INSTALLATION INSTRUCTIONS Two--Stage, Variable Speed, 35” Tall High Efficiency Condensing Gas Furnace F96VTN and G96VTN (Series A) NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4 Loose Parts Bag Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CODES AND STANDARDS . . . . . . . . . .
Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA--54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a.
A180203 FURNACE SIZE 0401410A 0401712A 0601412A 0601714A 0801716A 0802120A 1002120A 1202422A A B CABINET WIDTH 14--- 3/16 (361) 17--- 1/2 (445) 14--- 3/16 (361) 17--- 1/2 (445) 17--- 1/2 (445) 21 (533) 21 (533) 24--- 1/2 (622) OUTLET WIDTH 12--- 1/2 (319) 15--- 7/8 (403) 12--- 1/2 (319) 15--- 7/8 (403) 15--- 7/8 (403) 19--- 3/8 (492) 19--- 3/8 (492) 22--- 7/8 (581) C BOTTOM INLET WIDTH 12--- 9/16 (322) 16 (406) 12--- 9/16 (322) 16 (406) 16 (406) 19--- 1/2 (495) 19--- 1/2 (495) 23 (584) D AIR INTAKE 7
SAFETY CONSIDERATIONS WARNING ! FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage.
10. These Multipoise Gas--Fired Furnaces are CSA design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas. 11. See Table 1 for required clearances to combustible construction.
Table 2 – Loose Parts Bag DESCRIPTION Outlet Restrictor Plate (provided with 40K BTUH furnaces only; see Note) Air Intake Pipe Flange Vent Pipe Flange Pipe Flange Gaskets Sharp Tip Screws (Vent and Inlet Flanges) Vent Pipe Coupling Vent Pipe Coupling Clamps Pressure Switch Tube Rubber Drain Elbow Drain Tube Clamps 1/2---in. CPVC to 3/4---in.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE ! CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component damage. Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure.
! WARNING CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and unit component damage. Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life.
! WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual. Standard Method 1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2.
Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) FURNACE INPUT (BTUH) SINGLE DUCT OR OPENING (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) Free Area of Opening and Duct Sq. In (Sq. mm) Round Duct In. (mm) Dia 20 (12904) 30 (19355) TWO OPENINGS OR VERTICAL DUCTS (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW) Free Area of OpenRound Duct ing and Duct In. (mm) Dia. Sq. In (mm) Free Area of Opening and Duct Sq. In (Sq.
A11307 Fig. 8 -- Upflow Trap Configuration (Appearance may vary) A11573 Fig. 10 -- Horizontal Right Trap Configuration (Appearance may vary) A11587 Fig. 9 -- Downflow Trap Configuration (Appearance may vary) NOTICE The field--supplied, accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. It it NOT required for applications using single--pipe or ventilated combustion air venting.
To Relocate the Condensate Trap: S Remove the knockout in the casing for the condensate trap. S Install the grommet in the casing when required for direct--vent horizontal applications. S Orient the furnace in the desired position. S Allow for 2 in. (51 mm) of clearance underneath the furnace for the condensate trap and drain line. S Fig. 10 shows the condensate trap and tubing before and after relocation in the horizontal right position. S Fig.
A14532 Fig. 13 -- Example of Field Drain Attachment (Not Allowed) CONDENSATE DRAIN CONNECTION ! CAUTION FROZEN AND BURST WATER PIPE HAZARD Failure to protect against the risk of freezing may result in property damage. Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment has the potential of freezing, the drain trap and drain line must be protected.
Upflow/Downflow Orientation In the Upflow or Downflow orientation, the condensate trap is inside the furnace casing. The condensate drain must be routed from the trap through the furnace casing. The condensate drain can be routed through the left or right side of the casing. (The left or right side is as you are viewing/facing the furnace from the front.) An indoor coil condensate drain or humidifier drain can be connected to the external furnace condensate drain provided: a.
ATTACH ELBOW TO CONDENSATE TRAP CUT FORMED END OFF CONDENSATE DRAIN ELBOW FORMED END OF GROMMET CONNECT SHORT END OF ’Z’ PIPE TO MODIFIED DRAIN ELBOW FACTORY SUPPLIED 1/2ïIN. CPVC TO 3/4ïIN. PVC ADAPTER 17. Connect additional condensate piping to a code-approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil. Allow at least 1/4-in.
INSTALLATION Return Air Connections NOTICE ! This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to 1--in. water column with all present air inlets, including bottom closure in upflow and horizontal applications, air outlets, and plumbing and electrical ports sealed. Upflow Installation WARNING FIRE HAZARD A failure to follow this warning could cause personal injury, death and/or property damage.
Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, see Fig. 24. supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. See Fig. 20. Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers See Fig. 20.
Table 5 – Opening Dimensions -- In. (mm) FURNACE CASING WIDTH IN.
Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet. Not all horizontal furnaces are approved for side return air connections See Fig. 23. Where required by code, seal bottom closure to furnace with tape, mastic or other durable sealing method.
Table 7 – Filter Media Pressure Drop (Clean) Versus Airflow -- In. W.C. (Pa) 14 x 25 Filter (356 x 635 mm) CFM L/s 600 (283) 800 (378) 1000 (472) 1200 (566) Factory-Accessory Washable (1-in. / 2.5 cm) 0.04 (12) 0.06 (15) 0.07 (18) 0.08 (20) Factory-Accessory Media* (4-in. / 10 cm) 0.05 (12) 0.07 (19) 0.10 (27) 0.14 (36) Representative After-Market Filter Media* Fiberglass* Pleated* (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) 0.07 (17) 0.10 (26) 0.24 (60) 0.16 (40) 0.10 (25) 0.
COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305x559 mm) sheet metal in front of burner compartment area. The sheet metal MUST extend underneath the furnace casing by 1-in. (25 mm) with the door removed. The bottom closure panel may be used for flame roll-out protection when bottom of furnace is used for return air connection. A150580 Fig.
Table 9 – Cooling4 and Heating Air Delivery - CFM (Bottom Return5 with Filter) (SW1---5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 0401410A Clg Switches: Clg Default: Cooling (SW2--- 8,7,6) Clg/CF Switch settings SW2--- 8 SW2--- 7 SW2--- 6 OFF OFF OFF OFF OFF ON OFF ON OFF OFF ON ON ON OFF OFF ON OFF ON ON ON OFF ON ON ON Maximum Clg Airflow2 External Static Pressure (ESP) 0.1 1125 605 760 950 1125 1130 1130 1130 1130 0.2 1105 565 730 925 1105 1105 1105 1105 1105 0.
Table 9 - Cooling4 and Heating Air Delivery - CFM (Bottom Return5 with Filter) continued (SW1---5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 0601412A Clg Switches: Clg Default: Cooling (SW2--- 8,7,6) CF Switches Low--- Clg Default: Low--- Cooling (SW2--- 5,4,3) Cont.
Table 9 - Cooling4 and Heating Air Delivery - CFM (Bottom Return5 with Filter) continued (SW1---5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 0801716A Clg Switches: Clg Default: Cooling (SW2--- 8,7,6) CF Switches Low--- Clg Default: Low--- Cooling (SW2--- 5,4,3) Cont.
Table 9 - Cooling4 and Heating Air Delivery - CFM (Bottom Return5 with Filter) continued (SW1---5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 1002120A Clg Switches: Clg Default: Cooling (SW2--- 8,7,6) Clg/CF Switch settings SW2--- 8 SW2--- 7 SW2--- 6 OFF OFF OFF OFF OFF ON OFF ON OFF OFF ON ON ON OFF OFF ON OFF ON ON ON OFF ON ON ON Maximum Clg Airflow2 External Static Pressure (ESP) 0.1 1890 1015 1080 1155 1310 1520 1890 2290 2290 0.
Table 9 -- Cooling4 and Heating Air Delivery - CFM (Bottom Return5 with Filter) - NOTES 1. Nominal 350 CFM/ton cooling airflow is delivered with SW1 ---5 and SW2 ---2 set to OFF. Set both SW1 ---5 and SW2 ---2 to ON for +7% airflow (nominal 370 CFM/ton). Set SW1 ---5 to ON and SW2 ---2 to OFF for +15% airflow (nominal 400 CFM/ton). Set SW1 ---5 to OFF and SW2 ---2 to ON for ---7% airflow (nominal 325 CFM/ton). The above adjustments in airflow are subject to motor horsepower range/capacity.
A11338 Fig. 29 -- Gas Entry 1ï1/2 inch for Gas 7/8 inch for 115 VAC Electric For direct vent (2--pipe) applications, seal the gas pipe knockout to prevent air leakage. Remove the required knockout. Install the grommet in the knockout. Then insert the gas pipe. The grommet is included in the loose parts bag. Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected.
Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. Refer to current edition of NSCNGPIC in Canada. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.
Table 11 – Electrical Data Minimum* MAXIMUM UNIT AMPS UNIT AMPACITY# MINIMUM WIRE SIZE AWG 127 127 104 104 7.0 7.2 9.7 9.8 14 14 38 37 (11.7) (11.5) MAXIMUM FUSE OR CKT BKR AMPS{ 15 15 115--- 60--- 1 115--- 60--- 1 127 127 104 104 7.1 10.9 9.7 14.6 14 14 38 25 (11.7) (7.7) 15 15 0801716A 0802120A 115--- 60--- 1 115--- 60--- 1 127 127 104 104 10.0 14.7/11.2 13.4 19.3/14.01 14 12/141 27 29/241 (8.4) (8.8/7.
External Electrical Box on Furnace Casing A12226 Fig. 34 -- Installing J--Box (When Used) A190278 Fig. 35 -- External Electrical Box The J--Box cover, mounting bracket and screws are shipped in the loose parts bag included with the furnace. See Fig. 34 for J--Box mounting locations. The J--Box mounting bracket and green ground screw is used as a grounding point for all line voltage wiring options.
2. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing and J--Box bracket. 3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used. 4. Pull furnace power wires through 1/2--in. (12 mm) diameter hole in J--Box. If necessary, loosen power wires from strain—relief wire--tie on furnace wiring harness. 5. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Fig. 34. 6.
A190044 Fig. 38 -- Example of Variable Speed Furnace Control Accessories (See Fig. 37 and 38.) 1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in. female quick connect terminals to the two male 1/4--in. quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation. Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the ¼--in.
Contact the alternate power supply manufacturer for specifications and details. Variable Speed Furnace with Single Stage Air Conditioner Variable Speed Furnace with Single Stage Heat Pump (Dual Fuel) NOTE 9 NOTE 9 L09F026 Variable Speed Furnace with Two--Stage Air Conditioner Variable Speed Furnace with Two--Stage Heat Pump (Dual Fuel) NOTE 9 NOTE 9 L09F027 L09F028 Specifications subject to change without notice.
Variable Speed Furnace and Humidifier Only HP with Variable Speed Furnace, Humidifier, and Dehumidification L09F030 L09F029 AC with Variable Speed Furnace, Humidifier, and Dehumidification L09F029 Fig. 39 -- Thermostat Wiring Diagrams Refer to Fig. 39. NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8. 9. 34 Refer to outdoor equipment Installation Instructions for additional information and setup procedure. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.
VENTING NOTE: Planning for the venting system should be done in conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation. Venting for this furnace shall follow all Local codes for Category IV venting systems. This furnace is CSA approved for venting with PVC/ABS DWV venting systems.
! Venting Systems WARNING NOTICE CARBON MONOXIDE POISONING HAZARD Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death. For all venting configurations for this appliance and other gas appliances placed into operation for this structure, provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with: USA Installations: Section 9.3 current edition of NFPA 54/ANSI Z223.
Direct Vent / 2-Pipe System In a direct-vent (2-pipe) system, all air for combustion is taken directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. Combustion-air and vent pipes must terminate together in the same atmospheric pressure zone, either through the roof (preferred) or a sidewall. See Fig. 42 for references to clearances required by National code authorities.
A13305 Fig. 40 -- Combustion Air and Vent Pipe Termination for Direct Vent (2--Pipe) System A05091 Fig. 41 -- Vent Pipe Termination for Non--Direct Vent and Ventilated Combustion Air System Table 12 – Vent Termination Kit for Direct Vent (2--pipe) Systems Approved Two---Pipe Termination Fittings 2---in. 2 1/2---in. 3---in. (51 mm) (64 mm) (76---mm) Yes No No Yes No No Vent and Combustion Air Pipe Diameters 1 1/2--- in. (38 mm) 2--- in. (51 mm) 1 1/2---in. (38 mm) No No 2 1/2--- in.
A12326 Fig. 42 -- Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations.
A12325 Fig. 43 -- Ventilated Combustion Air and Non--Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations.
A190032 Fig. 44 -- Inside Corner Termination Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove. S The clearance distances apply when the vent is at least 3 feet (1 meter) from, but not more than 6 feet (2 meters) away from an inside corner.
NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS It is recommended that sidewall vent terminations in excess of 24 inches (.6 M) or rooftop terminations in excess of 36 inches (1 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 12 or by field--supplied brackets or supports fastened to the structure. ! WARNING CARBON MONOXIDE POISONING HAZARD A12220 Fig.
If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft. (1.2 M) and no greater than 8 ft. (2.4 M), it will be necessary to re-direct the flue gas plume. In this situation, a concentric vent kit cannot be used. A 2-pipe termination (or single pipe termination when permitted) that re-directs the flue gas away by use of an elbow or tee, certified to ULC S636 from the adjacent property line must be used. See Fig. 49.
NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 14 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 13 – Maximum Equivalent Vent Length -- Ft. Unit Size Pipe Dia. (in) 0--- 2000 2001--- 3000 3001--- 4000 4001--- 4500 Altitude 4501--- 5000 (feet) 5001--- 6000 6001--- 7000 7001--- 8000 8001--- 9000 9001--- 10000 Unit Size Pipe Dia.
A10497 Fig. 50 -- Vent Terminations for Ventilated Combustion Air Recommended Combustion Air Inlet Moisture Trap Recommended to prevent moisture from trickling into the furnace vestibule, a trap can be installed in the intake air pipe near the furnace. To prevent moisture, connecting a drain line to the trap is recommended as trace amounts of moisture will evaporate into the intake air stream.
A A A TO CODE-- APPROVED DRAIN OR CONDENSATE PUMP Recommend “T” fitting with 4--inch minimum height standpipe (A) of same diameter or larger extending upward. Tee Tee Dry Well Tee Dry Well Cap (water tight and removable) Cap (water tight and removable) Dry Well Representative drawing only, some models may vary in appearance. Fig.
9. If the Total Vent Length is longer than the Maximum Equivalent Vent Length for the diameter of pipe chosen, that diameter pipe MAY NOT be used for venting the furnace. Try the next larger diameter pipe. NOTE: If the calculated Total Equivalent Vent Lengths results in different diameter pipes for the vent and combustion air, select the larger diameter for both pipes.
Table 15 – Maximum Allowable Exposed Vent Lengths in Unconditioned Space Insulation Table -- Ft. / M Unit Size Winter Design Temp °F Pipe Dia. in. 20 0 -20 -40 40,000* BTUH Uninsulated 1½ 2 2½ 20 10 5 20 5 20 5 1½ 2 2½ 1½ 2 2½ Uninsulated 1½ 2 2½ 20 20 20 15 50 25 15 10 45 20 10 5 20 20 20 15 60 30 20 15 50 25 15 10 20 15 10 5 3/8-in. Insulation 1/2-in. Insulation Unit Size Winter Design Temp °F Pipe Dia. in.
7 Rotate vent elbow to required position. 3 6 2 5 4 5 1 Any other unused knockout may be used for combustion air connection. 4 Rotate vent elbow to required position. 5 1 3 2 & 5 6 UPFLOW LEFT CONFIGURATION 7 A11309A DOWNFLOW LEFT CONFIGURATION A11311A Rotate vent elbow to required position. 4 5 1 2 5 3 7 6 2 5 1 Any other unused knockout may be used for combustion air connection. Any other unused knockout may be used for combustion air connection.
ALTERNATE COMBUSTION AIR CONNECTIONS A11337 HORIZONTAL LEFT ---VERTICAL VENT CONFIGURATION A11327A Alternate combustion air connection. 4 Rotate vent elbow to required position. Vent Pipe 6 5 A11328A Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT LEFT VENT CONFIGURATION A11336 ALTERNATE COMBUSTION AIR CONNECTIONS Requires Accessory Vent Kit See Product Data for Current Kit Number A11329A Fig.
A14546 Fig. 56 -- Near Furnace Vent Connections A170006 Fig. 57 -- Inducer Vent Elbow Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter ! WARNING ! WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. To route the vent pipe and combustion air pipe through the furnace, the manufacturer supplied kit must be used.
A13074 Fig. 58 -- Vent Coupling and Adapter with Gaskets NOTICE The following instructions are for PVC/ABS DWV vent piping only. DO NOT USE THESE TECHNIQUES FOR POLYPROPYLENE VENT PIPING SYSTEMS. See the polypropylene vent system manufacturer’s instructions for installing polypropylene venting systems. Install the remaining vent and combustion air pipes as shown below. It is recommended that all pipes be cut, prepared, and pre--assembled before permanently cementing any joint. 1.
Optional Installation of the Vent Pipe NOTE: DO NOT USE THIS TECHNIQUE POLYPROPYLENE VENTING SYSTEMS. FOR This option provides a disconnect point for the vent pipe. The vent pipe must be cemented to the plastic vent pipe adapter to maintain a sealed vestibule. See Fig. 59. A13076 Fig. 59 -- Optional Vent Pipe Flush with Adaptor 1. Insert a length of vent pipe through the casing into the outlet of the vent elbow. 2.
Termination elbows will be installed after the vent and (if used) combustion air pipe is installed. Sidewall Terminations Concentric Vent NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference only. Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination” in this instruction. 1. Cut one 4--in. diameter hole for 2--in. kit, or one 5--in. diameter hole for 3--in. kit. 2.
Table 17 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (USA Installations) USA CANADA Material PVC MATERIALS 1. All pipe, fittings, primers*, and solvents* must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards or ULC S636 where required by code. 2. See Table below for approved materials for use in the U.S.A. 3.
Example 2 A direct-vent 60,000 BTUH furnace installed at 2100 ft. (640M). Venting system includes FOR EACH PIPE: 100 feet (30 M) of vent pipe, 95 feet (29 M) of combustion air inlet pipe, (3) 90º long-radius elbows, and a polypropylene concentric vent kit. Also includes 20 feet (6.1 M) of flexible polypropylene vent pipe, included within the 100 feet (30 M) of vent pipe. VERIFY FROM POLYPROPYLENE VENT MANUFACTURER’S INSTRUCTIONS for the multiplier correction for flexible vent pipe.
NOTE: If a bypass humidifier is used, setup switch SW1-4 (Comfort/Efficiency) should be in OFF=Efficiency position. This compensates for the increased temperature in return air resulting from bypass. Air Conditioning (A/C) Setup Switches (SW2-- 6, 7, 8) The air conditioning setup switches are used to match furnace airflow to required cooling airflow or high stage cooling airflow when a two--stage outdoor unit is used. Refer to the Adjustments section for setup switch configurations.
1. Default A/C airflow when A/C setup switches are in OFF position. 2. Default Low ---Stage A/C airflow when CF switches are in OFF position Fig. 61 -- Airflow Selection (based on 350 CFM/TON) for A/C (SW2--6, 7, 8) and *CF (SW2--3, 4, 5) Prime Condensate Trap with Water ! WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal injury or death.
WARNING ! FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. BURNER ORIFICE A93059 Fig. 63 -- Orifice Hole For proper operation and long term reliability, the Furnace input rate must be within +/--2 percent of input rate on furnace rating plate, or as adjusted for altitude.
8. When main burners ignite, confirm inlet gas pressure is Between 4.5 in. w.c. and 13.6 in. w.c. 9. Remove jumper across thermostat connections to terminate call for heat. Wait until the blower off delay is completed. 10. Turn furnace gas valve electric switch to OFF position. 11. Turn gas supply manual shutoff valve to OFF position. 12. Turn off furnace power supply. 13. Remove manometer from the inlet pressure tap of the gas valve. 14. Tighten set screw on inlet pressure tap with 3 /32--in.
2. Restore furnace to normal operating condition. a. Turn gas valve ON/OFF switch to OFF. b. Remove water column manometer or similar device from manifold pressure tap. ! WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Manifold pressure tap set screw must be tightened or 1/8--in. NPT pipe plug must be installed to prevent gas leaks. c. Tighten set screw on manifold pressure tap with 3/32--in. hex wrench, or if ⅛--in.
match the airflow required for low-speed cooling. Select the required airflow from Table 9 and Fig. 60. NOTE: The airflow selected via SW2--3, 4, 5 (Low-Speed Cooling Airflow) cannot exceed the airflow selected via SW2--6, 7, 8 (High-Speed Cooling Airflow). For other CFM per ton Setup switch selections, see Fig. 38 and 60. NOTE: The airflow settings for SW2--6, 7, 8 and SW2--3, 4, 5 selections are the same, EXCEPT for the default values. See Table 9.
Table 20 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. and Canada ft (m) U.S.A. and Canada U.S.A. Only U.S.A. Only 0.62 0.64 No. High/Low No. High/Low No. High/Low No. High/Low 900 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.4 0 925 43 3.6 / 1.5 43 3.7 / 1.
Table 20 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. Only ft (m) U.S.A. Only 0.60 0.62 0.64 Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press (Btu/cu ft) No. High/Low No. High/Low No. High/Low No. High/Low 650 42 3.4 / 1.
A190071 Fig. 67 -- Service Label Information Specifications subject to change without notice.
Table 21 – Gas Rate (CU ft./hr) 5 Cu Ft. SEC. FOR 1 REVOLUTION 1800 50 SIZE OF TEST DIAL 1 2 5 Cu Cu Cu Ft. Ft. Ft.
The electrical ground and polarity for 115--v wiring must be properly maintained. Refer to Fig. 32 for field wiring information and to Fig. 74 for furnace wiring information. NOTE: If the polarity is not correct, the STATUS LED on the control will flashes rapidly (Status Code 10) and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame--sensing electrode. The 24--v circuit contains an automotive--type, 3--amp.
! NOTE: If the filter has an airflow direction arrow, the arrow must point toward the blower. To clean or replace filters, proceed as follows: WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.
Blower Motor and Wheel Maintenance To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually. The inducer and blower motors are pre--lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. The following items should be performed by a qualified service technician. Clean blower motor and wheel as follows: 1. Turn off electrical supply to furnace. 2. Remove blower door.
NOTE: Use a back-up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner assembly. Refer to Fig. 69. A11403 Fig. 69 -- Burner Assembly ! WARNING FIRE OR EXPLOSION HAZARD 1. Disconnect power at external disconnect, fuse or circuit breaker. 2. Turn off gas at external shut-off or gas meter. 3. Remove control door and set aside. 4. Turn electric switch on gas valve to OFF. 5.
17. Run the furnace through two complete heating cycles to check for proper operation 18. Install control door when complete. 12. Clean the relief port on collect box and the trap with a small wire. Shake any water out of the tube. 13. Reconnect relief tube to trap and collector box ports. Servicing Hot Surface Igniter Cleaning Condensate Drain and Trap The igniter does NOT require annual inspection. Check igniter resistance before removal. Refer to Fig. 70, 71 and 69. 1.
Primary Heat Exchangers If the heat exchangers get an accumulation of light dirt or dust on the inside, they may be cleaned by the following procedure: NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design.
1. Obtain propylene glycol (RV/swimming pool antifreeze or equivalent). 2. Turn off gas and electrical supplies to your furnace. 3. Remove furnace control door. 4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. See Fig. 62. 5. Connect a field supplied 3/8--in. (9.5--mm) ID tube to the open port on the collector box 6. Insert a field supplied funnel into the tube. 7. Pour 1 quart of anti--freeze solution into the funnel/tube.
Fig. 73 -- Troubleshooting Guide A190196 74 Specifications subject to change without notice. 440 01 4800 02 START Go to section below for the status code that was flashed. Determine status code.
Troubleshooting Guide (Continued) A190197 440 01 4800 02 Specifications subject to change without notice. 75 PRESSURE SWITCH DID NOT OPEN – Check for: - Obstructed pressure tube. - Pressure switch stuck closed. LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED – If opens during blower on-delay period, blower will come on for the selected blower off-delay. If open longer than 5 minutes inducer shuts off for 15 minutes before retry. Check for: - Proper vent sizing.
SEQUENCE OF OPERATION NOTE: Furnace control must be grounded for proper operation or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram in Fig. 74, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.
2. Two--Stage Thermostat and Two--Stage Heating See Fig. 38 and 39 for thermostat connections. NOTE: In this mode the low--heat only switch SW1--2 must be ON to select the low--heat only operation mode in response to closing the thermostat R--to--W1 circuit. Closing the thermostat R--to-- W1--and--W2 circuits always causes high--heat operation, regardless of the setting of the low--heat only switch.
matically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow or low--heat airflow whichever is lowest. The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at heating airflow.
PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Bottom plate Control door Door knob assembly Top filler plate Burner Flame sensor Gas valve Hot surface igniter Manifold Orifice Electrical Group 3--Amp fuse Circuit board Control box Door switch Junction box Limit switch(es) Transformer Heat Exchanger Group Blower Group Inducer Group Blower housing Blower motor Blower wheel Cut--off plate Power choke (where used) Collector box Condensate trap Condensate trap elbow Gaske
Copyright 2019 International Comfort Products Lewisburg, TN 37091 USA 80 Specifications subject to change without notice.
