Procedure & Adjustment for use of this control during start up and shut down periods. 23
from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve.
CAUTION
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
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. Tighten all joints securely. Connect the furnace to the building piping by one of the following methods:
DIRECT/STANDARD INLET PIPING

When gas piping enters directly to the gas valve through the standard 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.
Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.
INDIRECT/ALTERNATE INLET PIPING

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.
Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace. 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.
GAS VALVE MANIFOLD BURNERS MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) MANUAL SHUT OFF VALVE (UPSTREAM FRO M GROUND JOINT PIPE UNION) ALTERNATE GAS LINE LOCATION
90 degree elbow. 2 inch close nipple. 90 degree elbow. 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 so as to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.
GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas connections.
PLUG IN ALTERNATE GAS LINE HOLE
ALTERNATE GAS LINE LOCATION
PLUG IN ALTERNATE GAS LINE HOLE
HEIGHT REQUIRED BY LOCAL CODE
HEIGHT REQ UIRED BY LOCAL CODE
WARNING
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR
OPEN FLAME TO TEST FOR LEAKS.
GROUND JOINT PIPE UNION
GROMMET IN STANDARD GAS LINE HOLE DRIP LEG DRIP LEG GROUND JOINT PIPE UNION
UPFLOW
MANUAL SHUT-OFF VALVE (UPSTREAM FROM GROUN D JOINT PIPE UNION) GROU ND JOINT PIPE UNION DRIP LEG GAS VALVE BURNERS GROMMET IN STANDARD GAS LINE HOLE BURNERS GAS VALVE GROUND JOINT PIPE UNION
COUNTERFLOW
MANUAL SHUT-OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION)
DRAIN TRAP MANIFOLD MANIFOLD ALTERNATE GAS LINE LOC ATION PLUG IN ALTERNATE GAS LINE HOLE ALTERNATE GAS LINE LOCATION PLUG IN ALTERNATE GAS LINE HOLE
HORIZONTAL [UPFLOW MODEL]

NOTES: 1. WHEN GAS LINE IS IN THE ALTERNATE LOCATION , SWAP THE POSITION OF THE PLUG AND GROMMET.
HORIZONTAL[COUNTERFLOW]
2. DRIP LEG MAY TERMINATE WITH A 1/2" X 1/8" PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT.
Gas Piping Connections
* GAS VALVE MANIFOLD B URNERS
GROMMET IN STANDARD GAS LINE HOLE
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods. NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. 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). 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).
DRIP LEG GROMMET IN STANDARD GAS LINE HOLE
DRAIN TRAP
PROPANE GAS TANKS AND PIPING

WARNING
ANY LOW AREAS OR CONFINED SPACES.
PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN TO PREVENT PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTION 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 propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the 24
presence of gas is suspected, follow the instructions on Page 5 of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. For satisfactory operation, propane gas pressure must be 11 inch w.c. 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). 3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances. Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied petroleum gases such as Gasolac, Stalactic, Clydes or John Crane are satisfactory. Refer to the following illustration for typical propane gas installations.
First Stage Regulator 5 to 15 PSIG (20 PSIG Max.) Continuous 11" W.C.
Sizing Between Single or Second Stage Regulator and 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 Tubing Size, O.D. Type L Schedule 40 Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1-1/8" 1/2" 3/4" 1" 1-1/4" 1-1/2" Feet 10 39 92 199 329 501 935 275 567 1,071 2,205 3,307 20 26 62 131 216 346 630 189 393 732 1,496 2,299 30 21 50 107 181 277 500 152 315 590 1,212 1,858 40 19 41 90 145 233 427 129 267 504 1,039 1,559 50 18 37 79 131 198 376 114 237 448 913 1,417 60 16 35 72 121 187 340 103 217 409 834 1,275 80 13 29 62 104 155 289 89 185 346 724 1,066 100 11 26 55 90 138 255 78 162 307 630 976 125 10 24 48 81 122 224 69 146 275 567 866 150 9 21 43 72 109 202 63 132 252 511 787 200 8 19 39 66 100 187 54 112 209 439 665 250 8 17 36 60 93 172 48 100 185 390 590 *Data in accordance with NFPA pamphlet NO. 54
Propane Gas Piping Chart II XIII. CIR CUL ATIN G AIR & FIL TER S CIRCUL CULA TING FILTER TERS
DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of America Manual D. A duct system must be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission. 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. A room, closet, or alcove must not be used as a return air chamber. 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 recommended 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. When the furnace is heating, the temperature of the return air entering the furnace must be between 55F and 100F.
200 PSIG Maximum
Second Stage Regulator
Propane Gas Installation (Typ.)

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. Pipe or Nominal Pipe Size Tubing Tubing Size, O.D. Type L Schedule 40 Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" Feet 10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 2,200 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 850 1,700 2,700 4,100 1,600 3,700 50 330 770 1,500 2,400 3,700 1,500 3,400 60 300 700 1,300 2,200 3,300 1,300 3,100 80 260 610 1,200 1,900 2,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 125 200 490 900 1,400 2,300 900 2,100 150 190 430 830 1,300 2,100 830 1,900 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500 To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879
Propane Gas Piping Chart I
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK
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 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 locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. NOTE: An undersized opening will cause reduced airflow. 25
Refer to Minimum Filter Area tables to determine filter area requirements.

COOLING AIRFLOW REQUIREMENT (CFM ) 600 0453_XA Input__Airflow 0703_XA 0704_XA 0904_XA 0905_XA 115_XA 188* ----------800 192 282* --------1000 240 282* 260* 376* ----1200 288 282* 260* 376* 376* 470* 1400 --336 336 376* 376* 470* 1600 ----384 384 384 470* 2000 --------480 480
NOTE: Internal filter retention is not provided on this furnace. If an internal installation is desired, an internal filter retention kit is available as an accessory. Please see your distributor for details.
HORIZONTAL INSTALLATIONS
Filters must be installed in either the central return register or in the return air duct work. XIV . ST AR TUP PR OCEDURE & AD JUST MENT XIV. STAR ARTUP PROCEDURE ADJUST JUSTMENT 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 Section XVI, Operational Checks.
HEAT ANTICIPATOR SETTING

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 setting to 0.7 amps. Follow the thermostat manufacturers instructions on how to adjust the heat anticipator setting.
*Minimum filter area dictated by heating airflow requirement. Permanent Minimum Filter Area (sq. in) [Based on a 600 ft/min filter face velocity]
COOLING AIRFLOW REQUIREMENT (CFM) 600 0453_XA Input__Airflow 0703_XA 0704_XA 0904_XA 0905_XA 1155_XA 376* ----------800 384 564* --------1000 480 564* 564* 752* ----1200 576 564* 564* 752* 752* 940* 1400 --672 672 752* 752* 940* 1600 ----768 768 768 940* 2000 --------800 800
DRAIN TRAP PRIMING

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.
FURNACE OPERATION
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, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed.
*Minimum filter area dictated by heating airflow requirement. Disposable Minimum Filter area (sq. in) [Based on 300 ft/min filter face velocity]
FURNACE STARTUP
1. 2. 3. 4. Close the manual gas shutoff valve external to the furnace. Turn off the electrical power to the furnace. Set the room thermostat to the lowest possible setting. Remove the burner compartment door.
UPRIGHT INSTALLATIONS
Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner NOTE: This furnace is equipped with an ignition device which can be used as the requested filter. automatically lights the burner. Do not try to light the burner by The following figure shows possible filter locations. hand.
FILTER
FILTER ACCESS DOOR
AIR FLOW CENTRAL RETURN GRILLE SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE)
RETURN DUCT FILTER SUPPORT BRACKET (PROVIDED)
CENTRAL RETURN GRILLE
5. Move the furnace gas valve manual control to the OFF position. 6. Wait five minutes then smell for gas. Be sure to check near the floor as some types of gas are heavier than air. 7. If you smell gas after five minutes, immediately follow the 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. 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.
FILTER
FILTER
FI LT ER
ER LT FI
AIR FLOW
FURNACE SHUTDOWN
1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. After a 90, 120, 150 or 180 second 26
Possible Upright Upflow
Possible Upright Counterflow
Filter Locations
delay period (field selectable), the circulator blower will be de-energized. 2. Remove the burner compartment door and move the furnace 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.
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.
GAS SUPPLY PRESSURE MEASUREMENT

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.
WHITE-RODGERS 36F22 GAS VALVE

The line pressure supplied to the gas valve must be within the range specified below.
If supply pressure differs from above, make necessary adjustments 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 started in step 3.
WHITE-RODGERS 36G22 GAS VALVE

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 tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the unit OFF. To measure inlet pressure, use the following procedure.
Gas Valve On/Off Selector Switch
The supply pressure can be measured at the gas valve inlet pressure tap 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 the following procedure.
Gas Valve On/Off Selector Switch
Inlet Pressure Tap
INLET
OUTLET
OUTLET
INLET
Inlet Pressure Tap (Side of Valve) Pressure Regulator Adjustment (Under Cap Screw)
Outlet (Manifold) Pressure Tap
Pressure Regulator Adjustment (Under Cap Screw)
Outlet Pressure Tap
White-Rodgers Model 36F22 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg.
Gas Line Gas Shutoff Valve
Gas Line To Furnace
Open To Atmosphere Drip Leg Cap With Fitting
Manometer Hose
Manometer
Measuring Inlet Gas Pressure (Alt. Method) NOTE: At either location, a hose fitting must be installed prior to making the hose connection. 27
White-Rodgers Model 36G22 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Using 3/32 hex wrench, loosen inlet pressure tap screw one turn. 3. Connect a 5/16 inch hose and calibrated water manometer to the gas valve inlet pressure tap. The hose should overlap the tap by 3/8 inch. 4. Turn ON the gas supply and operate the furnace 5. Leak test. Using a leak detection solution or non-chlorine soap suds, check for leaks at hose connection. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY BEFORE PROCEEDING TO NEXT STEP! 6. Measure furnace gas supply pressure. Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table. If supply pressure reading differs from the table, make necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. 7. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer and hose. Reinstall plug before turning on gas to furnace. 8. Seal pressure port. Tighten inlet pressure tap screw clockwise 7 in-lbs. minimum. 9. Retest for leaks. If bubbles form, shut down gas and fix leaks immediately. 10. Turn valve switch ON.
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

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.
WHITE-RODGERS 36F22 GAS VALVE

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. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap (refer to gas valve figure in previous section). 3. Turn ON the gas supply and operate the furnace. 4. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown.
decrease. Always adjust regulator to provide the correct pressure according to the original equipment manufacturer specifications listed on the appliance rating plate. 7. Replace regulator screw cover and finger-tighten securely. 8. Turn OFF all electrical power to the system. 9. Remove manometer and hose from outlet pressure tap. 10. Tighten outlet pressure tap clockwise 7 in-lbs minimum to seal port. 11. Turn ON system power and set thermostat to call for heat. 12. Using a leak detection solution or non-chlorine soap suds, check for leaks at hose connection. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY! Measure gas manifold pressure with burners firing. Adjust manifold pressure per the Manifold Gas Pressure table. Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice.
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

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. Turn OFF the gas supply to all other gas-burning appliances except the furnace. 2. While the furnace is operating, time and record one complete Manifold Gas Pressure revolution of the smallest gas meter dial. Natural Gas 3.5" w.c. 3. Calculate the number of seconds per cubic foot (sec/ft3) of Propane Gas 10.0" w.c. 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 The final manifold pressure must not vary more than 0.3 w.c. one. If the dial is a two cubic foot dial, divide the number of from the above specified pressures. Any necessary major changes seconds recorded in step 2 by two. in gas flow rate should be made by changing the size of the burner 4. Calculate the furnace input in BTUs per hour (BTU/hr). Input orifice. equals the sum of the installations gas heating value and a 5. To adjust the gas valve pressure regulator, remove the conversion factor (hours to seconds) divided by the number regulator cap. of seconds per cubic foot. The measured input must not be 6. Turn the adjustment screw clockwise to increase the pressure, greater than the input indicated on the unit rating plate. or counterclockwise to decrease the pressure. EXAMPLE: 7. Securely replace the regulator cap. Installations gas heating (HTG) value: 1,000 BTU/ft3 8. Turn OFF gas to furnace at the manual shutoff valve and (Obtained from gas supplier) disconnect manometer. Installations seconds per cubic foot: 34 sec/ ft3 9. Reinstall gas valve outlet pressure tap plug before turning Conversion Factor (hours to seconds): 3600 sec/hr on gas to furnace. Input = (Htg. value x 3600) seconds per cubic foot WHITE-RODGERS 36G22 GAS VALVE Input = (1,000 BTU/ft3 x 3600 sec/hr) 34 sec/ ft3 This valve is shipped from the factory with the regulator preset (see Input = 106,000 BTU/hr control label). Minor changes to the input rate may be accomplished through maniConsult the appliance rating plate to ensure burner manifold presfold pressure adjustments at the gas valve. Refer to Section XIV, sure is as specified. If another outlet pressure is required, follow Startup Procedure and Adjustment - Gas Manifold Pressure Meathese steps. surement and Adjustment for details. NOTE: The final manifold 1. Turn OFF all electrical power to the system. pressure cannot vary by more than 0.3 w.c. from the specified 2. Using a 3/32 inch hex wrench, loosen outlet pressure tap setting. Consult your local gas supplier if additional input rate adscrew one turn. Do not remove screw. justment is required. 3. Connect a calibrated water manometer and 5/16 inch hose 5. Turn ON gas to and relight all other appliances turned off in to the gas valve outlet pressure tap. Hose should overlap step 1. Be certain that all appliances are functioning properly tap by 3/8 inch. and that all pilot burners are operating. 4. Turn ON system power and set thermostat to a call for heat. 5. Using a leak detection solution or non-chlorine soap suds, check for leaks at hose connection. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY! 6. Remove regulator screw cover. Turn regulator screw either clockwise to increase pressure or counterclockwise to
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual. 28
TEMPERATURE RISE
Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the Product Data Book applicable to your model*. Determine and adjust temperature rise as follows: 1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position. 2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to see the heat exchanger.
HEAT EXCHANGER RADIATION "LINE OF SIG HT" SUPPLY AIR
T SU PP LY
and cooling blower speeds are the same, a jumper wire must be used between the heat and cool terminals. 4. Connect all unused blower motor leads to the PARK terminals on the integrated control module. Any leads not connected to the PARK terminals must be taped. 5. Turn ON power to furnace. 6. Verify proper temperature rise as outlined in Section XIV, Startup Procedure and Adjustment - Temperature Rise.
Circulator Blower Speeds Low Red Orange Medium Low Medium Blue Black High White Common/Neutral
XV . NO RM AL SEQUEN CE O F OPERA TI ON XV. NORM RMAL SEQUENCE OF OPERATI TIO
POWER UP
The normal power up sequence is as follows: 115 VAC power applied to furnace.
RISE =
TS UP PLY
T RE TURN
T RE TUR N
RETURN AIR
Integrated control module performs internal checks. Integrated control module flashes LED one time. Integrated control module monitors safety circuits continuously. Furnace awaits call from thermostat.
Temperature Rise Measurement 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. Decrease blower speed to increase temperature rise. Refer to Section XIV, Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.
HEATING MODE
The normal operational sequence in heating mode is as follows: R and W thermostat contacts close, initiating a call for heat.
Integrated control module performs safety circuit checks. Induced draft blower is energized for 15 second prepurge period causing pressure switch contacts to close. Humidifier terminals are energized with induced draft blower. Igniter warm up begins after 15 second prepurge expires. Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame. Integrated control module monitors flame presence. Gas valve will remain open only if flame is sensed. Circulator blower is energized on heat speed following a fixed thirty second blower on delay. Electronic air cleaner terminals are energized with circulator blower. Furnace runs, integrated control module monitors safety circuits continuously. R and W thermostat contacts open, completing the call for heat. Gas valve closes, extinguishing flame. Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are de-energized. Circulator blower is de-energized following the heat off delay period (selectable 90, 120, 150, 180; factory set at 150). Electronic air cleaner terminals are de-energized. Furnace awaits next call from thermostat.
CIRCULATOR BLOWER SPEEDS

WARNING
TO PREVENT PREMATURE FAILURE OF HEAT EXCHANGER, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, DO NOT ADJUST THE LIMIT CONTROL (FACTORY SET).
This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The Product Data Book applicable to your model* provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. The cooling blower speed is shipped set on HIGH, and the heating blower speed is set as indicated in the Product Data Book applicable to your model*. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM. To adjust the circulator blower speed, proceed as follows: 1. Turn OFF power to the furnace. 2. Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Product Data Book. 3. Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module. (Terminals are identified as HEAT and COOL (hot)). If heating 29
COOLING MODE
The normal operational sequence in cooling mode is as follows: R and Y thermostat contacts close, initiating a call for cool.
Integrated control module performs safety circuit checks. Outdoor fan and compressor are energized. Circulator blower is energized on cool speed following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower. Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously. R and Y thermostat contacts open, completing the call for cool. Outdoor fan and compressor are de-energized. Circulator blower is de-energized following a fixed forty five second cool off delay period. Electronic air cleaner terminals are de-energized. Furnace awaits next call from thermostat.
FAN ONLY MODE

The normal operational sequence in fan only mode is as follows: R and G thermostat contacts close, initiating a call for fan.
primary limit control does not function during this test, the cause must be determined and corrected. Function of this control should be verified by gradually blocking the furnace return air after the furnace has been operating (burners firing) for approximately ten minutes. Check the control as follows: 1. Allow the furnace to operate with burners firing continuously for approximately ten minutes. 2. Gradually block the return air to furnace. Remove airflow blockage when limit control is activated and turns off burners. Airflow blockage causes unit overheating and will produce the following reactions: The gas valve to close and extinguish flame, The induced draft blower to deenergized after a fifteen second postpurge, and The circulator blower to remain energized continuously until limit control resets. 3. Remove the return air blockage to clear overheating condition. After an acceptable temperature is reached during the cool down period, the limit control will reset and allow the furnace to resume normal operation. These checks establish that the primary limit control is functioning and will respond to a restriction in the return air, or a circulator blower failure. If the primary limit control does not function during this test, the cause must be determined and corrected. XVII. SAFET Y CIR CUIT DESCRIPTI ON SAFETY CIRCUIT DESCRIPTIO
Integrated control module performs safety circuit checks. Circulator blower is energized on heat speed. Electronic air cleaner terminals are energized. 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 terminals are de-energized. Furnace awaits next call from thermostat. XVI. OPERA TI ONAL CHECK S OPERATI TIO CHECKS
GENERAL
A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module.
INTEGRATED CONTROL MODULE

The integrated control module is an electronic device which, if a potential safety concern is detected, the module will take the necessary precautions and provide diagnostic information through an LED.
PRIMARY LIMIT
The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor. The limit guards against the overheating as a result of insufficient conditioned air passing over the heat exchanger.
BURNER FLAME
The burner flames should be inspected with the burner compartment door installed. A sight glass is provided for inspection purposes. Flames should stable, quiet, soft, and blue (dust may cause AUXILIARY LIMIT orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting The auxiliary limit control(s) are located on or near the circulator off. Flames must not impinge on the sides of the heat exchanger blower and monitors heat exchanger compartment temperatures. They are a normally-closed (electrically), manual-reset, temperafiring tubes. ture activated sensors. These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.
ROLLOUT LIMIT
The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed (electrically), manual-reset, temperature-activated sensors. These limits guard against burner flames not being properly drawn into the heat exchanger.
Check the burner flames for: 1. Good adjustment 2. Stable, soft and blue 3. Not curling, floating, or lifting off.
Burner Flame
PRESSURE SWITCHES
The pressure switches are normally-open (closed during operation), single-pole single-throw, negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft 30
PRIMARY LIMIT
The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger. If the
blower and the coil front cover. These switches guard against insuf- NOTE: If the condition which originally caused the lockout still exists, ficient airflow (combustion air and flue products) through the heat the control will return to lockout. Refer to Section XVIII, exchanger and/or blocked condensate drain conditions. Troubleshooting - Diagnostic Chart for aid in determining the cause.
FLAME SENSOR
The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame. OO TIN G XVIII. TR OUBLESH TING TROUBLESH OUBLESHOO OOTIN
XIX. MAINTENAN CE 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.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge bodys static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. 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 procedure is applicable to both installed and uninstalled (ungrounded) 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 bodys electrostatic charge to ground. 2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a persons 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.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 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 controls to their containers before touching any ungrounded object.
TOUCHING THE IGNITER ELEMENT WITH BARE ONLY A QUALIFIED SERVICER SHOULD
FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE. EVER HANDLE THE IGNITER.
ANNUAL INSPECTION
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 furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary. Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.
Heat exchanger. Check for corrosion and/or buildup within 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.
FILTERS
CAUTION
DIAGNOSTIC CHART
WARNING
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
GIVEN IN THE
TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES PRODUCT DATA BOOK APPLICABLE TO YOUR MODEL*.
Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems. The red diagnostic LED blinks to assist in troubleshooting the unit. The number of blinks refers to a specific fault code.
MAINTENANCE
Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size.
RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts, or when it has lost flame five times during a single call for heat. It is characterized by a non-functioning furnace and a one flash diagnostic LED code. If the furnace is in lockout, it will (or can be) reset in any of the following ways. 1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period. 2. Manual power interruption. Interrupt 115 volt power to the furnace for 0 - 20 seconds. 3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 0 - 20 seconds.
FILTER REMOVAL
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). A media 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. To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. To remove internal filters see Internal Filter Removal section. Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.
31
HORIZONTAL UNIT FILTER REMOVAL Filters in horizontal installations are located in the central return register or the ductwork near the furnace.
To remove:
1. 2. 3. 4. Turn OFF electrical power to furnace. Remove filter(s) from the central return register or ductwork. Replace filter(s) by reversing the procedure for removal. Turn ON electrical power to furnace.
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 in and out several times to obtain sufficient cleaning. Repeat for each tube. 9. Clean residue from furnace using a vacuum cleaner.
BOTTOM RETURN REMOVAL

1. Turn OFF electrical power to furnace. 2. Remove blower compartment door. 3. Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan. 4. Slide filter forward and out. 5. Replace filter by reversing the procedure.
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL Follow the manufacturers directions for service.
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.
BLOWER COMPARTMENT REMOVAL

1. Turn OFF electrical power to furnace. 2. Remove blower compartment door. 3. Grasp lower portion of filter and lift up.
Front of Furnace Front of Furnace
INDUCED DRAFT AND CIRCULATOR BLOWERS

The bearings in the induced draft blower and circulator blower motors 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.
Blower
Filter
Blower
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)

Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary.
Grab Here And Lift
FLAME SENSOR (QUALIFIED SERVICER ONLY)

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 cleaning, the flame sense signal should be 1 to 4 microamps at 115 volts.
4. Angle filter toward the blower until filter clears bottom rail. 5. Lower filter down and pull outward.
Front of Furnace Front of Furnace
Blower
Blower
FLUE PASSAGES (QUALIFIED SERVICER ONLY)

The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below. 1. Turn OFF the electrical power and gas supply to the 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 and, drain and pressure tap hoses from the recuperator coil front cover. 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 32
6. Replace filter by reversing procedure. XXI. BEFO RE LEA VIN G AN INST ALL ATI ON BEFORE LEAVIN VING INSTALL ALLA TIO
Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. Review the Owners Manual with the homeowner and discuss proper furnace operation and maintenance. Leave literature packet near furnace.
XXII. REP AIR & REPL ACEMENT PAR TS REPAIR REPLACEMENT PARTS
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. Functional Parts ListGas Valve Blower Motor Gas Manifold Blower Wheel Natural Gas Orifice Blower Mounting Bracket Propane Gas Orifice Blower Cutoff Igniter Blower Housing Flame Sensor Capacitor Rollout Limit Switch Heat Exchanger Primary Limit Switch Recuperator Coil Auxiliary Limit Switch Coil Front Cover Pressure Switch Integrated Control Module Induced Draft Blower Transformer Door Switch
33
TR OUBLESH OO TIN G CHAR T TROUBLESH OUBLESHOO OOTIN TING CHART
Symptoms of Abnormal Operation Furnace fails to operate. Integrated control module diagnostic LED provides no signal.
Associated 2 LED Code2

NONE
Fault Description(s)
Possible Causes
Corrective Action
Cautions and Notes
No 115 volt power to Manual disconnect switch furnace, or no 24 volt OFF, door switch open, or power to integrated 24 volt wires improperly control module. connected or loose. Blown fuse or circuit Blown fuse or circuit breaker. breaker. Integrated control module has an internal fault. Integrated control module has an internal fault.
LED is Steady On.

ON
CONTINUOUS ON
Normal Operation
Improper thermostat connection or setting.
Assure 115 and 24 volt Turn power OFF power to furnace prior to repair. integrated control Replace integrated module. control module Check integrated control fuse with 3A module fuse (3A). automotive fuse. Replace if necessary. Read precautions Check for possible shorts in Electrostatic in 115 and 24 volt circuits. Discharge section Repair as necessary. of manual. Replace bad integrated control module. Check thermostat Turn power OFF connections and prior to repair. settings. Improper thermostat connection or setting. Locate and correct gas interruption. Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary. Replace or realign igniter. Check flame sense signal. Sand sensor if coated and/or oxidized. Check flue piping for blockage, proper length, elbows, and termination. Verify proper induced draft blower performance. Turn power OFF prior to repair.
Furnace fails to operate. Integrated control module diagnostic LED is flashing ONE (1) flash.
1
1 FLASH
Furnace lockout due Failure to establish flame. to an excessive Cause may be no gas to number of ignition burners, front cover retries (3 total) or pressure switch stuck open, recycles infinite1. bad igniter or igniter alignment, improper orifices, or coated/oxidized or improperly connected flame sensor. Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.
Igniter is fragile, handle with care. Sand flame sensor with emery cloth. See Vent/Flue Pipe section for piping details.
Furnace fails to operate. Integrated control module diagnostic LED is flashing TWO (2) flashes. Induced draft blower runs continuously with no further furnace operation. Integrated control module diagnostic LED is flashing THREE (3) flashes.
Pressure switch circuit is closed. Induced draft blower is not 2 FLASHES operating.
2
Induced draft blower pressure switch contacts sticking. Shorts in pressure switch circuit.
Replace induced draft blower pressure switch. Repair short.
Turn power OFF prior to repair. Replace pressure switch with proper replacement part.
Pressure switch Pressure switch hose circuit not closed. blocked, pinched or Induced draft blower connected improperly. is operating. Blocked flue and/or inlet air 3 FLASHES pipe, blocked drain system, or weak induced draft blower.
3
Incorrect pressure switch setpoint or malfunctioning switch contacts. Loose or improperly connected wiring.
1 2
Inspect pressure Turn power switch hose. Repair, if OFF prior to necessary, repair. Inspect flue and/or inlet Replace air piping for blockage, pressure proper length, elbows, switch with and termination. Check proper drain system. Correct replacement as necessary. part. Correct pressure switch setpoint or contact motion. Tighten or correct wiring connection.
Integrated control module will automatically attempt to reset from lockout after one hour. 34
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
TR OUBLESH OO TIN G CHAR T TROUBLESH OUBLESHOO OOTIN TING CHART
Symptoms of Abnormal Operation
Associated LED Code2
Fault Description(s) Primary or auxiliary limit circuit is open.
Possible Causes Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.
Corrective Action Check filters and ductwork for blockage. Clean filters or remove obstruction. Check circulator blower speed and performance. Correct speed or replace blower if necessary. Tighten or correct wiring connection. Correct short at flame sensor or in flame sensor wiring.
Cautions and Notes Turn power OFF prior to repair. Replace pressure switch with proper replacement part.
Circulator blower runs continuously. No furnace 4 operation. Integrated control 4 FLASHES module diagnostic LED is flashing FOUR (4) flashes.
Loose or improperly connected wiring. Induced draft blower runs continuously. No furnace 5 operation. Integrated control 5 FLASHES module diagnostic LED is flashing FIVE (5) flashes. Circulator blower runs continuously. No furnace 6 operation. Integrated control 6 FLASHES module diagnostic LED is flashing SIX (6) flashes. Flame sensed with no call for heat. Short to ground in flame sense circuit.
Turn power OFF prior to repair.
Rollout limit circuit is Flame rollout. open. Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower. Loose or improperly connected wiring.
Check burners for proper alignment. Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary. Check induced draft blower for proper performance. Replace, if necessary. Tighten or correct wiring connection. Sand flame sensor is coated/oxidized. Inspect for proper sensor alignment. Check inlet air piping for blockage, proper length, elbows, and termination. Compare current gas pressure to rating plate info. Adjust as needed. Check and correct wiring from integrated control module to igniter. Replace bad igniter. Check and correct unit ground wiring. Review wiring diagram to correct polarity.
Turn power OFF prior to repair. See Vent/Flue Pipe section for piping details.
Ensure the correct pressure switch replacement is used.
Normal furnace operation. Integrated control module diagnostic LED is flashing SEVEN (7) flashes.
7
7 FLASHES
Flame sense microamp signal is low.
Flame sensor is coated/ oxidized. Flame sensor incorrectly positioned in burner flame. Lazy burner flame due to improper gas pressure or combustion air.
Turn power OFF prior to repair. Sand flame sensor with emery clot. See Vent/Flue Pipe section for piping details. See rating plate for proper gas pressure. Turn power OFF prior to repair.
Furnace not operating. Integrated control module diagnostic LED is flashing EIGHT (8) flashes.
8
8 FLASHES
Problem with igniter circuit.
Improperly connected igniter.
Bad igniter. Poor unit ground.
Replace igniter with proper silicon nitride replacement part. Turn power OFF prior to repair.
Furnace fails to operate. Integrated control C module diagnostic LED is flashing continuously. CONTINUOUS/
RAPID FLASH
Polarity of 115 or 24 volt power is reversed.
Polarity of 115 volt AC power to furnace or integrated control module is reversed. Orange and gray wires to transformer are reversed. Poor unit ground.
Reverse orange and gray wires going to transformer. Verify proper ground. Correct if necessary.
35
AMS9/ACS9 WIRIN G DIAGRA M WIRING DIAGRAM
WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT THE POWER
BEFORE SERVICING.
OR
BLOWER COMPARTMENT DOOR SWITCH (OPEN WHEN DOOR OPEN) INTEGRATED CONTROL MODULE
40 VA TRANSFORMER 24V HUMIDIFIER

24V THERMOSTAT CONNECTIONS
HUMIDIFIER TR (6) GND (8) MVC (9) GND
GY
24 VAC 115 VAC
C2 NO P3 C M1
GAS VALVE
MV (12) C
FRONT COVER PRESSURE SWITCH
BK WH
ID BLOWER PRESSURE SWITCH
BK
FUSE
24VAC 3A
DIAGNOSTIC LED
G Y W TO MICRO
PS (10) PSO (4) HLI (7) HLO (1)
NO
BK
OR
3 6 9 12 2 5 8 11 1 4 7 10
BLOWER HEAT OFF DELAY SELECTOR (SECONDS) DIP SWITCHES
115 VAC HOT AND PARK TERMINALS COOL-H HEAT-H
*
AS SHIPPED FROM FACTORY
ON ON OFF ON ON OFF OFF OFF
PK OR BU
YL
BU
90 120 150
GN
R FUSE 3 A RO2 (11) RO1 (5)
UAL RESETAUXILIARY M AN LS LIMIT CONTRO
ESET AUT OR Y AR PRIM LIMIT OL CONTR
180 GY GY RD
*
XFMR-H
OR BR
OR
XFMR-N
GY
TH (3)
LOUT MANUAL RESET ROL LIMIT CONTROL(S) (SINGLE CONTROL O ) N 45K BTU 24 VAC 40 VA TRANSFORMER
LINE-N
115 VAC NEUTRAL TERMINALS
4 3 2 1
WH
XFMR-H
115 VAC FLAME SENSOR
XFMR-N
9 CIRCUIT CONNECTOR
PK
CIRC-N
FP (2)
WH
BK
HOT SURFACE IGNITER IGN

GND WH
SEE NOTE 4
LINE-H
HUM-H HUMIDIFIER HUM-N ID BLWR COOL-H

CO OL
GN
RD
BK (HI) BU (MED) OR (MED LOW) RD (LOW) BR
RD
PK
WH YL
IND
BU
GY
BK
VT
YL
BU
BR
C IR C U L A T O R B L O W E R
OR
CIRCULATOR BLWR
AT HE
BR
CIR-N
WH
VT
OR
CAPACITOR
HEAT-H ELECTRONIC AIR CLEANER
BLOWER COMPARTMENT BURNER COMPARTMENT GND

MANUAL RESET AUXILARY LIMITS (1) IN UPFLOW BLOWER DECK (2) IN C'FLOW BLOWER HOUSING
EAC-H
LINE-H
EAC-N
LINE-N
JUNCTION BOX DOOR SWITCH
BK WH INDUCED DRAFT BLOWER
WH
WARNING: WH DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
DISCONNECT
SET AUTO RE ARYLIMIT PRIM L TRO CON BU

YL RD
VT
GND
OR
NO C
OR PK M L(S) TRO IT CON LLOUT LIM O ESET R ANUAL R OL ON45KBTU) TR N GLE CO ( SIN
FRONT COVER PRESSURE SWITCH GY GND BR FLAME SENSOR GN
BK
TO 115VAC/ 1 /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE

RD
WH
ID BLOWER PRSEEURE SWITCH
24V HUMIDIFIER
BU
JUNCTION BOX
WH
WARNING:DISCONNECT POWER BEFORE SERVICING.WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
T O1 1 5V A C /1 0 /6 0 H Z P O W E RS U P P L YW IT H O V E R C U R R E N TP R O T E C T IO N D E V IC E
2 CIRCUIT CONNECTOR
HOT SURFACE IGNITER
0
M1 P3 C2
GAS VALVE
GY
NO
N GND L
D IS C O N N E C T
STEADY ON = NORMAL OPERATION OFF = CONTROL FAILURE

LOW VOLTAGE (24V) LOW VOLTAGE FIELD HI VOLTAGE (115V) HI VOLTAGE FIELD JUNCTION EQUIPMENT GND FIELD GND
1 2 3 4 5 6 7 8 C
1 FLASH = SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED) 2 FLASHES = PRESSURE SWITCH STUCK CLOSED 3 FLASHES = PRESSURE SWITCH STUCK OPEN 4 FLASHES = OPEN HIGH LIMIT 5 FLASHES = FLAME SENSE WITHOUT GAS VALVE 6 FLASHES = OPEN ROLLOUT 7 FLASHES = LOW FLAME SIGNAL 8 FLASHES = CHECK IGNITER OR IMPROPER GROUNDING CONTINUOUS/RAPID FLASHES = REVERSED 115 VAC POLARITY PK PINK
BR BROWN WH WHITE BU BLUE GY GRAY RD RED
FIELD SPLICE SWITCH (TEMP.)

IGNITER
TERMINAL
INTERNAL TO INTEGRATED CONTROL
SWITCH (PRESS.)
OVERCURRENT PROT. DEVICE
PLUG CONNECTION
COLOR CODES: YL YELLOW OR ORANGE VT VIOLET GN GREEN BK BLACK
22314901 REV.01
NOTES: 1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS. 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 WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105C. USE COPPER CONDUCTORS ONLY. 4. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. UNUSED BLOWER LEADS MUST BE PLACED ON "PARK" TERMINALS OF INTEGRATED CONTROL OR TAPED. 5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring. 36
DMS9/DCS9 WIRIN G DIAGRA M WIRING DIAGRAM
WARNING
24 VAC HUMIDIFIER
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT THE POWER
BEFORE SERVICING.
OR GY
BLOWER COMPARTMENT DOOR SWITCH (OPEN WHEN DOOR OPEN)
HUMIDIFIER
TR (6) GND (8)
GND
24 VAC 40 VA TRANSFORM ER
24V THERMOSTAT CONNECTIONS C G R
C2
115 VAC
W
MVC (9) NO MV (12) FRONT COVER PRESSURE SWITCH

GAS VALVE
Y TWIN
M1
BK
WH
DIAGNOSTIC LED
ID BLOWER PRESSURE SWITCH C NO
BK
G Y W TO MICRO
BK
PS (10) PSO (4) HLI (7) HLO (1)
FUSE
OR INTEGRATED CONTROL MODULE

3 6 9 2 5 8 11 1 4 7 10
PK OR BU YL OR BR GN
BU
R RO2 (11) RO1 (5)
ILIARY AL RESET AUX M ANU LS O ONTR LIMIT C
BLOWER HEAT OFF DELAY SELECTOR (SECONDS) DIP SWITCHES

ON ON OFF ON ON OFF OFF OFF
12
AUTORESET PRIM ARY LIMIT CONTR OL
GY
GY RD GY
90 120 150 180

XFMR-H
TH (3)
T UAL RESET ROLLOU MAN LIMITCONTROL(S) LE CO K BTU) NTROLON 45 (SING 24 VAC 40 VA TRANSFORMER
OR
XFMR-N
115 VAC NEUTRAL TERMINALS
LINE-N
WH
9 CIRCUIT CONNECTOR
AS SHIPPED FROM FACTORY
XFMR-H
115 VAC FLAME SENSOR
XFMR-N
115 VAC HOT AND PARK TERMINALS COOL-H HEAT-H
*
GND BR BR
PK
2 1
CIRC-N
FP (2)
WH
BK
HOT SURFACE IGNITER IGN HUM-H HUMIDIFIER HUM-N ID BLWR COOL-H

CO OL
SEE NOTE 4 WH
LINE-H
GN
RD
BK (HI) BU (MED) OR (MED LOW) RD (LOW)

C IR C U L A T O R B L O W E R
RD
PK
WH
IND
YL
BU
BK
VT YL
GY
BU
OR BR
CIRCULATOR BLWR
AT HE
CIR-N
WH
VT
OR
CAPACITOR
HEAT-H
ELECTRONIC AIR CLEANER
BLOWER COMPARTMENT BURNER COMPARTMENT GND BK WH INDUCED DRAFT BLOWER WH ET AUTORES IT ARY LIM PRIM CON L TRO BU YL RD OR
NO C
EAC-H
EAC-N
LINE-N
MANUAL RESET AUXILIARY LIMITS (1) IN UPFLOW BLOWER DECK (2) IN C'FLOW BLOWER HOUSING
LINE-H JUNCTION BOX DOOR SWITCH
WH
WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
DISCONNECT
VT
GND
OR PK L(S) TRO IT CON T LIM LLOU O ET R L RES ANUA M OLON45KBT TR N ( SINGL E CO U)

FRONT COVER PRESSURE SWITCH
TO 115VAC/ 1 /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE

RD
WH ID BLOWER PRESSURE SWITCH

2 CIRCUIT CONNECTOR HOT SURFACE IGNITER
24 VAC HUMIDIFIER
BU
JUNCTION BOX
WARNING:DISCONNECT POWER BEFORE SERVICING.WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
T O 1 1 5V A C /1 0 /6 0 H Z P O W E RS U P P L YW IT H D E V IC E O V E R C U R R E N TP R O T E C T IO N
M1
GY
NO
GY GND GN
WH
N GND
C2
BR GAS VALVE FLAME SENSOR
BK
L
D IS C O N N E C T
STEADY ON = NORMAL OPERATION OFF = CONTROL FAILURE
LOW VOLTAGE (24V) LOW VOLTAGE FIELD HI VOLTAGE (115V) HI VOLTAGE FIELD JUNCTION TERMINAL INTERNAL TO INTEGRATED CONTROL PLUG CONNECTION
EQUIPMENT GND FIELD GND FIELD SPLICE SWITCH (TEMP.) IGNITER SWITCH (PRESS.) OVERCURRENT PROT. DEVICE
1 2 3 4 5 6 7 C
1 FLASH = SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED) 2 FLASHES = PRESSURE SWITCH STUCK CLOSED 3 FLASHES = PRESSURE SWITCH STUCK OPEN 4 FLASHES = OPEN HIGH LIMIT 5 FLASHES = FLAME SENSE WITHOUT GAS VALVE 6 FLASHES = OPEN ROLLOUT 7 FLASHES = LOW FLAME SIGNAL CONTINUOUS/RAPID FLASHES = REVERSED 115 VAC POLARITY PK PINK BR BROWN WH WHITE BU BLUE GY GRAY RD RED
COLOR CODES: YL YELLOW OR ORANGE VT VIOLET GN GREEN BK BLACK
22314801 REV.01
NOTES: 1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS. 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 WITH WIRING MATERIAL HAVING A TEMPERATURE C. USE COPPER CONDUCTORS ONLY. RATING OF AT LEAST 105 4. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. UNUSED BLOWER LEADS MUST BE PLACED ON "PARK" TERMINALS OF INTEGRATED CONTROL OR TAPED. 5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring. 37
is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved.
2550 North Loop West, Suite 400 Houston, TX 77092 www.amana-hac.com

2004-2006 Goodman Company, L.P. 38

DCS9 Installation Instructions

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DCS9 Installation Instructions

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AMS9/ACS9/DMS9/DCS9 GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS

Installer: Affix all manuals adjacent to the unit.

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 6

XII. Gas Supply and Piping .............................................................................................................................................. 22

XIII. Circulating Air & Filters ............................................................................................................................................ 25

XV. Normal Sequence of Operation ................................................................................................................................. 29

XVI. Operational Checks .................................................................................................................................................. 30

XVII. Safety Circuit Description ....................................................................................................................................... 30

XVIII. Troubleshooting ...................................................................................................................................................... 31

XIX. Maintenance .............................................................................................................................................................. 31

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

FOLLOW THE GAS SUPPLIERS INSTRUCTIONS.

CARBON MONOXIDE POISONING HAZARD

CO can cause serious illness including permanent brain damage or death.

Keep this literature in a safe place for future reference.

I. CO MPO NENT ID ENTIFI CATI ON COMPO MPONENT IDENTIFI ENTIFIC TIO

FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

EXISTING FURNACE REMOVAL

CLEARANCES AND ACCESSIBILITY

Chimney or Gas Vent Ventilation louvers (each end o f attic)

Inlet air duct [ends 1 ft (300 mm) above floor]

Outlet air duct

Water Heater Inlet air duct

Furnace Alternate air inlet

Ventilation louvers for unheated crawl space

Alternate Opening Location

DRAIN LINE WITH 1/4" PER FOOT DOWNWARD SLOPE

FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE

36" MINIMUM SERVICE CLEARANCE REQUIRED

DRAIN TRAP AND LINES

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS

ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS

Bottom Return Duct Connection

ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS

Side Return Duct Connection

Side Return Duct Connection

Bottom Return Duct Connection

Bottom Return Duct Connection

Bottom Return Duct Connection

UPFLOW HORIZONTAL LEFT AIR DISCHARGE

COUNTERFLOW HORIZONTAL RIGHT AIR DISCHARGE

NOTE: In Canada, gas furnaces are certified to 4500 feet.

Bottom Return Duct Connection

UPFLOW HORIZONTAL RIGHT AIR DISCHARGE

COUNTERFLOW HORIZONTAL LEFT AIR DISCHARGE

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS

LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

MATERIALS AND JOINING METHODS

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES

No Terminations Above Walkway

<10' 3' min.

Grade or Highest Anticipated Snow Level Forced Air Inlet

12" min. 12" min.

CANADIAN VENTING REQUIREMENTS

COMBUSTION AIR PIPE

STANDARD FURNACE CONNECTIONS