GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS (Type FSP Category IV Direct or Nondirect Vent Air Furnace) ATTENTION INSTALLATION PERSONNEL As a professional installer, you have an obligation to know the product better than the customer. This includes all safety precautions and related items. Prior to actual installation, thoroughly familiarize yourself with this instruction manual. Pay special attention to all safety warnings.
TABLE OF CONTENTS GAS FURNACE SAFETY PRECAUTIONS ....................................3 Electrostatic Discharge (ESD) Precautions..................................4 PRODUCT DESCRIPTION AND APPLICATION ..........................4 Shipping Inspection .....................................................................4 To the Installer..............................................................................4 Important Note to the Owner Regarding Product Warranty .......4 Component Identification.........
GAS FURNACE SAFETY PRECAUTIONS Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. Recognize this symbol as a safety precaution. WARNING Hazards or unsafe practices could result in property damage, product damage, severe personal injury or death.
WARNING Should overheating occur or the gas supply fail to shut off, turn off the manual gas shutoff valve external to the furnace before turning off the electrical supply. WARNING HIGH VOLTAGE! To avoid property damage, personal injury or death due electrical shock, the furnace must be located so that the electrical components are protected from water damage. Electrostatic Discharge (ESD) Precautions NOTE: Discharge static electricity accumulated in the body before touching the unit.
Component Identification Upflow/Horizontal E Counterflow/Horizontal F G G H I J E Z AA J K L * * * * * * * A * B AE AD AC M X O Y P R R S N Q C W AB V T U O N Burner Compartment K C S T AC AE P Q AD CU T FOR DEHU M R V AB W R S T T M B L AA Z I A. Gas control valve B. Gas line entrance (alternate) C. Pressure switch D. Gas manifold E. Combustion air intake connection/ coupling F. Hot surface igniter G. Rollout limit switch H.
Dual certification means that the combustion air inlet pipe is optional, and the furnace can be vented as a: ■ Nondirect vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or a, ■ Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Check that adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to “Combustion and Ventilation Air Requirements.” Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1¹⁄₂" (3.
Suspended Furnace B A C H G F E A. ³⁄₈" (1 cm) diameter threaded rod (6) B. 8" (20.3 cm) minimum clearance between center rod and furnace cabinet to allow for circulator blower removal. C. Level furnace end to end, slight forward tilt with front 0" to ³⁄₄" (1.9 cm) below back. D D. Tilt outward to allow for door and circulator blower removal. E. Position as close as possible to blower deck to allow for circulator blower removal. F. 2" x 2" x ¹⁄₈" (5.1 cm x 5.1 cm x 3.2 mm) angle iron (3) G.
The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section 5.3. 5.3.1 General: a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building.
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 sq. in. (6.5 cm2) per 4,000 Btu/h of total input rating of all equipment in the enclosure. 4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3" (7.6 cm). Equipment Located in Confined Spaces: All Air from Outdoors Through Ventilated Attic. See 5.3.
INSTALLATION POSITIONS This furnace may be installed in an upright position or horizontal on either the left or right side panel. NOTE: Do not install this furnace on its back. For upright upflow furnaces, the return air ductwork may be attached to the side panel(s) and/or base pan. For horizontal upflow furnaces, the return air ductwork must be attached to the base pan.
NOTES: ■ The field supplied drain hose is connected from the vent/ drain connection to the condensate drain line with a field supplied connector. ■ Make a small loop in the drain hose to serve as a P-trap. Recommended Installation Positions—Horizontal Counterflow—Right Side Panel Discharge B Recommended Installation Positions—Upright Upflow A C A B A. Bottom return duct connection C. Air discharge B.
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS WARNING Possible property damage, personal injury or death may occur if the correct conversion kits are not installed. The appropriate kits must be applied to ensure safe and proper furnace operation. All conversions must be performed by a qualified installer or service agency. This furnace is shipped from the factory configured for Natural gas at standard altitude.
Carefully follow¹⁄₂" (1.3 cm) thick closed-cell foam. Also all vent/ flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with ¹⁄₂" (1.3 cm) thinck closed_ the manufactures instructions for cutting, cleaning and solvent cementing of PVC. As an alternative to PVC pipe, primer, solvent cement and fittings, ABS materials which are in compliance with the following specifications may be used. 2" or 3" (5.1 cm or 7.
Standard Furnace Connections It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight and adequately supported. As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or base pan (counterflow). To use the standard connections, field-supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.
NOTE: Standard and alternate locations can be combined (for example, an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed. WARNING Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs. Alternate Vent/Flue Location The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet.
Alternate Vent/Flue Location—Counterflow A B Nondirect Vent (Single Pipe) Maximum Allowable Length of Vent/Flue Pipe—ft (m) Number of Elbows C D E F A. Vent/flue pipe B. Screw locations (4) C. Screw locations (3) Models Pipe—in. (kBtu_Tons) (cm) A A. Rubber coupling B. Vent/flue pipe B C 3 4 5 6 7 8 045_3 2 or 2¹⁄₂ 68 65 62 59 56 53 50 (5.12 or 6.4) (21) (20) (19) (18) (17) (16) (15) 070_3 2 or 2¹⁄₂ 68 65 62 59 56 53 50 (5.12 or 6.
Vertical Vent Termination (Single Pipe) Standard Horizontal Vent Termination (Single Pipe)— Above Highest Anticipated Snow Level A A B B C A. 12" (30.5 cm) minimum from wall B. Vent/flue tee or 90º elbow turned down C. 12" (30.5 cm) minimum to roof or highest anticipated snow level A. Tee B. 12" (30.5 cm) minimum to roof or highest anticipated snow level Alternate Vertical Vent Termination (Single Pipe) A B A. 90º medium radius elbows B. 12" (30.
Direct Vent (Dual Pipe) Maximum Allowable Length of Vent/Flue and Combustion Air Intake Pipe—ft (m) Number of Elbows Unit Input (Btu) Termination Style Pipe—in. (cm) 2 3 045_3 Standard 2 or 2¹⁄₂ (5.12 or 6.4) 68 (20.7) 65 (19.8) 62 (18.9) 59 (18) 56 (17.1) 53 (16.2) 50 (15.2) Alternate 2 or 2¹⁄₂ (5.12 or 6.4) 55 (16.8) 52 (15.8) 49 (14.9) 46 (14) 43 (13.1) 40 (12.2) 37 (11.3) Standard 2 or 2¹⁄₂ (5.12 or 6.4) 68 (20.7) 65 (19.8) 62 (18.9) 59 (18) 56 (17.1) 53 (16.2) 50 (15.
Standard Horizontal Vent Terminations (Dual Pipe) Alternate Horizontal Terminations (Dual Pipe)—Above Highest Anticipated Snow Level B A A C A E G D G F D F B D C E A. 24" (61 cm) maximum, 3" D. 12" (30.5 cm) minimum to roof or (7.6 cm) minimum highest anticipated snow level B. 12" (30.5 cm) minimum from E. Combustion air intake wall F. Screen C. Vent/flue tee G. 90º medium radius elbow Alternate Horizontal Vent Terminations (Dual Pipe) B A ■ C H G F E A. 90º medium radius elbow B.
Side Wall Vent Kit This kit is to be used with 2" or 3" (5.1 cm or 7.6 cm) direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located sideby-side or with one pipe above the other. NOTE: This kit is not intended for use with single pipe (nondirect vent) installations. Refer to the directions furnished with the Side Wall Vent Kit (Part Number 0170K00000S) for installation specifications.
Alternate Vent/Flue Drain Hose Connections Upright Installations—Trap on Left Side Upright installations using the alternate vent/flue outlet will require right side only drain hoses to be connected as follows. Refer to “Vent/Flue Pipe and Combustion Air Pipe” for details on alternate vent/flue pipe connection. 1. Remove the rubber plug/cap from the right-side drain port on the front cover. Save the rubber plug/cap for later use. 2. Secure Hose A to the drain port on the front cover with a red hose clamp.
Upright Drain Trap Mounting—Left or Right Side Panel 1. Insert the drain tubes into the drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap. 2. Secure the drain trap to the side panel at the mounting holes (dimples or crosshairs on counterflow models) located below the grommet drain holes. 3. Attach the PVC drain line to the drain trap outlet with either a 90° elbow or coupling.
Horizontal Upflow Connections—Left Side Down (Counterflow Similar) A B C C D E J I A. Front cover drain port B. Hose B C. Green hose clamps (3) D. Side panel grommet holes E. Tubes 2 H G C DE Horizontal Drain Trap Mounting—Left or Right Side Panel 1. Position the drain trap against the side panel with the drain tubes inserted into the trap. NOTE: The trap may be orientated with the outlet facing either the furnace’s top cover or base pan. 2.
Junction Box Relocation 24-Volt Thermostat Wiring WARNING Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs. 1. Remove the burner compartment door. 2. Remove and save the 2 screws securing the junction box to the side panel. 3. Relocate junction box and associated plugs and grommets to opposite side panel. 4. Secure with screws removed in Step 2.
Optional Accessories Wiring All line voltage wire splices must be made inside the furnace junction box. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.
Gas Control Valve This furnace is equipped with a 24-volt gas control valve controlled during the furnace operation by the integrated control module. As shipped, the gas control valve is configured for Natural gas. The gas control valve is field-convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.
Gas Piping Connections—Upflow B C Gas Piping Connections—Horizontal Upflow D C E D A E B A J J F I H G I H A. Alternate gas line location B. Manifold C. Gas control valve D. Burners E. Manual shutoff valve (upstream from ground joint pipe union) F. Height required by local codes G. Drip leg H. Ground joint pipe union I. Grommet in standard gas line hole J. Plug in alternate gas line hole Gas Piping Connections—Counterflow G A. Gas control valve B. Ground joint pipe union C.
Direct/Standard Inlet Piping Propane Gas Tanks and Piping WARNING WARNING Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs. When gas piping enters directly to the gas control valve through the standard inlet hole, the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace. The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration.
Sizing Between 1st and 2nd Stage Regulator* Maximum propane capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 Btu/h. Propane Gas Piping Chart I Tubing Size, O.D. Type L Nominal Pipe Size Schedule 40 Pipe or Tubing Length—ft (m) ³⁄₈" ¹⁄₂" ⁵⁄₈" ³⁄₄" ⁷⁄₈" ¹⁄₂" ³⁄₄" 10 (3) 730 1,700 3,200 5,300 8,300 3,200 7,500 20 (6.1) 500 1,100 2,200 3,700 5,800 2,200 4,200 30 (9.2) 400 920 2,000 2,900 4,700 1,800 4,000 40 (12.
CIRCULATING AIR AND FILTERS Ductwork—Airflow Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D. ■ Install the duct system in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B.
Refer to Minimum Filter Requirement charts to determine filter area requirements. Minimum Filter Requirements Chart Cooling Airflow Requirement (CFM)—Permanent Minimum Filter Area (sq. in.) Based On 600 ft (182.
START-UP PROCEDURE AND ADJUSTMENT This furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjustment items, refer to further information in “Operational Checks.” Heat Anticipator Setting The heat anticipator in the room thermostat must be correctly adjusted to obtain the proper number of cycles per hour and to avoid overshooting of the setting. Set the heat anticipator setting to 0.
Gas Control Valve—Honeywell VR9205 2-Stage A If the supply pressure differs from chart, make the necessary adjustments to the pressure regulator, gas piping size, etc., and/ or consult with local gas utility. 5. Turn off the gas supply to the furnace at the manual shutoff valve. 6. Disconnect the manometer. 7. Reinstall plug before turning on gas supply to furnace. 8. Turn off any unnecessary gas appliances started in Step 3. B Measuring Inlet Gas Pressure Alternate Method D A. Regulator vent B.
8. Adjust manifold pressure using the following Manifold Gas Pressure chart. 9. Remove the regulator cover screw from the low (LO) outlet pressure regulator adjust tower. 10. Turn the screw clockwise to increase pressure or counterclockwise to decrease pressure. 11. Replace regulator cover screw. 12. Close thermostat R and W2 contacts to provide a call for high-stage heat. 13. Remove the regulator cover screw from the high (HI) outlet pressure regulator adjust tower. 14.
Circulator Blower Speeds WARNING To prevent premature failure of heat exchanger, property damage, personal injury or death, do not adjust the limit control (factory set). This furnace is equipped with a multispeed circulator blower. This blower provides ease in adjusting blower speeds. The Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds.
■ If the furnace is operating in the low-stage heating mode when thermostat contacts open, circulator blower remains at low-heat speed for the selected delay off period. If the furnace is operating in high-stage heating mode when the thermostat contacts open, the circulator blower remains at high-heat speed for the selected heat-off delay period. The circulator blower then switches to low-heat speed for the remainder of the selected heat-off delay period.
MAINTENANCE WARNING HIGH VOLTAGE! To avoid personal injury or death due to electrical shock, disconnect electrical power before performing any maintenance. If you must handle the igniter, handle with care. Touching the igniter element with bare fingers, rough handling or vibration could damage the igniter resulting in premature failure. Only a qualified servicer should ever handle the igniter.
Flue Passages (Qualified Servicer Only) The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below. 1. Turn off the electrical power and gas supply to the furnace. 2. Disconnect the gas line and remove the burner/manifold assembly by removing the screws securing the assembly to the partition panel. 3. Disconnect the flue pipe system from the induced draft blower. 4.
Diagnostic Chart WARNING HIGH VOLTAGE! To avoid personal injury or death due to electrical shock, disconnect electrical power before performing any service or maintenance. The red diagnostic LED blinks to assist in troubleshooting the uit. The number of blinks refers to a specific fault code. Symptoms of Abnormal Operation ■ ■ Furnace fails to operate. Integrated control module diagnostic LED display provides no signal.
Symptoms of Abnormal Operation ■ ■ Induced draft blower runs continuously with no further furnace operation. Integrated control module diagnostic LED is flashing 3 flashes. Associated LED Code Fault Description Possible Causes 3 flashes ■ ■ Pressure switch circuit is not closed. Induced draft blower is operating. ■ ■ ■ ■ Pressure switch hose blocked, pinched or connected improperly. Blocked flue and/or inlet air pipe, blocked drain system or weak induced draft blower.
Symptoms of Abnormal Operation ■ ■ Normal furnace operation. Integrated control module diagnostic LED is flashing 7 flashes. Associated LED Code Fault Description Possible Causes 7 flashes Flame sense microamp signal is low. ■ ■ ■ ■ Notes and Cautions Corrective Actions Flame sensor is coated/ oxidized. Flame sensor incorrectly positioned in burner flame. Lazy burner flame due to improper gas pressure or combustion air. ■ ■ ■ Sand flame sensor if coated/oxidized.
Blower Performance Data CFM and Temperature Rise vs. External Static Pressure Tons AC at 0.5" ESP CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM 4.0 2,069 29 1,965 30 1,871 32 1,756 34 1,661 36 1,549 1,415 1,275 3.5 1,752 34 1,724 34 1,667 36 1,603 37 1,488 40 1,402 1,290 1,082 Med-Lo 3.0 1,437 41 1,437 41 1,417 42 1,369 43 1,320 45 1,256 1,140 984 Low 2.
3. For most jobs, about 400 CFM per ton when cooling is desirable. 4. Installation is to be adjusted to obtain temperature rise within the range specified on the rating plate. 5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating. The data for 0.6" W.C. to 0.8" W.C. is shown for air conditioning purposes only. 6.
NOTES: 1. Set heat anticipator on room thermostat at 0.7 amps. 2. Manufacturer’s specified replacement parts must be used when servicing. 3. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. Use copper conductors only. 4. If heating and cooling blower speeds are not the same, discard jumper before connecting blower leads.
NOTES: 1. Set heat anticipator on room thermostat at 0.7 amps. 2. Manufacturer’s specified replacement parts must be used when servicing. 3. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. Use copper conductors only. 4. If heating and cooling blower speeds are not the same, discard jumper before connecting blower leads.
NOTES: 1. Set heat anticipator on room thermostat at 0.7 amps. 2. Manufacturer’s specified replacement parts must be used when servicing. 3. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. Use copper conductors only. 4. If heating and cooling blower speeds are not the same, discard jumper before connecting blower leads.
NOTES: 1. Set heat anticipator on room thermostat at 0.7 amps. 2. Manufacturer’s specified replacement parts must be used when servicing. 3. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. Use copper conductors only. 4. If heating and cooling blower speeds are not the same, discard jumper before connecting blower leads.
