Bryant - 310AAV AHAA-AHAJ - Installation - Instructions PDF

310AAV/JAV
Induced-Combustion
4-Way Multipoise Furnace
Installation, Start-up, Operating, and

Service and Maintenance Instructions
-Series A
The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant

dealers for Bryant dealers. Applications are easy with 4-way multipoise
design, through-the-furnace downflow venting, 13 different venting options,
and a door designed for easy service access. An inner blower door is
provided for tighter sealing in sensitive applications. The 310AAV/JAV
furnace is approved for use with natural or propane gas, and the 310JAV is
also approved for use in Low NOx Air Quality Management Districts.
STANDARD FEATURES
• Noise elimination combustion system
• Microprocessor based control center
Adjustable heating air temperature rise
LED diagnostics and self test feature
• Patented blocked vent safeguard to ensure proper furnace venting
• All models are Chimney Friendly when used with accessory vent kit
• Four-position furnace: upflow, horizontal right, horizontal left,
downflow
Thirteen different vent options
• Heat pump compatible
• Hot surface ignition (HSI)
• Residential installations eligible for consumer financing through the Comfort
Credit Program
• Twinning in Upflow, Downflow and Horizontal
LIMITED WARRANTY
• 20-year warranty on “Super S™” heat exchanger
• 5-year parts warranty on all other components
Catalog No: 5331-205 Form No. II 310A-45-3 12-02

Single-Stage
Induced-Combustion
4-Way Multipoise Furnace
Cancels: II 310A-45-2/IM-PG8J-02 II 310A-
45-3 / IM-PG8J-03
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Series 100/A
NOTE: Read the entire instruction manual before starting the
EFFICIENCY
installation. RATING
CERTIFIED
This symbol → indicates a change since the last issue.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................2 ier
Cor pora
rr ti
INTRODUCTION ..........................................................................4
on
Ca
CODES AND STANDARDS........................................................4 CERTIFIED
REG
Safety.........................................................................................4
M
®
General Installation...................................................................4 ST
IR
E R E D F8 3
I
Combustion and Ventilation Air ..............................................4 SO
I
900
Duct Systems ............................................................................5 1 #A28
Acoustical Lining and Fibrous Glass Duct..............................5 REGISTERED QUALITY SYSTEM
Gas Piping and Gas Pipe Pressure Testing..............................5
Electrical Connections ..............................................................5
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 24-V Wiring.......................................................................17
PROCEDURE ................................................................................5 Accessories ........................................................................17
LOCATION....................................................................................5 Venting ....................................................................................18
General ......................................................................................5 General Venting Requirements .........................................19
Location Relative to Cooling Equipment ................................6 Masonry Chimney Requirements......................................19
AIR FOR COMBUSTION AND VENTILATION ......................6 Appliance Application Requirements ...............................21
Unconfined Space .....................................................................7 Additional Venting Requirements.....................................21
Confined Space .........................................................................7 Sidewall Venting ...............................................................21
INSTALLATION ...........................................................................8 START-UP, ADJUSTMENT, AND SAFETY CHECK ............21
Upflow Installation ...................................................................8 General ....................................................................................21
Bottom Return Air Inlet ......................................................8 Start-Up Procedures ................................................................23
Side Return Air Inlet...........................................................8 Adjustments.............................................................................23
Leveling Legs (If Desired)..................................................8 Check Safety Controls ............................................................29
Downflow Installation ..............................................................8 Checklist..................................................................................30
Bottom Return Air Inlet ......................................................9 SERVICE AND MAINTENANCE PROCEDURES..................30
Horizontal Installation ..............................................................9 Introduction .............................................................................30
Suspended Unit Support......................................................9 General...............................................................................30
Platform Unit Support .........................................................9 Electrical Controls and Wiring .........................................30
Roll-Out Protection..............................................................9 Care and Maintenance ............................................................31
Bottom Return Air Inlet ......................................................9 Cleaning and/or Replacing Air Filter ...............................32
Side Return Air Inlet...........................................................9 Blower Motor and Wheel..................................................32
Filter Arrangement....................................................................9 Cleaning Heat Exchanger..................................................33
Air Ducts...................................................................................9 Sequence of Operation............................................................34
General Requirements .........................................................9 Wiring Diagrams.....................................................................35
Ductwork Acoustical Treatment .......................................11 Troubleshooting ......................................................................35
Supply Air Connections ....................................................12
Return Air Connections.....................................................13
Gas Piping...............................................................................13
Electrical Connections ............................................................15
115-V Wiring.....................................................................16
J-Box Relocation ...............................................................16
Electrical Connection to J-Box .........................................16
For Power Cord Installation..............................................16
For BX Cable Installation .................................................17
For Power Cord Installation..............................................17
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4 PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-11SI Pg 1 12-02 Replaces: 58ST-2SI
Tab 6a 8a
28-7/8"
25-1/4"
1-9/16"
22-9/16" A 2-9/16"
AIRFLOW
JUNCTION BOX 19" 13/16"

LOCATION D 13/16"
OUTLET
F 4-13/16"
7/8" DIA
ACCESSORY 8-7/16" 11/16"
1-1/2" DIA.
1/2" DIA THERMOSTAT RIGHT HAND
WIRE ENTRY GAS ENTRY
3-15/16" 1/2" DIA. THERMOSTAT

WIRE ENTRY
LEFT HAND GAS 1-7/16"
ENTRY ALTERNATE
33-5/16" 24-7/8" JUNCTION BOX
LOCATION (TYP)
VENT OUTLET
5 PLACES (TYP) 14-7/8"
7/8" DIA. ACCESSORY 3-3/4" 7/8" DIA. ACCESSORY
11/16" 5-1/2"
21-5/8" 1-11/16" E 11/16" 1-1/4"
BOTTOM INLET 22-1/16" 1"
SIDE INLET
A02304
NOTES:
1. Two additional 7/8-in. diameter holes are located in the top plate.
2. Minimum return-air openings ar furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle.
b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.
c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
→ Fig. 1—Dimensional Drawing
SAFETY CONSIDERATIONS
Sheet metal parts may have sharp edges or burrs. Use care and
Improper installation, adjustment, alteration, service, mainte- wear appropriate protective clothing and gloves when han-
nance, or use can cause carbon monoxide poisoning, explo- dling parts. Failure to follow this caution could result in
sion, fire, electrical shock, or other conditions which may personal injury.
cause personal injury or property damage. Consult a qualified Wear safety glasses and work gloves. Have fire extinguisher
installer, service agency, local gas supplier, or your distribu- available during start-up and adjustment procedures and service
tor or branch for information or assistance. The qualified calls.
installer or agency must use only factory-authorized and
listed kits or accessories when modifying this product. Failure This is the safety-alert symbol . When you see this symbol on
to follow this warning could result in electrical shock, fire, the furnace and in instructions or manuals, be alert to the potential
personal injury, or death. for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
→ Application of this furnace should be indoors with special severe personal injury or death. WARNING signifies a hazard
attention given to vent sizing and material, gas input rate, air which could result in personal injury or death. CAUTION is used
temperature rise, unit leveling, and unit sizing. Improper to identify unsafe practices which would result in minor personal
installation or misapplication of furnace can require excessive injury or product and property damage. NOTE is used to highlight
servicing or cause premature component failure. suggestions which will result in enhanced installation, reliability,
→ Installing and servicing heating equipment can be hazardous due to or operation.
gas and electrical components. Only trained and qualified 1. Use only with type of gas approved for this furnace. Refer to
personnel should install, repair, or service heating equipment. the furnace rating plate.
Untrained personnel can perform basic maintenance functions 2. Install this furnace only in a location and position as specified
such as cleaning and replacing air filters. All other operations must in the “Location” section of these instructions.
be performed by trained service personnel. When working on
3. Provide adequate combustion and ventilation air to the furnace
heating equipment, observe precautions in literature, on tags, and
space as specified in “Air for Combustion and Ventilation”
on labels attached to or shipped with unit and other safety
section.
precautions that may apply.
4. Combustion products must be discharged outdoors. Connect
These instructions cover minimum requirements and conform to
this furnace to an approved vent system only, as specified in
existing national standards and safety codes. In some instances,
the “Venting” section of these instructions.
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residen- 5. Never test for gas leaks with an open flame. Use a commer-
tial construction practices. We require these instructions as a cially available soap solution made specifically for the detec-
minimum for a safe installation. tion of leaks to check all connections, as specified in the “Gas
Piping” section.
2
INSTALLATION
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES
This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and
natural gas at altitudes 0-10,000 ft (0-3,050m). HORIZONTAL installations.
An accessory kit, supplied by the Cette fournaise est approuvée pour línstallation HORIZONTALE
manufacturer,shall be used to convert to propane et la circulation dáir VERS LE HAUT et VERS LE BAS.
gas use or may be required for some natural gas 1" Les fléches de dégagement
Clearance arrows
applications.
DESSUS / CHAMBRED’AIR
do not change with ne changent pas avec
This furnace is for indoor installation in a furnace orientation. lórientation de la fournaise.
TOP / PLENUM
building constructed on site.
This furnace may be installed on combustible
flooring in alcove or closet at minimum clearance
as indicated by the diagram from combustible 0" 0"
B
SI T È *
material . A
R
AC DE
K
This furnace may be used with a Type B-1 Vent R IÈ E CÔ
RE AC SE
and may be vented in common with other gas- RN A I
F U URN
fired appliances. FO NT O
F R ANT
Cette fournaise à air pulsé est équipée AV S
E
EN R V
pour utilisation avec gaz naturel et altitudes TR I
DE F ET C E
comprises entre 0-3,050m (0-10,000 pi). SI
R
A V ON
IE
Utiliser une trousse de conversion, fournie par ÔT
É
A
N
T
N 30"
C T MIN
3"MIN
le fabricant, pour passer au gaz propane ou pour
certaines installations au gaz naturel.
* 0" Ø
DESSOUS
BOTTOM
Cette fournaise est prévue pour être
installée dans un bâtiment construit sur place. Clearance in inches
Cette fournaise peut être installée sur Dégagement (po).
0"
un plancher combustible dans une alcôve ou
†
dans un garde-robe en respectant le minimum
d'espace libre des matériaux combustibles, tel Vent Clearance to combustibles:
qu'indiqué
. sur le diagramme. For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
Cette fournaise peut être utilisée avec un
Dégagement de l´évent avec combustibles:
conduit d´évacuation de Type B-1 ou connectée Pour conduit d´évacuation à paroi simple 6 po (6 inches).
.au conduit commun dáutres appareils à gaz. Pour conduit d´évacuation de Type B-1 1 po (1 inch).
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DOWNFLOW POSITIONS:
† Installation on non-combustible floors only.
For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
Ø 18 inches front clearance required for alcove.
Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible
* between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists,
studs or framing.
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COMBUSTIBLES
POUR LA POSITION COURANT DESCENDANT:
† Pour línstallation sur plancher non combustible seulement.
Pour línstallation sur un plancher combustible seulement quand on utilise la base spéciale, pièce
no KGASB0201ALL, lénsemble serpentin, pièce no CD5 ou CK5, ou le carter de serpentin, pièce
no KCAKC.
Ø Dans une alcôve, on doit maintenir un dégagement à lávant de 18 po (450 mm).
La position indiquée concerne le côté déntrée ou de retour quand la fournaise est dans la
* position horizontale.
Le contact nést permis quéntre les lignes formées par les intersections du dessus et des
deux côtés de la chemise de la fournaise et les solives, montant sous cadre de charpente.
327590-101 REV. B
A02330
→ Fig. 2—Clearances to Combustibles

6. Always install furnace to operate within the furnace’s intended 8. A gas-fired furnace for installation in a residential garage must
temperature-rise range with a duct system which has an be installed as specified in the warning box in the “Location”
external static pressure within the allowable range, as speci- section.
fied in the “Start-Up, Adjustments, and Safety Check” section. 9. The furnace is not to be used for temporary heating of
See furnace rating plate. buildings or structures under construction.
7. When a furnace is installed so that supply ducts carry air → 10. These Multipoise Gas-Fired Furnaces are CSA (A.G.A. and
circulated by the furnace to areas outside the space containing C.G.A.) design-certified for natural and propane gases (see
the furnace, the return air shall also be handled by duct(s) furnace rating plate) and for installation in alcoves, attics,
sealed to the furnace casing and terminating outside the space basements, closets, utility rooms, crawlspaces, and garages.
containing the furnace. See “Air Ducts” section. The furnace is factory-shipped for use with natural gas. A
3
Table 1—Dimensions (IN.)
VENT
UNIT SIZE A B C SHIP WT. (LB)
CONN*
045-08/024045 14-3/16 12-9/16 12-11/16 4 104
045-12/036045 14-3/16 12-9/16 12-11/16 4 107
070-08/024070 14-3/16 12-9/16 12-11/16 4 111
070-12/036070 14-3/16 12-9/16 12-11/16 4 115
070-16/048070 17-1/2 15-7/8 16 4 123
090-14/042090 17-1/2 15-7/8 16 4 126
090-16/048090 21 19-3/8 19-1/2 4 139
090-20/060090 21 19-3/8 19-1/2 4 145
110-12/036110 17-1/2 15-7/8 16 4 134
110-16/048110 21 19-3/8 19-1/2 4 145
110-22/066110 21 19-3/8 19-1/2 4 151
135-16/048135 21 19-3/8 19-1/2 4 148
135-22/066135 24-1/2 22-7/8 23 4 163
155-20/060155 24-1/2 22-7/8 23 4 170
* 5” or 6” vent connector may be required in some cases.
CSA (A.G.A. and C.G.A.) listed gas conversion kit is required

to convert furnace for use with propane gas.
→ 11. See Fig. 2 for required clearances to combustibles.
→ 12. Maintain a 1-in. clearance from combustible materials to
supply air ductwork for a distance of 36 inches horizontally
from the furnace. See NFPA 90B or local code for further
requirements.
→ 13. These furnaces SHALL NOT be installed directly on carpet-
ing, tile, or any other combustible material other than wood
flooring. In downflow installations, factory accessory floor
base MUST be used when installed on combustible materials 60
and wood flooring. Special base is not required when this
furnace is installed on manufacturer’s Coil Assembly Part No.
CD5 or CK5, or when Coil Box Part No. KCAKC is used.
A02055
INTRODUCTION
Fig. 3—Return Air Temperature
→ This 4–way multipoise Category I fan-assisted furnace is CSA
(A.G.A. and C.G.A.) design-certified for natural and propane gas other codes. In absence of local codes, the installation must
and for installation in alcoves, attics, basements, closets, utility comply with the national codes listed below and all authorities
rooms, crawlspaces, and garages. A fan-assisted furnace is an having jurisdiction.
appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion In the United States and Canada, follow all codes and standards for
chamber and/or heat exchanger. The furnace is factory-shipped for the following:
use with natural gas. A CSA (A.G.A. and C.G.A.) listed gas Step 1—Safety
conversion kit is required to convert furnace for use with propane • US: National Fuel Gas Code (NFGC) NFPA 54–2002/ANSI
gas. This furnace is not approved for installation in mobile homes, Z223.1–2002 and the Installation Standards, Warm Air Heating
recreational vehicles, or outdoors. and Air Conditioning Systems ANSI/NFPA 90B
This furnace is designed for minimum continuous return-air • CANADA: CAN/CGA-B149.1–and .2–M00 National Standard
temperature of 60°F db or intermittent operation down to 55°F db of Canada. Natural Gas and Propane Installation Codes (NSC-
such as when used with a night setback thermostat. Return-air NGPIC)
temperature must not exceed 85°F db. Failure to follow these Step 2—General Installation
return-air limits may affect reliability of heat exchangers, motors,
• US: Current edition of the NFGC and the NFPA 90B. For
and controls. (See Fig. 3.) copies, contact the National Fire Protection Association Inc.,
For accessory installation details, refer to the applicable instruction Batterymarch Park, Quincy, MA 02269; or for only the NFGC,
literature. contact the American Gas Association, 400 N. Capitol, N.W.,
NOTE: Remove all shipping brackets and materials before oper- Washington DC 20001 or www.NFPA.org.
ating the furnace. • CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
CODES AND STANDARDS onto), Ontario, M9W 1R3 Canada
Follow all national and local codes and standards in addition to Step 3—Combustion and Ventilation Air
these instructions. The installation must comply with regulations • US: Section 5.3 of the NFGC, Air for Combustion and
of the serving gas supplier, local building, heating, plumbing, and Ventilation
4
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS THE BLOWER IS

LOCATED ABOVE THE LOCATED TO THE LEFT
BURNER SECTION, AND OF THE BURNER SECTION,
CONDITIONED AIR IS AND CONDITIONED AIR IS
DISCHARGED DOWNWARD DISCHARGED TO THE RIGHT.
A02097
Fig. 4—Multipoise Orientations
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air NOT move or shuffle your feet, do not touch ungrounded
Supply for Appliances objects, etc.).
Step 4—Duct Systems 4. If you touch ungrounded objects (and recharge your body with
• US and CANADA: Air Conditioning Contractors Association static electricity), firmly touch a clean, unpainted metal
(ACCA) Manual D, Sheet Metal and Air Conditioning Con- surface of the furnace again before touching control or wires.
tractors National Association (SMACNA), or American Soci- 5. Use this procedure for installed and uninstalled (ungrounded)
ety of Heating, Refrigeration, and Air Conditioning Engineers furnaces.
(ASHRAE) 2001 Fundamentals Handbook Chapter 34.
6. Before removing a new control from its container, discharge
Step 5—Acoustical Lining and Fibrous Glass Duct your body’s electrostatic charge to ground to protect the
• US and CANADA: current edition of SMACNA and NFPA control from damage. If the control is to be installed in a
90B as tested by UL Standard 181 for Class I Rigid Air Ducts furnace, follow items 1 through 4 before bringing the control
Step 6—Gas Piping and Gas Pipe Pressure Testing or yourself in contact with the furnace. Put all used and new
controls into containers before touching ungrounded objects.
• US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing
Codes 7. An ESD service kit (available from commercial sources) may
→• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E and H. also be used to prevent ESD damage.
Step 7—Electrical Connections LOCATION
Step 1—General
• US: National Electrical Code (NEC) ANSI/NFPA 70–2002
• CANADA: Canadian Electrical Code CSA C22.1 Some assembly and modifications are required when used in any
of the four applications shown in Figure 4.
→ ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS This furnace must:
PROCEDURE
• be installed so the electrical components are protected from
water.
• not be installed directly on any combustible material other than
Electrostatic discharge can affect electronic components.
wood flooring. Refer to Introduction section.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will pre- • be located close to the chimney/vent and attached to an air
distribution system. Refer to Air Ducts section.
vent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will • be provided ample space for servicing and cleaning. Always
help to avoid exposing the control to electrostatic discharge comply with minimum fire protection clearances shown on the
by putting the furnace, the control, and the person at the same furnace clearance to combustible label.
electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects may Do not install furnace in a corrosive or contaminated atmo-
be required. DO NOT TOUCH THE CONTROL OR ANY sphere. Make sure all combustion and circulating air require-
WIRE CONNECTED TO THE CONTROL PRIOR TO DIS- ments are met, in addition to all local codes and ordinances.
CHARGING YOUR BODY’S ELECTROSTATIC CHARGE
TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person’s
hand during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example; DO
5
furnace. If the dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless the
This gas furnace may be used for construction heat provided damper is in the full-heat or full-cool position.
that:
-The furnace is permanently installed with all electrical AIR FOR COMBUSTION AND VENTILATION
wiring, piping, venting and ducting installed according to Provisions for adequate combustion and ventilation air must be
these installation instructions. A return air duct is provided, provided in accordance with Section 5.3 of the NFGC, Air for
sealed to the furnace casing, and terminated outside the space Combustion and Ventilation, or applicable provisions of the local
containing the furnace. This prevents a negative pressure building codes.
condition as created by the circulating air blower, causing a Canadian installations must be installed in accordance with NSC-
flame rollout and/or drawing combustion products into the NGPIC Part 7 and all authorities having jurisdiction.
structure.
-The furnace is controlled by a thermostat. It may not be ″hot
wired″ to provide heat continuously to the structure without
thermostatic control.
-Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling and
plugging of furnace components.
-The temperature of the return air to the furnace is no less
than 55 degrees F, with no evening setback or shutdown. The
use of the furnace while the structure is under construction is
deemed to be intermittent operation per our installation
instructions.
-The air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the 18-IN. MINIMUM
nameplate value. TO BURNERS
A93044
-The filters used to clean the circulating air during the
construction process must be either changed or thoroughly Fig. 6—Installation in a Garage
cleaned prior to occupancy.
-The furnace, ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
When the furnace is installed in a residential garage, the
system components after construction is completed.
burners and ignition sources must be located at least 18 inches
above the floor. The furnace must be located or protected to
avoid damage by vehicles. When the furnace is installed in a
→ DO NOT install the furnace on its back or facing down. public garage, airplane hangar, or other building having a
Safety control operation will be adversely affected. Never hazardous atmosphere, the furnace must be installed in
connect return-air ducts to back of furnace. Failure to follow accordance with the NFGC or NSCNGPIC. (See Fig. 6.)
this warning could result in fire, personal injury, or death.
(See Fig. 5.)
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, deter-
gents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
All fuel-burning equipment must be supplied with air for fuel

combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area and from blocked vent
safeguard opening.
A02054
→ The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
Fig. 5—Prohibit Installation on Back NEGATIVE PRESSURE CONDITION at the furnace.
Make-up air MUST be provided for the ventilation devices, in
Step 2—Location Relative to Cooling Equipment addition to that required by the furnace. Refer to Carbon
Monoxide Hazard warning in venting section of these instruc-
The cooling coil must be installed parallel with, or on the tions to determine amount of make-up air required.
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or The requirements for combustion and ventilation air depend upon
other flow control must prevent chilled air from entering the whether the furnace is located in an unconfined or confined space.
6
Table 2–Minimum Free Area of Combustion Air Opening*
AIR FROM INDOOR OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH
FURNACE UNCONFINED SPACE VERTICAL DUCTS HORIZONTAL DUCTS SINGLE DUCT
INPUT Free Area Free Area of Free Area of Free Area of
(BTUH) Round Pipe Round Pipe Round Pipe
of Opening Opening and Duct Opening and Duct Opening and Duct
(in. Dia) (in. Dia) (In. Dia)
(Sq In.) (Sq. In.) (sq In.) (Sq In.)
44,000 100 11 4 22 6 14.7 5
66,000 100 16.5 5 33 7 22.0 6
88,000 100 22.0 6 44.0 8 29.3 7
110,000 110 27.5 6 55 9 36.7 7
132,000 132 33 7 66 10 44.0 8
154,000 154 38.5 7 77 10 51.3 8
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances
in the space require combustion air.
AIR VENT THROUGH ROOF

DUCTS
Step 1—Unconfined Space
An unconfined space has a volume of at least 50 cu ft for each
1000 Btuh total input for all appliances (furnaces, clothes dryers,
water heaters, etc.) in the space.
For example: 12″ MAX
FURNACE MINIMUM WITH
INPUT (BTUH) 7–1/2 FT CEILING (SQ. FT.) 1 SQ IN.
PER 1000
44,000 294 BTUH* IN DOOR
CONFINED
66,000 441 OR WALL
88,000 587
SPACE
INTERIOR UNCONFINED
110,000 734 HEATED SPACE
132,000 881 SPACE
154,000 1028 6″ MIN
(FRONT) †
If the unconfined space is constructed unusually tight, air for
combustion and ventilation must come from either the outdoors or 1 SQ IN.
PER 1000
spaces freely communicating with the outdoors. Combustion and BTUH* IN DOOR
ventilation openings must be equivalent to those used for a OR WALL
confined space (defined below). Return air must not be taken from
the room unless an equal or greater amount of air is supplied to the
room. 12″ MAX
Step 2—Confined Space

A confined space has a volume less than 50 cu ft per 1000 Btuh AIR DUCTS
of total input ratings of all appliances installed in that space. A
confined space must have provisions for supplying air for com- * Minimum opening size is 100 sq in. with
bustion, ventilation, and dilution of flue gases using one of the minimum dimensions of 3 in.
† Minimum of 3 in. when type-B1 vent is used.
following methods in Table 2 and Fig. 7 and 8. A02038
NOTE: When determining the free area of an opening, the
Fig. 7—Confined Space: Air for Combustion and
blocking effect of louvers, grilles, and screens must be considered. Ventilation from an Unconfined Indoor Space
If the free area of the louver or grille design is unknown, assume
wood louvers have a 20 percent free area and metal louvers or
grilles have a 60 percent free area. Screens must not be smaller
than 1/4-in. mesh. Louvers and grilles must be constructed so they c. If the furnace is installed on a raised platform to provide a
cannot be closed. return-air plenum, and return air is taken directly from the
The opening size depends upon whether air comes from outside of hallway or space adjacent to furnace, all air for combustion
the structure or an unconfined space inside the structure. must come from outdoors.
1. Air from inside the structure requires 2 openings (for struc- 2. Air from outside the structure requires 1 of the following:
tures not of unusually tight construction): a. If combustion air is taken from outdoors through 2 vertical
a. Each opening must have a minimum free area of not less ducts, the openings and ducts must have at least 1 sq in. of
than 1 sq in per 1000 Btuh of total input rating for all gas free area per 4000 Btuh of total input for all equipment
utilization equipment in the confined space, but not less within the confined space. (See Fig. 8 and Table 2.)
than 100 sq in. The minimum dimension of air openings b. If combustion air is taken from outdoors through 2 hori-
should be no smaller than 3 in. (See Table 2 and Fig. 7 ). zontal ducts, the openings and ducts must have at least 1 sq
b. If building construction is unusually tight, a permanent in. of free area per 2000 Btuh of total input for all
opening directly communicating with the outdoors shall be equipment within the confined space. (See Fig. 8 and Table
provided. (See next section). 2.)
7
1 SQ IN.
DUCTS PER 4000
TO BTUH*
OUTDOORS
12″ MAX D 12″

1 SQ IN. VENT MAX
PER 2000 A THROUGH F
BTUH* AIR ROOF
DUCTS 1 SQ IN.
PER
4000
BTUH*
OUTDOORS
DUCTS CONFINED
TO SPACE
OUTDOORS
A02098
1 SQ IN.
PER Fig. 9—Removing Bottom Closure Panel
4000
BTUH*
1 SQ IN.
PER 2000 B E G
BTUH* 12″
12″ MAX C MAX SIDE RETURN AIR INLET
12″ MAX
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when
AIR DUCTS only side return air is used.
DUCT 1 SQ IN.
TO
OUTDOORS
PER 4000
BTUH*
→ NOTE: Side return-air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return-air
*Minimum dimensions of 3 in. openings in DOWNFLOW configuration.
NOTE: Use any of the following
combinations of openings: LEVELING LEGS (IF DESIRED)
A&B C&D D&E F&G
A02165 In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field-supplied, 5/16 X 1 1/2 in. (max)
Fig. 8—Confined Space: Air for Combustion and corrosion-resistant machine bolts, washers and nuts.
Ventilation from Outdoors
NOTE: Bottom closure must be used when leveling legs are used.
It may be necessary to remove and reinstall bottom closure panel
to install leveling legs. To remove bottom closure panel, see Fig.
9.
c. If combustion air is taken from the outdoors through a
To install leveling legs:
single opening or duct (horizontal or vertical) commencing
within 12 in. of the top of the confined space, the opening 1. Position furnace on its back. Locate and drill a hole in each
and duct must have at least 1 sq in. of free area per 3000 bottom corner of furnace. (See Fig. 10.)
Btuh of the total input for all equipment within the confined 2. For each leg, install nut on bolt and then install bolt and nut in
space and not less than the sum of the areas of all vent hole. (Install flat washer if desired.)
connectors in the confined space. Equipment clearances to 3. Install another nut on other side of furnace base. (Install flat
the structure shall be at least 1 in. from the sides and back washer if desired.)
and 6 in. from the front of the appliances. See Table 2 and
4. Adjust outside nut to provide desired height, and tighten inside
Fig. 8.
nut to secure arrangement.
When ducts are used, they must be of the same cross sectional area
5. Reinstall bottom closure panel if removed.
as the free area of the openings to which they connect. The
minimum dimension of ducts must not be less than 3 in. Step 2—Downflow Installation
NOTE: For downflow applications, this furnace is approved for
INSTALLATION use on combustible flooring when any one of the 3 accessories are
Step 1—Upflow Installation used:
BOTTOM RETURN AIR INLET • Special Base, KGASB
These furnaces are shipped with bottom closure panel installed in • Cased Coil Assembly Part No. CD5 or CK5
bottom return-air opening. Remove and discard this panel when • Coil Box Part No. KCAKC
bottom return air is used. To remove bottom closure panel, 1. Determine application being installed from Table 3.
perform the following:
2. Construct hole in floor per Table 3 and Fig. 11.
1. Tilt or raise furnace and remove 2 screws holding bottom filler
3. Construct plenum to dimensions specified in Table 3 and Fig.
panel. (See Fig. 9.)
11.
2. Rotate bottom filler panel downward to release holding tabs.
4. If downflow subbase, KGASB is used, install as shown in Fig.
3. Remove bottom closure panel. 12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part
4. Reinstall bottom filler panel and screws. No. KCAKC is used, install as shown in Fig. 13.
8
5⁄16″ PLATFORM UNIT SUPPORT
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in.
5⁄16″
clearance requirement on side, set unit on non-combustible blocks,
bricks or angle iron. For crawlspace installations, if the unit is not
1 3⁄4″
suspended from the floor joists, the ground underneath unit must
be level and the unit set on blocks or bricks.
ROLL-OUT PROTECTION
1 3⁄4″
Provide a minimum 17 3/4″ X 22″ piece of sheet metal for roll-out
protection in front of burner area for units closer than 12 inches
above the combustible deck or suspended units closer than 12-in.
to joists. The sheet metal MUST extend underneath the furnace
5⁄16″ casing by 1 in. with the door removed.
The bottom closure pan on furnaces of widths 17 1/2 in. and larger
may be used for roll-out protection when bottom of furnace is used
for return air connection. See Fig. 17 for proper orientation of
5⁄16″
roll-out shield.
1 3⁄4″
1 3⁄4″ → BOTTOM RETURN AIR INLET
These furnaces are shipped with bottom closure panel installed in
A02071
bottom return-air opening. Remove and discard this panel when
Fig. 10—Leveling Legs bottom return air is used. To remove bottom closure panel,
perform the following:
panel. (See Fig. 9.)
NOTE: It is recommended that the perforated supply-air duct
flanges be completely folded over or removed from furnace when 2. Rotate bottom filler panel downward to release holding tabs.
installing the furnace on a factory-supplied cased coil or coil box. 3. Remove bottom closure panel.
To remove the supply-air duct flange, use wide duct pliers or hand 4. Reinstall bottom filler panel and screws.
seamers to bend flange back and forth until it breaks off. Be careful
of sharp edges. (See Fig. 14.) → SIDE RETURN AIR INLET
→ BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in
These furnaces are shipped with bottom closure panel installed in bottom return-air opening. This panel MUST be in place when
bottom return-air opening. Remove and discard this panel when only one side return air is used.
bottom return air is used. To remove bottom closure panel, → Not all horizontal furnaces are approved for side return air
perform the following: connections (See Fig. 20.)
panel. (See Fig. 9.) Step 4—Filter Arrangement
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws. Never operate a furnace without a filter or with filter access
door removed. Failure to follow this warning could result in
Step 3—Horizontal Installation
fire, personal injury, or death.
There are no provisions for an internal filter rack in these furnaces.

Do not install the furnace on its back or hang furnace with A field-supplied accessory external filter rack is required.
control compartment facing downward. Safety control opera- This furnace requires KGAFR0301ALL 1″ external filter rack or a
tion will be adversely affected. Never connect return-air ducts suitable field-supplied substitute, such as the Media Cabinet.
to the back of the furnace. Failure to follow this warning Refer to the instructions supplied with external filter rack for
could result in fire, personal injury, or death. assembly and installation options.
The furnace can be installed horizontally in an attic or crawl space
Step 5—Air Ducts
on either the left-hand (LH) or right-hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a GENERAL REQUIREMENTS
platform, non-combustible blocks, bricks or pad.
The duct system should be designed and sized according to
SUSPENDED UNIT SUPPORT accepted national standards such as those published by: Air
The furnace may be supported under each end with threaded rod, Conditioning Contractors Association (ACCA), Sheet Metal and
angle iron or metal plumber’s strap as shown. (See Fig. 15 and 16.) Air Conditioning Contractors National Association (SMACNA) or
Secure angle iron to bottom of furnace as shown. Heavy-gauge American Society of Heating, Refrigerating and Air Conditioning
sheet metal straps (plumber’s straps) may be used to suspend the Engineers (ASHRAE) or consult The Air Systems Design Guide-
unit from each bottom corner. To prevent screws from pulling out, lines reference tables available from your local distributor. The
use 2 # 8 x ¾-in. screw into the side and 2 # 8 x ¾-in. screw in the duct system should be sized to handle the required system design
bottom of the furnace casing for each strap. (See Fig. 15 and 16.) CFM at the design external static pressure.
9
FURNACE
(OR COIL CASING
WHEN USED)
A
PLENUM
OPENING COMBUSTIBLE
FLOORING
B D
FLOOR
DOWNFLOW
OPENING
SUBBASE
C
SHEET METAL
PLENUM
FLOOR
OPENING
A96283
Fig. 11—Floor and Plenum Opening Dimensions
A96285
Fig. 12—Furnace, Plenum, and Subbase Installed on
a Combustible Floor
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A96284
Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor
When a furnace is installed so that the supply ducts carry air to Flexible connections should be used between ductwork and
areas outside the space containing the furnace, the return air must furnace to prevent transmission of vibration. Ductwork passing
also be handled by a duct(s) sealed to the furnace casing and through unconditioned space should be insulated and sealed to
terminating outside the space containing the furnace. enhance system performance. When air conditioning is used, a
Secure ductwork with proper fasteners for type of ductwork used. vapor barrier is recommended.
Seal supply- and return-duct connections to furnace with code Maintain a 1-in. clearance from combustible materials to supply air
approved tape or duct sealer. ductwork for a distance of 36 in. horizontally from the furnace. See
NFPA 90B or local code for further requirements.
10
Table 3—Opening Dimensions (In.)
FURNACE PLENUM OPENING FLOOR OPENING
CASING APPLICATION
WIDTH A B C D
Upflow Applications on Combustible or Noncombustible
12-11/16 21-5/8 13-5/16 22-1/4
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring
12-9/16 19 13-3/16 19-5/8
(KGASB subbase not required)
14–3/16 Downflow applications on combustible flooring (KGASB
11-13/16 19 13-7/16 20-5/8
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase 12-5/16 19 13-5/16 20
not required)
16 21-5/8 16-5/8 22-1/4
15-7/8 19 16-1/2 19-5/8
17–1/2 Downflow applications on combustible flooring (KGASB
15-1/8 19 16-3/4 20-5/8
subbase required)
not required)
19-1/2 21-5/8 20-1/8 22-1/4
19-3/8 19 20 19-5/8
21 Downflow applications on combustible flooring (KGASB
18-5/8 19 20-1/4 20-5/8
subbase required)
CK5 Coil Assembly or KCAKC coil box (KGASB subbase 19 19 20 20
not required)
23 21-1/8 23-5/8 22-1/4
22-7/8 19 23-1/2 19-5/8
24-1/2 Downflow applications on Combustible flooring (KGASB
22-1/8 19 23-3/4 20-5/8
subbase required)
not required)
UPFLOW DOWNFLOW HORIZONTAL
90˚ 90˚
PREFERRED PREFERRED PREFERRED
120˚ PREFERRED 120˚ PREFERRED 120˚ PREFERRED

MIN MIN MIN
PERMITTED PERMITTED PERMITTED
A02329
→ Fig. 14—Duct Flanges
DUCTWORK ACOUSTICAL TREATMENT SMACNA construction standard on fibrous glass ducts. Both
Metal duct systems that do not have a 90 degree elbow and 10 ft acoustical lining and fibrous ductwork shall comply with NFPA
of main duct to the first branch take-off may require internal 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.
acoustical lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
11
" THREADED ROD
1/4
4 REQ.
OUTER DOOR
ASSEMBLY
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/4" SCREWS
TYPICAL FOR 2 SUPPORTS
8" MIN FOR DOOR
REMOVAL
1" SQUARE, 11/4" x 11/4" x 1/4" ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD
A02345
→ Fig. 15—Horizontal Unit Suspension
A02014
Fig. 16—Horizontal Suspension with Straps

SUPPLY AIR CONNECTIONS Upflow and Horizontal Furnaces
→ For a furnace not equipped with a cooling coil, the outlet duct shall Connect supply-air duct to flange on furnace supply-air outlet.
be provided with a removable access panel. This opening shall be Bend flange upward to 90° with wide duct pliers. The supply-air
accessible when the furnace is installed and shall be of such a size duct attachment must ONLY be connected to furnace supply-
that the heat exchanger can be viewed for possible openings using outlet-air duct flanges or air conditioning coil casing (when used).
light assistance or a probe can be inserted for sampling the air DO NOT cut main furnace casing to attach supply side air duct,
stream. The cover attachment shall prevent leaks. humidifier, or other accessories. All accessories MUST be con-
nected external to furnace main casing.
12
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
17 3/4″ OVER ALL
4 3/4″ UNDER DOOR
1″ UNDER FURNACE
GAS TYPE-B
ENTRY VENT EXTEND OUT 12″ OUT
FROM FACE OF DOOR
IN*
6″ M 30-IN. MIN
WORK AREA * WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
17 3/4″
SHEET
METAL
22″
MANUAL SHUTOFF
GAS VALVE
SEDIMENT
TRAP
A02164
Fig. 17—Typical Attic Installation
Downflow Furnaces Step 6—Gas Piping

Connect supply-air duct to supply-air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used). When → Never purge a gas line into a combustion chamber. Never test
installed on combustible material, supply-air duct attachment must for gas leaks with an open flame. Use a commercially
ONLY be connected to the accessory subbase, KGASB0201ALL, available soap solution made specifically for the detection of
or factory approved air conditioning coil casing. DO NOT cut leaks to check all connections. A failure to follow this
main furnace casing to attach supply side air duct, humidifier, or warning could result in fire, explosion, personal injury, or
other accessories. All accessories MUST be connected external to death.
furnace casing.
Gas piping must be installed in accordance with national and local
RETURN AIR CONNECTIONS codes. Refer to current edition of NFGC in the U.S., the NSCNG-
PIC in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
Never connect return-air ducts to the back of the furnace. A separate line running directly from meter to furnace.
failure to follow this warning can cause a fire, personal injury, Refer to Table 4 for recommended gas pipe sizing. Risers must be
or death. used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
Downflow Furnaces every 6 ft. Joint compound (pipe dope) should be applied sparingly
The return-air duct must be connected to return-air opening and only to male threads of joints. Pipe dope must be resistant to
(bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides the action of propane gas.
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. Bypass humidifier connections should be
made at ductwork or coil casing sides exterior to furnace. → If local codes allow the use of a flexible gas appliance
Upflow and Horizontal Furnaces connector, always use a new listed connector. Do not use a
The return-air duct must be connected to bottom, sides (left or connector which has previously serviced another gas appli-
right), or a combination of bottom and side(s) of main furnace ance. Black iron pipe shall be installed at the gas valve and
casing as shown in Fig. 1. Bypass humidifier may be attached to extend a minimum of 2-in. outside the furnace.
unused side return air portion of the furnace casing. (See Fig. 18,
19, and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
13
A02075
Fig. 18—Upflow Return Air Configurations and Restrictions
A02163
Fig. 19—Downflow Return Air Configurations and Restrictions
A02162
Fig. 20—Horizontal Return Air Configurations and Restrictions
14
→ Table 4—Maximum Capacity of Pipe*
GAS
NOMINAL SUPPLY
IRON INTERNAL LENGTH OF PIPE (FT) MANUAL
PIPE DIAMETER SHUTOFF
SIZE (IN.) VALVE
10 20 30 40 50 (REQUIRED
(IN.)
SEDIMENT
1/2 0.622 175 120 97 82 73 TRAP
3/4 0.824 360 250 200 170 151 UNION
1 1.049 680 465 375 320 285
1-1/4 1.380 1400 950 770 660 580
1-1/2 1.610 2100 1460 1180 990 900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14–in. wc) or less and a
pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas).
Ref: Table 12.2 NFPA 54-2002.
A02035
Connect gas pipe to gas valve using a backup wrench to avoid Fig. 21b—Typical Gas Pipe Arrangement
damaging gas controls.
Use proper length of pipe to avoid stress on gas control

manifold. Failure to follow this warning could result in a gas
leak resulting in fire, explosion, personal injury, or death.
→ An accessible manual shutoff valve MUST be installed external to → If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be
furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged disconnected from furnace and capped before pressure test. If test
tapping, accessible for test gage connection, MUST be installed pressure is equal to or less than 0.5 psig (14-in. wc), turn off
immediately upstream of gas supply connection to furnace and electric shutoff switch located on furnace gas control valve and
downstream of manual shutoff valve. accessible manual shutoff valve before test. After all connections
have been made, purge lines and check for leakage.
→ NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gage connection providing test pressure DOES NOT
→ The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
exceed maximum 0.5 psig (14-in. wc) stated on gas control valve.
the furnace burners ON and OFF.
(See Fig. 50.)
→ Some installations require gas entry on right side of furnace (as
viewed in upflow). (See Fig. 21a.) Step 7—Electrical Connections
Install a sediment trap in riser leading to furnace as shown in Fig
21b. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of gas controls. Place a ground joint
union between gas control manifold and exterior manual equip- Blower access panel door switch opens 115-v power to
ment gas shutoff valve. A 1/8-in. NPT plugged tapping, accessible control center. No component operation can occur. Do not
for test gage connection, MUST be installed immediately upstream bypass or close switch with panel removed. Failure to follow
of gas supply connection to furnace and downstream of manual this warning could result in personal injury or death.
shutoff valve.
See Fig. 24 for field wiring diagram showing typical field 115-v
→ Piping should be pressure and leak tested in accordance with wiring. Check all factory and field electrical connections for
NFGC in the United States or NSCNGPIC in Canada, local, and tightness.
national plumbing and gas codes before the furnace has been
connected. After all connections have been made, purge lines and
→ Field-supplied wiring shall conform with the limitations of 63°F
(33°C) rise.
check for leakage at furnace prior to operating furnace.
90° Elbow
The cabinet MUST have an uninterrupted or unbroken ground

according to NEC ANSI/NFPA 70-2002 and Canadian Elec-
trical Code CSA C22.1 or local codes to minimize personal
injury if an electrical fault should occur. This may consist of
electrical wire, conduit approved for electrical ground or a
2" Nipple listed, grounded power cord (where permitted by local code)
when installed in accordance with existing electrical codes.
Street Elbow Refer to the power cord manufacturer’s ratings for proper
wire gage. Do not use gas piping as an electrical ground.
Gas Valve
A02327 Failure to follow this warning could result in electrical shock,
fire, or death.
→ Fig. 21a—Right Side Gas Entry Example
15
→ Table 5—Electrical Data
VOLTS- OPERATING MAXIMUM
VOLTAGE RANGE MAXIMUM UNIT MAXIMUM MINIMUM
UNIT SIZE HERTZ- FUSE OR CKT BKR
UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡ WIRE GAGE
PHASE Maximum* Minimum* AMPS†
045-08/024045 115-60-1 127 104 5.6 7.77 47 15 14
045-12/036045 115-60-1 127 104 7.0 9.47 39 15 14
070-08/024070 115-60-1 127 104 5.0 7.06 52 15 14
070-12/036070 115-60-1 127 104 6.7 9.19 40 15 14
070-16/048070** 115-60-1 127 104 9.8 12.59 28 15 14
090-14/042090 115-60-1 127 104 8.1 10.83 34 15 14
090-16/048090 115-60-1 127 104 9.8 12.95 28 15 14
090-20/060090** 115-60-1 127 104 12.9 17.60 34 20 12
110-12/036110 115-60-1 127 104 8.2 10.75 34 15 14
110-16/048110 115-60-1 127 104 10.1 13.12 28 15 14
110-22/066110 115-60-1 127 104 13.7 17.62 32 20 12
135-16/048135 115-60-1 127 104 10.1 13.12 28 15 14
135-22/066135 115-60-1 127 104 14.4 18.55 30 20 12
155-22/060155 115-60-1 127 104 15.0 19.33 29 20 12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
# Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load
amps.
† Time-delay type is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
** Preliminary
Furnace control must be grounded for proper operation or

control will lock out. Control is grounded through
green/yellow wire routed to gas valve and manifold bracket
screw.
TWO
115-V WIRING
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 5 for equipment electrical
specifications. Make all electrical connections in accordance with
National Electrical Code (NEC) ANSI/NFPA 70-2002 and any
local codes or ordinances that might apply. For Canadian instal-
lations, all electrical connections must be made in accordance with
Canadian Electrical Code CSA C22.1 or authorities having juris- A02099
diction.
Fig. 22—Relocating J-Box
3. Locate box to desired location.

Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire. 4. Fasten J-Box to casing with screws.
5. Route J-box wires within furnace away from sharp edges and
Use a separate, fused branch electrical circuit with a properly sized hot surfaces.
fuse or circuit breaker for this furnace. See Table 5 for wire size
and fuse specifications. A readily accessible means of electrical ELECTRICAL CONNECTION TO J-BOX
disconnect must be located within sight of the furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control LED status indicator light will flash If manual disconnect switch is to be mounted on furnace,
rapidly and furnace will NOT operate. select a location where a drill or fastener will not contact
electrical or gas components.
J-BOX RELOCATION
1. Attach electrical box to J-Box bracket.
NOTE: If factory location of J-Box is acceptable, go to next
section (J-Box Cover Installation). 2. Route wires through hole in electrical box and J-Box bracket.
NOTE: On 14″ wide casing models, the J-Box shall not be 3. Secure ground wire to green screw on J-Box bracket.
relocated to other side of furnace casing when the vent pipe is 4. Connect line voltage leads as shown in Fig. 24.
routed within the casing. FOR POWER CORD INSTALLATION
1. Remove screws holding auxiliary J-box. (See Fig. 22.) Power cords must be able to handle the electrical requirements
2. Cut wire tie on loop in wires to J-box. listed in Table 5. Refer to power cord manufacturer’s listings.
16
TWINNING AND/OR
BLOWER OFF-DELAY COMPONENT TEST
TERMINAL
J2 JUMPER
BLOWER OFF-DELAY
90 150
120 180
J2
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
G
24-V THERMOSTAT
TERMINALS
24V
Com W
TRANSFORMER 24-VAC
CONNECTIONS
PLT
Y
TEST/TWIN
HUM
R
0.5 AMP@24VAC
3-AMP FUSE STATUS CODE LED

FUSE 3-AMP
SEC-2 SEC-1
LED OPERATION & EAC-2 L2

DIAGNOSTIC LIGHT
NUETRAL BLW
PLT
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
115-VAC(L2)NEUTRAL
CONNECTIONS
1
COOL
COOL
HEAT
HEAT
1-AMP@
SPARE-1 SPARE-2 EAC-1 115VAC PR-1 L1
PL2 1
SPARE-1
115 VAC (L1) LINE PL2-HOT SURFACE
SPARE-2 VOLTAGE CONNECTION IGNITER & INDUCER
BLOWER SPEED
MOTOR CONNECTOR
SELECTION TERMINALS
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
A02100
Fig. 23—Furnace Control
1. Route listed power cord through hole in J-Box. maintenance could cause this fuse to blow. If fuse replacement is
2. Secure power cord to J-Box bracket with a strain relief required, use ONLY a 3-amp fuse of identical size.
bushing or a connector approved for the type of cord used. ACCESSORIES
3. Secure ground wire to green screw on J-Box bracket. 1. Electronic Air Cleaner (EAC)
4. Connect line voltage leads as shown in Fig. 24. Connect an accessory Electronic Air Cleaner (if used) using
1/4-in female quick connect terminals to the two male 1/4-in
FOR BX CABLE INSTALLATION quick-connect terminals on the control board marked EAC-1
1. Route BX cable to hole in J-Box. and EAC-2. The terminals are rated for 115 VAC, 1.0 amps
2. Secure BX cable to J-Box bracket with connectors approved maximum and are energized during blower motor operation.
for the type of cable used. 2. Humidifier (HUM)
3. Secure ground wire to green screw on J-Box bracket. Connect an accessory 24 VAC, 0.5 amp maximum humidifier
(if used) to the 1/4-in male quick-connect HUM terminal and
4. Connect line voltage leads as shown in Fig. 24.
COM-24V screw terminal on the control board thermostat strip.
J-BOX COVER INSTALLATION The HUM terminal is energized when pressure switch (PRS)
1. Remove J-Box cover from blower access door on furnace and closes.
reinstall blower access door screw. NOTE: A field-supplied, 115-v controlled relay connected to
2. Fold tab on J-box cover to bracket with pliers. EAC terminals may be added if humidifier operation is desired
3. Insert tab of J-box cover into slot of J-box bracket. during blower operation.
4. Secure J-Box cover to bracket with screw provided.
5. Remove U-shaped cut-out from outer door to clear J-box.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
23.) Connect terminal Y as shown in Fig. 24 for proper cooling
operation. Use only AWG No. 18, color-coded, copper thermostat
wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. Any direct shorts during installation, service, or
17
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
W C R G Y THERMOSTAT
FIVE WIRE TERMINALS FIELD-SUPPLIED
THREE-WIRE DISCONNECT
HEATING-ONLY
208/230- OR
BLOWER DOOR SWITCH 460-V
THREE
W PHASE
BLK BLK
C R
WHT WHT
O
N 208/230-V
GND GND T SINGLE
R G PHASE
115-V FIELD- AUXILIARY O
SUPPLIED J-BOX L COM GND
DISCONNECT NOTE 1
Y/Y2
CONDENSING
UNIT
24-V TWO
TERMINAL WIRE
BLOCK
FURNACE NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A99440
Fig. 24—Heating and Cooling Application Wiring Diagram with 1–Stage Thermostat
→ When an existing furnace is removed or replaced in a venting
system, the venting system may not be properly sized to vent the
DO NOT connect furnace control HUM terminal to HUM attached appliances. An improperly sized Category I venting
(humidifier) terminal on Thermidistat™, Zone Controller or system could cause the formation of condensate in the furnace and
similar device. See Thermidistat™, Zone Controller, thermo- vent, leakage of condensate and combustion products, and spillage
stat, or controller manufacturer’s instructions for proper of combustion products into the living space, etc.
connection.
Step 8—Venting
→ The furnace shall be connected to a factory built chimney or vent
complying with a recognized standard, or a masonry or concrete
chimney lined with a lining material acceptable to the authority
having jurisdiction. Venting into an unlined masonry chimney or
concrete chimney is prohibited.
18
The following information and warning must be considered in
addition to the requirements defined in the NFGC and the
CARBON MONOXIDE POISONING HAZARD NSCNGPIC.
Failure to follow the steps outlined below for each appliance 1. If a vent (common or dedicated) becomes blocked, the furnace
connected to the venting system being placed into operation will be shut off by the draft safeguard switch located on the
could result in carbon monoxide poisoning or death. vent elbow.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation: Do not bypass the draft safeguard switch, as an unsafe
1. Seal any unused openings in venting system. condition could exist which must be corrected. Failure to
2. Inspect the venting system for proper size and horizontal follow this warning could result in a build-up of carbon
pitch, as required in the National Fuel Gas Code, ANSI monoxide and lead to personal injury or death.
Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and
2. Do not connect this appliance to a single-wall dedicated or
Propane Installation Codes and these instructions. Deter-
common vent. The dedicated or common vent is considered to
mine that there is no blockage or restriction, leakage,
be the vertical portion of the vent system that terminates
corrosion and other deficiencies, which could cause an
outdoors.
unsafe condition.
3. As far as practical, close all building doors and windows 3. Vent connectors serving Category I furnaces shall not be
and all doors between the space in which the appliance(s) connected into any portion of a mechanical draft system
connected to the venting system are located and other operating under positive pressure.
spaces of the building. 4. In the US, do not vent this appliance with any solid fuel
4. Close fireplace dampers. burning appliance. In Canada, check with the authority having
5. Turn on clothes dryers and any appliance not connected to jurisdiction for approval on use with solid fuel burning
the venting system. Turn on any exhaust fans, such as appliance.
range hoods and bathroom exhausts, so they are operating → 5. Category I furnaces must be vented vertically or nearly
at maximum speed. Do not operate a summer exhaust fan. vertically unless equipped with a listed power ventor.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so appli-
→ 6. Do not vent this appliance into an unlined masonry chimney.
Refer to Chimney Inspection Chart, Fig. 25.
ance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the MASONRY CHIMNEY REQUIREMENTS
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above These furnaces are CSA design-certified for use in exterior
tests, the venting system must be corrected in accordance clay tile-lined masonry chimneys with a factory accessory
with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 Chimney Adapter Kit. Refer to the furnace rating plate for
and/or CSA B149.1, Natural Gas and Propane Installation correct kit usage. The Chimney Adapter Kits are for use with
Codes. ONLY furnaces having a Chimney Adapter Kit number
9. After it has been determined that each appliance connected marked on the furnace rating plate.
to the venting system properly vents when tested as
outlined above, return doors, windows, exhaust fans, If a clay tile-lined masonry chimney is being used and it is exposed
fireplace dampers and any other gas-fired burning appli- to the outdoors below the roof line, relining might be required.
ance to their previous conditions of use. Chimneys shall conform to the Standard for Chimneys, Fireplaces,
Vents, and Soild Fuel Burning Appliances ANSI/NFPA 211-2000
→ Vent system or vent connectors may need to be resized. For any in the United States and to a Provincial or Territorial Building
other appliances when resizing vent systems or vent connectors, Code in Canada (in its absence, the National Building Code of
system or connector must be sized to approach minimum size as Canada) and must be in good condition.
determined using appropriate table found in the NFGC or NSC-
U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the
NGPIC.
authority having jurisdiction to determine whether relining is
GENERAL VENTING REQUIREMENTS required. If relining is required, use a properly sized listed metal
liner, Type-B vent, or a listed alternative venting design.
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code (NFGC) ANSI Z223.1-2002/NFPA 54-2002, Parts 7 and
13 in the United States or the National Standard of Canada, Natural
Gas and Propane Installation Code (NSCNGPIC) CSA-B149.1-00,
Section 7 and Appendix C in Canada.
These furnaces are design-certified as Category I furnaces in
accordance with ANSI Z21.47/CSA 2.3-2001 and operate with a
non-positive vent static pressure to minimize the potential for vent
gas leakage. Category I furnaces operate with a flue loss not less
than 17 percent to minimize the potential for condensation in the
venting system. These furnaces are approved for common venting
and multi-story venting with other fan assisted or draft hood
equipped appliances in accordance with the NFCG or the NSC-
NGPIC.
19
NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative Table B—Minimum Allowable Input Rating of
venting design and the exception, which cover installations such as Space-Heating Appliance in
the Chimney Adapter Kits KGACA02014FC and
Thousands of BTU per Hour
KGACA02015FC, which are listed for use with these furnaces.
INTERNAL AREA OF CHIMNEY
The Chimney Adapter Kit is listed alternative venting design for VENT (SQ. IN.)
these furnaces. See the kit instructions for complete details. HEIGHT (FT)
12 19 28 38
Canada-This furnace is permitted to be vented into a clay Local 99% Winter Design
Temperature: 17 to 26 degrees F*
tile-lined masonry chimney that is exposed to the outdoors below
6 0 55 99 141
the roof line, provided:
8 52 74 111 154
17 to 26 F
1. Vent connector is Type-B double-wall, and 10 NR 90 125 169
2. This furnace is common vented with at least 1 draft hood- 15 NR NR 167 212
equipped appliance, and 20 NR NR 212 258
3. The combined appliance input rating is less than the maximum 30 NR NR NR 362
capacity given in Table A, and Local 99% Winter Design

Temperature: 5 to 16 degrees F*
4. The input rating of each space heating appliance is greater 6 NR 78 121 166
than the minimum input rating given in the appropriate Table 8 NR 94 135 182
5 to 16 F
B for Masonry Chimneys for the local winter design tempera- 10 NR 111 149 198
ture. Chimneys having internal areas greater than 38 square 15 NR NR 193 247
inches require furnace input ratings greater than the input 20 NR NR NR 293
ratings of these furnaces. See footnote at bottom of Table B, 30 NR NR NR 377
and Local 99% Winter Design
Temperature: -10 to 4 degrees F*
5. The authority having jurisdiction approves.
6 NR NR 145 196
If all of these conditions cannot be met, an alternative venting 8 NR NR 159 213
-10 to 4 F
design shall be used, such as the listed chimney adapter kit with 10 NR NR 175 231
these furnaces listed for use with the kit, a listed chimney-lining 15 NR NR NR 283
system, or a Type-B common vent. 20 NR NR NR 333
30 NR NR NR NR
Exterior Masonry Chimney, Local 99% Winter Design
FAN + NAT Installations with Temperature: -11 degrees F or lower*
Type-B Double-Wall Vent Connectors Not recommended for any vent
configuration
-11 F or lower
Table A—Combined Appliance

Maximum Inut Rating in
Thousands of BTU per Hour
INTERNAL AREA OF CHIMNEY
VENT (SQ. IN.)
HEIGHT (FT) *The 99% Winter Design Dry-Bulb (db) temperatures are found in the 1993
12 19 28 38 ASHRAE Fundamentals Handbook, Chapter 24, Table 1 (United States) and
2 (Canada), or use the 99.6% heating db temperatures found in the 1997 or
6 74 119 178 257 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chap-
8 80 130 193 279 ter, Table 1A (United States) and 2A (Canada).
10 84 138 207 299 Inspections before the sale and at the time of installation will
15 NR 152 233 334 determine the acceptability of the chimney or the need for repair
20 NR NR 250 368 and/or (re)lining. Refer to Fig. 25 to perform a chimney inspection.
30 NR NR NR 404 If the inspection of a previously used tile-lined chimney:
a. Shows signs of vent gas condensation, the chimney should
be relined in accordance with local codes and the authority
having jurisdiction. The chimney should be relined with a
listed metal liner, Type-B vent, or a listed chimney adapter
kit shall be used to reduce condensation. If a condensate
drain is required by local code, refer to the NFGC, Section
10.9 for additional information on condensate drains.
b. Indicates the chimney exceeds the maximum permissible
size in the tables, the chimney should be rebuilt or relined
to conform to the requirements of the equipment being
installed and the authority having jurisdiction.
20
A chimney without a clay tile liner, which is otherwise in good NOTE: Vent connector length for connector sizing starts at
condition, shall be rebuilt to conform to ANSI/NFPA 211 or be furnace vent elbow. The 4 inch vent elbow is shipped for upflow
lined with a UL listed (ULC listed in Canada) metal liner or UL configuration and may be rotated for other positions. Remove the
listed Type-B vent. Relining with a listed metal liner or Type-B 3 screws that secure vent elbow to furnace, rotate furnace vent
vent is considered to be a vent-in-a-chase. elbow to position desired, re-install screws. The factory-supplied
If a metal liner or Type-B vent is used to line a chimney, no other vent elbow does NOT count as part of the number of vent
appliance shall be vented into the annular space between the connector elbows.
chimney and the metal liner. The vent connector can exit the door through one of 5 locations on
the door.
APPLIANCE APPLICATION REQUIREMENTS 1. Attach the single wall vent connector to the furnace vent
Appliance operation has a significant impact on the performance elbow, and fasten the vent connector to the vent elbow with at
of the venting system. If the appliances are sized, installed, least two field-supplied, corrosion-resistant, sheet metal
adjusted, and operated properly, the venting system and/or the screws located 180° apart.
appliances should not suffer from condensation and corrosion. The 2. Vent the furnace with the appropriate connector as shown in
venting system and all appliances shall be installed in accordance Fig. 26–38.
with applicable listings, standards, and codes.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates Personal injury can result form sharp metal edges, etc. Be
can be made using approved methods available from Air Condi- careful when removing parts. Gloves and safety glasses
tioning Contractors of America (Manual J); American Society of should be worn when servicing equipment.
Heating, Refrigerating, and Air-Conditioning Engineers; or other
3. Orient the door to determine the correct location of the door
approved engineering methods. Excessive oversizing of the fur-
cutout to be removed.
nace could cause the furnace and/or vent to fail prematurely.
4. Use aviation-type tin snips to remove the correct U-shaped
When a metal vent or metal liner is used, the vent must be in good
cut-out on door.
condition and be installed in accordance with the vent manufac-
turer’s instructions. An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED
for downflow applications for use where the vent exits through the
To prevent condensation in the furnace and vent system, the
lower portion of the furnace casing door. Refer to the Vent Guard
following precautions must be observed:
Kit Instructions for complete details.
1. The return-air temperature must be at least 60°F db except for
The horizontal portion of the venting system shall maintain a
brief periods of time during warm-up from setback at no lower
minimum of 1/4-in. upward slope per linear ft and it shall be
than 55°F db or during initial start-up from a standby
rigidly supported every 5 ft or less with metal hangers or straps to
condition.
ensure there is no movement after installation.
2. Adjust the gas input rate per the installation instructions. Low
gas input rate causes low vent gas temperatures, causing SIDEWALL VENTING
condensation and corrosion in the furnace and/or venting
This furnace is not approved for direct sidewall horizontal venting
system. Derating is permitted only for altitudes above 2000 ft.
without the use of an add-on power venter.
3. Adjust the air temperature rise range to the midpoint or
In the U.S.: Per the NFGC, any listed power venter may be used,
slightly above. Low air temperature rise can cause low vent
when approved by the authority having jurisdiction.
gas temperature and potential for condensation problems.
In Canada: Only power venters approved by the appliance
4. Set the thermostat heat anticipator or cycle rate to reduce short
manufacturer and where allowed by the authority having jurisdic-
cycling.
tion may be used for sidewall venting.
Air for combustion must not be contaminated by halogen com-
The only approved power venter is the Field Controls SWG-4D
pounds which include chlorides, fluorides, bromides, and iodides.
and SWG-5D sidewall power venter. Select the power venter to
These compounds are found in many common home products such
match the btuh input of the appliance being vented. Follow all
as detergent, paint, glue, aerosol spray, bleach, cleaning solvent,
manufacturer’s installation requirements for venting and termina-
salt, and air freshener, and can cause corrosion of furnaces and
tion included with the power venter.
vents. Avoid using such products in the combustion-air supply.
Furnace use during construction of the building could cause the
furnace to be exposed to halogen compounds, causing premature START-UP, ADJUSTMENT, AND SAFETY CHECK
failure of the furnace or venting system due to corrosion.
Step 1—General
Vent dampers on any appliance connected to the common vent can
cause condensation and corrosion in the venting system. Do not
use vent dampers on appliances common vented with this furnace.
This furnace is equipped with manual reset limit switches in

ADDITIONAL VENTING REQUIREMENTS
the gas control area. The switches open and shut off power to
A 4″ round vent elbow is supplied with the furnace. A 5 inch or 6 the gas valve if a flame rollout or overheating condition
inch vent connector may be required for some model furnaces. A occurs in the gas control area. DO NOT bypass the switches.
field-supplied 4 inch to 5 inch or 4 inch to 6 inch sheet metal Correct inadequate combustion air supply problem and reset
increaser fitting is required when 5 inch or 6 inch vent connector the switches. Failure to follow this warning can cause fire,
is used. See Fig. 26–38 Venting Orientation for approved vent explosion, personal injury, or death.
configurations.
21
CHIMNEY INSPECTION CHART
For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian
installation Codes CSA-B149.1 in Canada.
Crown
condition: Yes Rebuild
Missing mortar crown.
or brick?
No
Is chimney
property lined with No
clay tile liner?
Yes
Is Repair
liner and top No liner or top seal Reline
seal in good or reline chimney as
condition? necessary.
Yes Repair
Debris
in cleanout? Yes Mortar Yes
or tile Remove mortar
Mortar, tile, metal vent and tile debris
fuel oil residue? debris?
No Remove metal vent

No
or liner.
Clay
tile misalignment, Yes
missing sections,
gaps?
Consult
Part B of Not Suitable
No chimney adapter venting
No instructions for
application
suitability.
Is chimney
Condensate lined with properly Line chimney with property
Suitable sized, listed flexible metal
drainage at bottom sized, listed liner or
of chimney? Yes liner or Type-B vent per
Type-B vent? NFGC or NSCNGPIC Vent
Yes Sizing Tables and liner or
Install chimney
adapter per vent manufacturer’s
No Installation instructions.
instructions.
Yes Not Suitable
Consult
Chimney Is chimney Part C of
exposed to No Suitable
to be dedicated to chimney adapter venting
outdoors below a single instructions for
roof line? Yes furnace? application
suitability
No Install chimney
adapter per
instructions.
Chimney is
acceptable for use.
A02101
Fig. 25—Chimney Inspection Chart
22
6. Verify furnace restarts by raising thermostat setting above
room temperature.
Personal injury can result form sharp metal edges, etc. Be
careful when removing parts. Gloves and safety glasses Step 3—Adjustments
should be worn when servicing equipment.
1. Maintain 115-v wiring and ground. Improper polarity will

result in rapid flashing LED and no furnace operation.
2. Make thermostat wire connections at the 24-v terminal block DO NOT bottom out gas valve regulator adjusting screw.
on the furance control. Failure to make proper connections This can result in unregulated manifold pressure and result in
will result in improper operation. (See Fig. 24.) excess overfire and heat exchanger failures.
3. Gas supply pressure to the furnace must be greater than 4.5-in.
wc (0.16 psig) but not exceed 14-in. wc (0.5 psig).
4. Check all manual-reset switches for continuity.
5. Install blower compartment door. Door must be in place to DO NOT redrill orifices. Improper drilling (burrs, out-of-
operate furnace. round holes, etc.) can cause excessive burner noise and
6. Replace outer door. misdirection of burner flames. This can result in flame
impingement of heat exchangers, causing failures. (See Fig.
Step 2—Start-Up Procedures 41.)
Furnace gas input rate on rating plate is for installations at altitudes

up to 2000 ft. Furnace input rate must be within ±2 percent of
Never purge a gas line into a combustion chamber. Never use furnace rating plate input.
matches, candles, flame, or other sources of ignition for the In the U.S.A., the input rating for altitudes above 2,000 ft. must be
purpose of checking leakage. Use a soap-and-water solution reduced by 4 percent for each 1,000 ft. above sea level. In Canada,
to check for leakage. Failure to follow this warning can cause input rating must be reduced by 10 percent for altitudes of 2,000
fire, explosion, personal injury, or death. ft. to 4,500 ft. above sea level.
1. Purge gas lines after all connections have been made. 1. Determine the correct gas input rate.
2. Check gas lines for leaks. In the U.S.:
For installations below 2000 ft., refer to the unit rating plate.
For installations above 2000 ft., multiply the input on the
rating plate by the de-rate multiplier in Table 6 for the correct
→ Blower access door switch opens 115-v power to control. No input rate.
component operation can occur unless switch is closed. In Canada:
Caution must be taken when manually closing this switch for At installation altitudes from 2000 to 4500 ft, this furnace must be
service purposes. Failure to follow this warning could result derated 10 percent by an authorized Gas Conversion Station or
in electrical shock, personal injury, or death. Dealer. To determine correct input rate for altitude, see example 1
3. To Begin Component Self-Test: Disconnect the thermostat R and use 0.90 as derate multiplier factor.
lead from furnace control board. Manually close the blower EXAMPLE 1:
door switch. Briefly short the TEST/TWIN terminal to the 88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.
COM 24V terminal until LED goes out. Remove jumper from Derate Furnace Input Rate
terminals. (See Fig. 23.) Furnace Input Rate X Multiplier = at Installation
at Sea Level Factor Altitude
NOTE: The furnace control allows all components, except the gas
88,000 X 0.90 = 79,200
valve, to be run for short period of time. This feature helps
diagnose a system problem in case of a component failure. 2. Determine the correct orifice and manifold pressure adjust-
Component test feature will not operate if any thermostat signal is ment. There are two different orifice and manifold adjustment
present at the control. tables.
All models in all positions, except Low NOx models in
Component test sequence is as follows: downflow or horizontal positions, use Table 10 (22,000
Refer to service label attached to furnace or see Fig. 43. BTUH/Burner)
a. LED will display previous status code 4 times. Low NOx models in the downflow or horizontal positions
must use Table 11 (21,000BTUH/Burner). See input listed on
b. Inducer motor starts and continues to run until Step f of
furnace rating plate.
component test sequence.
a. Obtain average yearly gas heat value (at installed altitude)
c. Hot surface ignitor is energized for 15 sec., then off.
from local gas supplier.
d. Blower motor operates on HEAT speed for 10 sec.
b. Obtain average yearly gas specific gravity from local gas
e. Blower motor operates on COOL speed for 10 sec. supplier.
f. Inducer motor stops. c. Find installation altitude in Table 10 or 11.
g. Reconnect R lead to furnace control board, release blower d. Find closest natural gas heat value and specific gravity in
door switch and re-install blower door. Table 10 or 11.
4. Operate furnace per instruction on door. e. Follow heat value and specific gravity lines to point of
5. Verify furnace shut down by lowering thermostat setting intersection to find orifice size and manifold pressure
below room temperature. settings for proper operation.
23
SEE NOTES: 1,2,4,7,8,9 SEE NOTES: 1,2,3,4,7,8,9 SEE NOTES:1,2,3,4,5,7,8,9
A02058 A02059 A02060
Fig. 26—Upflow Application- Fig. 27—Upflow Application- Fig. 28—Downflow

Vent Elbow Up Vent Elbow Right Application-Vent Elbow Up
then Left
SEE NOTES: 1,2,4,5,7,8,9

SEE NOTES: 1,2,4,5,6,7,8,9
A02061 A02062 SEE NOTES: 1,2,3,4,7,8,9 A02063
Fig. 29—Downflow Fig. 30—Downflow Fig. 31—Downflow
Application-Vent Elbow Up Application-Vent Elbow Left Application-Vent Elbow Up
then Up then Right
See Venting Notes on page 26.
24
SEE NOTES: 1,2,4,7,8,9
A02064
SEE NOTES: 1,2,4,5,7,8,9
Fig. 32—Horizontal Left Application-Vent Elbow Left
A02067
Fig. 35—Horizontal Left Application-Vent Elbow Right
SEE NOTES: 1,2,4,5,7,8,9

A02065
Fig. 33—Horizontal Left Application-Vent Elbow Right SEE NOTES: 1,2,4,5,7,8,9

then Up
A02068
Fig. 36—Horizontal Right Application-Vent Elbow Left
See Venting Notes on Page 26

SEE NOTES: 1,2,4,5,7,8,9
A02066
Fig. 34—Horizontal Left Application-Vent Elbow Up
f. Check and verify burner orifice size in furnace. NEVER c. Connect a water column manometer or similar device to
ASSUME ORIFICE SIZE. ALWAYS CHECK AND manifold pressure tap.
VERIFY. d. Turn gas valve ON/OFF switch to ON.
g. Replace orifice with correct size if required by Table 13 or e. Set thermostat to call for heat.
14. Use only factory-supplied orifices. See EXAMPLE 2.
f. Jumper R and W thermostat connections on furnace control
board to start furnace.
22,000 BTUH burner applications use Table 10
g. Remove regulator seal cap and turn regulator adjusting
EXAMPLE 2: (0–2000 ft altitude)
screw counterclockwise (out) to decrease input rate of
Heating value = 1000 Btu/cu ft
clockwise (in) to increase input rate.
Specific gravity = 0.62
Therefore: Orifice No. 43* h. Install regulator seal cap.
Manifold pressure: 3.7-in. wc i. Leave manometer or similar device connected and proceed
* Furnace is shipped with No. 43 orifices. In this example to Step 4.
all main burner orifices are the correct size and do not need NOTE: DO NOT set manifold pressure less than 3.2-in wc or
to be changed to obtain proper input rate. more than 3.8-in. wc for natural gas at sea level. If manifold
pressure is outside this range, change main burner orifices or refer
3. Adjust manifold pressure to obtain correct input rate. Table 10 or 11.
a. Turn gas valve ON/OFF switch to OFF NOTE: If orifice hole appears damaged or it is suspected to have
b. Remove manifold pressure tap plug from gas valve. (See been redrilled, check orifice hole with a numbered drill bit of
Fig. 40.) correct size. Never redrill an orifice. A burr-free and squarely
aligned orifice hole is essential for proper flame characteristics.
25
Venting Notes for Fig. 26-38
1. For common vent, vent connector sizing and vent material: United
States, latest edition of the National Fuel Gas Code (NFGC), ANSI
Z223.1/NFPA 54. In Canada, latest edition of the National Standards
of Canada, Natural Gas and Propane Installation Code (NSCNGPIC),
CSA B149.1-00.
2. Immediately increase to 5–inch vent connector outside furnace
A02069
casing when 5-inch vent connector required, refer to Note 1 above.
SEE NOTES: 1,2,4,7,8,9 3. Side outlet vent for upflow and downflow installations must use
Fig. 37—Horizontal Right Application-Vent Elbow Type B vent immediately after exiting the furnace, except when
Right KGAVG0101DFG is used in the downflow position.
4. Type B vent where required, refer to Note 1 above.
5. 4” single wall (26 ga. min.) vent must be used inside furnace casing
and when the KGAVG0101DFG Downflow Vent Guard Kit is used
external to the furnace.
6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required
in downflow installations with bottom vent configuration.
7. Chimney Adapter Kit required for exterior masonry chimney
applications. Refer to Chimney Adapter Kit, KGACA02014FC and
KGACA02015FC for sizing and complete application details.
SEE NOTES: 1,2,4,5,7,8,9 8. Secure vent connector to furnace elbow with (2) corrosion-resistant
A02070
sheet metal screws, spaced approximately 180° apart.
Fig. 38—Horizontal Right Application-Vent Elbow Left 9. Secure all other single wall vent connector joints with (3) corrosion
then Up resistant screws spaced approximately 120° apart. Secure Type B vent
connectors per vent connector manufacturer’s recommendations.
4. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment cap must be in place for
proper input to be clocked. Disconnect 115-v electrical power before changing speed tap.
Failure to follow this warning could result in personal injury.
a. Turn off all other gas appliances and pilots.
b. Run furnace for 3 minutes in heating operation. c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
c. Measure time (in sec) for gas meter to complete 1 revolu-
blower speed to increase temperature rise.
tion and note reading. The 2 cubic feet dial provides a more
accurate measurement of gas flow. d. Turn thermostat down below room temperature and re-
move blower access door.
d. Refer to Table 8 for cubic ft of gas per hr.
e. To change motor speed selection for heating, remove
e. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft) to
blower motor lead from control HEAT terminal (See Fig.
obtain input.
39.) Select desired blower motor speed lead from one of the
If clocked rate does not match required input from Step 1, increase other terminals and relocate it to the HEAT terminal (See
manifold pressure to increase input or decrease manifold pressure Table 7 for lead color identification). Reconnect original
to decrease input. Repeat steps b through e until correct input is lead to SPARE terminal.
achieved. Re-install regulator seal cap on gas valve.
f. Repeat steps a through e.
5. Set temperature rise.
g. When correct input rate and temperature rise is achieved,
The furnace must operate within the temperature rise ranges
turn gas valve ON/OFF switch to OFF.
specified on the furnace rating plate. Do not exceed tempera-
ture rise range specified on unit rating plate. Determine the h. Remove manometer or similar device from gas valve.
temperature rise as follows: i. Re-install manifold pressure tap plug in gas valve.
a. Place thermometers in return and supply ducts as close to
furnace as possible. Be sure thermometers do not see
radiant heat from heat exchangers. Radiant heat affects
temperature rise readings. This practice is particularly Failure to reinstall manifold pressure tap plug in gas valve
important with straight-run ducts. will result in fire, explosion, personal injury, property damage
b. When thermometer readings stabilize, subtract return-air or death.
temperature from supply-air temperature to determine air j. Re-install blower access door if removed.
temperature rise.
k. Turn gas valve ON/OFF switch to ON.
NOTE: Blower access door must be installed for proper tempera-
ture rise measurement.
NOTE: If the temperature rise is outside this range, first check:
1.) Gas input for heating operation. Recheck temperature rise. It must be within limits specified
2.) Derate for altitude if applicable. on the rating plate. Recommended operation is at the mid-
3.) Return and supply ducts for excessive restrictions causing static point of rise range or slightly above
pressures greater than 0.50-in. wc.
4.) Dirty filter. 6. Set thermostat heat anticipator.
26
CONNECTION DIAGRAM TO 115VAC FIELD DISCONNECT SWITCH SCHEMATIC DIAGRAM
BLOWER OFF-DELAY FRS2 LS1 LS2 (NATURAL & PROPANE GASES)
JUMPER SELECT OR PCB GV
L1 L2 NEUTRAL
J2
EQUIPMENT GROUND
RED RED RED
90 RED
(WHEN USED) ILK LO CAP
120 SPARE-1
G
150 GRN/YEL NOTE #10 HEAT MED LO
Com
24V NOTE #5 HI
180 FRS1 DSS BVSS START L2
W J1 L1 OL
RED COOL EAC-2
Y TEST/TWIN RED ORG
ORG BLWM
R BLWR EAC-1 BHT/CLR COM
(WHEN USED)
BLU
HUM
HSIR
PRINTED CIRCIUT BOARD

FU1 BLU BLK
NOTE #6
IDR 1 1 HSI
TRAN
RED WHT
SEC-2 SEC-1 2
L 2 NEUTRAL
PL2 2 PL3
RED
(WHEN USED)
LED PRS LGPS PR1 115VAC
GRN/YEL
IDM
EAC-2 L2 RED TRAN
ORN 24VAC
SEC-1 SEC-2
NOTE #8
YEL
NOTE #11
NEUTRAL
YEL
1 2 3 4 5 6 7 8 9 10 11
WHT
PL1 FSE BVSS
BLW
FRS1 DSS (WHEN USED)
BLK
PL2 NOTE #6
IDM FU1
BHT/CLR BLWR PL1-6
COOL 2 1
GRN/YEL NOTE #10
HEAT L1 PL3 FRS2 LS1
BLK 1 PL1-8 LS2
HSI
WHT 2 R
SPARE 1 SPARE 2 EAC-1
PR1 WHT
W (WHEN USED)
WHT BLK (HI) WHT (COM) PL1-2
WHT HUM NOTE #11
(COM)
BLK
27
BLWM FUSE OR CIRCUIT BREAKER &
DISCONNECT SWITCH (WHEN REQ’D) LGPS
GRN/YEL JB NOTE #2 PRS
BRN (WHEN USED)
OL NEUTRAL PL1-4
BLU WHT WHT
(MED LO) FU2 TEST/TWIN
START L1 GV
RED (LO) BLK BLK GVR PL1-10
CAP CPU
GND Y
BRN ILK
PL1-5 NOTE #3
PRINTED CIRCIUT BOARD
L BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT LS 1, 2 LIMIT SWITCH, AUTO-RESET, SPST(N.C.) PL1-1
BLWR BLOWER MOTOR RELAY, SPST-(N.O.) OL AUTO-RESET INTERNAL MOTOR OVERLOAD FSE
E
BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR TEMPERATURE SWITCH (N.C.)
G BVSS BLOCKED VENT SHUTOFF SWITCH, MANUAL-RESET, SPST -(N.C.) G PL1-9
PCB PRINTED CIRCUIT BOARD CONTROL
E CAP CAPACITOR PL1-11
PL1 11-CIRCUIT PCB CONNECTOR
N CPU MICROPROCESSOR AND CIRCUITRY PL1-3
PL2 2-CIRCUIT CONNECTOR
DSS DRAFT SAFE GUARD SWITCH, AUTO-RESET, SPST -(N.C.) COM 24V
D PL3 2-CIRCUIT HSI, CONNECTOR PCB NOTE #5 PL1-7
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON) PRS PRESSURE SWITCH, SPST-(N.O.)
FRS 1, 2 FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.) TEST/TWIN COMPONENT TEST & TWIN TERMINAL
FSE FLAME-PROVING ELECTRODE TRAN TRANSFORMER-115VAC/24VAC NOTES:
FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED JUNCTION 1. If any of the original equipment wire is replaced use wire rated for 105°C.
FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE 2. Use only copper wire between the disconnect switch and the furnace junction box (JB).
UNMARKED TERMINAL
(FIELD INSTALLED & SUPPLIED) 3. This wire must be connected to furnace sheet metal for control to prove flame.
GND EQUIPMENT GROUND PCB CONTROL TERMINAL 4. Symbols are electrical representation only.
GV GAS VALVE-REDUNDANT FACTORY WIRING (115VAC) 5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.
GVR GAS VALVE RELAY, SPST-(N.O.) FACTORY WIRING (24VAC) 6. Replace only with a 3 amp fuse.
HSI HOT SURFACE IGNITER (115 VAC)
HSIR HOT SURFACE IGNITER RELAY, SPST-(N.O.) FIELD WIRING (115VAC) 7. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) FIELD WIRING (24VAC)
8. Neutral connections are interchangeable within the NEUTRAL connector block.
IDM INDUCED DRAFT MOTOR, SHADED-POLE 9. Blower motor speed selections are for average conditions, see installation instructions for details on
CONDUCTOR ON CONTROL PCB
IDR INDUCED DRAFT MOTOR RELAY, SPST-(N.O.) optimum speed selection.
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.) FIELD WIRING SCREW TERMINAL 10. Factory connected when BVSS (Chimney Adapter Accessory Kit) is not installed.
J1 BLOWER - OFF DELAY JUMPER SELECTOR - HEATING FIELD EARTH GROUND 11. Factory connected when LGPS is not used.
J2 BLOWER - OFF DELAY JUMPER - COOLING EQUIPMENT GROUND 12. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will
JB JUNCTION BOX auto-reset after three hours.
LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED FIELD SPLICE
327559-101 REV. E
LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.) 13. Blower-on delay: gas heating 25 seconds, cooling or heat pump 2 seconds.
PLUG RECEPTACLE
14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
90 seconds or 5 seconds when J2 is cut.
Fig. 39—Furnace Wiring Diagram A02141

Caution!! For the following applications, use the minimum vertical vent sections as specified below.
For all other applications, follow exclusively the National Fuel Gas Code.
MINIMUM
FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR) MINIMUM VERTICAL VENT HEIGHT (FT)**
VENT DIAMETER (IN.)*
154,000
Vent elbow left, then up
Downflow 132,000 5 12
Fig. 30
110,000(036/-12 only)
Vent elbow right,
154,000
Horizontal Left then up 5 7
132,000
Fig. 33
Vent Elbow up 154,000
Horizontal Left 5 7
Fig. 34 132,000
Vent elbow right
Horizontal Left 154,000 5 7
Fig. 35
Vent elbow up then left 110,000
Downflow 5 10
Fig. 28 (036/-12 only)
Vent elbow up, then right 110,000
Downflow 5 10
Fig. 31 (036/-12 only)
NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.
*4 in. inside casing or vent guard
**Including 4 in. vent section(s)
Table 6–Altitude Derate Multipler for U.S.A.

ALTITUDE PERCENT DERATE MULTIPLIER
(FT) OF DERATE FACTOR*
0–2000 0 1.00
2001–3000 8–12 0.90
3001–4000 12–16 0.86
4001–5000 16–20 0.82
5001–6000 20–24 0.78
6001–7000 24–28 0.74
7001–8000 28–32 0.70
8001–9000 32–36 0.66
9001–10,000 36–40 0.62 BURNER
ORIFICE
* Derate multiplier factors are based on midpoint altitude for altitude range.
ON AND OFF
SWITCH A93059
Fig. 41—Orifice Hole
Table 7—Speed Selection

GAS PRESSURE
REGULATOR COLOR SPEED AS SHIPPED
ADJUSTMENT White Common BLW
Black High COOL
Yellow† Med-High SPARE
Blue* Med-Low SPARE
Red* Low HEAT
* 1/5 HP motor models: BLUE to HEAT, RED to SPARE.
† Not available on 1/5 HP motors.
NOTE: Continuous blower is the HEAT speed.
(1.) Remove thermostat from subbase or from wall.

INLET
PRESSURE (2.) Connect an amp meter as shown in Fig. 42 across the
TAP MANIFOLD
PRESSURE TAP R and W terminals or R and W wires.
A00157
(3.) Record amp draw across terminals when furnace is in
Fig. 40—Redundant Automatic Gas Control Valve heating and after blower starts.
(4.) Set heat anticapator on thermostat per thermostat
instructions and install on subbase or wall.
a. Mechanical thermostat—Set thermostat heat anticipator to
match the amp draw of the electrical components in the b. Electronic thermostat: Set cycle rate for 4 cycles per hr.
R-W circuit. Accurate amp draw readings can be obtained 7. Adjust blower off delay
at the wires normally connected to thermostat subbase The blower off delay has 4 adjustable settings from 90 sec to
terminals, R and W. The thermostat anticipator should 180 sec. The blower off delay jumpers are located on the
NOT be in the circuit while measuring current. furnace control board. (See Fig. 23.)
28
Table 8–GAS RATE (CU FT/HR)
SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL THERMOSTAT SUBBASE
FOR 1 1 2 5 FOR 1 1 2 5 TERMINALS WITH
REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft THERMOSTAT REMOVED
10 360 720 1800 50 72 144 360 (ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
11 327 655 1636 51 71 141 355
12 300 600 1500 52 69 138 346 HOOK-AROUND
13 277 555 1385 53 68 136 340
AMMETER
14 257 514 1286 54 67 133 333
15 240 480 1200 55 65 131 327
R Y W G
16 225 450 1125 56 64 129 321
17 212 424 1059 57 63 126 316
18 200 400 1000 58 62 124 310
19 189 379 947 59 61 122 305
20 180 360 900 60 60 120 300
21 171 343 857 62 58 116 290
22 164 327 818 64 56 112 281
23 157 313 783 66 54 109 273
10 TURNS
24 150 300 750 68 53 106 265
25 144 288 720 70 51 103 257
26 138 277 692 72 50 100 250 FROM UNIT 24-V
27 133 267 667 74 48 97 243 CONTROL TERMINALS
28 129 257 643 76 47 95 237
29 124 248 621 78 46 92 231 EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT
10 TURNS AROUND JAWS ANTICIPATOR SETTING
30 120 240 600 80 45 90 225
A96316
31 116 232 581 82 44 88 220
32 113 225 563 84 43 86 214 Fig. 42—Amp Draw Check With Ammeter
33 109 218 545 86 42 84 209
34 106 212 529 88 41 82 205 d. Burners will re-light when furnace cools down.
35 103 206 514 90 40 80 200
2. Check draft safeguard switch.
36 100 200 500 92 39 78 196
The purpose of this control is to permit the safe shutdown of
37 97 195 486 94 38 76 192
38 95 189 474 96 38 75 188
the furnace during certain blocked vent conditions.
39 92 185 462 98 37 74 184 a. Verify vent pipe is cool to the touch.
40 90 180 450 100 36 72 180 b. Disconnect power to furnace and remove vent connector
41 88 176 439 102 35 71 178 from furnace vent elbow.
42 86 172 429 104 35 69 173
c. Restore power to furnace and set room thermostat above
43 84 167 419 106 34 68 170
room temperature.
44 82 164 409 108 33 67 167
45 80 160 400 110 33 65 164 d. After normal start-up, allow furnace to operate for 2
46 78 157 391 112 32 64 161 minutes, then block vent elbow in furnace 80 percent of
47 76 153 383 116 31 62 155 vent area with a piece of flat sheet metal.
48 75 150 375 120 30 60 150 e. Furnace should cycle off within 2 minutes.
49 73 147 367
f. Remove blockage and reconnect vent pipe to furnace vent
elbow.
g. Switch will auto-reset when it cools.
To change the blower off delay setting, move the jumper from
h. If control board locks out furnace, cycle 115 vac power to
one set of pins on the control to the pins used for the selected
reset control.
blower off delay. Factory off delay setting is 120 sec.
3. Check Pressure Switch(es)
Step 4—Check Safety Controls
This control proves operation of the draft inducer blower.
The flame sensor, gas valve, and pressure switch were all checked
a. Turn off 115-v power to furnace.
in the Start-up procedure section as part of normal operation.
b. Disconnect inducer motor lead wires from wire harness.
1. Check Main Limit Switches
This control shuts off combustion control system and ener- c. Turn on 115-v power to furnace.
gizes air-circulating blower motor, if furnace overheats. By d. Set thermostat to ″call for heat″ and wait 1 minute. When
using this method to check limit control, it can be established pressure switch is functioning properly, hot surface igniter
that limit is functioning properly and will operate if there is a should NOT glow and control diagnostic light flashes a
restricted duct system or motor failure. If limit control does status code 32. If hot surface igniter glows when inducer
not function during this test, cause must be determined and motor is disconnected, shut down furnace immediately.
corrected. e. Determine reason pressure switch did not function properly
a. Run furnace for at least 5 minutes. and correct condition.
b. Gradually block off return air with a piece of cardboard or f. Turn off 115-v power to furnace.
sheet metal until the limit trips. g. Reconnect inducer motor wires, replace outer door, and
c. Unblock return air to permit normal circulation. turn on 115-v power.
29
Step 5—Checklist The control system also requires an earth ground for proper
1. Put away tools and instruments. Clean up debris. operation of the control and flame-sensing electrode.
2. Check that blower OFF-DELAY time is selected as desired. The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. (See Fig. 23.) Any shorts of the 24-v wiring during
3. Verify that blower and burner access doors are properly
installation, service, or maintenance will cause this fuse to blow. If
installed.
fuse replacement is required, use ONLY a 3-amp fuse. The control
4. Cycle test furnace with room thermostat. LED will display status code 24 when fuse needs to be replaced.
5. Check operation of accessories per manufacturer’s instruc- Proper instrumentation is required to service electrical controls.
tions. The control in this furnace is equipped with a Status Code LED
6. Review User’s Guide with owner. (Light-Emitting Diode) to aid in installation, servicing, and
7. Leave literature packet near furnace. troubleshooting. It can be viewed through the sight glass in blower
access door. The furnace control LED is either ON continuously,
rapid flashing, or a code composed of 2 digits. The first digit is the
SERVICE AND MAINTENANCE PROCEDURES number of short flashes, the second digit is the number of long
flashes.
For an explanation of status codes, refer to service label located on
blower access door or Fig. 43, and the troubleshooting guide at the
The ability to properly perform maintenance on this equip-
end of this procedure. The furnace control will store 1 status code
ment requires certain knowledge, mechanical skills, tools, and
for 72 hours.
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those For Controls With a Red LED
procedures recommended in the User’s Manual. FAILURE The stored status codes WILL be erased from the control memory,
TO FOLLOW THIS WARNING COULD RESULT IN if 115- or 24-v power is interrupted.
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS 1. To retrieve status code, proceed with the following:
PERSONAL INJURY, OR DEATH.
NOTE: NO thermostat signal may be present at control, and all
blower-OFF delays must be completed.
a. Leave 115-v power to furnace turned on.
→ ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD b. Remove outer access door.
Failure to follow safety warnings exactly could result in
c. Look into blower access door sight glass for current LED
dangerous operation, serious injury, death, or property dam-
status. DO NOT remove blower access door or terminate
age.
115-v power to control or status code will be lost.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage. d. BRIEFLY remove insulated terminal wire from the draft
- Before servicing, disconnect all electrical power to furnace. safeguard switch (DSS) until LED goes out (1 to 2 sec),
- When servicing controls, label all wires prior to disconnect- then reconnect it.
ing. Reconnect wires correctly. 2. When above items have been completed, the LED flashes
- Verify proper operation after servicing. status code 4 times. Record this status code for further
troubleshooting.
3. Component self-test will begin. Refer to COMPONENT
TEST section for complete test sequence.
Label all wires prior to disconnection when servicing con-
trols. Wiring errors can cause improper and dangerous 4. Check LED status.
operation. 5. Refer to the SERVICE label on the front of the blower access
door for more information.
Step 1—Introduction
Component Self-Test
GENERAL
Component Test can also be initiated by performing the following:
These instructions are written as if the furnace is installed in an
upflow application. An upflow furnace application is where the 1. Remove outer access door.
blower is located below the combustion and controls section of the 2. Remove blower access door.
furnace, and conditioned air is discharged upward. Since this 3. Remove the wire from the ″R″ terminal of the control board.
furnace can be installed in any of the 4 positions shown in Fig. 4,
4. Manually close blower access door switch.
you must revise your orientation to component location accord-
ingly.
ELECTRICAL CONTROLS AND WIRING
Blower access door switch opens 115-v power to control. No
component operation can occur unless switch is closed.
Caution must be taken when manually closing this switch for
There may be more than 1 electrical supply to the unit. Check service purposes. Failure to follow this warning could result
accessories and cooling unit for additional electrical supplies in electrical shock, personal injury, or death.
The electrical ground and polarity for 115-v wiring must be 5. BRIEFLY short (jumper) TEST/TWIN, 3/16-in. quick-
properly maintained. Refer to Fig. 24 for field wiring information connect male terminal on control (behind Y terminal) to the
and to Fig. 39 for furnace wiring information. COM-24V terminal on furnace control. (See Fig. 23.)
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
30
SERVICE
If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After
status code recall is completed component test will occur.
LED CODE STATUS
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours. On 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than five minutes,
RED LED boards stored status codes can also be erased when power inducer shuts off for 15 minutes before retry. Check for: - Excessive wind
(115 VAC or 24 VAC) to control is interrupted. - Proper vent sizing - Defective inducer motor
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90 seconds, - Low inducer voltage (115VAC) - Defective pressure switch
if unit is powered up during a call for heat (R-W closed) or R-W opens during blower - Inadequate combustion air supply - Disconnected or obstructed pressure tubing
on-delay. - Low inlet gas pressure (if LGPS used) - Restricted vent
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit, draft safeguard, flame rollout, or If it opens during blower on-delay period, blower will come on for the selected blower
blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips off-delay.
occurred during high-heat. - Control will auto reset after three hours. - Refer to #33. 33 LIMIT CIRCUIT FAULT - Indicates the limit, draft safeguard, flame rollout, or blocked vent
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. switch (if used) is open or the furnace is operating in high-heat only mode due to 2
21 GAS HEATING LOCKOUT - Control will NOT auto reset. successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes
Check for: - Mis-wired gas valve -Defective control (valve relay) whichever is longer. If open longer than 3 minutes, code changes to lockout #13.
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de- If open less than 3 minutes status code #33 continues to flash until blower shuts off.
energized. Inducer will run until fault is cleared. Check for: - Leaky gas valve Flame rollout switch and BVSS require manual reset. Check for: - Restricted vent
- Stuck-open gas valve - Proper vent sizing - Loose blower wheel. - Excessive wind
23 PRESSURE SWITCH DID NOT OPEN Check for: - Dirty filter or restricted duct system.
- Obstructed pressure tubing. - Pressure switch stuck closed. - Defective blower motor or capacitor. - Defective switch or connections.
24 SECONDARY VOLTAGE FUSE IS OPEN Check for:
- Short circuit in secondary voltage (24VAC) wiring. - Inadequate combustion air supply (Flame Roll-out Switch open).
34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14
occurs. If flame signal lost during blower on-delay period, blower will come on for the
COMPONENT TEST selected blower off-delay. Check for: - Flame sensor must not be grounded
- Oxide buildup on flame sensor (clean with fine steel wool).
To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" - Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).
thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED - Gas valve defective or gas valve turned off - Manual valve shut-off
will flash code and then turn ON the inducer motor. The inducer motor will run for the entire - Defective Hot Surface Ignitor - Control ground continuity
component test. The hot surface ignitor, blower motor fan speed (on AMBER LED boards - Low inlet gas pressure - Inadequate flame carryover or rough ignition
only) blower motor-heat speed, and blower motor-cool speed will be turned ON for 10-15 - Green/Yellow wire MUST be connected to furnace sheet metal
seconds each. Gas Valve and Humidifier will not be turned on. 45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;
- Gas valve relay stuck open - Flame sense circuit failure - Software check error
327596-101 REV. A Reset power to clear lockout. Replace control if status code repeats.
A02027
Fig. 43—Service Label

NOTE: If TEST/TWIN to COM-24V terminals are jumpered
longer than 2 sec, LED will flash rapidly, and test request will be
ignored. Never store anything on, near, or in contact with the furnace,
6. Component Test will function as follows: such as:
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
a. LED flashes a status code 4 times. Record this status code cleaners, or other cleaning tools.
for further troubleshooting. 2. Soap powders, bleaches, waxes or other cleaning com-
b. Inducer motor starts and continues to run until step f of pounds, plastic or plastic containers, gasoline, kerosene,
component test sequence. cigarette lighter fluid, dry cleaning fluids, or other volatile
c. Hot surface igniter is energized for 15 sec, then de- fluids.
energized. 3. Paint thinners and other painting compounds, paper bags,
or other paper products.
d. Blower operates at HEAT speed for 10 sec, then turns off.
A failure to follow this warning could result in corrosion of
e. Blower operates at COOL speed for 10 sec, then turns off. the heat exchanger, fire, personal injury, or death.
f. Inducer motor turns off.
Items a through f above will assist in furnace troubleshooting since
all components are functionally operated except the gas valve. This
procedure is also referred to as ″Component Test Sequence.″ Turn off the gas and electrical supplies to the unit before
7. Check LED status. If no previous fault is in history, control performing any maintenance or service. Follow the operating
will flash status code 11. instructions on the label attached to the furnace. A failure to
8. If LED status indicates proper operation, RELEASE follow this warning could result in personal injury.
BLOWER ACCESS DOOR SWITCH, reattach wire to ″R″
terminal on furnace control board, replace blower access door,
and replace burner access door.
Step 2—Care and Maintenance Never operate unit without a filter or with filter access door
For continuing high performance and to minimize possible equip- removed. A failure to follow this warning could result in fire,
ment failure, periodic maintenance must be performed on this personal injury, or death.
equipment. Consult your local dealer about proper frequency of
maintenance and the availability of a maintenance contract.
→ Personal injury can result from sharp metal edges, etc. Be

careful when removing parts. Gloves and safety glasses
should be worn when servicing equipment
The minimum maintenance on this equipment is as follows:

1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean as necessary.
31
3. Check electrical connections for tightness and controls for BLOWER MOTOR AND WHEEL
proper operation each heating season. Service as necessary.
4. Inspect burner compartment before each heating season for
rust, corrosion, soot or excessive dust. If necessary, have → Blower access door switch opens 115-v power to control. No
furnace and burner serviced by a qualified professional. component operation can occur unless switch is closed.
5. Inspect the vent pipe/vent system before each heating season Caution must be taken when manually closing this switch for
for rust, corrosion, water leakage, sagging pipes or broken service purposes. Failure to follow this warning could result
fittings. Have vent pipes/vent system serviced by a qualified in personal injury or death.
professional.
6. Inspect any accessories attached to the furnace such as a
humidifier or electronic air cleaner. Perform any service or
The blower wheel should not be dropped or bent as balance
maintenance to the accessories as recommended in the acces-
will be affected.
sory instructions.
CLEANING AND/OR REPLACING AIR FILTER The following steps should be performed by a qualified service
The air filter arrangement may vary depending on the application. technician.
The filter is exterior to the furnace casing. To ensure long life and high efficiency, clean accumulated dirt and
grease from blower wheel and motor annually.
NOTE: If the filter has an airflow direction arrow, the arrow must
point towards the blower. The inducer and blower motors are pre-lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
Personal injury can result from sharp metal edges, etc. Be Clean blower motor and wheel as follows:
careful when removing parts. Gloves and safety glasses 1. Turn off electrical supply to furnace.
should be worn when servicing equipment 2. Unscrew the thumbscrew on outer door and remove outer
door.
Media cabinet filter procedures:
3. For downflow or horizontal furnaces having vent pipes within
NOTE: Media cabinet or 1″ Filter Rack are accessories and are the furnace that pass in from of the blower access door:
not included from the factory with the standard furnace model.
a. Disconnect vent connector from furnace vent elbow.
1. Turn off electrical supply to furnace before removing filter
access door. b. Disconnect and remove short piece of vent pipe from
within furnace.
2. Remove filter cabinet door.
4. Remove 2 screws from blower access door and remove blower
3. Slide filter out of cabinet. access door.
4. If equipped with permanent, washable 1″ filter, clean filter by 5. Disconnect blower leads from furnace control. Note wire color
spraying cold tap water through filter in opposite direction of and location for reassembly. All other factory wires can be left
airflow. Rinse filter and let dry. Oiling or coating of the filter connected, but field thermostat connections may need to be
is not recommended. See Table 9 for size information. disconnected depending on their length and routing.
5. If equipped with factory-specified disposable media filter, 6. Remove 2 screws from control box to blower shelf.
replace only with media filter having the same part number
and size. For expandable replacement media, refer to the 7. Hang control box from front of furnace casing and away from
instructions included with the replacement media. If equipped blower compartment.
with KGAFR0301ALL external filter rack, See Table 9. 8. Remove 2 screws holding blower assembly to blower deck
6. Slide filter into cabinet. and slide blower assembly out of furnace.
7. Replace filter cabinet door. 9. Clean blower wheel and motor using a vacuum with soft brush
attachment. Blower wheel blades may be cleaned with a small
8. Turn on electrical supply to furnace. paint or flux brush. Do not remove or disturb balance weights
(clips) on blower wheel blades.
10. Vacuum any loose dust from blower housing, wheel and
motor.
11. If a greasy residue is present on blower wheel, remove wheel
Table 9—FILTER SIZE INFORMATION (IN.) from the blower housing and wash it with an appropriate
FURNACE FILTER QUANTITY AND SIZE FILTER degreaser. To remove wheel:
CASING WIDTH Side Return Bottom Return TYPE NOTE: Before disassembly, mark blower motor, and blower
14-1/2 (1) 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable* housing so motor and each arm is positioned at the same location
17-1/2 (1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable* during reassembly.
21 (1) 16 X 25 X 1 (1) 20 X 25 X 1 Cleanable* a. Disconnect capacitor wires and ground wire attached to
24** (1) 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable* blower housing.
* Recommended
** Some furnaces may have 2 filters b. Remove screws securing cutoff plate and remove cutoff
plate from housing.
c. Loosen set screw holding blower wheel on motor shaft.
d. Remove bolts holding motor to blower housing and slide
motor out of wheel.
32
e. Remove blower wheel from housing. CLEANING HEAT EXCHANGER
f. Clean wheel and housing. The following steps should be performed by a qualified service
12. Reassemble motor and blower by reversing steps 11f, finish- technician:
ing with 11a. Be sure to reattach ground wire to the blower NOTE: If the heat exchangers get a heavy accumulation of soot
housing. and carbon, they should be replaced rather than trying to clean
13. Verify that blower wheel is centered in blower housing and set them thoroughly. A build-up of soot and carbon indicates that a
screw contacts the flat portion of the motor shaft. Loosen set problem exists which needs to be corrected, such as improper
screw on blower wheel and reposition if necessary. adjustment of manifold pressure, insufficient or poor quality
combustion air, incorrect size or damaged manifold orifice(s),
14. Spin the blower wheel by hand to verify that the wheel does
improper gas, or a restricted heat exchanger. Action must be taken
not rub on the housing.
to correct the problem.
15. Reinstall blower assembly in furnace.
If it becomes necessary to clean the heat exchangers because of
16. Reinstall control box assembly in furnace. dust or corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
Heating fan speed(s) MUST be adjusted to provide proper air 3. Disconnect vent connector from furnace vent elbow.
temperature rise as specified on the rating plate. Failure to
4. For downflow or horizontal furnace having an internal vent
adjust the heating speed(s) may shorten heat exchanger life.
pipe, remove internal vent pipe within the casing.
Recommended operation is at the midpoint of the rise range
or slightly above. Refer to ″SET TEMPERATURE RISE″ 5. Disconnect wires to the following components. Mark wires to
under START-UP, ADJUSTMENT, and SAFETY CHECK. aid in reconnection of:
a. Draft safeguard switch.
NOTE: Refer to Table 7 for motor speed lead relocation if leads
were not identified before disconnection. b. Inducer motor.
17. Reconnect blower leads to furnace control. Refer to furnace c. Pressure switch(es).
wiring diagram, and connect thermostat leads if previously d. Limit overtemperature switch.
disconnected. (See Fig. 39.) e. Gas valve.
18. To check blower for proper rotation: f. Hot surface igniter.
a. Turn on electrical supply. g. Flame-sensing electrode
h. Flame rollout switches.
i. Remove NOx baffles on low NOx models.
Blower access door switch opens 115-v power to furnace 6. Remove screws that fasten the collector box assembly to the
control. No component operation can occur. Caution must be cell panel. Be careful not to damage the collector box. Inducer
taken when manually closing this switch for service purposes. assembly and elbow need not be removed from collector box.
Failure to follow this warning could result in electrical shock,
7. Disconnect gas line from gas manifold.
personal injury, or death.
8. Remove the 4 screws that attach the burner assembly to the
b. Manually close blower access door switch. cell panel. The gas valve and individual burners need not be
NOTE: If thermostat terminals are jumpered at the time blower removed from support assembly.
access door switch is closed, blower will run for 90 sec before NOTE: Be very careful when removing burner assembly to avoid
beginning a heating or cooling cycle. breaking igniter. See Fig. 44 and 45 for correct igniter location.
c. Perform component self-test as shown at the bottom of the
SERVICE label, located on the front of blower access door.
9/32”
d. Verify blower is rotating in the correct direction.
19. If furnace is operating properly, RELEASE BLOWER AC- 11/32”
CESS DOOR SWITCH. Replace blower access door and
remove any jumpers or reconnect any disconnected thermostat
leads.
20. Downflow or horizontal furnaces with vent pipe through
furnace only:
a. Install and connect short piece of vent pipe inside furnace
to existing vent.
b. Connect vent connector to vent elbow.
21. Reinstall casing door.
22. Turn on gas supply and cycle furnace through one complete
heating and cooling cycle. Verify the unit temperature rise as
shown in Adjustments Section. Adjust temperature rise as
shown in Adjustments Section. If outdoor temperature is
A02150
below 70° F, turn off circuit breaker to outdoor unit before
running furnace in the cooling cycle. Turn outdoor circuit Fig. 44—Position of Igniter to Burner
breaker on after completing cooling cycle.
33
7/8”
A02151 A91252
Fig. 45—Position of Igniter to Burner Fig. 46—Cleaning Heat Exchanger Cell
9. Using field-provided 25-caliber rifle cleaning brush, 1/4″

diameter steel spring cable, 36 in. long, a variable speed,
reversible electric drill, and vacuum cleaner, clean cells as 13. Reconnect wires to the following components (Use connection
follows: diagram on wiring label, if wires were not marked for
reconnection locations.):
a. Remove metal screw fitting from wire brush to allow
insertion into cable. a. Draft safeguard switch.
b. Insert the twisted wire end of brush into end of spring b. Inducer motor.
cable, and crimp tight with crimping tool or crimp by c. Pressure switch(es).
striking with ball-peen hammer. TIGHTNESS IS VERY d. Limit overtemperature switch.
IMPORTANT.
e. Gas valve.
NOTE: The materials needed in item 9 can usually be purchased
f. Hot surface igniter.
at local hardware stores.
g. Flame-sensing electrode.
(1.) Attach variable-speed, reversible drill to the end of
spring cable (end opposite brush). h. Flame rollout switches.
i. Install NOx baffles (if removed).
(2.) Insert brush end of cable into the outlet opening of cell
and slowly rotate with drill. DO NOT force cable. 14. Reinstall internal vent pipe, if applicable.
Gradually insert cable into upper pass of cell. (See Fig. 15. Reinstall vent connector on furnace vent elbow. Securely
46.) fasten vent connector to vent elbow with 2 field-supplied,
(3.) Work cable in and out of cell 3 or 4 times to obtain corrosion-resistant, sheet metal screws located 180° apart.
sufficient cleaning. DO NOT pull cable with great 16. Replace blower access door only.
force. Reverse drill and gradually work cable out. 17. Set thermostat above room temperature and check furnace for
(4.) Insert brush end of cable in burner inlet opening of proper operation.
cell, and proceed to clean 2 lower passes of cell in 18. Verify blower airflow and speed changes between heating and
same manner as upper pass. cooling.
(5.) Repeat foregoing procedures until each cell in furnace 19. Check for gas leaks.
has been cleaned.
(6.) Using vacuum cleaner, remove residue from each cell.
(7.) Using vacuum cleaner with soft brush attachment, Never use a match or other open flame to check for gas leaks.
clean burner assembly. Use a soap-and-water solution. A failure to follow this
warning could result in fire, personal injury, or death.
(8.) Clean flame sensor with fine steel wool.
(9.) Reinstall burner assembly. Center burners in cell 20. Replace outer access door.
openings. Step 3—Sequence of Operation
10. Remove old sealant from cell panel and inducer backing plate → NOTE: Furnace control must be grounded for proper operation or
flange. control will lock out. Control is grounded through green/yellow
11. Spray releasing agent on the heat exchanger cell panel where wire routed to gas valve and manifold bracket screw.
collector box assembly contacts cell panel. Using the schematic diagram in Fig. 39, follow the sequence of
NOTE: A releasing agent such as cooking spray or equivalent operation through the different modes. Read and follow the wiring
(must not contain corn or canola oil, aromatic or halogenated diagram very carefully.
hydrocarbons or inadequate seal may occur) and RTV sealant NOTE: If a power interruption occurs during a call for heat (W),
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting the control will start a 90-second blower-only ON period two
installation. DO NOT substitute any other type of RTV sealant. seconds after power is restored, if the thermostat is still calling for
G.E. 162 (P771-9003) is available through RCD in 3-oz tubes. gas heating. The red LED light will flash code 12 during the
12. Apply new sealant to flange of inducer assembly and attach to 90-second period, after which the LED will be ON continuous, as
cell panel using existing screws, making sure all screws are long as no faults are detected. After the 90-second period, the
secure. furnace will respond to the thermostat normally.
34
The blower door must be installed for power to be conducted circuit starts the outdoor unit, and the R-to-G and Y circuits
through the blower door interlock switch ILK to the furnace start the furnace blower motor BLWM on COOL speed.
control CPU, transformer TRAN, inducer motor IDM, blower The electronic air cleaner terminal EAC-1 is energized with
motor BLWM, hot-surface igniter HSI, and gas valve GV. 115 vac when the blower motor BLWM is operating.
1. Heating When the thermostat is satisfied, the R-to-G-and-Y circuits are
(See Fig. 24 for thermostat connections.) opened. The outdoor unit will stop, and the furnace blower
The wall thermostat ″calls for heat″, closing the R to W motor BLWM will continue operating on the COOL speed for
circuit. The furnace control performs a self-check, verifies the an additional 90 seconds. Cut jumper J2 to reduce the cooling
pressure switch contacts PRS is open, and starts the inducer off-delay to 5 seconds. (See Fig. 23.)
motor IDM. 3. Continuous Blower Mode
a. Inducer Prepurge Period- As the inducer motor IDM When the R-to-G circuit is closed by the thermostat, the
comes up to speed, the pressure switch contacts PRS close, blower motor BLWM will operate on continuous-blower
24 vac power is supplied for a field installed humidifier at speed (same as HEAT speed). Terminal EAC-1 is energized as
the HUM terminal and the control begins a 15-second long as the blower motor BLWM is energized.
prepurge period. During a call for heat, the blower BLWM will stop during
igniter warm-up (17 seconds), ignition, and blower-ON delay
b. Igniter Warm-Up- At the end of the prepurge period, the
(25 seconds), allowing the furnace heat exchangers to heat up
Hot-Surface Igniter HSI is energized for a 17-second
more quickly, then restarts at the end of the blower-ON delay
igniter warm-up period.
period at HEAT speed.
c. Trial-for-Ignition Sequence- When the igniter warm-up When the thermostat ″calls for cooling″, the blower motor
period is completed the main gas valve relay contacts GVR BLWM will operate at COOL speed. When the thermostat is
close to energize the gas valve GV, the gas valve opens. satisfied, the blower motor BLWM will operate an additional
The gas valve GV permits gas flow to the burners where it 90 seconds on COOL speed before reverting back to
is ignited. After 5 seconds, the igniter HSI is de-energized continuous-blower speed.
and a 2-second Flame-Proving period begins. When the R-to-G circuit is opened, the blower motor BLWM
d. Flame-Proving- When the burner flame is proved at the will continue operating for an additional 5 seconds, if no other
flame-proving sensor electrode FSE, the furnace control function requires blower motor BLWM operation.
CPU begins the blower-ON delay period and continues to 4. Heat Pump
hold the gas valve GV open. If the burner flame is not When installed with a heat pump, the furnace control auto-
proved within two seconds, the control CPU will close the matically changes the timing sequence to avoid long blower
gas valve GV, and the control CPU will repeat the ignition off times during demand defrost cycles. When the R-to-W-
sequence for up to three more Trials-For-Ignition before and-Y or R-to-W-and-Y-and-G circuits are energized the
going to Ignition-Lockout. Lockout will be reset auto- furnace control CPU will continue to turn on the blower motor
matically after three hours, by momentarily interrupting BLWM at HEAT speed, and begin a heating cycle. The
115 vac power to the furnace, or by interrupting 24 vac blower motor BLWM will remain on until the end of the
power at SEC1 or SEC2 to the furnace control CPU (not at prepurge period, then shut off for 24 seconds then come back
W, G, R, etc.) on at HEAT speed. When the W input signal disappears, the
If flame is proved when flame should not be present, the furnace control begins a normal inducer post-purge period and
furnace control CPU will lock out of Gas-Heating mode the blower switches to COOL speed after a 3 second delay. If
and operate the inducer motor IDM until flame is no longer the R-to-W-and-Y-and-G signals disappear at the same time,
proved. the blower motor BLWM will remain on for the selected
e. Blower-On Delay- If the burner flame is proven, the blower-OFF delay period. If the R-to-W-and-Y signals disap-
blower motor is energized on HEAT speed 25 seconds after pear, leaving the G signal, the blower motor BLWM will
the gas valve GV is energized. continue running the blower motor BLWM at HEAT speed
Simultaneously, the electronic air cleaner terminal EAC-1 after the selected blower-OFF delay period is completed.
is energized and remains energized as long as the blower
motor BLWM is energized. Step 4—Wiring Diagrams
f. Blower-Off Delay- When the thermostat is satisfied, the Refer to Fig. 24 and 39 for wiring diagrams.
R-to-W circuit is opened, de-energizing the gas valve GV,
stopping gas flow to the burners, and de-energizing the Step 5—Troubleshooting
humidifier terminal HUM. The inducer motor IDM will
remain energized for a 5-second post-purge period. The Refer to the service label. (See Fig. 43—Service Label.)
blower motor BLWM and air cleaner terminal EAC-1 will The Troubleshooting Guide can be a useful tool in isolating
remain energized for 90, 120, 150, or 180 seconds (depend- furnace operation problems. Beginning with the word “Start,”
ing on the blower-OFF delay selection). The furnace answer each question and follow the appropriate arrow to the next
control CPU is factory-set for a 120-second blower-OFF item.
delay. The Guide will help to identify the problem or failed component.
2. Cooling Mode After replacing any component, verify correct operation sequence.
(See Fig. 24 for thermostat connections)
The thermostat closes the R-to-G-and-Y circuits. The R-to-Y
35
TABLE 10—Orifice Size* and Manifold Pressure For Gas Input Rate
(Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level)
SPECIFIC GRAVITY OF NATURAL GAS
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
(FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold
No. Pressure No. Pressure No. Pressure No. Pressure
900 42 3.5 42 3.6 42 3.7 41 3.5

U.S.A. and Canada
925 42 3.3 42 3.4 42 3.5 42 3.7

950 43 3.8 42 3.3 42 3.4 42 3.5
0 975 43 3.6 43 3.8 42 3.2 42 3.3
to 1000 43 3.5 43 3.6 43 3.7 43 3.8
2000
1025 43 3.3 43 3.4 43 3.5 43 3.6
1050 44 3.6 43 3.2 43 3.4 43 3.5
1075 44 3.4 44 3.5 43 3.2 43 3.3
1100 44 3.3 44 3.4 44 3.5 43 3.2
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
U.S.A. 800 42 3.4 42 3.5 42 3.6 42 3.7
Altitudes
U.S.A. and Canada
2001 825 42 3.2 42 3.3 42 3.4 42 3.5

to 850 43 3.7 43 3.8 42 3.2 42 3.3
3000 875 43 3.5 43 3.6 43 3.7 43 3.8
or 900 43 3.3 43 3.4 43 3.5 43 3.6
Canada
Altitudes 925 43 3.1 43 3.2 43 3.3 43 3.4
2000 950 43 2.9 43 3.0 43 3.1 43 3.2
to 975 43 2.8 43 2.9 43 3.0 43 3.1
4500 1000 43 2.6 43 2.7 43 2.8 43 2.9
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
775 42 3.2 42 3.3 42 3.4 42 3.5

800 43 3.6 43 3.8 42 3.2 42 3.3
825 43 3.4 43 3.5 43 3.7 43 3.8
3001
U.S.A. Only to 850 43 3.2 43 3.3 43 3.4 43 3.6
4000 875 43 3.0 43 3.1 43 3.3 43 3.4
900 43 2.9 43 3.0 43 3.1 43 3.2
925 43 2.7 43 2.8 43 2.9 43 3.0
950 43 2.6 43 2.7 43 2.8 43 2.8
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
750 43 3.6 43 3.8 42 3.2 42 3.3

775 43 3.4 43 3.5 43 3.6 43 3.8
U.S.A. Only
800 43 3.2 43 3.3 43 3.4 43 3.5

4001
to 825 43 3.0 43 3.1 43 3.2 43 3.3
5000 850 43 2.8 43 2.9 43 3.0 43 3.1
875 43 2.7 43 2.8 43 2.9 43 2.9
900 43 2.5 43 2.6 43 2.7 43 2.8
925 43 2.4 43 2.5 43 2.6 43 2.6
* Orifice numbers 43 are factory installed
36
Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued)
AVG GAS SPECIFIC GRAVITY OF NATURAL GAS
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold
(FT)
(BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure
725 43 3.4 43 3.5 43 3.6 43 3.7

750 43 3.2 43 3.3 43 3.4 43 3.5
U.S.A. Only
775 43 3.0 43 3.1 43 3.2 43 3.3

5001
to 800 43 2.8 43 2.9 43 3.0 43 3.1
6000 825 43 2.6 43 2.7 43 2.8 43 2.9
850 43 2.5 43 2.5 43 2.6 43 2.7
875 43 2.3 43 2.4 43 2.5 43 2.6
900 43 2.2 43 2.3 43 2.3 43 2.4
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
675 43 3.4 43 3.5 43 3.6 43 3.7

700 43 3.1 43 3.3 43 3.4 43 3.5
U.S.A. Only
725 43 2.9 43 3.0 43 3.1 43 3.2

6001
to 750 43 2.7 43 2.8 43 2.9 43 3.0
7000 775 43 2.6 43 2.7 43 2.7 43 2.8
800 43 2.4 43 2.5 43 2.6 43 2.7
825 43 2.3 43 2.3 43 2.4 43 2.5
850 43 2.1 43 2.2 43 2.3 43 2.4
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
650 43 3.1 43 3.2 43 3.4 43 3.5

675 43 2.9 43 3.0 43 3.1 43 3.2
U.S.A. Only
700 43 2.7 43 2.8 43 2.9 43 3.0

7001
to 725 43 2.5 43 2.6 43 2.7 43 2.8
8000 750 43 2.4 43 2.4 43 2.5 43 2.6
775 43 2.2 43 2.3 43 2.4 43 2.4
800 43 2.1 43 2.1 43 2.2 43 2.3
825 48 3.7 43 2.0 43 2.1 43 2.2
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
625 43 2.9 43 3.0 43 3.1 43 3.2
650 43 2.7 43 2.8 43 2.9 43 3.0
U.S.A. Only
8001 675 43 2.5 43 2.6 43 2.7 43 2.8

to 700 43 2.3 43 2.4 43 2.5 43 2.6
9000 725 43 2.2 43 2.2 43 2.3 43 2.4
750 43 2.0 43 2.1 43 2.2 43 2.2
775 48 3.6 48 3.7 43 2.0 43 2.1
37
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
600 43 2.7 43 2.8 43 2.9 43 3.0

U.S.A. Only
625 43 2.5 43 2.6 43 2.6 43 2.7

9001
to 650 43 2.3 43 2.4 43 2.4 43 2.5
10,000 675 43 2.1 43 2.2 43 2.3 43 2.3
700 48 3.7 43 2.0 43 2.1 43 2.2
725 48 3.5 48 3.6 48 3.7 43 2.0
38
TABLE 11—Orifice Size* and Manifold Pressure For Gas Input Rate
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
900 42 3.2 42 3.3 42 3.4 42 3.5

U.S.A. and Canada
925 43 3.7 43 3.8 42 3.2 42 3.3

950 43 3.5 43 3.6 43 3.7 43 3.8
0 975 43 3.3 43 3.4 43 3.5 43 3.7
to 1000 44 3.6 43 3.3 43 3.4 43 3.5
2000
1025 44 3.4 44 3.6 43 3.2 43 3.3
1050 44 3.3 44 3.4 44 3.5 43 3.2
1075 45 3.8 44 3.2 44 3.3 44 3.4
1100 46 3.8 45 3.7 44 3.2 44 3.3
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
U.S.A. 800 43 3.8 42 3.2 42 3.3 42 3.4
Altitudes
U.S.A. and Canada
2001 825 43 3.5 43 3.7 43 3.8 42 3.2

to 850 43 3.3 43 3.5 43 3.6 43 3.7
3000 875 43 3.2 43 3.3 43 3.4 43 3.5
or 900 43 3.0 43 3.1 43 3.2 43 3.3
Canada
Altitudes 925 43 2.8 43 2.9 43 3.0 43 3.1
2000 950 43 2.7 43 2.8 43 2.9 43 2.9
to 975 43 2.5 43 2.6 43 2.7 43 2.8
4500 1000 43 2.4 43 2.5 43 2.6 43 2.7
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
775 43 3.5 43 3.7 43 3.8 42 3.2

800 43 3.3 43 3.4 43 3.5 43 3.7
825 43 3.1 43 3.2 43 3.3 43 3.4
3001
U.S.A. Only to 850 43 2.9 43 3.0 43 3.1 43 3.2
4000 875 43 2.8 43 2.9 43 3.0 43 3.1
900 43 2.6 43 2.7 43 2.8 43 2.9
925 43 2.5 43 2.6 43 2.7 43 2.7
950 43 2.4 43 2.4 43 2.5 43 2.6
ALTITUDE AVG GAS
0.58 0.60 0.62 0.64
RANGE HEAT VALUE
750 43 3.3 43 3.4 43 3.5 43 3.6

775 43 3.1 43 3.2 43 3.3 43 3.4
U.S.A. Only
800 43 2.9 43 3.0 43 3.1 43 3.2

4001
to 825 43 2.7 43 2.8 43 2.9 43 3.0
5000 850 43 2.6 43 2.7 43 2.8 43 2.8
875 43 2.4 43 2.5 43 2.6 43 2.7
900 43 2.3 43 2.4 43 2.5 43 2.5
925 43 2.2 43 2.2 43 2.3 43 2.4
39
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
725 43 3.1 43 3.2 43 3.3 43 3.4

750 43 2.9 43 3.0 43 3.1 43 3.2
U.S.A. Only
775 43 2.7 43 2.8 43 2.9 43 3.0

5001
to 800 43 2.5 43 2.6 43 2.7 43 2.8
6000 825 43 2.4 43 2.5 43 2.5 43 2.6
850 43 2.2 43 2.3 43 2.4 43 2.5
875 43 2.1 43 2.2 43 2.3 43 2.3
900 43 2.0 43 2.1 43 2.1 43 2.2
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
675 43 3.1 43 3.2 43 3.3 43 3.4

700 43 2.9 43 3.0 43 3.1 43 3.2
U.S.A. Only
725 43 2.7 43 2.8 43 2.9 43 2.9

6001
to 750 43 2.5 43 2.6 43 2.7 43 2.8
7000 775 43 2.3 43 2.4 43 2.5 43 2.6
800 43 2.2 43 2.3 43 2.3 43 2.4
825 43 2.1 43 2.1 43 2.2 43 2.3
850 48 3.7 43 2.0 43 2.1 43 2.1
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
650 43 2.9 43 3.0 43 3.1 43 3.2

675 43 2.7 43 2.7 43 2.8 43 2.9
U.S.A. Only
700 43 2.5 43 2.6 43 2.6 43 2.7

7001
to 725 43 2.3 43 2.4 43 2.5 43 2.5
8000 750 43 2.1 43 2.2 43 2.3 43 2.4
775 43 2.0 43 2.1 43 2.2 43 2.2
800 48 3.6 48 3.7 43 2.0 43 2.1
825 48 3.3 48 3.5 48 3.6 48 3.7
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
625 43 2.7 43 2.7 43 2.8 43 2.9

650 43 2.5 43 2.5 43 2.6 43 2.7
U.S.A. Only
8001 675 43 2.3 43 2.4 43 2.4 43 2.5

to 700 43 2.1 43 2.2 43 2.3 43 2.3
9000
725 48 3.7 43 2.0 43 2.1 43 2.2
750 48 3.5 48 3.6 48 3.7 43 2.0
775 49 3.8 48 3.4 48 3.5 48 3.6
40
ALTITUDE
HEAT VALUE 0.58 0.60 0.62 0.64
RANGE
(FT)
600 43 2.4 43 2.5 43 2.6 43 2.7

U.S.A. Only
625 43 2.3 43 2.3 43 2.4 43 2.5

9001
to 650 43 2.1 43 2.2 43 2.2 43 2.3
10,000 675 48 3.6 48 3.8 43 2.1 43 2.1
700 48 3.4 48 3.5 48 3.6 48 3.7
725 49 3.7 49 3.8 48 3.4 48 3.5
41
TROUBLESHOOTING GUIDE
START
NO NO NO
Is LED status light on? Is there 115V at L1 and L2? Is door switch closed? Is door switch closed?
YES
YES YES
NO NO
Is there 24V at SEC-1 and SEC-2? Is there 115V going to switch? Is circuit breaker closed?
YES YES YES
NO
Replace furnace control. Replace door switch. Check for continuity in wire from circuit breaker
to furnace.
YES Check for correct line voltage polarity. If units Replace transformer. Close circuit breaker and go back to START.
Is LED status light blinking rapidly without a
are twinned, check for proper low-voltage
pause?
(24V) transformer phasing.
NO
Is LED status light blinking ON/OFF slowly NO To recall status code briefly remove and reconnect one RED wire from the draft
with a combination of short and long flashes? safeguard switch to display stored status code. On RED LED control do not
remove power or blower access panel before initiating status code recall. You
can also recall the previous status code by momentarily shorting the TEST/TWIN
YES
terminal to Com24V terminal until the LED goes out. LED will flash the status
code of the previous fault or status code #11 (1 short and 1 long flash) if there
Determine status code. The status code is a was no previous fault. After the control repeats the code 4 times, the control
2 digit number with the first digit determined will go through a brief component test sequence. The inducer will start and run
42
by the number of short flashes and the second for the entire component test. The HSI, blower motor FAN speed (AMBER LED
digit by the number of long flashes? boards only) HEAT speed, and COOL speed will run for 10 – 15 seconds each. Check room thermostat or
Gas valve and humidifier will not be turned on. interconnecting cable.
NO
YES Does the control respond to W, Y1 (if present), NO Is 24V present at W, Y1 (if present), Y/Y2 or
Go to section below for the status code that Was there a previous status code NO
was flashed. other than #11? Y/Y2, and G (24V) thermostat signals? G thermostat terminals on the furnace control?
YES YES
Run system through a heating or cooling cycle Disconnect all the thermostat wires from the
to check operation. Status codes are erased furnace control.
after 72 hours. On RED LED boards stored
status codes can also be erased whenever
(115V or 24V) is interrupted.
YES Does the problem repeat when using

Replace furnace control.
a jumper wire?
NO
The thermostat is not compatible with the

furnace control. Either install a ballast resistor,
connect the Com24V thermostat terminal to
the thermostat, or replace the thermostat.
A02106a
11 NO PREVIOUS CODE – Stored codes 31 PRESSURE SWITCH DID NOT CLOSE 45 CONTROL CIRCUITRY LOCKOUT
are erased after 72 hours. On RED LED OR REOPENED – If open longer than 5 Auto-reset after 1 hour lockout due to:
boards stored status codes can also be minutes, inducer shuts off for 15 minutes - Flame circuit failure.
erased whenever power (115V or 24V) before retry. If opens during blower on- - Gas valve relay stuck open.
delay period, blower will come on for the
is interrupted. Run system through a selected blower off-delay. Check for: - Software check error.
heating or cooling cycle to check system. - Proper vent sizing. Reset power to clear lockout. Replace
- Low inducer voltage (115V). control if code repeats.
- Low inlet gas pressure (if LGPS used).
12 BLOWER ON AFTER POWER UP – - Inadequate combustion air supply. NO
(115V OR 24V) – Normal operation. - Disconnected or obstructed pressure Unplug igniter harness from control and initiate Replace furnace control.
Blower runs for 90 seconds, if unit is tubing. another component test sequence. Check
powered up during a call for heat (R-W - Defective inducer motor. for 115V between pin 1 and NEUTRAL-L2 on
closed) or when (R-W opens) during the - Defective pressure switch. the control. Was 115V present for the 15
- Excessive wind. YES Check for continuity in the harness and igniter.
blower on-delay period. second period? Replace defective component.
- Restricted vent.
13 LIMIT CIRCUIT LOCKOUT – Lockout 33 LIMIT CIRCUIT FAULT – Indicates the NO

occurs if the limit, draft safeguard, flame Reconnect the R thermostat lead and set Check connections. If OK, replace control.
limit, draft safeguard, flame rollout, or thermostat to call for heat. Connect voltmeter
rollout, or blocked vent switch*(if used) is blocked vent switch* (if used) is open.
open longer than 3 minutes. Control will across gas valve connections. Does gas valve
Blower will run for 4 minutes or until open receive 24V?
auto-reset after 3 hours. See code 33. switch remakes whichever is longer. If Check that all gas valves are turned on.
Replace valve.
open longer than 3 minutes, code YES
changes to lockout #13. If open less
14 IGNITION LOCKOUT – System failed to than 3 min. status code #33 continues Does gas valve open and allow gas to flow?
ignite gas and prove flame in 4 attempts. to flash until blower shuts off. Flame NO Check for:
Control will auto-reset after 3 hours. rollout switch and BVSS requires manual - Inadequate flame carryover or rough
See status code 34. YES ignition.
reset. Check for:
- Dirty filter or restricted duct system. NO - Low inlet gas pressure.
Do the main burners ignite? - Proper firing rate.
- Loose blower wheel.
- Defective switch or connections. - Blocked or incorrect carryover gap.
21 GAS HEATING LOCKOUT – Turn off
- Defective blower motor or capacitor. YES (.045” nominal)
power and wait 5 minutes to retry.
43
Check for: - Inadequate combustion air supply
- Stuck closed gas valve relay on control. (flame rollout switch open). Do the main burners stay on? YES Allow blower to come on and repeat test to
- Miswire or short to gas valve wire. - Restricted vent. check for intermittent operation.
- Proper vent sizing.
- Excessive wind. NO
22 ABNORMAL FLAME-PROVING SIGNAL
Flame is proved while gas valve is de- Repeat call for heat and check flame sensor Check connections and retry. If current is
current during trial for ignition period. Is the NO near typical value (4.0-6.0 nominal) and
energized. Inducer will run until fault is 34 IGNITION PROVING FAILURE – If flame
cleared. Check for: DC microamps below 0.5? burners will not stay on, replace control.
is not sensed during the trial for ignition
- Stuck open or leaky gas valve. period, the control will repeat the ignition
sequence 3 more times before lockout NO
#14 occurs. If flame signal is lost during YES
23 PRESSURE SWITCH DID NOT OPEN the blower on-delay period, blower will YES
Check for: come on for the selected blower off-delay. Clean flame sensor with fine steel wool and
- Obstructed pressure tube. Check the following items first before recheck current. Nominal current is 4.0 to 6.0
- Pressure switch stuck closed. proceeding to the next step. microamps.
- Gas valve turned off.
- Manual shut-off valve.
24 SECONDARY VOLTAGE FUSE IS OPEN - Green/Yellow wire MUST be connected
Check for: to furnace sheet metal.
- Short circuit in secondary voltage (24V) - Flame sensor must not be grounded. NO
Is current near typical value? Replace electrode.
wiring including thermostat leads. To determine whether the problem is in
Disconnect thermostat leads to isolate the gas valve, igniter, or flame sensor the
short circuit. system can be operated in the component YES
test mode to check the igniter. First
Will main burners ignite and stay on? NO Replace furnace control.
remove the R thermostat connection from
the control and initiate the component
test sequence. Does the igniter glow
YES
orange/white by the end of the 15 second
warm-up period?
Fixed.
* Blocked vent switch used in Chimney Adapter Kit
A02106b
Copyright 2002 Carrier Corporation 58st11si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4 PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-11SI Pg 44 12-02 Replaces: 58ST-2SI
Tab 6a 8a

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310AAV/JAV

Installation, Start-up, Operating, and

The 310AAV/JAV 4-Way Multipoise Gas Furnace was designed by Bryant

Catalog No: 5331-205 Form No. II 310A-45-3 12-02

JUNCTION BOX 19" 13/16"

3-15/16" 1/2" DIA. THERMOSTAT

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

→ Fig. 2—Clearances to Combustibles

CSA (A.G.A. and C.G.A.) listed gas conversion kit is required

THE BLOWER IS THE BLOWER IS

Fig. 4—Multipoise Orientations

All fuel-burning equipment must be supplied with air for fuel

AIR VENT THROUGH ROOF

Step 2—Confined Space

12″ MAX D 12″

There are no provisions for an internal filter rack in these furnaces.

UPFLOW DOWNFLOW HORIZONTAL

PREFERRED PREFERRED PREFERRED

120˚ PREFERRED 120˚ PREFERRED 120˚ PREFERRED

PERMITTED PERMITTED PERMITTED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

→ Fig. 15—Horizontal Unit Suspension

Fig. 16—Horizontal Suspension with Straps

Fig. 17—Typical Attic Installation

Downflow Furnaces Step 6—Gas Piping

Use proper length of pipe to avoid stress on gas control

The cabinet MUST have an uninterrupted or unbroken ground

Furnace control must be grounded for proper operation or

3. Locate box to desired location.

3-AMP FUSE STATUS CODE LED

LED OPERATION & EAC-2 L2

capacity given in Table A, and Local 99% Winter Design

Table A—Combined Appliance

This furnace is equipped with manual reset limit switches in

No Remove metal vent

1. Maintain 115-v wiring and ground. Improper polarity will

Furnace gas input rate on rating plate is for installations at altitudes

Fig. 26—Upflow Application- Fig. 27—Upflow Application- Fig. 28—Downflow

SEE NOTES: 1,2,4,5,7,8,9

See Venting Notes on page 26.

SEE NOTES: 1,2,4,5,7,8,9

Fig. 33—Horizontal Left Application-Vent Elbow Right SEE NOTES: 1,2,4,5,7,8,9

See Venting Notes on Page 26

4. Verify natural gas input rate by clocking meter.

PRINTED CIRCIUT BOARD

Fig. 39—Furnace Wiring Diagram A02141

Table 6–Altitude Derate Multipler for U.S.A.

Fig. 41—Orifice Hole

Table 7—Speed Selection

(1.) Remove thermostat from subbase or from wall.

Fig. 43—Service Label

→ Personal injury can result from sharp metal edges, etc. Be

The minimum maintenance on this equipment is as follows:

Fig. 45—Position of Igniter to Burner Fig. 46—Cleaning Heat Exchanger Cell

9. Using field-provided 25-caliber rifle cleaning brush, 1/4″

900 42 3.5 42 3.6 42 3.7 41 3.5

925 42 3.3 42 3.4 42 3.5 42 3.7

2001 825 42 3.2 42 3.3 42 3.4 42 3.5

775 42 3.2 42 3.3 42 3.4 42 3.5