INSTALLATION AND OPERATION INSTRUCTIONS - … · 2017-11-26 · section 3 user’s information...

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92-24161-20-11SUPERSEDES 92-24161-20-10

USE THE INFORMATION IN THIS BOOKLET TOINSTALL THE FURNACE AND THE

INSTALLER: FURNACE CONTROLLER. LOCATE THISBOOKLET ADJACENT TO THE UNIT AFTERINSTALLATION.

KEEP THIS BOOKLET OF INFORMATION FORFUTURE REFERENCE.USER:

INSTALLATION AND OPERATION INSTRUCTIONS

SECTION 1 INSTALLATION INSTRUCTIONS

SECTION 2 THERMOSTAT INSTRUCTIONS

SECTION 3 USER’S INFORMATION MANUAL

CONTENTS

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPERINSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONSTHOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESEINSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE ORMAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING,EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

INSTALLATION INSTRUCTIONS

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92-24161-22-11SUPERSEDES 92-24161-22-10

INSTALLATION INSTRUCTIONSFOR (-)GFD UPFLOW & (-)GGD DOWNFLOW HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES

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IMPORTANT: To insure proper installation and operation of this product, com-pletely read all instructions prior to attempting to assemble, install, operate, main-tain or repair this product. Upon unpacking of THE furnace, inspect all parts fordamage prior to installation and start-up.

CONTENTS

Safety Information ....................................................................................................3

Installation Check List ..............................................................................................4

General Information .................................................................................................5

Location Requirements and Considerations............................................................6

Venting and Combustion Air Piping .......................................................................14

Non-Direct Vent Pipe Installation ...........................................................................16

Direct Vent Pipe Installation ...................................................................................20

Condensate Drain/Optional Neutralizer .................................................................29

Gas Supply and Piping ..........................................................................................33

Electrical Wiring......................................................................................................38

Accessories ............................................................................................................41

Installation w/Heat Pump Systems ........................................................................45

High Altitude Installations .......................................................................................50

Installation with Premium/High Efficiency Cooling Systems..................................53

Integrated Furnace Control ....................................................................................54

Start-Up Procedures ..............................................................................................57

Maintenance...........................................................................................................60

Troubleshooting......................................................................................................63

Wiring Diagram.......................................................................................................71

Installation Instructions are updated on a regular basis. This is done as productchanges occur or if new information becomes available. In this publication, anarrow ➤ denotes changes from the previous edition or additional new material.

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USE ONLY WITH TYPE OF GASAPPROVED FOR THIS FUR-NACE. REFER TO THE FUR-NACE RATING PLATE.

INSTALL THIS FURNACE ONLYIN A LOCATION AND POSI-TION AS SPECIFIED IN THELOCATION REQUIREMENTSAND CONSIDERATIONS SEC-TION OF THESE INSTRUC-TIONS. PROVIDE ADEQUATECOMBUSTION AND VENTILA-TION AIR TO THE FURNACESPACE AS SPECIFIED IN THEVENTING SECTION OF THESEINSTRUCTIONS.

PROVIDE ADEQUATE COM-BUSTION AND VENTILATIONAIR TO THE FURNACE SPACEAS SPECIFIED IN THE COM-BUSTION AND VENTILATIONAIR SECTION OF THESEINSTRUCTIONS.

COMBUSTION PRODUCTSMUST BE DISCHARGED OUT-DOORS. CONNECT THIS FUR-NACE TO AN APPROVEDVENT SYSTEM ONLY, ASSPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.

NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TOCHECK ALL CONNECTIONS,AS SPECIFIED IN GAS SUPPLYAND PIPING SECTION OFTHESE INSTRUCTIONS.

ALWAYS INSTALL FURNACETO OPERATE WITHIN THEFURNACE'S INTENDED TEM-PERATURE-RISE RANGE WITHA DUCT SYSTEM WHICH HASAN EXTERNAL STATIC PRES-SURE WITHIN THE ALLOW-ABLE RANGE, AS SPECIFIEDIN DUCTING SECTION OFTHESE INSTRUCTIONS. SEEALSO FURNACE RATINGPLATE.

WHEN A FURNACE ISINSTALLED SO THAT SUPPLYDUCTS CARRY AIR CIRCU-LATED BY THE FURNACE TOAREAS OUTSIDE THE SPACECONTAINING THE FURNACE,THE RETURN AIR SHALLALSO BE HANDLED BYDUCT(S) SEALED TO THEFURNACE CASING AND TER-MINATING OUTSIDE THESPACE CONTAINING THEFURNACE.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BEINSTALLED SO THE BURNERSAND IGNITION SOURCE ARELOCATED NO LESS THAN 18INCHES ABOVE THE FLOOR.THIS IS TO REDUCE THE RISKOF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUSTBE LOCATED OR PROTECTEDTO AVOID PHYSICAL DAMAGEBY VEHICLES. FAILURE TOFOLLOW THESE WARNINGSCAN CAUSE A FIRE OREXPLOSION, RESULTING INPROPERTY DAMAGE, PER-SONAL INJURY OR DEATH.

USE OF THIS FURNACE ISALLOWED DURING CON-STRUCTION IF THE FOLLOW-ING TEMPORARY INSTALLA-TION REQUIREMENTS AREMET. INSTALLATION MUSTCOMPLY WITH ALL INSTALLA-TION INSTRUCTIONS INCLUD-ING:• PROPER VENT INSTALLA-

TION;• FURNACE OPERATING

UNDER THERMOSTATICCONTROL;

• RETURN AIR DUCT SEALEDTO THE FURNACE;

• AIR FILTERS IN PLACE;• SET FURNACE INPUT RATE

AND TEMPERATURE RISEPER RATING PLATE MARK-ING;

• MEANS FOR PROVIDINGOUTDOOR AIR REQUIREDFOR COMBUSTION;

• RETURN AIR TEMPERA-TURE MAINTAINEDBETWEEN 55°F (13°C) AND80°F (27°C); AND;

• CLEAN FURNACE, DUCTWORK AND COMPONENTSUPON SUBSTANTIAL COM-PLETION OF THE CON-STRUCTION PROCESS, ANDVERIFY FURNACE OPERAT-ING CONDITIONS INCLUD-ING IGNITION, INPUT RATE,TEMPERATURE RISE ANDVENTING, ACCORDING TOTHE INSTRUCTIONS.

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SAFETY INFORMATION

DO NOT INSTALL THIS FUR-NACE IN A MOBILE HOME!!THIS FURNACE IS NOTAPPROVED FOR INSTALLA-TION IN A MOBILE HOME.DOING SO COULD CAUSEFIRE, PROPERTY DAMAGE,PERSONAL INJURY ORDEATH.

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INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

ELECTRICAL

115 V.A.C. supply (Single Circuit)

Polarity observed

Furnace properly grounded (Earth ground)

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling speed

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connectedand clamped

Freeze protection (if necessary)

______ Neutralizer (if needed)

VENTING – DIRECT VENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

VERTICAL – CONCENTRIC (RXGY-E03)

Intake – 12" min. above roof/snow level

HORIZONTAL – STANDARD (RXGY-D02, -D03)


12" min. above grade/snow level

HORIZONTAL – ALTERNATE (RXGY-D02, -D03 OR -D04)


Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-E03)


Intake “Y” rotated above center

Exhaust sloped toward furnace

VENTING – NON-DIRECT VENT (VERTICAL ONLY)

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)

12" min. above roof/snow level

Model #

Serial #

Date of installation

HORIZONTAL – STANDARD


HORIZONTAL – ALTERNATE

Above anticipated snow level

➤ FIGURE 2DOWNFLOW/HORIZONTAL FURNACE

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GENERAL INFORMATIONThe (-)GFD and (-)GGD series fur-naces are design-certified by CSA foruse with natural and L.P. gases asfollows:

• As direct vent, central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special air intakesystem outlined in these instruc-tions.

• As non-direct, central forced air fur-nace taking combustion air fromthe installation area or using airducted from the outside.

FIGURE 1UPFLOW FURNACE

Install this furnace in accordance withthe American National StandardZ223.1 – latest edition entitled“National Fuel Gas Code” (NFPA54,90A and 90B) and requirements orcodes of the local utilities or otherauthorities having jurisdiction. This isavailable from the following:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

CSA International - U.S.8501 East Pleasant Valley RoadCleveland, Ohio, 44131

Canadian installations must beinstalled in accordance with CSA,local installation codes andauthorities having jurisdiction.CSA is available from:

CSA International - Canada178 Rexdale Blvd.Etobicoke (Toronto), Ontario,Canada M9W-1R3

I678

ITEMNO. PART NAME

1 CONDENSATE TRAP

2 DOOR SWITCH

3 JUNCTION BOX

4 TRANSFORMER

5 LOW PRESSURE SWITCH

6 HIGH PRESSURE SWITCH

7 EXHAUST TRANSITION

8 CONNECTOR

9 MAIN LIMIT

10 EXHAUST AIR PIPE

11 VENT CAP PLUG

12 FLAME SENSOR

13 OVERTEMPERATURE SWITCH

ITEMNO. PART NAME

14 TOP PLATE

15 BURNER

16 IGNITER

17 COMBUSTION AIR INLET

18 GAS VALVE

19 CAPACITOR

20 INDUCED DRAFT BLOWER

21 POWER FACTOR CHOKE

22 IGNITION CONTROL

23 INTEGRATED FURNACE CONTROL

24 BLOWER MOTOR

25 R/A SENSOR

26 BLOWER HOUSING

ITEMNO. PART NAME

1 GAS VALVE

2 CAPACITOR



5 BLOWER HOUSING


7 BLOWER MOTOR

8 DOOR SWITCH

9 JUNCTION BOX


11 HALC

12 TOP PLATE

13 RETURN AIR SENSOR

ITEMNO. PART NAME

14 VENT CAP PLUG

15 EXHAUST AIR PIPE16 INTEGRATED FURNACE CONTROL

17 TRANSFORMER

18 IGNITION CONTROL


20 CONNECTOR


22 MAIN LIMIT

23 CONDENSATE TRAP

24 IGNITER


26 BURNER

27 FLAME SENSOR

trap and along the entire lengthof the condensate drain in theunconditioned space.

The heat tape should meet thefollowing requirements:

a. The heat tape must be UL list-ed.

b. Install the heat tape per themanufacturer’s instructions forthe entire length of drain pipein the unconditioned space.

c. The heat tape should be ratedat 3 or 5 watts per foot at120V.

6. IMPORTANT: If installing in autility room, be sure the door iswide enough to:

a. allow the largest part of thefurnace to pass; or

b. allow any other appliance(such as a water heater)to pass.

7. Install the furnace level andplumb. If it is not level, conden-sate cannot drain properly, possi-bly causing furnace to shutdown.

IMPORTANT: Do not attempt to twinthe modulating furnace. The charac-teristics of the ecm2 blower motorpreclude twinning applications.

LOCATE AND REMOVE THE SHIP-PING BRACKET FROM THE SIDEOF THE BLOWER HOUSINGBEFORE OPERATING UNIT. SEEFIGURE 5.

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LOCATION REQUIREMENTS AND CONSIDERATIONSGENERAL INFORMATION

DO NOT USE THIS FURNACEDURING CONSTRUCTION IFAIR LADEN CORROSIVE COM-POUNDS ARE PRESENT SUCHAS CHLORINE AND FLUORINE.OTHERWISE, PROVISIONSMUST BE TAKEN TO PROVIDECLEAN, UNCONTAMINATEDCOMBUSTION AND VENTILA-TION AIR TO THE FURNACE.FURNACE COMBUSTION ANDVENTILATION AIR CONTAMI-NATED WITH THESE COM-POUNDS FORMS ACIDS DUR-ING COMBUSTION WHICHCORRODES THE HEATEXCHANGER AND COMPO-NENT PARTS. SOME OF THESECONTAMINANTS ARE FOUNDIN, BUT NOT LIMITED TO, PAN-ELING, DRY WALL, ADHESIVES,PAINTS, STAINS, VARNISHES,SEALERS, AND MASONRYCLEANING MATERIALS.

DO NOT INSTALL THIS FUR-NACE IN A MOBILE HOME!!THIS FURNACE IS NOTAPPROVED FOR INSTALLATIONIN A MOBILE HOME. DOING SOCOULD CAUSE FIRE, PROPER-TY DAMAGE, PERSONALINJURY OR DEATH.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BEINSTALLED SO THE BURNERSAND IGNITION SOURCE ARELOCATED NO LESS THAN 18INCHES ABOVE THE FLOOR.THIS IS TO REDUCE THE RISKOF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOL-LOW THESE WARNINGS CANCAUSE A FIRE OR EXPLOSION,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH. 1. IMPORTANT: When installing the

-GGD furnace in the horizontalconfiguration, a special kit mustbe used to convert the furnace forhorizontal installation. The neces-sary kits are listed here.

HORIZONTALFURNACE CONVERSION

MODEL KIT(-)GGD-06 . . . . . . . . RXGY-G01(-)GGD-07 . . . . . . . . RXGY-G02(-)GGD-09 . . . . . . . . RXGY-G03(-)GGD-10 . . . . . . . . RXGY-G04(-)GGD-12 . . . . . . . . RXGY-G05

2. IMPORTANT: If installing the unitover a finished ceiling or livingarea, be certain to install an auxil-iary condensate drain pan underthe entire unit. Extend this auxiliarydrain pan under any evaporatorcoil installed with the furnace andthe open portion of the condensatedrain assembly. See “CondensateDrain/Neutralizer” section for moredetails.

3. IMPORTANT: If using a coolingevaporator coil with this furnace.Be sure the air passes over theheat exchanger before passingover the cooling coil. The cooledair passing over the warm ambientair inside the heat exchangertubes can cause condensationinside the tubes resulting in corro-sion and eventual failure.

4. IMPORTANT: Install the furnacelevel. If it is not level, condensatecannot drain properly, possiblycausing furnace shut down.

NOTE: These furnaces are approvedfor installation in attics, as well asalcoves, utility rooms, closets andcrawlspaces. Make provisions to pre-vent freezing of condensate.

5. IMPORTANT: If this furnace isinstalled in a garage, attic or anyother unconditioned space, a self-regulating heat tape must beinstalled around the condensate

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CAUTION!

CAUTION!

FIGURE 3HORIZONTAL FURNACE WITH HEAT TAPE ON CONDENSATE TRAP

SUPPLYAIR

RETURNAIR

DRAINPIPE

HEATTAPE

TRAP

THIS FURNACE IS NOTAPPROVED OR RECOMMENDEDFOR INSTALLATION ON ITS BACK,WITH ACCESS DOORS FACINGUPWARDS, OR WITH SUPPLY AIRDISCHARGING TO THE RIGHTHAND SIDE WHEN FACING THEFRONT OF THE FURNACE.

SEE FIGURES 3 AND 4 FOR PROP-ER INSTALLATION OF HORIZON-TAL MODELS.

CLEARANCE -ACCESSIBILITYIMPORTANT: When installing the -GGD furnace in the horizontal con-figuration, a special kit must be usedto convert the furnace for horizontalinstallation. The necessary kits arelisted here.


MODEL KIT(-)GGD-06 . . . . . . . . . . RXGY-G01(-)GGD-07 . . . . . . . . . . RXGY-G02(-)GGD-09 . . . . . . . . . . RXGY-G03(-)GGD-10 . . . . . . . . . . RXGY-G04(-)GGD-12 . . . . . . . . . . RXGY-G05

The design of forced air furnaces withmodels as listed in the tables underFigures 6, 7 and 8 are certified by CSALaboratories for the clearances tocombustible materials shown in inches.

See name/rating plate and clearancelabel for specific model number andclearance information.

Service clearance of at least 24 inchesis recommended in front ofall furnaces.

FOR PURPOSES OF SERVICINGTHIS APPLIANCE, ACCESSIBILITYCLEARANCES, WHERE GREATER,SHOULD TAKE PRECEDENCEOVER FIRE PROTECTION CLEAR-ANCES.

FURNACES MUST NOT BEINSTALLED DIRECTLY ON CARPET,TILE OR OTHER COMBUSTIBLEMATERIAL. INSTALLATION ON ACOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING MAYRESULT IN FIRE CAUSING DAMAGE,PERSONAL INJURY OR DEATH.

-GGD FURNACES CONFIGUREDFOR DOWNFLOW INSTALLATIONSMAY NOT BE INSTALLED DIRECTLYTO A COMBUSTIBLE FLOOR. A SPE-CIAL FLOOR BASE IS REQUIRED.

-GFD upflow furnaces and -GGD fur-naces mounted in the horizontalconfiguration are designed and certi-

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! WARNING

fied for installation on combustible(wood only) floors. -GGD furnacesmounted in the downflow configu-ration may be installed on a casedevaporator coil mounted on a com-bustible (wood only) floor or (forinstallations without an evaporatorcoil) installed on a special com-bustible floor base mounted to acombustible (wood only) floor. Thenecessary floor base for installing a-GGD furnace in the downflow con-figuration to a combustible (woodonly) floor is an accessory soldthrough finished goods. Followingis a list of floor base models by fur-nace input size.-GGD Furnace Combustible

BTU’s Floor Base60, 75 RXGC-B1790, 105 RXGC-B21

120 RXGC-B24

Upflow furnaces are shipped witha bottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle. See filter sec-tion for details.

SITE SELECTION1. Select a site in the building near

the center of the proposed, orexisting, duct system.

2. Give consideration to the ventsystem piping when selecting thefurnace location. Vent from thefurnace to the termination withminimal length and elbows.

3. Locate the furnace near theexisting gas piping. If running anew gas line, locate the furnaceto minimize the length andelbows in the gas piping.

4. Locate the furnace to maintainproper clearance to combustiblesas shown in Figures 4 & 5.

COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET. THEAREA AROUND THE FURNACEMUST BE KEPT CLEAR AND FREEOF ALL COMBUSTIBLE MATERI-ALS INCLUDING GASOLINE ANDOTHER FLAMMABLE VAPORSAND LIQUIDS. PLACEMENT OFCOMBUSTIBLE MATERIALS ON,AGAINST OR AROUND THE FUR-NACE JACKET CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE, PERSON-AL INJURY OR DEATH. THEHOMEOWNER SHOULD BE CAU-TIONED THAT THE FURNACEAREA MUST NOT BE USED AS ABROOM CLOSET OR FOR ANYOTHER STORAGE PURPOSES.

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FIGURE 5REMOVING SHIPPING BRACKET

92-24379-01

CAUTION!

FIGURE 4HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GASPIPE

INTAKEVENT

ELECTRICALCONDUIT

RETURNAIR

SUPPLYAIR

EXHAUSTVENT

TRAP

8

AO39201

FIGURE 6PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS

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�FIGURE 7DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS

IMPORTANT: THIS FURNACE MAYONLY BE INSTALLED SO AS WHENFACING THE FRONT OF THE FUR-NACE, SUPPLY AIR IS DIS-CHARGED ON THE LEFT HANDSIDE.

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�FIGURE 8DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS

A084901.S01JWR 7-21-99

DO

WN

FLO

W M

OD

ELS

(Dow

nflo

w C

onfig

urat

ion)

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DUCTINGProper airflow is required for the correctoperation of this furnace.Too little airflow can cause erratic oper-ation and can damage the heatexchanger. The duct system must carrythe correct amount of air for heatingand cooling if summer air conditioningis used.

Size the ducts according to acceptableindustry standards and methods. Thetotal static pressure drop of the air dis-tribution system should not exceed 0.2"w.c.

NEVER ALLOW THE PRODUCTSOF COMBUSTION FROM THEFLUE TO ENTER THE RETURNAIR DUCTWORK OR THE CIRCU-LATED AIR SUPPLY. ALL RETURNDUCTWORK MUST BE ADE-QUATELY SEALED ANDSECURED TO THE FURNACEWITH SHEET METAL SCREWS;AND JOINTS, TAPED. SECUREALL OTHER DUCT JOINTS WITHAPPROVED CONNECTIONS ANDSEAL AIRTIGHT. WHEN A FUR-NACE IS MOUNTED ON A PLAT-FORM WITH RETURN THROUGHTHE BOTTOM, IT MUST BESEALED AIRTIGHT BETWEENTHE FURNACE AND THERETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE PHYSICAL SUPPORTOF THE FURNACE WITHOUTSAGGING, CRACKS, OR GAPSAROUND THE BASE, PROVIDINGA SEAL BETWEEN THE SUPPORTAND THE BASE.

FAILURE TO PREVENT PROD-UCTS OF COMBUSTION FROMBEING CIRCULATED INTO THELIVING SPACE CAN CREATEPOTENTIALLY HAZARDOUS CON-DITIONS, INCLUDING CARBONMONOXIDE POISONING THATCOULD RESULT IN PERSONALINJURY OR DEATH.DO NOT, UNDER ANY CIRCUM-STANCES, CONNECT RETURN ORSUPPLY DUCTWORK TO ORFROM ANY OTHER HEAT PRO-DUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.IMPORTANT: Some high efficiency filtershave a greater than normal resistance toairflow. This can adversely affect furnaceoperation. Be sure to check airflow ifusing any filter other than the factory-pro-vided filter.

UPFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

UPFLOW FURNACE: A SOLID METALBASE PLATE MUST BE INSTALLED INTHE FURNACE BOTTOM WHENUSING SIDE AIR RETURN. FAILURETO INSTALL A BASE PLATE COULDCAUSE THE PRODUCTS OF COM-BUSTION TO CIRCULATE INTO THELIVING SPACE AND CREATE POTEN-TIALLY HAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.

2. Open the return air compartment.a. If using side return air, do not

remove the bottom base. b. Cut an opening in the side .

The opening should be cut thefull width of the knockouts onthe unit. NOTE: When using sidereturn, return air plenums,RXGR-C17B, C21B and C24Bare available from the factory.

c. Remove the bottom base, ifusing bottom return air.Remove the panel by remov-ing the two screws attachingthe base to the front baseangle. See Figure 6. NOTE: Where the maximumairflow is 1800 CFM or more,both sides or the bottom mustbe used for return air.

3. Connect the return duct or returnair cabinet to the unit. Make theconnection air tight to prevententraining combustion gases froman adjacent fuel-burning appli-ance.

4. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas. DO NOTuse a rear air return.

5. If summer air conditioning isdesired, position the indoor coil onthe top of the unit. Insure that noair can bypass this coil.

6. Connect the supply air plenum tothe furnace plenum opening. IMPORTANT: If a flexible ductconnector must be used, it MUSTbe rated for a minimum tempera-ture of 250°F. continuous.

! WARNING

FIGURE 9BOTTOM PANEL REMOVAL

NOTE: FILTER AND FILTER-ROD ARE SHIPPED ON TOP OF SOLID BOTTOM. REMOVE FILTER AND FILTER ROD TO ACCES SOLID BOTTOM 542201-B1

! WARNING

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FIGURE 11SUPPLY AIR SENSOR TERMINALS

DOWNFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning is desired,position the indoor coil on the bottomof the unit. Insure that no air canbypass this coil.

3. If installing on a combustible floorand not using an air conditioningplenum, install the special non-com-bustible floor base. See Figure 7.

THE DOWNFLOW/HORIZONTALFURNACE DESIGN IN DOWNFLOWMODE IS CERTIFIED FOR INSTAL-LATION ON A NON-COMBUSTIBLEFLOOR. USE THE SPECIAL BASESPECIFIED ON THE FURNACECLEARANCE LABEL. FAILURE TOINSTALL THE SPECIAL BASE MAYRESULT IN FIRE, PROPERTY DAM-AGE, PERSONAL INJURY ORDEATH. THIS SPECIAL BASE ISSHIPPED FROM THE FACTORY ASAN ACCESSORY.

4. Connect the furnace to the supplyair plenum.

5. Connect the return air ducting tothe return air opening at the top ofthe unit. Make the connection airtight to prevent entraining combus-tion gases from an adjacent fuel-burning appliance.

6. Be sure to have adequate spacefor the unit filter.

NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

HORIZONTAL UNITSIMPORTANT: This furnace may only beinstalled so as when facing the front ofthe furnace, supply air is discharged onthe left hand side.

IMPORTANT: When installing the -GGD furnace in the horizontal configu-ration, a special kit must be used toconvert the furnace for horizontal instal-lation. The necessary kits are listedhere.


MODEL KIT(-)GGD-06 . . . . . . . . . . RXGY-G01(-)GGD-07 . . . . . . . . . . RXGY-G02(-)GGD-09 . . . . . . . . . . RXGY-G03(-)GGD-10 . . . . . . . . . . RXGY-G04(-)GGD-12 . . . . . . . . . . RXGY-G05

! WARNING

1. Position the unit to minimize longruns or runs with many turns andelbows.

2. If summer air conditioning is desired,position the indoor coil on the leftend of the unit. Insure that no air canbypass this coil.

3. Connect the furnace to the supply airplenum.

4. Connect the return air ducting to thereturn air opening at the right end ofthe unit. Make the connection airtight to prevent entraining combus-tion gases from an adjacent fuel-burning appliance.

5. Be sure to have adequate spacefor the unit filter.

NOTE: DO NOT take return airfrom bathrooms, kitchens, fur-nace rooms, garages, utility orlaundry rooms, or cold areas.

� Return air can come from : (1)outside the building, (2) from returnair ducting from several inside rooms,or (3) a combination of the two.When using outside air, design andadjust the system to maintain areturn air temperature above 50°Fduring the heating season. If returnair combes from both inside and out-side the building, design the ductingsystem with a diverting damper sothat the volume of return air enteringthe furnace equals that which wouldnormally enter through the return air

FIGURE 10COMBUSTIBLE FLOOR BASE

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intake of the furnace. Any duct openingpulling return air from the outside mustnot be any higher nor closer than 10feet to the furnace exhaust vent.

SUPPLY AIR SENSOREach furnace comes shipped from thefactory with a supply air sensor. Installthe sensor, in the supply air plenumtrunk, with two, field supplied, #8 sheetmetal screws, using the following guide-lines:

1. 12” downstream of the evaporatorcoil, if installed.

2. If no evaporator coil is used locatethe sensor at least 18” downstreamof the furnace outlet. Always locatethe supply air sensor out of directline of sight of the heat exchangertubes, if possible.

3. Attach the supply air sensor wiresonto the terminals marked “SASensor” on the integrated furnacecontrol board (See Figure 5).

NOTE: Improper placement of thesupply air sensor can adverselyaffect furnace temperature rise.

NOTE: In downflow circumstanceswhere building construction does notallow for the placement of the sensor tofall within these parameters, the supplyair sensor should not be connected.This means that the furnace will rununder default parameters. When run-ning under default parameters, the “82”code will appear for 1.5 minutes. Afterthat the fault code will be stored in thecontrol board’s memory and will showupon power cycling. Default airflowparameters can be manually adjusted.See section discussing IntegratedFurnace Control (IFC) board in thismanual.

14

GENERAL INFORMATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SEC-TION. FAILURE TO PROPERLYVENT THIS FURNACE OR PRO-TECT IT FROM INADEQUATECOMBUSTION AIR CAN CAUSECARBON MONOXIDE POISON-ING, AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

OVER TEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the burner compartment toprotect against over temperature condi-tions. If a switch is tripped it must bemanually reset.

DO NOT JUMPER OVERTEM-PERATURE SAFETY SWITCHES!IF ONE OF THESE OVER TEM-PERATURE SWITCHES SHOULDTRIP, CALL A QUALIFIEDINSTALLER, SERVICE AGENCYOR THE GAS SUPPLIER. DONOT RESET THE SWITCHESWITHOUT TAKING CORRECTIVEACTION. FAILURE TO DO SOCAN RESULT IN CARBONMONOXIDE POISONING ORDEATH. IF THIS UNIT ISINSTALLED IN A CLOSET, THEDOOR MUST BE CLOSED WHENMAKING THIS CHECK.

REPLACE THE OVER TEMPERA-TURE SAFETY SWITCHES ONLYWITH THE IDENTICALREPLACEMENT PART.

INSTALLATION WITHPRE-EXISTING VENTSYSTEMSWhen the installation of this furnacereplaces an existing furnace that isremoved from a vent system servingother appliances (such as a waterheater), the existing vent system is likelyto be too large to properly vent theremaining attached appliances.

Follow the steps below with each appli-ance remaining connected to the origi-nal common vent system. Place theappliance to be tested in operation,while the other appliances remainingconnected to the common vent systemare not in operation. Test the operationof each appliance individually by the fol-lowing method.

1. Permanently seal any unusedopenings in the common ventingsystem.

2. Visually inspect the venting systemfor proper size and horizontal pitchand determine that there is noblockage, restriction, leakage, cor-rosion or other deficiencies whichcould cause an unsafe condition.

3. If practical, close all building doors,windows and all doors between thespace where the appliancesremaining connected to the com-mon venting system are located.Turn on clothes dryers and anyappliance not connected to thecommon venting system. Turn onany exhaust fans, such as rangehoods and bathroom exhausts, sothey will operate at maximumspeed. Do not operate a summerexhaust fan. Close fireplacedampers.

4. Follow the lighting instructions.Place the appliance being inspect-ed into operation. Adjust the ther-mostat so the appliance will operatecontinuously.

5. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigaror pipe.

6. After it has been determined thateach appliance that remains con-nected to the common ventingsystem properly vents (whentested as outlined above), returndoors, windows, exhaust fans,fireplace dampers and any othergas-burning appliance to theirprevious conditions of use.

7. If improper venting is observedduring any of the above tests,resize the common venting sys-tem. Refer to latest edition of theNational Fuel Gas Code ANSIZ223.1, or the CSA-GAMA vent-ing tables for Category I fur-naces.NOTE: Schedule 40 ABS-DWVpipe and fittings may be used asan alternate to PVC pipe for thecombustion air inlet and ventpipes.NOTE: Cellular core PVC is alsoapproved for use. It must beschedule 40 PVC-DWV cellularpipe manufactured under ASTMF-891.

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING

15

IMPORTANT: For Proper InstallationDO NOT use solvent cement that hasbecome curdled, lumpy or thickened.DO NOT thin. Observe shelf precau-tions printed on containers. For appli-cation below 32°F, use only low-tem-perature-type solvent cement.For correct installation of the ventpipe, follow the instructions providedby the manufacturers of the pipe,primer and solvent.

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLY FLAM-MABLE. PROVIDE ADEQUATEVENTILATION AND DO NOTASSEMBLE COMPONENTSNEAR HEAT SOURCE OR ANOPEN FLAME. DO NOTSMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALL CAU-TIONS AND WARNINGS PRINT-ED ON MATERIAL CONTAIN-ERS. FAILURE TO FOLLOWTHESE GUIDELINES MAYRESULT IN FIRE, EXPLOSIONOR ASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures must conformto American National StandardInstitute and American Society forTesting and Materials (ANSI/ASTM)standards in the U.S.Pipe and Fittings - ASTM-D1785,D2466, D2665, D2231, D2661, andF628PVC Primer and Solvent Cement -ASTM-D2564ABS Pipe and Fittings - Use ABSPrimer and Solvent Cement D2235Procedure for Cementing Joints -ASTM-D2855In Canada all combustion air and ventpipe must be CSA- or ULC-certifiedSchedule 40 PVC, PVC-DWV orABS-DWV.

IMPORTANT: The plastic combustionair and venting components areMADE of PVC. If using ABS piping,ensure that the solvent cement iscompatible for joining PVC to ABScomponents or use a mechanical con-nection that can withstand the venttemperatures and is corrosion resis-tant.

CEMENTING JOINTSProperly seal all joints in the PVC ventusing the following materials and proce-dures:PVC CLEANER-PRIMER ANDPVC MEDIUM-BODY SOLVENTCEMENTIMPORTANT: After cutting pipe, removeall ragged edges and burrs. This isimportant to prevent increase in pres-sure drop throughout the system.1. Cut pipe end square. Chamfer edge

of pipe. Clean fitting socket andpipe joint area of all dirt, grease andmoisture.

2. After checking pipe and socket forproper fit, wipe socket and pipe withcleaner-primer. Applya liberal coat of primer to inside sur-face of socket and outside of pipe.READ INSTRUCTIONS INCLUDEDWITH THE PRIMER FOR PROPERINSTALLATION.

3. Apply a thin coat of cement evenlyin the socket. Quickly apply a heavycoat of cement to the pipe end andinsert pipe into fitting with a slighttwisting movement until it bottomsout.NOTE: Cement must be fluid; if not,recoat.

4. Hold the pipe in the fitting for 30seconds to prevent the taperedsocket from pushing the pipe out ofthe fitting.

5. Wipe all excess cement from thejoint with a rag. Allow 15 minutesbefore handling. Cure time variesaccording to fit, temperature andhumidity.NOTE: Stir the solvent cement fre-quently while using. Use a naturalbristle, one inch wide brush or theapplicator supplied with the can.

! WARNING

16

COMBUSTION AIR

ALWAYS PROVIDE THIS FUR-NACE AND ANY OTHER FUELBURNING APPLIANCE WITHENOUGH FRESH AIR FORPROPER COMBUSTION ANDVENTILATION OF THE FLUEGASES. MOST BUILDINGCODES REQUIRE THAT OUT-SIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAIL-URE TO DO SO CAN CAUSEDEATH FROM CARBONMONOXIDE POISONING.

Provide adequate facilities for com-bustion and ventilation air in accor-dance with section 5.3, Air forCombustion and Ventilation of theNational Fuel Gas Code, ANSIZ223.1 - latest edition; CAN/CGAB149.1 and .2, or applicable provi-sions of the local building codes.These combustion and ventilationfacilities must not be obstructed.

IMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any furnacefailure due to corrosive elements inthe atmosphere is excluded fromwarranty coverage.

The following types of installation (butnot limited to the following) REQUIREOUTDOOR AIR for combustion, dueto chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundryrooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemicalstorage areas.

Exposure to the following substancesin the combustion air supply (but notlimited to the following) alsoREQUIRE OUTDOOR AIR for com-bustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming poolchemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon Tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as per-chloroethylene)

• Printing inks, paint removers,varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Anti-static fabric softeners forclothes dryers

• Masonry acid washing materials

Combustion air must be free of acidforming chemicals such as sulphur,fluorine, and chlorine. These ele-ments are found in aerosol sprays,detergents, bleaches, cleaning sol-vents, air fresheners, paint and var-nish removers, refrigerants and manyother commercial and householdproducts. Vapors from these productswhen burned in a gas flame form acidcompounds. The acid compoundsincrease the dew point temperatureof the flue products and producehighly corrosive condensate.

TABLE 1UNCONFINED SPACE DIMENSIONS

ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THE FUR-NACE. FAILURE TO DO SO CANRESULT IN EXPLOSION, FIRE,PROPERTY DAMAGE, CARBONMONOXIDE POISONING, PER-SONAL INJURY OR DEATH.

Combustion air requirements aredetermined by whether the furnaceis in an open (unconfined) area or ina confined space such as a closet orsmall room.

FURNACE LOCATED IN ANUNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have atleast 50 cubic feet for each 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. Thesizes are based on 8 foot ceilings.See Table 1.

If the open space containing the fur-nace is in a building constructed toseverely limit outside air infiltration(contemporary energy efficient con-struction methods), outside air maystill be required for the furnace tooperate and vent properly. Outsideair openings should be sized thesame as for a confined space.

BTUH Minimum Sq. Feet Typical Room SizeInput With 8 foot Ceiling60,000 375 15' x 25' OR 19' x 20'75,000 469 15' x 32' OR 20' x 24'90,000 563 20' x 28' OR 24' x 24'105,000 657 20' x 33' OR 26' x 25'120,000 750 25' x 30' OR 24' x 32'

! WARNING

! WARNING

NON-DIRECT VENT PIPE INSTALLATION(FOR VERTICAL TERMINATIONS ONLY)

17

FURNACE LOCATED IN ACONFINED SPACE.

A confined space (any space small-er than shown before as “uncon-fined”) must have openings intothe space, which are located inaccordance with the require-ments set forth in the followingsubsections A and B. The open-ings must be sized by how theyconnect to the heated area or to theoutside, and by the input of allappliances in the space.

If the confined space is within abuilding with tight construction,combustion air must be taken fromoutdoors or areas freely communi-cating with the outdoors.

FIGURE 12AIR FROM HEATED SPACE

A. USING INDOOR AIR FORCOMBUSTION

IMPORTANT: DO NOT take air froma heated space with a fireplace,exhaust fan or other device that mayproduce a negative pressure.

If combustion air is taken from theheated area (see Figure 12), theopenings must each have at least100 square inches of free area.Each opening must have at leastone square inch of free area foreach 1,000 BTUH of total input inthe space. See Table 2.

TABLE 2INDOOR AIR OPENING DIMENSIONS

BTUH Free AreaInput Each Opening

60,000 100 square inches





B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: Do not take air froman attic space that is equipped withpower ventilation.

The confined space must communi-cate with the outdoors in accordancewith Methods 1 or 2. The minimumdimension of air openings shall notbe less than 3 inches. Where ductsare used, they shall be of the samecross-sectional area as the free areaof the openings to which they con-nect.

Method 1Two permanent openings, one locat-ed within 12 inches of the top andone located within 12 inches of thebottom of the enclosure, shall be pro-vided. The openings shall communi-cate directly, or by ducts, with the out-doors or spaces (crawl or attic) thatfreely communicate with the out-doors.

a. Where directly communicating with the outdoors or where com-municating to the outdoorsthrough vertical ducts as shown inFigure 13, each opening shallhave a minimum free area of 1square inch for each 4000 BTUHof total appliance input rating inthe enclosure. See Table 3.

BTUH Free Area Round PipeInput Each Opening Size

60,000 15.00 square inches 5"





AO77501

TABLE 3VERTICAL OUTDOOR AIR OPENINGDIMENSIONS

18

b. Where communicating with out-doors through horizontal ducts,each opening shall have a minimumfree area of 1 square inch for each2000 BTUH of total input rating ofall equipment in the enclosure. SeeTable 4 and Figure 14.

Method 2One permanent opening, locatedwithin 12 inches of the top of theenclosure, shall be permitted wherethe equipment has clearances of atleast 1 inch from the sides and backand 6 inches from the front of theappliance. The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors, andshall have a minimum free area of:

a. One square inch for each 3000BTUH of the total input rating ofall equipment located in theenclosure (see Table 5), and

b. Not less than the sum of theareas of all vent connectors in theconfined space.

If the unit is installed where there isan exhaust fan, sufficient ventilationmust be provided to prevent theexhaust fan from creating a negativepressure.

FIGURE 13AIR FROM ATTIC/CRAWL SPACE

FIGURE 14OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

TABLE 4HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS







TABLE 5VERTICAL OR HORIZONTALOUTDOOR AIR OPENING DIMENSIONS

Combustion air openings must not berestricted in any manner.

CONSULT LOCAL CODES FOR SPE-CIAL REQUIREMENTS.

AO77601

AO77701







19

INSTALLATION GUIDELINESIMPORTANT: When installed as a non-direct furnace, only vertical terminationsare allowed. Do not use horizontal termi-nations when the furnace is installedwith a non-direct vent.

All exhaust vent piping must be installedin compliance with Part 7, Venting ofEquipment, of the latest edition of theNational Fuel Gas Code NFPA 54/ANSIA223.1, or CAN/CGA-B149.1 and .2,local codes or ordinances and theseinstructions.

VENTING GUIDELINES - Non-DirectVent

1. IMPORTANT: Do not common ventwith any other appliance. Do notinstall in the same chase or chimneywith a metal or high temperatureplastic pipe from another gas or fuel-burning appliance unless therequired minimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

2. Use only medium or long radiussweep elbows.

NOTE: For upflow and downflowinstallations, extend the exhaustpipe a minimum of 18" verticallyabove the furnace cabinet beforeturning the vent.

3. Vertical vent piping is preferred.

4. Install all horizontal piping as fol-lows:

• Slope horizontal vent piping upwarda minimum of 1/4" per foot of run sothat condensate drains toward thefurnace.

• Support horizontal vent piping atleast every four feet. No sags ordips are permitted.

5. Insulate all vent runs through uncon-ditioned spaces where below-freez-ing temperatures are expected, with1" thick medium density, foil facedfiber glass or equivalent

Rubatex/Armaflex insulation. Forhorizontal runs where water maycollect and freeze, wrap the ventpipe with self-regulating, 3 or 5Watt heat tape. The heat tapemust be U.L. listed and installedper the manufacturer’s instructions.

6. All piping between the furnace andthe roof penetration is 2" or 3" asspecified in Table 6. Table 6 liststhe maximum allowable exhaustvent pipe length for the number ofelbows used, based on the furnacesize.

IMPORTANT: Use Only standard verti-cal terminations when installing themodulating furnace as a non-directvent appliance.

7. The minimum vent length is 5feet.

8. All piping through the roof is 2".When using 3" pipe, reduce to2" within 18" of the inside ofthe roof.

9. Vertical through-the-roof installa-tions do not require any specialvent termination. Use 2" PVCpipe extending a minimum of12 inches above the anticipat-ed level of snow accumula-tion.

➤ TABLE 6NON-DIRECT VENT APPLICATIONSMAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE

UPFLOW FURNACES

FURNACEINPUT

PIPESIZE

TERMINATION(VERTICAL VENTTERMINATIONS

ONLY)

NUMBER OF ELBOWS45° OR 90°

MEDIUM / LONG RADIUS ONLY

1 - 2 3 - 4 5 - 6

60,0002" STANDARD 40' 35' 30'

3" STANDARD 120' 120' 120'

75,0002" STANDARD 20' 15' 10'

3" STANDARD 120' 120' 120'

90,000 3" STANDARD 110' 105' 95'

105,000 3" STANDARD 110' 105' 95'

120,000 3" STANDARD 45' 35' 30'

DOWNFLOW/HORIZONTAL FURNACES

60,0002" STANDARD 30' 25' 20'

3" STANDARD 120' 120' 120'

75,0002" STANDARD 20' 15' 10'

3" STANDARD 120' 120' 120'

90,000 3" STANDARD 90' 80' 75'

105,000 3" STANDARD 45' 40' 35'

120,000 3" STANDARD 40' 35' 30'

20

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SEC-TION. FAILURE TO PROPERLYVENT THIS FURNACE CANCAUSE CARBON MONOXIDEPOISONING OR AN EXPLOSIONOR FIRE, RESULTING IN PROP-ERTY DAMAGE, PERSONALINJURY OR DEATH.Direct vent installations require a dedi-cated combustion air and venting sys-tem. All air for combustion is takenfrom outside and all combustion prod-ucts are discharged to the outdoors.Therefore, no ventilation or com-bustion air openings are required.

INSTALLATION GUIDELINESAll exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA 54, 90Aand 90B ANSI Z223.1-, local codes orordinances and these instructions.

1. IMPORTANT: Do not commonvent with any other appliance. Donot install in the same chase orchimney with a metal or high tem-perature plastic pipe from anothergas or fuel-burning applianceunless the required minimumclearances to combustibles aremaintained between the PVC pipeand other pipes.

2. Use only medium or long radiussweep elbows.

NOTE: For upflow and downflowinstallations, extend the combus-tion air exhaust pipe a minimumof 18" vertically above the furnacecabinet before turning the vent.

3. Vertical piping is preferred.

4. Install all horizontal piping as fol-lows:

• Slope horizontal vent pipingupward a minimum of 1/4" per footof run so that condensate drainstoward the furnace.

• Support horizontal vent piping atleast every four feet. No sags ordips are permitted.

! WARNING

DIRECT VENT PIPE INSTALLATION➤ TABLE 7DIRECT VENT APPLICATIONSMAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE

UPFLOW FURNACES

FURNACEINPUT

PIPESIZE TERMINATION

VENT TERMINATION KIT RECOMMENDED

NUMBER OF ELBOWS221⁄2°, 45° OR 90°MEDIUM / LONG

RADIUS ONLY1 - 2 3 - 4 5 - 6

60,000

2"

STANDARD RXGY-D0240' 35' 30'

CONCENTRIC RXGY-E03

ALTERNATE RXGY-D02 30' 25' 20'

3"


CONCENTRIC RXGY-E03


75,000

2" STANDARD RXGY-D02 20' 15' 10'

3"


CONCENTRIC RXGY-E03


90,000 3"


CONCENTRIC RXGY-E03


105,000 3"


CONCENTRIC RXGY-E03


120,000 3"


CONCENTRIC RXGY-E03


ALTERNATE RXGY-D04 105' 95' 90

DOWNFLOW/HORIZONTAL FURNACES

60,000

2"STANDARD RXGY-D02 30' 25' 20'

CONCENTRIC RXGY-E03 30’ 25’ 20’

3"STANDARD RXGY-D03 120' 120' 120'


75,000

2"STANDARD RXGY-D02 20' 15' 10'


3"STANDARD RXGY-D03 120' 120' 120'

CONCENTRIC RXGY-E03 120' 120' 120'

90,000 3"STANDARD RXGY-D03 70' 60' 55'


105,000 3"STANDARD RXGY-D03 45' 40' 35'

CONCENTRIC RXGY-E03 45' 40' 35'

120,000 3"STANDARD RXGY-D03 40' 35' 30'


FIGURE 15STANDARD VERTICAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

21

VERTICAL TERMINATIONSSTANDARD VERTICAL TERMINA-TIONS (See Figure 15)

Combustion Air Piping: Use two medi-um-radius sweep elbows to keep theinlet downward and prevent the entry ofrain. The inlet opening of the com-bustion air termination must be aminimum of 12" above the anticipat-ed level of snow accumulation.

Exhaust Vent Piping: The exhaust ventmust terminate at least 12 inchesabove the combustion air terminationinlet. The 2" vent pipe used to pene-trate the roof must be reduced to 1 1/2"PVC for the last 12" for the 60,000 and75,000 BTUH furnace models. Noreduction of the 2" pipe is necessary forthe 90,000 through 120,000 BTUHmodels. The maximum length of theexposed vent pipe above the roof is30".

ST-A0407-00

5. Insulate all vent runs throughunconditioned spaces wherebelow-freezing temperatures areexpected with 1" thick mediumdensity, foil faced fiber glass orequivalent Rubatex/Armaflex insu-lation. For horizontal runs wherewater may collect, wrap the ventpipe with self-regulating, 3 or 5Watt heat tape. The heat tapemust be U.L. listed and installedper the manufacturer’s instruc-tions.

6. All piping between the furnace andthe roof or outside wall penetrationis 2" or 3" as specified in Table 7.Table 7 lists the maximum allow-able length for the exhaust ventpipe and intake air pipe for thenumber of elbows used, based onthe type of termination and fur-nace size.

7. The minimum vent length is 5 feet.

8. All piping through the roof or out-side wall is 2". When using 3"pipe, reduce to 2" within 18" ofthe inside of the roof or outsidewall (except 120,000 BTUHmodel using the RXGY-D04Horizontal Vent Kit).

9. Terminate the vent using one ofthe following termination options.

NOTES:

1 THE COMBUSTION AIR PIPEMUST TERMINATE IN THESAME PRESSURE ZONE ASTHE EXHAUST PIPE.

2 INCREASE THE 12-IN. MINIMUMTO KEEP TERMINAL OPENING ABOVEANTICIPATED LEVEL OF SNOW ACCU-MULATION WHERE APPLICABLE.

3 WHEN 3-IN. DIAM. PIPE IS USED,REDUCE TO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUM OF18 IN. OF 2-IN. PIPE MAY BE USEDBEFORE PASSING THROUGH ROOF.

4 SUPPORT VERTICAL PIPE EVERY 6FEET.

5 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHES WITH 2” PVCPIPE ON 90,000 AND 120,000 BTUHMODELS. REDUCE AND TERMINATETHE LAST 12 INCHES WITH 11/2” PVCPIPE ON 45,000 THROUGH 75,000BTUH MODELS.SEE DETAIL A.

4

1

2

3

5

5

5

DETAIL A

EXHAUSTTERMINATION

12”

5

22

FIGURE 16CONCENTRIC VENT KIT NO. RXGY-E03(DIRECT VENT INSTALLATIONS)

HORIZONTAL INSTALLATION

VERTICAL INSTALLATION

1" MAXIMUM

FIELD-SUPPLIEDSTRAP

NOTE: AIR INTAKE NOTORIENTATION SENSITIVE.

ITEM No. DESCRIPTION

1 2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG

2 4" PVC PIPE SCHEDULE 40 -- 24" LONG

3 3" x 3" x 4" SPECIAL CONCENTRIC FITTING

4 3" x 45° STREET ELBOW (FIELD SUPPLIED)

5 PVC RAINCAP

CONCENTRIC TERMINATIONS

CONCENTRIC VENT KIT NO. RXGY-E03 (SEE FIGURE 16)

This kit is for vertical and horizontalintake air/vent runs. One5-in. diameter hole is required forinstallation. See Figure 13 for the gen-eral layout. Complete installationinstructions are included with the kit.

MAINTAIN 12 IN. MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOWLEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

23

HORIZONTAL TERMINATIONS

STANDARD HORIZONTAL TERMINA-TIONS (SEE FIGURE 17)

NOTE: All furnaces with horizontal airintakes (except those using horizontalconcentric vent kit RXGY-E03) musthave a drain tee assembly and trapinstalled in the combustion air pipe asclose to the furnace as possible. This isto drain any water that may enter thecombustion air pipe to prevent it fromentering the furnace vestibule area.These parts are included in horizontalvent kits RXGY-D02, RXGY-D03 andRXGY-D04.

NOTE: The combustion air and exhaustterminations must be at least 12 inchesabove grade or anticipated snow levels.Use alternate horizontal terminationswhen termination locations are limitedand higher snow levels are anticipated.

NOTE: Ensure the location of the com-bustion air inlet with respect to theexhaust vent terminal complies withFigure 17, detail C.

Combustion Air Piping: Use a 2" PVCcoupling with a wind deflector vane (pro-vided) installed as follows:

1. Install a 2" coupling to the combus-tion air pipe at the outside wall toprevent the termination from beingpushed inward.

2. Cut a 2 1/4" length of 2" PVC pipeand connect this to the coupling.

3. Connect another 2" coupling to theend of the 2 1/4" length of pipe.Terminate this outer coupling 4inches from the wall.

4. Attach the vane in the final 2" cou-pling in the vertical position withPVC cement.

IMPORTANT: To insure proper fur-nace operation, install the vane in thevertical position as shown in Figure17, Detail B. Failure to install the vaneproperly can result in nuisance trip-ping of the pressure switch.

Exhaust Vent Piping:60,000 and 75,000 BTUH models:Install a 2" to 1 1/2" reducer cou-pling at the outside wall to preventthe termination from being pushedinward. Reduce the 2" vent pipeused to penetrate the wall to 1 1/2"PVC for the last 12" of the run.Terminate the 1 1/2" PVC exhaustvent at least 12 inches from the out-side wall.

90,000 through 120,000 BTUHmodels: Install a 2" coupling at theoutside wall to prevent the termina-tion from being pushed inward. Noreduction of the 2" pipe used topenetrate the wall is necessary.Terminate the 2" PVC exhaust ventat least 12 inches from the outsidewall.

FIGURE 17STANDARD HORIZONTAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

ST-A0407-00

12”

4NOTES:

1 SUPPORT HORIZONTALPIPE EVERY FOUR FEET.

2 WHEN 3 IN. PIPE IS USED REDUCETO 2 IN. BEFORE PENETRATINGOUTSIDE WALL.

3 18 IN. MAXIMUM. 2 IN. DIAMETERPIPE MAY BE USED INSIDE THEWALL.

4 DETAIL “A” - EXHAUST TERMINATIONTERMINATE THE LAST 12 INCHESWITH 2” PVC PIPE ON 90,000 AND120,000 BTUH MODELS. REDUCEAND TERMINATE THE LAST 12 INCH-ES WITH 11/2” PVC PIPE ON 45,000THROUGH 75,000 BTUH MODELS.

5 INCREASE THE 12 IN. MINIMUMABOVE GRADE TO KEEP TERMINALOPENINGS ABOVE ANTICIPATEDLEVEL OF SNOW ACCUMULATIONWHERE APPLICABLE.

6 DETAIL “B”, INSTALL WIND DEFLEC-TOR VANE IN 2 IN. PVC COUPLING INVERTACLE POSITION USING PVCSOLVENT.THE COMBUSTION AIR TERMINA-TION MUST BE IN THE SAME PRES-SURE ZONE AS THE EXHAUST TER-MINATION.

DETAIL A

EXHAUSTTERMINATION

DETAIL BCOMBUSTION AIR TERMINATION

2

DETAIL CEXHAUST/INTAKE RELATIONSHIP

1 3

5

6

24

FIGURE 18ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

60" MAX.

PIPESUPPORTSTRAP

3" MAX.NOTE: 3-1/2"MAX. WHEND04 KIT ISUSED.

EXHAUST VENT FOR MODELS WITH INPUT OF60,000 AND 75,000 BTU

EXHAUST VENT21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT(KIT NO. RXGY-D04)

2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000BTUH. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF60,000 AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTUH INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 75,000THRU 120,000 BTUH.USE KIT NO. RXGY-D02 WHEN 2" PIPEIS USED BETWEEN FURNACE AND OUT-SIDE WALL. USE KIT NO. RXGY-D03WHEN 3" PIPE IS USED.

I339

12" FROM W

ALL

ALTERNATE HORIZONTAL TERMI-NATIONS (See Figure 18)

NOTE: This method is NOTALLOWED on downflow furnaces.

NOTE: The combustion air andexhaust terminations must be at least12 inches above grade or anticipatedsnow levels. Alternate horizontal ter-minations allow the combustion airand exhaust terminations to be raiseda maximum of 60 inches above thewall penetrations to maintain therequired clearance.

NOTE: If combustion air vent pipe isextended more than 24 inches, insu-late the vent pipe between the twooutside 90° elbows with closed cellinsulation such as rubatex, armaflexor equivalent.

NOTE: Ensure the location of thecombustion air inlet with respect tothe exhaust vent terminal complieswith Figure 18.

Combustion Air Piping: Use a 2" PVCelbow with a wind deflector vane (pro-vided) installed as follows:

1. Install a 2" elbow to the combustionair pipe at the outside wall to preventthe termination from being pushedinward.

2. Cut an adequate length of 2" PVCpipe as needed to clear the antici-pated snow level and connect this tothe elbow.

3. Connect another 2" elbow to theend of the pipe such that the inlet isfacing away from the wall. This outercoupling must terminate 4 inchesfrom the wall.

4. Attach the vane in the final 2" elbowin the vertical position with PVCsolvent.

IMPORTANT: To insure proper fur-nace operation, the supplied vanemust be installed in the vertical posi-tion as shown in Figure 18, Detail A.

Exhaust Vent Piping:

1. Install a 2" elbow to the exhaust ventpipe at the outside wall to prevent thetermination from being pushedinward.

2. Cut an adequate length of 2" PVCpipe as needed to insure proper loca-tion of the exhaust vent terminationwith respect to the combustion airinlet and connect this to the elbow.

3. Connect another 2" elbow to the endof the pipe such that the inlet is fac-ing away from the wall.

Exhaust Vent Termination:

60,000 and 75,000 BTUH models:Reduce the 2" vent pipe used topenetrate the wall and extend theterminations to 1 1/2" PVC for thelast 12" of the run. Install a 2" to 11/2" reducer bushing in the last 2"elbow. Connect a length of 1 1/2"PVC pipe such that the exhaust ventterminates at least 12 inches fromthe outside wall. See Figure 18,Detail A.90,000 through 120,000 BTUH mod-els: No reduction of the 2" pipe usedto penetrate the wall is necessary.Terminate the 2" PVC exhaust ventat least 12 inches from the outsidewall. 120,000 BTUH model with theRXGY-D04 Horizontal Vent Kit:Venting and terminations install thesame as above except the 2" pipeand connectors are replaced with 21/2" pipe and connectors.

DETAIL A

DETAIL CEXHAUST/INTAKE RELATIONSHIP

25

LOCATION REQUIREMENTSHORIZONTAL DIRECT VENTS

THE COMBUSTION PRODUCTSAND MOISTURE IN THE FLUEGASES WILL CONDENSE ASTHEY LEAVE THE TERMINA-TION. THE CONDENSATE CANFREEZE ON THE EXTERIORWALL, UNDER THE EAVES ANDON SURROUNDING OBJECTS.SOME DISCOLORATION TO THEEXTERIOR OF THE BUILDING ISTO BE EXPECTED. HOWEVER,IMPROPER LOCATION ORINSTALLATION CAN RESULT INSTRUCTURAL OR EXTERIORFINISH DAMAGE TO THE BUILD-ING AND MAY RECIRCULATEPRODUCTS OF COMBUSTIONINTO THE COMBUSTION AIRTERMINAL AND FREEZE.NOTE: In Canada vent terminationsmust be in accordance with the currentCSA-B149 Gas Installation Code and/orlocal codes.

The vent must be installed with the fol-lowing minimum clearances. SeeFigures 19 and 20.

1. Locate the bottom of the vent ter-minal and the air inlet at least 12inches above grade. Increase the12-in. minimum to keep the termi-nal openings above the level ofsnow accumulation, where applica-ble.

2. Do not terminate the vent over pub-lic walkways or over an area wherecondensate or vapor could create anuisance or hazard.

3. Locate the vent terminal at leastone foot from any opening throughwhich flue gases could enter abuilding.

4. Locate the vent terminal at least 3feet above any forced air inletlocated within 10 feet, except thecombustion air inlet of a direct ventappliance.

5. Allow the vent terminal minimumhorizontal clearance of 4 feet fromelectric meters, gas meters, regula-tors and relief equipment.

6. Locate the furnace combustion airinlet a sufficient distance from thevent of any other gas or fuel burn-ing appliance or electric clothesdryer to prevent recirculation of theflue gases into the furnace com-bustion air inlet. The only exceptionto this requirement is the case ofmultiventing two or more furnaces,which is covered in the section onmultiventing in these instructions.

In addition to the minimum clearanceslisted above, the vent location shouldbe governed by the following guide-lines.

1. Do not terminate under any kind ofpatio or deck. If running the ventunder a deck, insulate it to insureno condensate freezes and blocksthe pipe.

2. Do not terminate behind any areathat may allow the flue products tobecome stagnant and recirculate.

3. Do not locate on the side of abuilding with prevailing winterwinds. This will help prevent mois-ture from freezing on walls andoverhangs (under eaves).

4. Do not extend vent directlythrough brick or masonry sur-

faces. Use a rust-resistant sheetmetal or plastic backing platebehind vent. See Figure 16.

5. Do not locate too close to shrubsas condensate may stunt orkill them.

6. Minimum vertical clearances of 1foot are recommended for over-hangs up to 1 foot horizontal.The vertical clearance should beincreased equally for each addi-tional increase in horizontal over-hang to a maximum verticalclearance of 6 feet.

7. Caulk all cracks, seams andjoints within 6 feet horizontallyas well as 6 feet above andbelow vent. See Figure 16.

FIGURE 19MOISTURE ZONES

! CAUTION

2 FT. SQ. SHEET METAL PLATE ON BRICK ORMASONRY SURFACE RECOMMENDED, BUTNOT REQUIRED BY CODE.

26

FIGURE 20DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

e In

stal

latio

n C

ode

Nat

iona

l Fue

l Gas

Cod

e

Can

adia

n In

stal

lati

on

sU

S In

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

27

FIGURE 22TWO FURNACE VENTING THROUGH WALL

FIGURE 21TWO FURNACE VENTING THROUGH ROOF

8. Painted surfaces must be soundand in good condition with nocracking, peeling, etc. Paintedsurfaces will require mainte-nance.

9. Do not expose 3" x 2" reducer/bushing to outdoor ambient tem-peratures.

MULTIVENTING

IF VENTING TWO OR MORE FUR-NACES NEAR EACH OTHER ISREQUIRED, EACH FURNACEMUST BE INDIVIDUALLY VENTED– NO COMMON VENTING IS PER-MITTED. See Figures 18 and 19 forpositioning of the terminations. Whenmore than two furnaces are to bevented, there must be at least 4 feetbetween the first two furnaces andthe third, etc.

EXHAUST VENTMODELS 06-07TO BE REDUCED TO1-1/2” PVC LAST 12”.

3” MININUM24” MAXIMUM

CONNECTING TOFURNACEIMPORTANT: Clean and deburr allpipe cuts. The shavings must not beallowed to block the exhaust, inlet orcondensate drain pipes.

IMPORTANT: When indoor combus-tion air is used, the inlet air openingat the furnace must be protectedfrom accidental blockage. On down-flow models, install a double elbow inthe top inlet air opening. See Figure25.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MINIMUM 12" ABOVE AVERAGE SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

SEE CONCENTRICVENT SECTION ON PAGE 20 FOR MORE INFORMATION.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MAXIMUM 1" DISTANCE

FROM WALL

MINIMUM 12" ABOVE GRADE

6' MINIMUM10' RECOMMENDED

SEE CONCENTRIC VENT SECTION ON PAGE 20 FOR MORE INFORMATION.




28

FIGURE 23UPFLOW MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION

I515

FIGURE 24UPFLOW MODELS -- COMBUSTION AIR FITTING

1337

➤ FIGURE 25DOWNFLOW/HORIZONTAL MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION

UPFLOW MODELSThe exhaust air pipe connection is a 2-in. female PVC pipe fitting extendingthrough the left side of the furnace topplate. See Figure 23. This opening has aprotective cap which should be removedjust prior to installing the exhaust pipe.When 2-in. pipe is used, connect itdirectly to this fitting. When 3-in. pipe isused, connect a 2 to 3-in. coupling tothis fitting with a short piece of 2-in. PVCpipe.

The inlet combustion air connectionis at the right side of the top plate.An alternate combustion inlet air connec-tion may be made on the right side ofthe jacket. The alternate connectionopening has a plastic cap. A combustioninlet air connection fitting is supplied withthe furnace and it must be installed inthe furnace by screwing it into the open-ing. Make sure the rubber “O-ring” sup-plied with the furnace is used with thisfitting. See Figures 23 and 24.

IMPORTANT: When using indoor com-bustion air, the furnace air opening mustbe protected from accidental blockage.Install a 2-inch 90° elbow pointing down-ward on the side or a double elbowpointing downward in the top opening.See Figure 24.

➤ DOWNFLOW/HORIZONTALMODELS

NOTE: Combustion air inlet and exhaustoutlet air pipes are reversed for down-flow from that of upflow.

The exhaust pipe connection is a 2-in.PVC pipe fitting extending through theright side of the furnace top cover. Thisopening has a protective cap whichshould be removed just prior to installingthe exhaust pipe. When 2-in. pipe isused, connect it directly to this fitting.When 3-in. pipe is used, connect with a2- to 3-in. coupling directly to the 2-in.pipe.

The combustion inlet air connection is a2-in. extruded hole on the left side of thetop plate. When a 2-in. pipe is used,attach a 2-in. PVC coupling over thishole with RTV sealant and also add twosheet metal screws through the couplinginto the extrusion to secure it in place,and add the required piping. When 3-in.pipe is required, use a 2- to 3-in. cou-pling and add the required piping. SeeFigure 25

IMPORTANT: Always pre-drill holesbefore securing with screws. Using self-tapping screws without first pre-drillingcauses the PVC fitting to crack.

“O” RING

TOP PLATE

VENT CAP/PLUG

EXHAUST AIR PIPE

EXHAUST TRANSITION

CONNECTOR

CONDENSATE TRAP

INDUCED DRAFTBLOWER

COMBUSTIONAIR ADAPTER

NOTE:WHEN COMBUSTION AIR INLET IS INOPTIONAL POSITION SWAP LOCATIONOF INLET AIR ADAPTER AND “O” RINGWITH PLUG.

PLUG OPT. COMBUSTIONAIR INLET POSITION

ATTACH DOUBLE ELBOW TO TOP INLET AIROPENING OR 90° ELBOW TO SIDE INLET AIROPENING TO PREVENT ACCIDENTAL BLOCKAGEOF INTAKE OPENING. PLUG OPENING NOT USED.

EXHAUSTTOP INLETAIR OPTION

2” PVC DOUBLEELBOW

2” PVC ELBOW

SIDE INLET AIROPTION

UPFLOW

ATTACH DOUBLE ELBOW TO INTAKE AIR COLLAR ANDSECURE WITH TWO SHEET METAL SCREWS TO PREVENTACCIDENTAL BLOCKAGE OF INTAKE AIR OPENING.

2” PVC DOUBLEELBOW

EXHAUSTINLET AIR

29

CONDENSATE DRAIN/OPTIONAL NEUTRALIZERFIGURE 26UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS.FREEZING OF CONDENSATE CANCAUSE PROPERTY DAMAGE.IMPORTANT: Do not connect into a com-mon drain line with an air conditionerevaporator coil drain located below thefurnace. A blocked or restricted drain linecan result in overflow of the coil pan andnegate the furnace blocked-drain shutoffcontrol.➤ IMPORTANT: If installing the unit overa finished ceiling or living area, be certainto install an auxiliary condensate drainpan under the entire unit extending outunder the condensate tee. With the mini-mum 51⁄2" riser for upflow models or 13⁄4" for downflow models installedabove the tee, a blocked drain will resultin overflow from the riser. if the furnace isinstalled in an attic, crawlspace or otherarea where freezing temperatures mayoccur, the furnace drain can freeze whileshut off for long periods of time.

If required by local codes, install a con-densate neutralizer cartridge in the drainline. Install cartridge in horizontal positiononly. Also install an overflow line if routingto a floor drain (see Figure 23). If avail-able, install a condensate pump that isresistant to acidic water. Pumps are avail-able from your local distributor. If pumpused is not resistant to acidic water, acondensate neutralizer must be usedahead of the pump. The condensatepump must have an auxiliary safetyswitch to prevent operation of the furnaceand resulting overflow of condensate inthe event of pump failure. The safetyswitch must be wired through the “R” cir-cuit only (low voltage) to provide operationin either heating or cooling modes.

UPFLOW MODELSThe condensate drain trap is located inthe blower compartment on the left- handside of the jacket. A short piece of 1⁄2-in.PVC pipe and a 1⁄2-in. tee are provided.Connect the 1⁄2-in. pipe to the elbow onthe trap and the tee to this pipe so thatthe open end is upward. Run a drain tubefrom the bottom of the tee to a floor drainor condensate pump. IMPORTANT: If installing the unit over afinished ceiling or living area, be certainto install an auxiliary condensate drainpan under the entire unit extending outunder the condensate tee.IMPORTANT: There are two optionswhen choosing a height for the conden-sate riser:

! CAUTION

AO51601

➤ FIGURE 27DOWNFLOW CONNECTION

A085001

NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE: SEE DOWNFLOWMODEL NOTES

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)


CONDENSATE TRAP

CONDENSATE TRAP

DRAIN LINE

DRAIN LINE

TO FLOOR DRAIN OR CONDENSATE PUMP

TO FLOOR DRAIN OR CONDENSATE PUMP

NEUTRALIZER CARTRIDGE(OPTIONAL)

NEUTRALIZER CARTRIDGE(OPTIONAL)

30

FIGURE 28UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

CONDENSATE OVERFLOW: With a51⁄2 inch riser installed above the tee, ablocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To cause thefurnace to shut down when a blockeddrain is present, install a riser which isa minimum of 1013⁄16”. If the furnace isinstalled in an attic, crawlspace orother area where freezing tempera-tures may occur, the furnace draincan freeze while shut off for long peri-ods of time.Use a solvent cement that is compati-ble with PVC material. Cut the drainhoses to the appropriate length andconnect to the trap with hose clamps.Tighten the clamps with pliers andcheck for leaks after attaching.

DOWNFLOW MODELSIMPORTANT: There are two optionswhen choosing a height for the con-densate riser:CONDENSATE OVERFLOW: With a13⁄4 inch riser installed above the tee, ablocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To cause thefurnace to shut down when a blockeddrain is present, install a riser which isa minimum of 51⁄2”. If the furnace isinstalled in an attic, crawlspace orother area where freezing tempera-tures may occur, the furnace draincan freeze while shut off for long peri-ods of time.Use a solvent cement that is compati-ble with PVC material.

REVERSING THE TRAPUPFLOW MODELSThe trap may be moved to the rightside for right side drainage. Open theknockout for the drain on the right sideof the cabinet. Remove the bracketholding the trap from the left side.Seal the left side drain hole with aplug provided in the cloth bag with thefurnace. Position the mounting bracketand trap so that the drain elbow iscentered in the hole on the right. SeeFigure 28.Drill two holes in the cabinet to mountthe bracket. Mount the trap and brack-et to the right side with the drainelbow pointing through the knockout.Connect the 1⁄2" pipe and tee as notedabove. Route the drain hoses behindthe top of the electric box, cut to theappropriate length, and connect to thetrap with hose clamps.IMPORTANT: Do not connect into acommon drain line with an air condi-tioner evaporator coil drain locatedabove the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked drain shutoff control.

➤ DOWNFLOW MODELSTo convert to left side drainage, firstremove the drainage hoses from thetrap. Remove the trap from its mount-ing bracket, rotate it 180°, and mountin place with the drainage elbow point-ing to the left. Reattach the drainhoses. Remove the plastic drainageknockout from the left side. SeeFigure 29.IMPORTANT: When changing to theleft side, interchange the rubber grom-met on the right side with the holeplug on the left side. The hole plugmust be in place to assure that thecontrol compartment is sealed.A length of 1⁄2" PVC pipe is providedfor left hand drainage. Glue one endof the pipe to the elbow in the trap.Cut the pipe so that it extends throughthe left cabinet side one inch. Connectthe 1⁄2" tee to the pipe with a 13⁄4" riserand drain tube as listed above. Use

A051701

the plastic plug from the left sidedrainage knockout to seal the rightside drainage knockout.IMPORTANT: Do not connect into acommon drain line with an air condi-tioner evaporator coil drain locatedabove the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked drain shutoff control.

FILLING THE TRAPFILL THE TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. Do this by removing thedrain hose from the trap or from theconnection to the secondary coil.Pour about a cup of water into thevent trap. Any excess water flows intothe house drain when the trap is full.

➤ FIGURE 29DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

51/2” MINIMUMHEIGHT OPEN

END

A086301

31

CONDENSATE DRAINFOR HORIZONTALINSTALLATIONIMPORTANT: When installing the -GGD furnace in the horizontal config-uration, a special kit must be used toconvert the furnace for horizontalinstallation. The necessary kits are list-ed here.


MODEL KIT(-)GGD-06 RXGY-G01(-)GGD-07 RXGY-G02(-)GGD-09 RXGY-G03(-)GGD-10 RXGY-G04(-)GGD-12 RXGY-G05

Refer to Figure 31 for Steps 1-5.

1. This unit is shipped factory readyfor downflow installation. The con-densate trap assembly and drainhoses require conversion for hori-zontal installation.Remove the existing condensatetrap with the unit in the uprightposition.

2. Remove the burner compartmentdoor from the unit.

3. Remove the two screws from theright side of the furnace jacketwhich support the trap mountingbracket ➁ . Remove the two plas-tic plugs on either side of the trapoutlet hole and discard.

4. Remove the (L-shaped) clear,ribbed vinyl drain tube (3) fromthe top of the existing trap (1).Do not disconnect the short endfrom the furnace collector box.

5. Remove the clear ribbed draintube (4) from the existing trap (3)and the exhaust transition (5).Discard this tube. Retain theclamps for future use. Additionalclamps are provided in the partsbag if any clamps are damagedduring conversion process.

NOTE: The following steps shouldtake place with the furnace in thehorizontal position.Refer to Figure 32 for Steps 6-11.6. Locate the parts bag in the burner

compartment. Install two plasticplugs (6) in the side of the jacketfrom bottom side up.

7. Fill the replacement trap assem-bly (7) with 1/2 cup of water.

8. Attach the self-adhesive gasket(8) onto the trap assembly so thatthe gasket holes on the gasketline up with the holes on the trapassembly.

9. Remove plastic plugs from thetwo screw holes to be used in thehorizontal position (see Figure32). Insert the trap assembly withgasket up through the existinghole in the jacket and secure frominside the jacket. Use two screwsprovided. Screw down into thetwo “ears” molded into either sideof the trap. Snug the trap assem-bly against the furnace jacketcompressing the gasket slightly toeliminate any air leaks. Do notovertighten!

10. Attach the black molded rubber90° elbow (9) to the straight spouton the trap top using a blacknylon clamp (10). Attach the otherend of the rubber elbow to thespout (1) located on the exhausttransition (5) using a black nylonclamp

11. Attach the end of the ribbed tube(3) to the 45° elbow molded intothe top of the trap assemblyusing a black nylon clamp.IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks after conver-sion is complete.

12. Connect a 51⁄2� riser to the top ofthe tee and run a drain tube fromthe bottom of the tee to a floordrain or condensate pump. Usea solvent cement that is compati-ble with PVC material.

FIGURE 30HORIZONTAL CONDENSATE DRAIN

32

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ST-A0872-01

33

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPEDAT THE FACTORY FOR USE ONNATURAL GAS ONLY. CONVER-SION TO LP GAS REQUIRES ASPECIAL KIT SUPPLIED BY THEDISTRIBUTOR OR MANUFAC-TURER. MAILING ADDRESSESARE LISTED ON THE FURNACERATING PLATE, PARTS LISTAND WARRANTY. FAILURE TOUSE THE PROPER CONVER-SION KIT CAN CAUSE FIRE,CARBON MONOXIDE POISON-ING, EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

See the conversion kit index sup-plied with the furnace. This indexidentifies the proper LP GasConversion Kit required for eachparticular furnace.

IMPORTANT: Any additions, changesor conversions required for the furnaceto satisfactorily meet the applicationshould be made by a qualified installer,service agency or the gas supplier,using factory-specified or approvedparts.

IMPORTANT: Connect this furnaceonly to gas supplied by a commercialutility.

IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) are rec-ommended in all applications, and theirinstallation should be in accordancewith the manufacturer’s recommenda-tions and/or local laws, rules, regula-tions or customs.

GAS PIPINGInstall the gas piping according to alllocal codes and regulations of the utili-ty company.

If possible, run a separate gas supplyline directly from the meter to the fur-nace. Consult the local gas companyfor the location of the manual mainshut-off valve. The gas line and man-ual gas valve must be adequate insize to prevent undue pressure dropand never smaller than the pipe size

! WARNING

FIGURE 33GAS PIPING -- UPFLOW INSTALLATION

STA0518-01

TOP VIEW OF GAS LINE AND VALVEIN OPTIONAL POSITION

OPTIONAL GAS LINEPOSITION

PLUG(IN NORMALPOSITION)

MANIFOLDPRESSURE TAP

MANIFOLD

GROMMET

GAS VALVEDRIP LEG

4 TO 5 FEETABOVE FLOORREQ’D BY SOMEUTILITIES.

IGNITER

NOTE: WHEN GAS LINE IS INOPT. POSITION, SWAP LOCA-TION OF GROMMET ANDPLUG.

MAIN GAS VALVE

IMPORTANT: Do not run a flexible gas connector inside the unit.

A087301-01-00

TOP VIEW OF GAS LINE AND VALVEIN OPTIONAL POSITION

BURNERS

GROMMET(IN NORMALPOSITION)

UNION(TYPICAL INSTALLATION)

➤ FIGURE 35GAS PIPING -- DOWNFLOW INSTALLATION

MAIN GAS VALVE

GAS VALVE

DRIP LEG

BURNERSUNIONIGNITOR

MANIFOLD

GROMMET


NOTE:WHEN GAS LINE IS IN OPT.POSITION, SWAP LOCATIONOF GROMMET AND PLUG.

PLUG(IN NORMALPOSITION)

GROMMET(IN NORMALPOSITION)

4 TO 5 FT.ABOVEFLOOR

REQ’D BYSOME

UTILITIES.

A087401-01

➤ FIGURE 34GAS PIPING -- HORIZONTAL INSTALLATION

MANUAL GAS VALVE

GAS VALVE

DRIP LEG

BURNERS

IGNITOR

MANIFOLD


34

GAS PRESSURENatural gas supply pressure shouldbe 5" to 10.5" w.c. LP gas supplypressure should be 11" to 13" w.c.This pressure must be maintainedwith all other gas-fired appliances inoperation.

The minimum supply pressure to thegas valve for proper furnace inputadjustments is 5" w.c. for natural gas,however 6" to 7" is recommended. Theminimum supply pressure is 10.5" w.c.for LP gas.

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAMEOR ANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURETO ADHERE TO THIS WARNINGCAN CAUSE A FIRE OR EXPLO-SION RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

To check for gas leakage, use anapproved chloride-free soap and watersolution, an electronic combustible gasdetector, or other approved method.

! WARNING

FIGURE 36GAS VALVE

MANUAL CONTROL

to the combination gas valve on thefurnace. Refer to Table 8 for the recom-mended gas pipe size for natural gasand Table 9 for L.P. See Figures 27 &28 for typical gas pipe connections.

Install a ground joint union inside thecabinet to easily remove the controlvalve assembly. Install a manualshut-off valve in the gas line outsidethe furnace casing. The valve shouldbe readily accessible to turn the gassupply on or off. Install a drip leg in thegas supply line as close to the furnaceas possible. Always use a pipe com-pound resistant to the action of liquefiedpetroleum gases on all threaded con-nections.

IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve.

Any strains on the gas valve canchange the position of the gas orifices inthe burners. This can cause erratic fur-nace operation.

IMPORTANT: Do not run a flexible gasconnector inside the unit. If local codesallow the use of a flexible gas applianceconnector, always use a new listed con-nector. Do not use a connector whichhas previously serviced another gasappliance. Massachusetts law requiresthat all flexible gas connectors be lessthan 36”.

The gas pipe grommet in the cabinetdoes not seal around a flexible gas con-nector. It is important to have allopenings in the cabinet burner com-partment sealed for proper furnaceoperation.

IMPORTANT: Ensure that the furnacegas control valve is not subjected tohigh gas line supply pressures (13.5”w.c. or above).

DISCONNECT the furnace and its indi-vidual shut-off valve from the gas supplypiping during any pressure testing thatexceeds 1/2 PSIG (3.23 kPa or 13"w.c.).

GAS VALVEThis furnace has a 24-volt operatedvalve. It has ports for measuringsupply pressure and manifold pres-sure. A manual control is on thevalve body. It can be set to only the“ON” or “OFF” positions. SeeFigure 36.

35

TABLE 8NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. andspecific gravity of 0.60 (natural gas).

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170

1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubicfeet per hour required for the gas input rating of the furnace. By formula:

Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas(BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

TABLE 9LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11inches water column inlet pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 633/4 567 393 315 267 237 217 196 182 173 162 146 1321 1,071 732 590 504 448 409 378 346 322 307 275 252

1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 5111-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.

LP COPPER TUBE SIZING TABLESizing between single or second stage (low pressure) regulator and appliance. Maximum capacity of pipe in thousands of BTUper hour of undiluted propane gases (at 11" w.c. setting).

Outside Diameter Length of Pipe, FeetCopper Tubing,Type L 10 20 30 40 50 60 80 100 125 150

3/8" 49 34 27 23 20 19 16 14 11 10

1/2" 110 76 61 52 46 42 36 32 28 26

5/8" 206 141 114 97 86 78 67 59 52 48

3/4" 348 239 192 164 146 132 113 100 89 80

7/8" 536 368 296 253 224 203 174 154 137 124

36

LP CONVERSIONIMPORTANT: LP gas from trucks usedto transport liquid-based fertilizers cancontain chemicals that will damage thefurnace. Verify that your gas supplierdoes not use the same truck to trans-port materials other than LP.

This furnace is shipped from the facto-ry for use on natural gas only. For useon LP gas, a proper conversion isrequired.

Conversion of this furnace for use onLP gas requires conversion kit RXGJ-FP07 for U.S. and RXGJ-FP08 forCanada. This kit includes an LP gasvalve.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT)NEED TO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

NOTE: Order the correct LP conver-sion kit from the furnace manufacturer.Furnace conversion to LP gas must beperformed by a qualified installer, ser-vice agency, or the gas supplier.

To change orifice spuds for either con-version to LP or for elevation:

1. Shut off the manual gas valve anddisconnect the gas line at theunion ahead of the unit gas valve.

SUPPLY-LINEPRESSURE TAP

2. Remove the gas valve and mani-fold assembly.

3. Replace the orifice spuds.

4. Remove the natural gas valve fromthe manifold assembly and replacewith the LP valve included in thekit.

5. Re-attach the manifold assembly tothe unit and connect the gas line tothe gas valve.

6. Place the conversion label, includ-ed in the kit, adjacent to the CSArating plate.

FIGURE 37SUPPLY-LINE PRESSURE TAP

7. Check unit for leaks

8. Follow lighting instructions toput the furnace into operation.

Consult Table 11, if there is anyquestion concerning orifice sizing.

NOTE: No LP orifices are includedin the kit. LP orifices must be select-ed based on the altitude of theinstallation. See orifice chart.

CAUTION!

37

SETTING GAS PRESSUREA properly calibrated pressure gaugeor U-Tube manometer is required foraccurate gas pressure measure-ments.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDAND THAT THE SIZE OF THEBURNER ORIFICES BE RE-CAL-CULATED BASED ON ELEVATIONAND GAS HEATING VALUE. THEBURNER ORIFICES MAY (OR MAYNOT) NEED TO BE CHANGED. SEETHE SECTION TITLED “HIGH ALTI-TUDE INSTALLATIONS” OF THISBOOK FOR INSTRUCTIONS.

Supply Gas Pressure Measure-ment.

1. With gas shut off to the furnace at the manual gas valve outside the unit, remove the linepressure tap plug on the gas valve. See Figure 30.

2. Connect a U-Tube manometer tothe pressure tap.

3. Turn on the gas supply andoperate the furnace at 100% andall other gas-fired units on thesame gas line as the furnace.

4. Note or adjust the supply-linepressure to give:

A. 5" - 10.5" w.c. for natural gas.

B. 11" - 13" w.c. for LP gas.

5. Shut off the gas at the manualgas valve and remove theU-Tube manometer.

6. Replace the supply-line pressuretap plug before turning on thegas.

If the supply-line pressure is abovethese ranges, install an in-line gasregulator to the furnace for naturalgas units. With LP gas, have the LPsupplier reduce the supply-line pres-sure at the regulator.

If supply-line pressure is below theseranges, either remove any restrictions

FIGURE 38MANIFOLD PRESSURE TAP LOCATION

in the gas supply piping or enlargethe gas pipe. See Tables 8 and 9.With LP gas, have the LP supplieradjust the supply-line pressure at theregulator.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDAND THAT THE SIZE OF THEBURNER ORIFICES BE RE-CAL-CULATED BASED ON ELEVATIONAND GAS HEATING VALUE. THEBURNER ORIFICES MAY (OR MAYNOT) NEED TO BE CHANGED. SEETHE SECTION TITLED “HIGH ALTI-TUDE INSTALLATIONS” OF THISBOOK FOR INSTRUCTIONS.

➤ MANIFOLD GAS PRESSURE MEASUREMENT.

1. With the gas to the unit shut offat the manual gas valve, removethe outlet pressure tap plug inthe gas valve. See Figure 31.

2. Connect the positive pressurehose to the pressure tap.

3. Note the manifold gas pressureto be:

A. 3.5" w.c. (±.3) for naturalgas .

B. 10.0" w.c. ( ±.5) for LP gas.

4. To adjust the pressure regulator,remove the regulator cap.

NOTE: Only small variations ingas pressure should be made byadjusting the pressure regulator.

5. Turn the adjustment screw, usinga 3/32" allen wrench, clockwise toincrease pressure, or counter-clockwise to decrease pressure.See Figure 32.

6. Check manifold gas pressure.

7. Repeat step 5 & 6 if needed.

8. Securely replace the regulatorcap.

NOTE: Shut off gas at the manu-al gas valve and remove the U-Tube manometer.

9. Replace the manifold pressuretap plug before turning onthe gas.

NOTE: Do not use gas valve pres-sure adjustment as a means toadjust temperature rise. The blowermotor will change speed to maintaina reasonably constant temperaturerise.

MANIFOLD PRESSURE TAP

FIGURE 39GAS VALVE PRESSURE ADJUSTMENT (3/32" ALLEN WRENCH)

REGULATOR CAP

CAUTION!CAUTION!

38

the electrical disconnect to the junctionbox on the left side of the furnace, insidethe blower compartment. See Figure 33.For the proper connection, refer to theappropriate wiring diagram located on theinside cover of the furnace control boxand in these instructions.

NOTE: The electrical junction box maybe moved to the right side if necessary. Aknockout is provided. Seal the oppositehole with plug provided.

IMPORTANT: 120 vac terminal and neu-tral terminal polarity must be observedwhen making field connections to the fur-nace. The ignition control WILL not senseflame if 120 vac and neutral terminalsreversed.

Make all electrical connections inaccordance with the latest edition ofthe National Electrical CodeANSI/NFPA70 – or in Canada, theCanadian Electrical Code Part 1-CSA Standard C22.1 and local codeshaving jurisdiction.

These may be obtained from:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

Canadian Standards Association178 Rexdale BoulevardRexdale, Ontario, Canada M9W 1R3

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANY ELECTRI-CAL CONNECTIONS. FAILURETO DO SO CAN CAUSE ELECTRI-CAL SHOCK RESULTING IN PER-SONAL INJURY OR DEATH.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/NFPA70-, OR IN CANADA, THECANADIAN ELECTRICAL CODE,CSA-C22.1 OR LOCAL CODESTHAT APPLY. A GROUND SCREWIS PROVIDED IN THE JUNCTIONBOX. FAILURE TO PROPERLYCONNECT THE GROUND WIRECAN CAUSE ELECTRICALSHOCK RESULTING IN PERSON-AL INJURY OR DEATH.

THIS FURNACE IS EQUIPPEDWITH A BLOWER DOOR SAFETYSWITCH. DO NOT DISABLE THISSWITCH. FAILURE TO FOLLOWTHIS WARNING CAN RESULT INELECTRICAL SHOCK, PERSON-AL INJURY OR DEATH.

IMPORTANT: The furnace must beinstalled so that the electrical compo-nents are protected from water (conden-sate).

A grounding wire is provided to connectto the incoming grounding wire fromline power. The furnace must be perma-nently grounded in accordance with allnational and local codes.

Before proceeding with the electricalconnections, be certain that the servicepanel voltage, frequency and phase cor-responds to that specified on the fur-nace rating plate. Maximum over-currentprotection is 15 amperes.

Use a separate, fused branch electricalcircuit containing a properly sized fuse orcircuit breaker. Run this circuit directlyfrom the main switch box to an electricaldisconnect that is readily accessible andlocated near the furnace. Connect from

! WARNING

! WARNING

! WARNING

FIGURE 40JUNCTION BOX LOCATION

UPFLOWMODELS

➤ DOWNFLOW/HORIZONTAL

MODELS

39

FIGURE 4124-VOLT TERMINALS

THERMOSTAT WIRINGNOTE: Do not use 24 volt control wiresmaller than No. 18 AWG.

Wire all thermostats to the 24V con-nections on the integrated furnace con-trol. See Figures 34, 35, and 36.

NOTE: A larger wire gage may be berequired for longer lengths of thermo-stat wire.

For proper installation of the VariableOutput Thermostat, follow the“Thermostat Installation, Programmingand Troubleshooting Manual” includedas section II of this manual. For properinstallation of a Single-Stage or Two-Stage Thermostat, see the InstallationInstructions included with the thermo-stat.

➤ FURNACE OPERATION USINGMODULATING, SINGLE-STAGE, ANDTWO-STAGE THERMOSTATS

The modulating furnace with the UTElectronic Controls IFC is also capableof operating with a single-stage or atwo-stage thermostat as well as themodulating thermostat. Furnacesequipped with part # 62-24174-01 (rev-02 or newer) or 62-24174-02 (all revi-sions) will operate with either single-stage or two-stage thermostats as amodulating system using an algorithmthat utilizes three distinct firing rates;40%, 65% and 100% of the furnaceheating capacity (See below for opera-tion of each).

Figures 42, 43, and 44 detail how towire the modulating furnace for opera-tion with a modulating thermostat, asingle-stage thermostat and a two-stage thermostat respectively.

➤ FURNACE OPERATION WITH AMODULATING THERMOSTATAs described previously in this manual,operation with a modulating thermostatwhen installed as shown in Figure 42is fully modulating between 40% and100% of furnace capacity. The firingrate is first determined by the thermo-stat and then sent to the furnace. Thisis the optimum mode of operation andwill give the best temperature controlwith minimal temperature variationfrom the desired set point.

➤ FURNACE OPERATION WITH ASINGLE STAGE THERMOSTAT To operate the furnace with a single-stage thermostat, set switches 1 & 2 ofSW2 (See Figure 47) to the “OFF”position. Note that these switchesshould be in the “OFF” position fromthe factory. The lack of the modulating“V” signal will automatically be sensedas a single-stage thermostat and thefurnace will operate accordingly.

ELECTRICAL CHECKSLine Power CheckThe furnace must have a nominal 115volt power supply for proper opera-tion. If there is not a consistent powersupply, contact a licensed electricianto correct the problem.

1. With the blower compartment dooroff, manually hold the push buttondoor switch in.

2. Call for heat at the thermostat.3. With the unit operating, use a volt-

meter to measure the voltage fromany 120 VAC terminal to any neu-tral connection.

4. The voltage should be a nominal115 volts (acceptable 105-120VAC).

This test should be made with the unitin full operation.

Polarity CheckProper line voltage polarity, or phas-ing, is a must for this furnace to oper-ate. Use a volt meter to make thischeck.

1. With the blower compartment dooroff, manually hold the push buttondoor switch in.

2. Use a voltmeter to measure thevoltage from any 120 VAC terminalto any bare metal ground on thefurnace.

3. The voltage should be a nominal115 volts (acceptable 105-120VAC).

4. Use a voltmeter to measure thevoltage from any neutral terminalto the bare metal ground on thefurnace.

5. The voltage should be approxi-mately (0) volts.

6. If the voltage from any 120 VACterminal to ground is approximate-ly zero (0) volts and the voltagefrom a neutral to ground is a nomi-nal 115 volts, the polarity isreversed.

7. To correct the problem, eitherreverse the hot and neutral wiresto the furnace or have a licensedelectrician check the buildingwiring.

Control Voltage Check1. With the blower compartment

door off, manually hold the pushbutton door switch in.

2. Call for heat at the thermostat.3. With the unit operating, use a

voltmeter to measure the voltagefrom control voltage terminal “W”to terminal “C” on the furnacecontrol board.

4. The voltage should be a nominal24 volts (Acceptable 105-120VAC).

This test should be made with theunit in full operation.

With a single stage thermostat(installed as shown in Figure 43),during a call for heat, the furnace willoperate as follows:Phase 1: 0 to 5 minutes = 40% offurnace capacityPhase 2: 5 to 12 minutes = 65% offurnace capacityPhase 3: After 12 minutes = 100 %of furnace capacity

NOTE: If the call for heat ends dur-ing any phase, the furnace will termi-nate immediately at the firing rate ofthat phase.

If switches 1 & 2 of SW2 are in the“ON” position (See Figure 47), thefurnace will always operate at 40%with a single stage thermostatinstalled as shown in Figure 36.THIS CONFIGURATION IS NEI-THER RECOMMENDED NORAPPROVED.

40

FIGURE 42WIRING DIAGRAM FOR MODULATING HEAT

FIGURE 43WIRING DIAGRAM FOR SINGLE-STAGE HEAT

V / W2

MODULATING THERMOSTAT

* NO MECHANICAL THERMOSTATS.** 40%, 65%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION (DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).

1-STAGE ELECTRONIC THERMOSTAT*

➤➤

41

FIGURE 44WIRING DIAGRAM FROM TWO-STAGE HEAT

FIELD-INSTALLEDOPTION ACCESSORIESELECTRONIC AIR CLEANER

Line voltage power can be supplied fromthe screw terminal “EAC”, see Figure 45,and a line voltage neutral screw terminalon the control board. This will power theelectronic air cleaner whenever theECM2+ blower is operating and deliver-ing the recommended minimum CFM.The 60 and 75 KBTU models, which arecapable of a maximum delivery of 1200

ACCESSORIES CFM, will operate the electronic aircleaner at 500 CFM and above. The90, 105 and 120 KBTU models,which are capable of a maximumdelivery of 2000 CFM, will operatethe electronic air cleaner at 800CFM and above. These limits are setto prevent excessive production ofozone at the lower airflows of themodulating furnace and are based onaverage requirements of commercial-ly available electronic air cleaners.The continuous fan speeds are set toalways provide adequate airflow forelectronic air cleaner operation.

HUMIDIFIER

The humidifier contacts (labeledHUMIDIFIER on the IFC) are “dry”contacts on the IFC. This meansthat the terminals are connecteddirectly to the contacts of a board-mounted relay. The coil of the relayis controlled by the microprocessorof the IFC. The coil is engagedroughly any time the heat speedblower is engaged so that humidifi-cation is active any time the heatblower is running. In addition to thiscontrol, on 24 VAC humidifiers orhumidifiers controlled by a 24 VACcontrol circuit, an optional 24 VAChumidistat can be installed (seeFigure 46). With the optionalhumidistat, two separate conditionsmust be met before humidification ofthe conditioned space can begin: 1)There must be a heat call and theheat speed blower must be runningand 2) The humidistat must deter-mine that there is a need for humidi-fication.

FIGURE 45EAC TERMINAL

FURNACE OPERATION WITH ATWO-STAGE THERMOSTAT To set the furnace for operation withtwo-stage thermostats, set switches 1 &2 of SW2 to the “ON” position (SeeFigure 47). Note that these switchesshould be in the “OFF” position fromthe factory. With both switches in the“ON” position, the furnace can still rec-ognize a “V” signal present and will stilloperate with a modulating thermostat.However, with both switches of SW2 inthe “ON” position, the furnace is set tooperate with a two-stage thermostat aswell.

With a two-stage thermostat (installedas shown in Figure 44) and switch set-tings configured as described above,during a call for heat, the furnace willoperate as follows:

First Stage(“W”=ON and “W2”=OFF)40% of furnace capacity always

Second Stage(“W”=ON and “W2”=ON)

Phase 1: 0 to 5 minutes = 65% of fur-nace capacityPhase 2: After 5 minutes = 100% offurnace capacity

NOTE: If the call for heat ends duringany phase and/or stage, the furnacewill terminate immediately at the firingrate of that phase and/or stage.

* NO MECHANICAL THERMOSTATS.** 40%, 60%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION (DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).*** 65% and 100% FIRING RATE IN TWO-STAGE OPERATION (W & W2 ENERGIZED).

2-STAGE ELECTRONIC THERMOSTAT*2-STAGE ELECTRONIC THERMOSTAT*

42

FIGURE 46WIRING FOR OPTIONAL HUMIDIFIER

I681

LOW VOLTAGE

CONTROL WIRING

43

there is only one input used for both.Also, if neither feature is to be used, itdoes not matter if the dip switch is inthe “ON” or “OFF” position. Anyhumidistat can be used provided it is ofthe type that can handle 24 volts andopens the contacts when there is aneed for de-humidification.

For proper installation of On-DemandDe-Humidification, ensure the following:

A. Install one wire from one humidistatcontact terminal to the IFC “YL” ter-minal and another wire from theremaining humidistat contact termi-nal to the IFC “R” terminal.

B. When installing, be sure to use ahumidistat and NOT a de-humidistat.

C. Position dip switch #6 of bank SW-1to the “ON” position.

D. It is not possible to use two-stagecooling and de-humidification fea-ture at the same time.

NOTE: When the dip switch position #6of bank SW-1 is in the on position, a 24volt signal from the humidistat must besupplied at all times to keep the blowerrunning at the correct cooling speed.When the 24 VAC signal is absent, theIFC assumes there is a need for de-humidification and operates the blowerat the reduced rate. This is what isknown as “reverse-logic”. In otherwords, when a 24 VAC signal is pre-sent, normal operation occurs (100%cooling CFM), however, when there isno signal present, the IFC goes into thedehumidification mode and reduces theairflow by 15%. This could be confus-ing and will cause the cooling speed tobe reduced by 15% if the dip-switch isin the “on” position but no humidistat isconnected.

ON DEMAND DEHUMIDIFICATIONIFC #62-24174-02For IFC Revision #62-24174-02 (AVAIL-ABLE 2ND QUARTER 2005) or later, anew dehumidification terminal has beenadded to the thermostat terminal block.This terminal will permit the user toinstall dehumidification without the needto manipulate any dip-switches.However, to activate the ODD feature,a jumper located at position J5(between the thermostat terminal blockand dip switch bank SW-2 on the IFC –see Figure 47) must be removed anddiscarded. This jumper applies 24 voltsto the “dehum” terminal at all times inorder to prevent the control from revert-ing to the lower (dehumidification)speed when no voltage is applied.

IMPORTANT: Do not remove thejumper at J5 unless a humidistat isinstalled to the “DEHUM” terminal ofthe IFC. In addition, the control allowsthe use of two-stage cooling and dehu-midification at the same time and sepa-rate cooling airflows for high efficiency(up to16 SEER) cooling. (see sectionlabeled “FURNACE INSTALLATIONWITH HIGH EFFICIENCY PREMIUMCOOLING SYSTEMS”).

For proper installation of On-Demand De-Humidification, ensurethe following:

A. Install one wire from one humidi-stat contact terminal to the IFC“DEHUM” terminal and anotherwire from the remaining humidis-tat contact terminal to the IFC“R” terminal.

B. When installing, be sure to use ahumidistat and NOT a de-humidi-stat.

C. The jumper at position J5 on thecontrol (see Figure 47) has beenremoved.

DEHUMIDIFICATION IN COOLINGOPERATIONDehumidification in the cooling modecan be accomplished by two differentmethods. Both methods will reduce theamount of airflow in cooling by 15%.This reduced airflow will cause morewater to condense on the evaporatorcoil thus reducing the humidity in theconditioned space.

IMPORTANT: The manufacturerrequires that all cooling systemsinstalled with either dehumidificationfeature enabled MUST have a coil of thetype with an expansion valve. RCBAcoils can be used with the feature(s)enabled provided that there is anexpansion valve kit installed with thecoil. In addition to these requirements,RCGA, RCBA and RCHA coils musthave a freeze-stat (part #RXRX-AM01)installed to prevent possible coil freeze-up. Note that the RCBA coils must haveBOTH an expansion valve kit and afreeze-stat installed.

Method A: THERMOSTAT DEMANDDE-HUMIDIFICATIONThis method for dehumidification relieson an algorithm in the modulating ther-mostat (part #41-24312-04) to calculatea need for dehumidification based onthe number and frequency of coolingcalls over a specified period of time.The feature is enabled on the thermo-stat interface panel. Please read andfollow the instructions for the modulat-ing thermostat to enable this feature.

Please note that the thermostat canonly estimate when there is a need fordehumidification by looking at therecent history of cooling calls. This isnot a true measurement of humidity.For true humidity measurement, ahumidistat must be installed per theinstructions in method B below.

Method B: ON-DEMAND DE-HUMID-IFICATION–REFERENCE FIGURES40A THRU COn UTECH IFC Revision –03 (62-24174-01 rev 03)or newer (After May12, 2004) or all revisions of 62-24174-02, an additional method for dehumidifi-cation was added to the function of theIFC. This method is not available onunits constructed before this date.

The following methods for dehumidifica-tion utilize the most accurate means forsensing humidity. A humidistat shouldbe installed to the control board “YL” or“DEHUM” and “R” terminals.

ON DEMAND DEHUMIDIFICATIONON UTECH IFC #62-24174-01REVISION 03 (62-24174-01 Rev -03)A humidistat should be installed to thecontrol board “YL” and “R” terminals.PLEASE NOTE THAT TWO-STAGECOOLING AND ON-DEMAND DE-HUMIDIFICATION CANNOT BE USEDAT THE SAME TIME (IFC REV. 03ONLY). The dip switch position #6 ofbank SW-1 is used to select betweeneither two-stage cooling or on-demandde-humidification, both features can notbe used at the same time because

FIGURE 47UT Electronic Controls IFC. 62-24174-02Shown with Nec. Jumper location shownto activate dehumidification.

Remove this jumper (J5)to enable dehumidification

44

FIGURE 49WIRING FOR OPTIONAL DEHUMIDIFIER WITH HUMIDIFIERRING FOR OPTIONAL DEHUMDIFIERAND DEHUMIDIFIER WITH HUMIDIFIER

FIGURE 48WIRING FOR OPTIONAL DEHUMDIFIER

HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING

IFC 62-24174-01 REV. 03 ONLY! POSITION #6OF SW1 MUST BE IN “ON” POSITION

IFC 62-24174-02: REMOVE THIS JUMPER(J5) TO ENABLE DEHUMIDIFICATION

(IFC 62-24174-01 REV. 03) OR DEHUM (IFC 62-24174-02 -ALLREVISIONS)

RE

MO

VE

FO

RD

EH

UM

EN

AB

LE

J5

HUMIDISTAT(24V)

(CONTACTS OPENWHEN HUMIDITY

IS ABOVE SET POINT)


(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02-ALL REVISIONS)

NEUTRAL OR COMMON

IFC

+110VAC OR 24VAC

HUMIDIFIER WITHINTERNALPOWER SUPPLY

J5

IFC 62-24174-02: REMOVETHIS JUMPER (J5) TO ENABLEDEHUMIDIFICATION

RE

MO

VE

FO

RD

EH

UM

EN

AB

LE

J5

HUMIDISTAT(24V)

(CONTACTSOPEN WHENHUMIDITY ISABOVE SET

POINT)

SPST RELAYW/ N.O CONTACTSRATED 24V COILAND 24V OR 110VCONTACTS ASNECESSARY FORHUMIDIFIER

HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATINGAND DEHUMIDIFIER IN COOLING (HUMIDIFIER WITH INTEGRALPOWER SUPPLY)

45

FIGURE 50WIRING FOR OPTIONAL DEHUMIDIFICATION WITH HUMIDIFIER AND SEPARATE POWERSUPPLY.WIRING DIAGRAM FROM TWO-STAGE HEAT

HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATINGAND DEHUMIDIFIER IN COOLING (110V HUMIDIFIER WITHOUTINTEGRAL POWER SUPPLY)


(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02-ALL REVISIONS)

NEUTRAL OR COMMON

+110VAC OR 24VAC

HUMIDIFIER WITHEXTERNAL 110VOR 24V POWERSUPPLY

IFC 62-24174-02: REMOVETHIS JUMPER (J5) TO ENABLEDEHUMIDIFICATION

RE

MO

VE

FO

RD

EH

UM

EN

AB

LE

J5

HUMIDISTAT(24V)

(CONTACTSOPEN WHENHUMIDITY ISABOVE SET

POINT)

110V OR 24VPOWER SUPPLYAS NECESSARYFOR HUMIDIFIER

SPST RELAYW/N.O CONTACTSRATED 24V COILAND 24V OR 110VCONTACTS ASNECESSARY FORHUMIDIFIER

RXPF-F02 SYSTEMINSTALLATION WITHHEAT PUMPS (REFER TOWIRING DIAGRAMS OFFIGS 51 THRU 53)As of May 12, 2004, the modulatingfurnace systems can be installedwith heat pump systems providedthat the IFC is part number 62-24174-01 REV –03 or greater or 62-24174-02 and that an RXPF-F02fossil fuel kit is used to install thesystem.

Refer to Figures 51 thru 53 for vari-ous installation wiring diagrams cov-ering different defrost controls,refrigerant types and optional heat-pump monitor installations. For fur-ther instructions, refer to the instruc-tions delivered with the fossil fuel kit.

System Operation withModulating Gas Furnace withRXPF-F02NOTE: Modulating control must bepart number 62-24174-01 Rev. –03or newer or 62-24174-02.

NOTE: Both dip switches of SW-2 ofthe modulating control (IFC) must bein the “ON” position (timed two-stage heat operation).

NOTE: Thermostat must have a“W2” connection for second-stageheat when configured for a modulat-ing furnace.

(continued on next page)

46

A. First-Stage Heat Call (Thermostat“Y”+”B”)(1) The system receives a demand

for heat from the indoor thermo-stat (“Y” and “B”)“B” is energized when the indoorthermostat is set to “HEAT”“Y” is energized when the indoorthermostat calls for heat.

(2) “B” is routed directly to the out-door unit for the heat pump heat-ing control system. (Usually areversing valve).

(3) “Y” is routed to the outdoor ther-mostat:Condition 1: When the outdoorair temperature is above the set-point of the outdoor thermostatand the indoor thermostat onlysenses a need for first-stageheat, the operation is normalheat pump. Both the coolingcontactor on the condenser andcooling speed fan on the controlboard (IFC) (via “Y”) are ener-gized at this point. Condition 2: When the outdoorair temperature is below the set-point of the outdoor thermostatand the indoor thermostat onlysenses a need for first-stageheat, heating control is switcheddirectly to the modulating gasfurnace by energizing “W” on themodulating control (IFC) alone.This will give 40% (low fire) gasheat until either a second-stageheat call is present or the ther-mostat heat call is satisfied. Atthis point, the thermostat hasenergized both “Y” and “B”, butthe fossil fuel kit changes the “Y”signal into a “W” call to the mod-ulating control. The cooling con-tactor is de-energized during thismode and the compressor andcondenser fan are turned off.

The reversing valve (via “B”) is ener-gized throughout Condition 1 or 2,but is ignored and has no conse-quence in Condition 2 since thecompressor and condensing fan arenot running in Condition 2.

B. Second-Stage Heat Call(Thermostat “W2”+”Y”+”B”)(1) When the system thermostat

determines that the indoor airtemperature is significantlybelow the setpoint of the ther-mostat, it will call for second-stage heat. Second-Stage heatwith a modulating furnace asinstalled and wired per this doc-ument will be gas heat startingat 65% of full fire.“W2”, “Y” and “B” are simultane-ously energized by the thermo-stat.“W2” is routed to the modulatingfurnace control to energize both“W” and “V/W2” on the modulat-ing control board (IFC) (throughthe relay provided with theRXPF-F02). This turns on gasheat at 65% for seven minutesfollowed by 100% gas heat untilthe Second-Stage heat call issatified.

“Y” is turned off by the FFK IWB(Fossil Fuel Kit Interface WiringBoard) so that the cooling con-tactor is NOT energized. NOTE:At this point, “Y” from the ther-mostat to the FFK IWB will beenergized, however, neither “Y”between the FFK IWB and thecooling contactor nor “Y”between the FFK IWB and themodulating control (IFC) will beenergized.

The reversing valve (via “B”) isenergized during the Second-Stageheat call, but is ignored and has noconsequence on the system sincethe compressor and condensing fanwill not be running during Second-Stage Heat.

C. Defrost (Thermostat “Y”+”B”)(Defrost Control “W2”or”D”)(1) The system receives a backup

heat demand from the outdoorunit defrost control (DefrostControl “W2”or”D”)

(2) When the defrost control deter-mines there is a need to defrostthe coil, the heating call is re-routed by the defrost controlback to the FFK IWB. TheDefrost control also forces thereversing valve to run the ACsystem in cooling.

(3) The Defrost mode heat call fromthe outdoor unit is routed to theFFK IWB, through the PlenumSensor and finally to “W” and“V/W2” on the modulating con-trol (IFC). The modulating fur-nace begins heating at 65% offull fire for seven minutes fol-lowed by 100% until theheat/defrost call is satisfied.

(4) A plenum switch is provided tocontrol heat in the defrost mode.This switch prevents the evapo-rator coil from overheating whengas heat is running in thedefrost mode.

(5) The “Y” (Cooling) circuit remainsenergized on the modulatingcontrol (IFC). This means thatthe furnace is running at either65% or 100% of full fire heatwith cooling speed blower.

(6) The compressor and condens-ing fan of the cooling system willbe running in the cooling direc-tion during the Defrost mode totransfer heat to the condensingcoil to melt away any frost or icebuild-up on the condenser.

The reversing valve (via B) is de-energized during the defrost cycle.During defrost mode, “B” from thethermostat through the FFK IWBand out to the defrost control will beenergized, but the circuit from thedefrost control to the reversingvalve will NOT be energized as thedefrost control forces the reversingvalve into cooling.

D. Call for Emergency Heat(Thermostat “E”)(1) In the Emergency Heat mode,

the indoor thermostat routes allheat demands (first- and sec-

ond-stage) to the modulatingfurnace so that, with anEmergency heat call from thethermostat, gas heat will turnon at 65% of full fire forseven minutes followed by100% until the EmergencyHeat call is satisfied.

The reversing valve (via “B”) isenergized during the EmergencyHeat call, but is ignored and hasno consequence on the systemsince the compressor and con-densing fan will not be runningduring Emergency Heat.

E. Call for Cooling (Thermostat“O”, “Y” & “G” or “Y” & “G”)(1) In the cooling mode, the sys-

tem receives a demand forcooling from the indoor ther-mostat.When the thermostat recog-nizes a need for cooling, “Y”is energized by the thermo-stat and the FFK IWB usesthis signal to energize “Y” tothe modulating control (IFC)and to the cooling contactor.In cooling, “B” is de-ener-gized and “O” is energized.This sets the reversing valvefor the cooling mode.

(2) “O” is routed to the outdoorunit for the heat pump cool-ing control system (usuallythe “Low-Ambient” relay oralternate reversing valvecontrol system.)

F. Call for Continuous Fan(Thermostat “G”)(1) The system receives a

demand from the indoor ther-mostat “G”.

(2) The fan call is routed directlyto the “G” terminal on themodulating control (IFC).

OTHER ACCESSORIESAVAILABLEThese kits are available through thefinished goods department.

CONCENTRIC VENT TERMINA-TION KIT = RXGY-E03

HORIZONTAL, TWO-PIPE TERMI-NATION KIT = RXGY-D02, RXGY-D03, OR RXGY-D04

CONDENSATE PUMP KIT: RXGY-B01

NEUTRALIZER KIT: RXGY-A01

EXTERNAL BOTTOM FILTERRACK: RXGF-CB

EXTERNAL SIDE FILTER RACK:RXGF-CA

These parts are available throughProStock parts department.

PROGRAMMABLE MODULATINGTHERMOSTAT: 41-24312-04

NON-PROGRAMMABLE MODU-LATING THERMOSTAT: 41-25347-01

47

FIGURE 51RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, SINGLE-PHASE CONDENSOR, R410A REFRIGERANT WITH RHEEM/RUUD MODULATINGGAS FURNACE (TVA COMPLIANT)

48

FIGURE 52RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, SINGLE-PHASE CONDENSOR, R22 REFRIGERANT WITH RHEEM/RUUD MODULATINGGAS FURNACE (TVA COMPLIANT)

49

FIGURE 53RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, THREE PHASE CONDENSOR, R22 REFRIGERANT WITH RHEEM/RUUD MODULATINGGAS FURNACE (TVA COMPLIANT)

50

TABLE 10Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace.Burner Input (per burner) 25,000 BTU @ Sea Level

Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 toto 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 6999 ft 7999 ft 8999 ft47 48 48 49 49 49 50 50

48 49 49 49 50 50 50 51

49 50 50 50 51 51 51 52

50 51 51 51 51 52 52 52

51 51 52 52 52 53 53 53

-GFD/-GGD -HIGHALTITUDE OPTION #278

FOR -GGD-06 MODELS, A PRES-SURE SWITCH CHANGE IS NOT NEC-ESSARY AT ANY ELEVATION. FOR -GGD-07 MODELS, A PRESSURESWITCH CHANGE IS REQUIRED ATELEVATIONS ABOVE 8,000 FT. FORALL OTHER -GFD/-GGD FURNACES,A PRESSURE SWITCH CHANGE ISREQUIRED AT ELEVATIONS ABOVE5,000 FT. OPTION CODE -278 OR THEAPPROPRIATE HIGH-ELEVATION KITWILL CONVERT THE FURNACE FORUSE ABOVE THE APPROPRIATE ELE-VATION STATED HERE. DO NOTINSTALL THE -278 OPTION FURNACEOR THE HIGH ALTITUDE KIT BELOWTHE STATED ELEVATION. DOING SOCAN CAUSE SERIOUS PERSONALINJURY OR DEATH OR EQUIPMENTFAILURE.

Furnaces can be ordered from the facto-ry already converted for high altitudeelevations. The factory option for highaltitude elevations would be ordered asa 278 option (example: a 105k BTUupflow furnace which is factory convert-ed for high altitude elevations wouldhave the model number -GFD-10EZCMS278). These factory convertedfurnaces come with pressure switchesfor high-altitude elevations alreadyattached. Also, different burner orificesare installed at the factory which are onedrill size smaller (#51 DMS) than stan-dard -GFD/GGD gas furnaces (#50DMS). The smaller orifice is installed toaccommodate for average heating val-ues expected in most high altitude areasand a required 4% per thousand feetreduction in input as specified by theNational Fuel Gas Code (NFGC).Specific orifices should always be recal-culated for all high altitude installationsas outlined below. Orifices should bechanged, if necessary, based on gasheating value and elevation.

HIGH ALTITUDE CONVERSIONKITS AND OPTIONS

FOR -GGD-06 MODELS, A PRES-SURE SWITCH CHANGE IS NOT NEC-ESSARY AT ANY ELEVATION. FOR -GGD-07 MODELS, A PRESSURESWITCH CHANGE IS REQUIRED ATELEVATIONS ABOVE 8,000 FT. FORALL OTHER -GFD/-GGD FURNACES,A PRESSURE SWITCH CHANGE ISREQUIRED AT ELEVATIONS ABOVE5,000 FT. OPTION CODE -278 OR THEAPPROPRIATE HIGH-ELEVATION KITWILL CONVERT THE FURNACE FOR

USE ABOVE THE APPROPRIATEELEVATION STATED HERE. DO NOTINSTALL THE -278 OPTION FUR-NACE OR THE HIGH ALTITUDE KITBELOW THE STATED ELEVATION.DOING SO CAN CAUSE SERIOUSPERSONAL INJURY OR DEATH OREQUIPMENT FAILURE.

HIGH ALTITUDE FIELDCONVERSION KITS (GFD MODELS)MODEL INPUT(BTU) KIT NO.-GFD-06XXXXX 60,000 RXGY-F06-GFD-07XXXXX 75,000 RXGY-F07-GFD-09XXXXX 90,000 RXGY-F06-GFD-10XXXXX 105,000 RXGY-F05-GFD-12XXXXX 120,000 RXGY-F05

HIGH ALTITUDE FIELDCONVERSION KITS (GGD MODELS)MODEL INPUT(BTU) KIT NO.-GGD-06XXXXX 60,000 No Kit Required-GGD-07XXXXX 75,000 RXGY-F23

(8000 ft andabove only)

-GGD-09XXXXX 90,000 RXGY-F24-GGD-10XXXXX 105,000 RXGY-F25-GGD-12XXXXX 120,000 RXGY-F26

Orifice Selection for High AltitudeApplicationsNatural Gas

DO NOT ATTEMPT TO ADJUSTMANIFOLD GAS PRESSURE FORELEVATION ON (-)GGD OR (-)GFDFURNACE MODELS. THIS METHODIS NOT PERMITTED ON THESEMODELS!Caution. The National Fuel Gas Code(NFGC) guidelines should be followedwhen converting these furnaces forhigh altitude operation.

34” 90 Plus furnaces (except for opt -278 models) installed at high eleva-tions require the installation of a highaltitude kit for proper operation. Thehigh altitude kit consists of a high alti-tude pressure switch that replaces thepressure switch attached to the induceddraft blower.

The pressure switch must be installedat elevations above those listed.Elevations above 2000 ft. require thefurnace to be de-rated 4% per thou-sand feet. NOTE: Factory installed ori-

Annual Avg. HeatValue (btu per ft3)

850900

100010751170

fices are calculated and sized basedon a sea level Natural Gas heatingvalue of 1075 BTU per cubic ft.Regional reduced heating valuesmay nullify the need to change ori-fices except at extreme altitudes.Table 10 shows some quick conver-sions based on elevation and gasheating value. This table is com-bined and simplified from Tables F1and F4 of the NFGC.

The following are examples of orificesizing using the National Fuel GasCode Appendix F. For a simplifiedestimation of orifice size based onheating value and elevation useTables 10 and 11. However, calcula-tions are the best method.

Example: 900 BTU/ft3 RegionalNatural Gas Heating ValueI / H = Q15000 / 900 = 16.68 ft3/hr

I = Sea Level input (per burner):15000 H = Sea Level Heating Value: 900Q = 16.68 ft3 Natural Gas per hour.

From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5� w.c. col-umn)Orifice required at Sea Level: # 48

From Table F.4 of National fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft): # 50Orifice required at 8000 ft. elevation(4% de-rate per thousand ft): # 51

Example: 1050 BTU/ft3 RegionalNatural Gas Heating Value I / H = Q15000 / 1050 = 14.63 ft3/hr

I = Sea Level input (per burner):15000H = Sea Level Heating Value: 1050Q= 14.28 ft3 Natural Gas.

From Table F.1 of National Fuel Gascode Handbook, 2002 (3.5� w.c. col-umn)Orifice required at Sea Level: # 50

From Table F.4 of National Fuel Gascode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft): # 51Orifice required at 8000 ft. elevation(4% de-rate per thousand ft): # 52

CAUTION!

! WARNING

! WARNING

HIGH ALTITUDE INSTALLATIONS

51

TAB

LE 1

1S

UP

PLE

ME

NTA

L O

RIF

ICE

SIZ

E C

HA

RT

90 P

lus

ON

LY m

od

els

wit

h 15

,000

Btu

's p

er B

urne

r. D

O N

OT

US

E T

HIS

CH

AR

T F

OR

AN

Y 8

0 P

LUS

MO

DE

L.N

AT

UR

AL

GA

S Q

UIC

K R

EF

ER

EN

CE

CH

AR

TF

OR

OR

IFIC

E S

ELE

CT

ION

, AT

3.5"

W.C

. AN

D A

PP

RO

XIM

AT

E F

INA

LF

IRIN

G R

AT

ES

Fin

al F

iring

Rat

e pe

r B

urne

r

Sea

Le

vel

Orif

ice

Siz

e

Sea

Lev

elC

ubic

Foo

t at

3.5"

W.C

.

90 P

lus

Hea

tV

alue

at

15,0

00 B

tu’s

per

Bur

ner

0-99

910

00-1

999

2000

-299

930

00-3

999

4000

-499

950

00-5

999

6000

-699

970

00-7

999

8000

-899

990

00-9

999

ELE

VA

TIO

N C

HA

RT

(NF

G r

ecom

men

ded

orifi

ce b

ased

on

4% d

erat

e fo

r ea

ch 1

000

foot

of

elev

atio

n, b

ased

on t

he in

ters

ectio

n of

the

orif

ice

requ

ired

at S

ea L

evel

and

the

ele

vatio

n re

quire

d be

low

)

4618

.57

808

4646

4747

4748

4849

4950

4717

.52

856

4747

4848

4949

4950

5051

4816

.36

917

4848

4949

4950

5050

5151

4915

.298

749

4950

5050

5151

5152

52

5013

.92

1078

5050

5151

5151

5252

5253

5112

.77

1175

5151

5152

5252

5253

5353

15,0

0014

,400

13,8

0013

,200

12,6

0012

,000

11,4

0010

,800

10,2

009,

600

All

calc

ulat

ions

are

per

form

ed b

y us

ing

the

fir

st t

hree

co

lum

ns o

f in

form

atio

n o

nly.

Bef

ore

beg

inni

ng a

ny c

alcu

lati

ons

, det

erm

ine

the

ind

ivid

ual b

urne

r B

tu s

ize

and

hea

ting

val

ue a

t S

ea L

evel

fo

r th

e in

stal

lati

on

site

. Eac

h va

lue

sho

wn

in t

he H

eat

Valu

e co

lum

n is

per

bur

ner

at 3

.5"

W.C

.

NO

TE

: H

eat

Val

ue a

t S

ea L

evel

, fo

r th

e lo

catio

n of

the

inst

alla

tion,

is a

vaila

ble

from

the

Nat

ural

Gas

Sup

plie

r to

tha

t si

te.

Orif

ices

for

all

altit

udes

are

bas

edon

Sea

Lev

el v

alue

s.

Div

ide

the

indi

vidu

al b

urne

r ca

paci

ty (

15,0

00 f

or 9

0 pl

us)

by t

he H

eat

Val

ue f

or t

he s

ite t

o de

term

ine

the

Cub

ic F

oot

valu

e at

Sea

Lev

el,

or d

ivid

ebu

rner

cap

acity

by

the

Cub

ic F

oot

valu

e fo

r th

e H

eat

Val

ue.

Onc

e yo

u ha

ve e

ither

the

Cub

ic F

oot

Val

ue o

r th

e H

eat

Val

ue y

ou c

an e

stim

ate

the

Sea

Leve

l orif

ice

for

the

site

. To

sele

ct t

he c

orre

spon

ding

hig

h al

titud

e or

ifice

, lo

cate

the

site

ele

vatio

n on

the

cha

rt a

bove

and

the

orif

ice

requ

ired

at S

eaLe

vel f

rom

you

r ca

lcul

atio

n in

the

firs

t co

lum

n. T

he c

orre

ct h

igh

altit

ude

orifi

ce t

hat

mus

t be

inst

alle

d in

eac

h in

divi

dual

bur

ner

is t

he in

ters

ectio

n of

thes

e tw

o po

ints

on

the

char

t ab

ove.

52

LP GAS AT HIGH ALTITUDEELEVATIONSLP Gas is a manufactured gas that hasconsistent heating value across mostregions.

The NFGC guidelines are used with thefollowing exception:

The recommended LP Gas high altitudeorifice selections differ slightly in thatthe NFGC LP orifice chart, as they arenot accurate for the (-)GFD or (-)GGDgas furnace. The National Fuel GasCode LP orifices are based on an 11” ofwater column pressure at the orifice,which differs from products that use 10”of water column at the orifice. This dif-ference requires a deviation from theNFGC orifice size recommendations.The Sea Level input should still bereduced by 4% per thousand ft. and theorifice size must be selected based onthe reduced input selection shown inTable 12.

Orifice Ordering InformationOrifice sizes are selected by addingthe 2-digit drill size required in the ori-fice part number. Drill sizes availableare 39 through 64; metric sizes avail-able 1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:#60 drill size orifice requiredPart #62-22175-60Example 2:1.15mm drill size orifice requiredPart #62-22175-91

TABLE 12LP Gas Orifice Drill Size and per burner de-rate by elevation basedon 15,000 btu 90+ burners.IMPORTANT: For 90+ Furnaces only. Do not use this chart for any80+ Furnace.

Input (per OrificeAltitude burner) 15000 Size

0 to 2000 ft. 15000 1.15 mm (factory)

2001� to 3000� 13200 1.15 mm

3001� to 4000� 12600 1.10 mm

4001� to 5000� 12000 #58

5001� to 6000� 11400 #59

6001� to 7000� 1080 #60

7001� to 8000� 10200 #62

8001� to 9000� 9600 #63

9001� to 10000� 9000 #64

53

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.(See condenser spec. sheet, I&O and other literature for evaporator selection)

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.(See condenser spec. sheet, I&O and other literature for evaporator selection)

TABLE 14AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (2 STAGE COOL ONLY)

TABLE 13AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (1 STAGE COOL ONLY)

ZONING SYSTEMSThe manufacturer does not currentlyprovide or support zoning with modulat-ing furnace. However, zoning systemscan be installed with the system as longas the zoning equipment manufacturersspecifications and installation instruc-tions are met and followed.

The preferred zoning method is to usea “bypass” system which is properlyinstalled for maximum efficiency. Inthese systems, excess air is routedback through the system to be usedagain – this is opposed to a “dump”system in which excess air is routed toa zone where it is expected that theextra heat or cooling would be leastnoticed.

If installed as a “bypass” system, theinstallation must have an optionalfreeze stat installed to prevent the coilfrom icing with excess bypass cooling.Also, if the zoning equipment manufac-turer provides a limit switch (usuallyprovided by the zoning manufacturer),this limit must be installed in the systemto prevent the furnace from overheat-ing.

FURNACE INSTALLATIONWITH HIGH-EFFICIENCYPREMIUM COOLINGSYSTEMSFurnace installation with Rheem/Ruud -ARA or -ARL outdoor condensing unitscan provide high efficiency (up to 16SEER) cooling operation when com-bined with proper evaporator coil. Forlisted cooling equipment combinations,see the -ARA or -ARL specificationsheets. Using Tables 13 and 14 and lit-erature provided with the cooling equip-ment, the installer needs to make surethat the proper evaporator coil, con-densing coil and airflow is configured toachieve rated efficiency.

UP TO 16 SEER COOLING OPERATIONCheck the revision number of the inte-grated furnace control (IFC) to deter-mine how best to configure your fur-nace for high SEER operation.

IFC #62-24174-02To achieve high SEER operation, turndip switch #6 of bank SW1 to the “on”position. This will enable the furnaceoperation for 16 SEER. Actual SEERvalues will vary and depend on theequipment combination. Consult thespecifications sheets and installationinstructions of the cooling equipmentpurchased for a listing of the SEER rat-ings for a specific combination.

TONSFURNACE

MODEL WIDTH

APPROX.AIRFLOW

(CFM) SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4CONDENSING

UNITMOD. FURNACE IFC DIP-SWITCH SETTINGS

2 -GFD/GGD-06 & -07 17.5" 800 -ARA-24 OFF ON OFF OFF2-1/2 -GFD/GGD-06 & -07* 17.5" 1000 -ARA-30 ON OFF OFF OFF

3 -GFD/GGD-09 & -10* 21" 1200 -ARA-36 ON ON OFF OFF3-1/2 -GFD/GGD-09 & -10* 21" 1400 -ARA-42 ON ON OFF OFF

3 -GFD/GGD-12 24.5" 1200 -ARA-36 ON ON OFF OFF3-1/2 -GFD/GGD-12 24.5" 1400 -ARA-42 ON ON OFF OFF

TONSFURNACE

MODEL WIDTH

APPROX.AIRFLOW

(CFM) SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4CONDENSING

UNITMOD. FURNACE IFC DIP-SWITCH SETTINGS

2 -GFD/-GGD-06 & -07 17.5" 800 -ARL-24 OFF ON OFF OFF3 -GFD/-GGD-06 & -07 17.5" 1200 -ARL-36 OFF OFF OFF OFF3 -GFD/-GGD-09 & -10 21" 1200 -ARL-36 ON ON OFF OFF3 -GFD/-GGD-12 24.5" 1200 -ARL-36 ON ON OFF OFF4 -GFD/-GGD-09 & -10 21" 1600 -ARL-48 ON OFF OFF OFF4 -GFD/-GGD-12 24.5" 1600 -ARL-48 ON OFF OFF OFF5 -GFD/-GGD-12 24.5" 1800 -ARL-60 OFF OFF OFF OFF

ALL OTHER INTEGRATEDFURNACE CONTROLSHigh SEER operation with IFC’sother than 62-24174-02 may notachieve rated performance ordesired comfort levels. For theseolder models, there are no additionaladjustments necessary to the fur-nace. For optimum performance,replace with IFC #62-24174-02.

A NOTE ABOUT DEHUMIDIFICATION:High SEER systems may require theuse of the onboard dehumidificationfeature of this system. Be sure toconsult the section titled “ONDEMAND DEHUMIDIFICATION” onpage 42 of this document.

HORIZONTALCONVERSION KITSRXGY-G02, RXGY-G03,RXGY-G04 & RXGY-G05Horizontal installation of the (-)GGDmodulating gas furnace is permittedwith the use of special kits availablefrom the manufacturer. The gasvalve must be mounted upright. Thisis accomplished with a special mani-fold supplied with the conversion kit.Assembly requires the removal ofthe existing gas manifold andreplacing it with the one supplied inthe kit.

54

GENERALThe UT Electronic Controls IFC board(see Figure 41) is a recent addition tothe furnace and will be a direct replace-ment for all Johnson Controls IFCboards. New features have beenadded to the IFC board to improve air-flow performance in the heating mode.The new board also adds two-stagecapability in addition to the existingmodulating and single-stage operation.Also, the locations of the original dipswitches (SW1 & SW2), and the loca-tion of the seven segment display aredifferent than the previous JohnsonControls IFC board. The function ofthese components has not changed.

➤ IMPORTANT: The dip switches onSW2 (used for test mode and for oper-ation with two-stage thermostats) mustbe in the “OFF” position for modulatingor single-stage operation. If bothswitches are in the “ON” position, amissing “V” signal with a call on “W” willcause the furnace to run only at 40%.However, with both switches in the“ON” position, the furnace will functionwith a two-stage thermostat when con-nected as shown in Figure 44.

DIP SWITCH SET SW1For proper setting of the airflow switchesto meet requirements, see Figures 55and 56.

IMPORTANT: Do not attempt to install a(-)GFD or (-)GGD modulating furnacewith a conventional, add-on zone sys-tem. System performance and occupantcomfort may be compromised.

➤ DIP SWITCH SET SW2The UT Electronic Controls IFC boardhas added two-stage capabilities. Thisfeature is activated by changing theswitches 1 & 2 of SW2 to the “ON” posi-tion and installing a two-stage thermo-stat as shown in Figure 44. This featureallows the furnace to be used with astandard two-stage thermostat. Withswitches 1 & 2 of SW2 set to the “ON”position, the furnace will go to 40% ofcapacity when “W” is energized alone.In this configuration, when “W” and “W2”

are energized, the furnace runs at65% for five minutes and thenchanges to 100%. If the call for heatends at any time the furnace termi-nates immediately at the present fir-ing rate.

DIP SWITCH SET SW3The UT Electronic Controls IFCboard has an added set of dipswitches labeled SW3 (see Figure53). The function of these dip switch-es is to fine-tune airflow in the heat-ing mode. The dip switches will beset to either the 40% or 100% (orboth) firing rate, and will adjust everypoint in between accordingly.

SW3 will allow for airflow adjust-ments at high altitude, improper tem-perature probe locations, or no tem-perature probe applications. If tem-perature rise range is a problem, thetechnician must use temperatureprobes to determine the rise rangeand adjust the airflow using SW3’sdip switches until the temperaturerise is within the specified range.

ADJUSTING AIRFLOWAll airflow adjustments on SW3should be made with the main powerOFF. Dip switches 1 through 3 willadjust airflow at the 100% firing rateand dip switches 4 through 6 willadjust the airflow at the 40% firingrate.

100% Firing RateTo use SW3 to change the airflow atthe 100% rate:1) Dip switch 1 must be “ON” (or

“ADJ”). This instructs the IFC thatthe high firing rate airflow will beoverridden.

2) Dip switch 2 in the “OFF” positionwill decrease airflow at 100% fire,and in the “ON” position willincrease airflow at 100% fire.

3) If dip switch 3 is “OFF” the amountairflow will be adjusted by 7.5%. Ifit is “ON” amount of airflow will beadjusted by 15%.

40% FIRING RATETo use SW3 to change the airflow atthe 40% rate:1) Dip switch 4 must be “ON” (or

“ADJ”). This instructs the IFC thatthe high firing rate airflow will beoverridden.

2) Dip switch 5 in the “OFF” positionwill decrease airflow at 40% fire,and in the “ON” position willincrease airflow at 40% fire.

3) If dip switch 6 is “OFF” the amountairflow will be adjusted by 7.5%. Ifit is “ON” amount of airflow will beadjusted by 15%.

INTEGRATED FURNACE CONTROL

FIGURE 54UT ELECTRONIC CONTROLS IFC BOARD

Mode Switch 1 Position Switch 2 Position

Modulating/Single-Stage OFF OFF

Test 40% ON OFF

Test 100% OFF ON

Two-Stage ON ON

TABLE 15SW2 MODE SELECTION SETTINGS

55

FIGURE 55AIRFLOW SWITCHES (SW1)

56

FIGURE 56EXAMPLE 1

AIRFLOW ADJUSTMENTEXAMPLESThree examples of airflow adjustmentare shown below.

NOTE: All dip switches on SW3 will beshipped in the “OFF” position.

Example 1 (see Figure 56)

PROBLEM: Temperature rise is too highat 40% firing rate although it is withinthe published range at 100% firing rate.

SOLUTION: More airflow is needed tolower the temperature rise at 40%. 1) Set dip switches 4 and 5 of SW3 to

the “ON” position. This will produce a7.5% increase in blower output.

2) Allow furnace to run for several min-utes at 40% firing rate until tempera-ture probes reach equilibrium.

3) If the temperature rise is still abovethe published range, set switch 6 ofSW3 to the “ON” position. This willincrease the airflow rate from +7.5%to +15% above the standard value.

EXAMPLE 2 (see Figure 57)

PROBLEM: Temperature rise is too lowat 100% firing rate although it is withinthe published range at 40% firing rate.

SOLUTION: Less airflow is needed toincrease temperature rise at 100%. 1) Set dip switch 1 of SW3 to the “ON”

position, which overrides standardairflow.

2) Leave switches 2 and 3 in the“OFF” position to decrease airflowby 7.5%.

3) Allow furnace to run for severalminutes at 100% rate until tempera-ture probes reach equilibrium.

4) If the temperature rise is still belowthe published range, set switch 3 tothe “ON” position. This willdecrease the airflow rate from -7.5% to -15% below the standardvalue.

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switches 4 & 5 to “ON” position toincrease airflow by 7.5% at the 40%fire rate.

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. If +7.5% is not enough, increase airflowby setting switch 6 to “ON” position togive +15%.

FIGURE 57EXAMPLE 2

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switch #1 to “ON” position andleave #2 and #3 in the “OFF” positionto decrease airflow by 7.5% at the100% fire rate.

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. If -7.5% is not enough, decrease airflow by setting switch 3 to “ON”position to give -15%.

FIGURE 58EXAMPLE 3

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switch #4 to “ON” and leave #5and #6 set to “OFF” to decrease air-flow by 7.5% at the 40% fire rate. Ifnecessary, set switch #6 to “ON” todecrease airflow by 15%.

12

34

56

ONOFF

40%

100%

SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. Set switches #1 and #2 to “ON” andleave #3 set to “OFF” to increaseairflow by 7.5% at the 100% firerate. If necessary, set switch #3 to“ON” to increase airflow by 15%.

EXAMPLE 3 (see Figure 58)

PROBLEM: Temperature rise is too lowat 40% firing rate and is too high at100%.

SOLUTION: Less airflow is needed toincrease temperature rise at 40% fir-ing rate and more is needed todecrease temperature rise at 100%. 1) Set dip switch 4 of SW3 to the

“ON” position to override standardairflow at 40% firing rate. Leaveswitches 5 and 6 in “OFF” positionto decrease airflow by 7.5%.

2) Allow furnace to run for severalminutes at 40% rate until tempera-ture probes reach equilibrium.

3) If temperature rise is still lowerthan the published range, setswitch 6 to the “ON” position todecrease the airflow rate from -7.5% to -15% below the standardvalue.

4) Set dip switches 1 to the “ON”position to override standard air-flow at 100% firing rate. Set switch2 to the “ON” position to increaseairflow by 7.5%.

5) Allow furnace to run for severalminutes at 100% rate until temper-ature probes reach equilibrium.

6) If temperature rise is still higherthan the published range, setswitch 3 to “ON” position toincrease the airflow rate from 7.5%to 15% above the standard value.

57

When the furnace is powered with thetest switches in a position other thanmodulating/single-stage or in 2-stagemode, the first call for heat within thefirst hour after power-up will instruct thefurnace to perform as follows:

1. Normal ignition sequence

2. A calibration cycle will be performedunless the Test Switches are set forTest 40%. The LED status indicatorwill flash “H” or “h” during the cali-bration cycle (see Table 18).

NOTE: The return air sensor (facto-ry installed) and the supply air sen-sor (field installed) are required forthe furnace calibration cycle. If theair sensors are faulty, or not proper-ly connected, the furnace will notattempt a calibration cycle and willoperate on factory default parame-ters pre-programmed into the micro-processor.

3. After calibration, the furnace willthen adjust to the desired Testcapacity. This allows time for thetechnician to check steady-stateoperation and evaluate furnace per-formance.

NOTE: Refer to Figure 54 (FurnaceTest Mode Sequence of Operation/Troubleshooting), and FurnacePerformance Data Table 17.

4. The furnace will operate at the fixedTest capacity until one of the follow-ing conditions:

a. The thermostat is satisfied andthe call for heat is removed.

b. The furnace has been in testmode continuously for sixty min-utes, at which time the controllerwill go into modulating/single-stage operation.

NOTE: The IFC will only check thetest mode switches on power up.Terminating the test mode by either4a or 4b will place the furnace intomodulating or single-stage opera-tion regardless of the test modeswitch positions.

START-UP PROCEDURESFURNACE TEST MODEFURNACE TEST SWITCHES

NOTE: The integrated furnace controldoes not recognize switch settingchanges while energized. To change set-tings, remove power to the board, makechanges, then return power.

The Integrated Furnace Control isequipped with three sets of field selec-table switches. The set with five switches(SW1) (See Figures 45 and 46) is forselecting airflow operation options(Airflow Switches). The set with twoswitches (SW2) is for placing the furnaceinto test mode for initial set-up and trou-bleshooting and for choosing betweenmodulating, single-stage and two-stagefunctions. (see Figure 45).

The Test Switches will place the IFC intoa test mode, operating the furnace atcontinuous input rates of either 100% offull rate (maximum fire) or 40% of fullrate (minimum fire and 2-stage opera-tion). This is accomplished by setting theTest Switches as indicated in Table 16.

To enter the Furnace Test Mode, proceedas follows:

1. Switch the 115 volt power to the fur-nace OFF. Do not change settingswith control energized.

2. Position Test Switches 1 and 2 forthe desired test mode.

3. Switch the 115 volt power to the fur-nace ON.

4. Set the thermostat mode to HEAT,adjust the setpoint at least 4°F aboveroom temperature to demand a callfor heating.

Mode Switch 1 Position Switch 2 Position

Modulating/Single-Stage OFF OFF

Test 40% ON OFF

Test 100% OFF ON

Two-Stage ON ON

TABLE 16SW2 MODE SELECTION SETTINGS

To set the furnace for normal oper-ation:1. Set the thermostat mode to OFF.

Always allow furnace to completethe cool down cycle.

2. Switch the 115 volt power to thefurnace OFF. Do not changesettings with control energized.

3. Position Test Switches 1 and 2 formodulating/single-stage mode or2-stage mode.

4. Switch the 115 volt power to thefurnace ON.

5. Set the thermostat as desired.

THERMOSTAT TESTMODESEE THERMOSTAT SECTION OFTHESE INSTRUCTIONS FOR TEST-MODE DIRECTIONS.

TO START THE FURNACE1. Remove the burner compartment

control access door.2. IMPORTANT: Be sure that the

manual gas control has been inthe “OFF” position for at leastfive minutes. Do not attempt tomanually light the main burners.

3. Set the room thermostat to itslowest setting and turn off thefurnace electrical power.

4. Turn the gas control knob to the“ON” position.

5. Replace the burner compartmentcontrol access door.

FAILURE TO REPLACE THEBURNER DOOR CAN CAUSEPRODUCTS OF COMBUSTIONTO BE RELEASED INTO THECONDITIONED AREA RESULT-ING IN PERSONAL INJURY ORDEATH.

6. Turn on the furnace electricalpower.

7. Set the room thermostat at least4° F above room temperature tolight the main burners.

8. After the burners are lit, set theroom thermostat to a desiredtemperature.

! WARNING

58

TABLE 18NORMAL OPERATION INDICATORS - DIAGNOSTIC LED

LED SYMBOL DESCRIPTION COMMENTS

All symbols indicate furnace control board is properly powered.

O System OFF There is no demand from the thermostat. There are no active faults.

F System FAN ONLY The IFC is receiving 24V on the “G” terminal ONLY. There are no active faults.

C System COOL The IFC is receiving 24 V on the “YL” and/or “YH” terminals. There are no active faults.

H System HEAT The IFC is receiving 24 V on the “W” terminal. The modulating signal is present on the “V” terminal. There are no active faults.

h System HEAT The IFC is receiving 24 V on the “W” terminal. The modulating signal is NOT present on the “V” terminal. There are no active faults.

“H” Calibration Cycle The IFC is receiving 24 V on the “W” Flashing terminal. The modulating signal is present on the

“V” terminal. The furnace is in calibration mode. There are no active faults.

“h” Calibration Cycle The IFC is receiving 24 V on the “W” Flashing terminal. The modulating signal is NOT present on

the “V” terminal. The furnace is in calibration mode. There are no active faults.

TABLE 17FURNACE PERFORMANCE DATA

Operating Inducer Servo ValveManifold Pressure

TemperatureLevel Speed Current Rise

100% High ~180 milliampsNatural - 3.5" w.c. (±0.3")

40°-70° FLP - 10.0" w.c. (±0.5")


40°-70° FLP - 8.1" w.c. (±0.5")

80% High ~144 milliampsNatural - 2.2" w.c. (± 0.3")

40°-70°FLP - 6.4" w.c. (± 0.5")


40°-70°FLP - 4.9" w.c. (± 0.5")


40°-70°FLP - 3.6" w.c. (± 0.5")


40°-70°FLP - 2.5" w.c. (± 0.5")

40% Low ~72 milliampsNatural - 0.6" w.c. (± 0.3")

40°-70°FLP - 1.6" w.c. (± 0.5")

Calibration High ~135 milliampsNatural - 2.0" w.c. (± 0.3")

40°-70°FLP - 5.6" w.c. (± 0.5")

NOTE: Gas valve milliamp readings may vary ± 05%.

59

TO SHUT DOWNTHE FURNACE1. Set the room thermostat to its low-

est setting.2. Remove the burner compartment

control access door.3. Shut off the gas to the main burners

by turning the gas control knob tothe “OFF” position.

4. Replace the burner compartmentcontrol access door.

SHOULD OVERHEATING OCCUROR THE GAS SUPPLY FAIL TOSHUT OFF, CLOSE THE MANU-AL GAS VALVE FOR THE APPLI-ANCE BEFORE SHUTTING OFFTHE ELECTRICAL SUPPLY. FAIL-URE TO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULT-ING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATIONHeating Cycle InitiationThe heating cycle is always initiated bya 24 volt signal on W of the thermostat.When the controller senses 24 volts onW, the following sequence occurs:• High and low pressure switches are

checked to insure contacts are open.• Inducer is powered on high speed for

a thirty (30) second prepurge.• Pressure switches are monitored as

the inducer creates the vacuum toclose the contacts.

• The servo valve on the gas valve isenergized with ~180 milliamps current.(No flow yet.)

• The controller sends 120 volts to theignition control, which sparks acrossthe electrodes.

• The main solenoids on the gas valveare energized allowing gas to flow tothe burners.

• When flame is proven, the ignitioncontrol is de-energized - 8 secondmaximum trial time.

• The gas valve maintains 100% ratethrough the warm-up period - 20 sec-onds.

Heating Cycle ResponseThe heating cycle is always initiated by a24 volt signal on W1. When the controllersenses 24 volts on W1, the followingsequence occurs:

MODULATING FUNCTION:(“W” and “V” signal inputs, refer to dip

switch set SW2 on IFC)After the warm-up period, the furnacewill respond to the thermostat demandby adjusting the gas valve pressureand blower speed anywhere between40% to 100% heating capacity.

➤ TWO-STAGE FUNCTION:(Two-stage function only applies when

both switches of SW2 are in the “ON”position and a two-stage thermostat isinstalled as shown in Figure 30.)After the warm-up period, the furnacewill respond to the thermostat demandby adjusting the gas valve pressure andblower heating speeds to the “W” signalvalues. “W” only = 40% gas valve pres-sure and blower heating speed. “W2” =65% gas valve pressure and blowerheating speed for first five minutes and100% thereafter. Also, if the call for heatends, the furnace terminates at the pre-sent rate.

➤ SINGLE-STAGE FUNCTION:(“W” signal only)

After the warm-up period, the furnacewill respond to the thermostat demandby altering the gas valve pressure andblower speed as follows:

Phase 1: 0 to 5 minutes = 40% of furnacecapacity (gas valve output and blowerspeed)

Phase 2: 5 to 12 minutes = 65% of fur-nace capacity (gas valve output andblower speed)

Phase 3: After 12 minutes = 100% of fur-nace capacity (gas valve output andblower speed)

NOTE: If the call for heat ends during anyphase, the furnace will terminate imme-diately at the firing rate of that phase.

Heating Cycle Termination(“W” signal only, refer to dip switch set

SW2 on IFC)When the 24 volt signal is removed fromW1, the heating cycle will end and the fur-nace will shut down and return to theproper off cycle operation.

TABLE 19METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACESEQUIPPED FOR NATURAL OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.METER

900 1000 1040 1100 2500 (LP)INPUT SIZE

BTU/HR CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

ONE 0 54 1 0 1 3 1 6 2 30

60,000 TEN 9 0 10 0 10 24 11 0 25 0

ONE 0 44 0 48 0 50 0 53 2 0

75,000 TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 36 0 40 0 42 0 44 1 40

90,000 TEN 6 0 6 40 7 0 7 20 16 40

ONE 0 31 0 34 0 36 0 38 1 26

105,000 TEN 5 10 5 40 6 0 6 20 14 20

ONE 0 27 0 30 0 31 0 33 1 15

120,000 TEN 4 30 5 0 5 10 5 30 12 30

DRY Heating Value of Gas (BTU/FT3) x 3600Formula: Input BTU/HR = x C • F

Time in Seconds (for 1 cu. ft.) of Gas

SETTING INPUT RATEChecking furnace input is importantto prevent over firing beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE. Use the follow-ing table or formula to determineinput rate. Prior to checking the fur-nace input, make certain that allother gas appliances are shut off,with the exception of pilot burners.Time the meter with only the furnacein operation. Start the furnace, inFurnace Test Mode, 100% rate, andmeasure the time required to burnone cubic foot of gas. The furnace is shipped from the fac-tory with #50 orifices. They are sizedfor natural gas having a heatingvalue of 1075 BTU/cu. ft. and a spe-cific gravity of .60. For high-altitudemodels (option 278) the furnacecomes equipped with #51 orificesinstalled for elevations above 5,000ft. These orifices may still need to bechanged based on both elevationand gas heating value. Consult thesection of this book titled “HighAltitude Installation” for details.Since heating values vary geographi-cally, the manifold pressure and/orgas orifice size may need to bechanged to adjust the furnace to itsnameplate input. The rate will alsovary with altitude. Consult the localgas utility to obtain the yearly aver-age heating value and orifice sizerequired to fire each individual burnerat 15,000 BTUH. For high altitudeinstallations, also consult the sectionof this manual titled “High AltitudeInstallations” for details on how tocalculate the correct orifice size.

Gas Pressure (inch • Hg) x 520 (˚F)Where C • F =

Gas Temperature (˚F) x 30 (inches • Hg)

! WARNING

60

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTE-NANCE. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

FILTERSKeep the filters clean at all times.Remove the filter. Vacuum dirt from filter,wash with detergent and water, air drythoroughly and reinstall.

NOTE: Some filters must be resized to fitcertain units and applications. See Table14 and Figures 59, 60, 61 and 62.

1. 21" - 90,000 & 105,000 BTUH unitsrequire removal of a 31/2-in. segmentof filter and frame to get the properwidth for a side filter.

2. 241/2" - 120,000 BTUH unit requiresremoval of a 7" segment of filter andframe to get the proper width for aside filter.

! WARNING TABLE 20FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH KBTUH SIZE SIZE

171/2" 60 AND 75 153/4" X 25" 153/4" X 25" 1

21" 90 AND 105 191/4" X 25" 153/4" X 25" 1

241/2" 120 223/4" X 25" 153/4" X 25" 1

FIGURE 60RESIZING FILTERS AND FRAME

MAINTENANCE

FIGURE 59UPFLOW — FILTER REPLACEMENT

REMOVE SEGMENT TO SIZEAS REQUIRED

2409401

542201

61

FIGURE 61UPFLOW -- SIDE FILTER LOCATIONS

CUT-OUT AND DRILL DETAIL ROD & FILTER SUPPORT ANGLE ASSEMBLY 1332

FIGURE 62DOWNFLOW -- FILTER INSTALLATION

A087001.S01

FIGURE 63HORIZONTAL -- FILTER INSTALLATION

A087101.S01

62

IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the flame sensor be cleaned withsteel wool by a qualified installer, ser-vice agency or the gas supplier.

IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the condensate trap be inspect-ed for debris or blockage. A blockedcondensate trap can cause water toback up into the primary heatexchanger and lead to nuisance trip-ping of the over temperature switchesand/or pressure switches.

IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the condensate neutralizer ifused be replaced by a qualifiedinstaller, service agency or the gassupplier.

IMPORTANT: It is recommended thatan annual inspection and cleaning ofall furnace markings be made toassure legibility. Attach a replacementmarking, which can be obtainedthrough the distributor, if any arefound to be ILlegible or missing.

REPLACEMENT PARTSContact your local distributor for acomplete parts list.

TROUBLESHOOTINGFigure 64 is a troubleshooting flow-charts for the sequence of operation.Table 21 is for fault-code descriptions.

WIRING DIAGRAMFigure 65 is a complete wiring dia-gram for the furnace and powersources.

DO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODS WITH-OUT FILTERS. A PORTION OFTHE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. ANYRECIRCULATED DUST PARTI-CLES WILL BE HEATED ANDCHARRED BY CONTACT WITHTHE FURNACE HEAT EXCHANG-ER. THIS RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHER HOUSE-HOLD ARTICLES.

LUBRICATIONIMPORTANT: Do Not attempt to lubri-cate the bearings on the blower motor orthe induced draft blower motor. Additionof lubricants can reduce the motor lifeand void the warranty.

The blower motor and induced draftblower motor bearings are prelubricatedby the manufacturer and do not requirefurther attention.

The blower motor and induced draftblower motor must be cleaned periodi-cally by a qualified installer, serviceagency, or the gas supplier to preventthe possibility of overheating due to anaccumulation of dust and dirt on thewindings or on the motor exterior. Theair filters should be kept clean. As dirtyfilters can restrict airflow. The motordepends upon sufficient airflowingacross and through it to keep from over-heating.

SYSTEM OPERATIONINFORMATIONAdvise The Customer

IMPORTANT: Replace all blower doorsand compartment covers after servicingthe furnace. Do not operate the unitwithout all panels and doors securely inplace.

1. Keep the air filters clean. The heat-ing system will operate more effi-ciently and more economically.

2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.

3. Close doors and windows. This willreduce the heating load on the sys-tem.

4. Avoid excessive use of kitchenexhaust fans.

5. Do not permit the heat generatedby television, lamps or radios toinfluence the thermostat operation.

6. Explain proper operation of thesystem with constant air circulation.

ANNUAL INSPECTIONThe furnace should operate for manyyears without excessive scale build-upin the flue passageways. However, it isrecommended that a qualified installer,service agency, or the gas supplierannually inspect the flue passageways,the vent system and the main burnersfor continued safe operation. Pay partic-ular attention to deterioration from cor-rosion or other sources.

During the annual inspection, all electri-cal power to the furnace should beturned off and then restored. This willput the furnace into a calibration cycleon the initial call for heat. This is a fiveminute (or until the heat call is satisfied)cycle which allows the furnace to evalu-ate conditions It should be noted, thata calibration cycle will occur on the ini-tial call for heat each time after line volt-age has been interrupted to the unit.

IMPORTANT: It is recommended that atthe beginning and at approximately halfway through the heating season, a visu-al inspection be made of the main burn-er flames for the desired flame appear-ance by a qualified installer, serviceagency or the gas supplier. If the flamesare distorted and/or there is evidence ofback pressure, check the vent and inletair system for blockage. If there is car-bon and scale in the heat exchangertubes, the heat exchanger assemblyshould be replaced.

HOLES IN THE VENT PIPE OR HEATEXCHANGER CAN CAUSE TOXICFUMES TO ENTER THE HOME,RESULTING IN CARBON MONOXIDEPOISONING OR DEATH. THE VENTPIPE OR HEAT EXCHANGER MUSTBE REPLACED IF THEY LEAK.

! CAUTION

! WARNING

63

SEQUENCE OF OPERATION TROUBLESHOOTING FLOWCHARTFIGURE 64

Start

1. De-energize furnace IFC

2. Set test switches (SW2) todesired setting: 100% or 40%

3. Re-energize furnace IFC

4. Set thermostat to heat, set 4°above room temperature

LED status display shows "H"or “h”LED status display is blank

1. Check transformer secondary voltage

2. Check line voltage

3. Check transformer secondary fuse

If 1, 2, and 3 check OK, replace IFC

LED status display shows "0", "C", or "F"

1. Call for heat at the thermostat, cycle furnace power, go to"start"

LED status display shows numeric function code

1. See function code troubleshooting guide

Induced draft motor (IDM) startson high speed for 30 secondprepurge

Motor does not start

1. Check status display - FUNCTION CODE 44 or 55, Checkpressure switches. FUNCTION CODE 45 or 57, Check IDM

2. Check voltage to IDM high speed tap

3. Check IDM run capacitor

If 2 & 3 check OK, replace IDM assembly

4. Check wiring

5. Check voltage on IDM pin on IFC

If 5 checks bad, replace IFC

Motor runs for 60 seconds, then cycle terminates

1. Check status display - FUNCTION CODE 45 or 57 expected,see function code troubleshooting guide

Motor starts on low speed

1. Check wiring

Gas valve servo valve set to100% rate (~180 milliamps D.C.)

Direct spark igniter is activated (8 second trial for ignition)

continued on next page

yesno

yes

no

yesno

yes

no

Servo current measures less than 170 milliamps D.C.

1. Check status display - possible codes 77 or 78, see functioncode troubleshooting guide

No spark present at igniter

1. Check status display - FUNCTION CODE 45 or 57 expected

2. Check pressure switches

3. Check 120 volts to igniter control during trial for ignition (30seconds after IDM starts). If 3 checks OK, go to step 6. If120 volts not present, then

4. Check wiring

5. Check 120 volts on IFC spark igniter pins, if bad replace IFC

6. Check spark wire connection

7. Check spark wire & electrode ceramic

8. Check spark gap (0.10 inches), if 6, 7, and 8 check OKreplace spark control

64

Burners light Ignition trial duration is 8 seconds. The gas valve will be ener-gized (24 volts between M/P & C) for this period and will remainenergized only if the flame sense signal is above a minimumthreshold by this time. If the first trial is not successful, three addi-tional trials will be made with IDM purge periods of 30 seconds athigh speed between retries.

If the burners do not light:

1. Check status display - FUNCTION CODE 11 expected

2. Check for 24 volts between "M/P" and "C" - if 24 volts notpresent, go to step 5

3. Check gas line inlet pressure

4. Check manifold pressure - if steps 2 & 3 are OK, but 4 is bad- replace gas valve

5. Check wiring

6. Check for 24 volts on the IFC valve pins - if 6 checks bad -replace IFC

7. Check spark electrode position

Burners remain lit beyond 8 sec-ond trial time

Failure to sense flame:

1. Check status display - FUNCTION CODE 11 expected - seefunction code troubleshooting guide

Indoor blower motor starts 20seconds after gas valve opens

Motor does not start:

1. Check status display -FUNCTION CODE 67 or 68 expected

2. Check for 120 volts to motor (5 pin plug)

3. Check wiring

4. Test motor with ECM2+ motor tester (see ECM2+ motor testprocedures)

If 2, 3, and 4 test OK, replace IFC

If furnace test switches are setto 100%, calibration cycle exe-cutes and status display blinks"H" or ''h''. Duration is 5 minutes.Calibration is performed with thefurnace operating at 75% capac-ity. The inducer will run on highspeed, the servo valve currentwill be set at about 135 mil-liamps resulting in a manifoldpressure of around 2.0" w.c. Nat.(5.6" w.c. L.P.)

Supply air sensor faulty or not installed


2. Ensure supply air sensor is installed in the plenum and isproperly wired to the IFC

3. Check resistance of supply air sensor - if step 3 checks bad,replace sensor

Return air sensor faulty or not installed


2. Check return air sensor wiring

3. Check resistance of return air sensor - if step 3 checks bad,replace sensor

continued on next page

noyes

no

yes

yes

no

no

yes

65

FURNACE TEST SWITCHES SETAT 100 %

Furnace runs at 100% rate, statusdisplay shows "H" or “h”, induceron high speed, servo current is~180 milliamps, manifold pressureis ~3.5 " w.c. and temperature riseis 40 - 70 ºF

Monitor status display for abnormal indications, see function codetroubleshooting guide

FURNACE TEST SWITCHES SETAT 40 %

Furnace runs at 40% rate, statusdisplay shows "H" or “h”, inducer onlow speed, servo current is ~ 72milliamps, manifold pressure is~0.6 " w.c. and temperature rise is40 - 70°F

Monitor status display for abnormal indications, see function codetroubleshooting guide

Terminate test mode

1. Test mode times out in 60minutes.

2. Remove the call for heatfrom the W terminal

Induced draft motor stops after 5seconds

Induced draft motor doesn't stop

1. Check status display - FUNCTION CODE 22 or 33 expected

2. Check over-temperature switch(es)

3. Check wiring

If steps 2 & 3 check OK, replace IFC

ECM2+ indoor blower motor stopsafter 90 seconds

ECM2+ indoor blower motor does not stop running

1. Check status display - FUNCTION CODE 22, 23 or 33 expect-ed

2. Check main limit and over temperature switch(es)

3. Test motor with ECM2+ motor tester (see ECM2+ motor testprocedures)

If steps 2 & 3 check OK, replace IFCTroubleshooting ends

To return system to modulating/single-stage operation (SW2):

1. De-energize IFC

2. Set furnace test switches (SW2) for desired operation

3. Re-energize IFC

4. Set thermostat for desired operation

REPEAT PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED IN100% AND 40% TEST MODES

no

no

yes

no

yes

no

yes

no

yes

Status display shows "C", "F", or "H"

1. Ensure thermostat is off

2. Check thermostat wiring

Flames remain on

1. Check 24 volts to gas valve solenoids (M/P) - if present, go tostep 2, if 24 volts is not present, shut off gas and replace thegas valve

2. Check wiring

3. Check 24 volts on IFC valve pins (MV) - if status displayshows "O" and 24 volts is present in step 3, replace IFC

LED status display shows "O" gasvalve off, flames off

yes

20

66

TABLE 21FAULT CODE TROUBLESHOOTING CHART

Low

Fla

me

Sens

e

Flam

e se

nse

leve

l is

belo

wpr

edet

erm

ined

thre

shol

d bu

tab

ove

min

imum

ope

ratin

g th

resh

-ol

d. R

emai

ns d

ispl

ayed

unt

il fl

ame

sens

e le

vel r

ises

abo

ve th

resh

old

leve

l or

heat

dem

and

is r

emov

ed.

1.C

heck

for

mis

-wir

ing

in f

urna

ce2.

Rep

lace

IFC

1.In

sure

gas

sup

ply

is c

onne

cted

to f

ur-

nace

and

che

ck f

or p

rope

r lin

e pr

essu

re

1.T

urn

gas

valv

e to

the

“ON

” po

sitio

n

1.C

heck

24

VA

C to

gas

val

ve.

2.C

heck

for

170

- 1

90 m

Am

ps to

ser

vova

lve.

3.A

djus

t val

ve f

or p

rope

r m

anif

old

pres

-su

re a

t 100

% r

ate

4.If

gas

val

ve w

ill n

ot a

djus

t, re

plac

e ga

sva

lve.

1.C

heck

120

VA

C a

t ig

nite

r co

ntro

l du

ring

igni

tion

tri

al.

2.C

heck

spa

rk w

ire

conn

ecti

on a

t ig

nite

rco

ntro

l tr

ansf

orm

er a

nd e

lect

rode

.3.

Che

ck f

or s

hort

to

grou

nd o

f el

ectr

ode

(cra

cked

cer

amic

, tou

chin

g bu

rner

s, e

tc.)

4. C

heck

ign

iter

wir

e f

or d

amag

e.5.

If a

ll c

heck

s O

K, r

epla

ce i

gnit

er c

ontr

ol

1.C

heck

for

pro

per

mou

ntin

g an

d pl

ace-

men

t spa

rk e

lect

rode

ass

embl

y.2.

Che

ck f

or p

rope

r m

ount

ing

of b

urne

ras

sem

bly.

1.C

heck

for

pro

per

pola

rity

of

line

volt-

age.

2.C

heck

fla

me

sens

or w

irin

g an

d co

nnec

-tio

ns.

3.C

heck

for

impr

oper

ly m

ount

ed f

lam

ese

nsor

(po

sitio

ned

out o

f fl

ame,

gr

ound

ed).

4.C

heck

fla

me

sens

e cu

rren

t.5.

Cle

an f

lam

e se

nsor

rod

.

1.C

lean

fla

me

sens

or r

od

1.R

e-in

stal

l / r

epla

ce f

lam

e se

nsor

, che

ckw

irin

g an

d co

nnec

tions

.

Faile

d m

icro

proc

esso

r se

lf te

st o

rm

ain

gas

valv

e sa

fety

cir

cuit

faul

t.H

ard

lock

out

No

flam

e se

nse

duri

ng ig

nitio

n tr

ial.

Rem

ains

dis

play

ed u

ntil

succ

essf

ulig

nitio

n, o

ne h

our

retr

y is

sta

rted

or

heat

dem

and

is r

emov

ed

Faul

t is

stor

ed in

buf

fer

afte

r fo

urco

nsec

utiv

e fa

iled

igni

tion

tria

ls in

a

sing

le h

eat c

all

A.

Vol

tage

sen

sed

on th

e M

Vou

tput

B.

Soft

war

e Se

lf-t

est o

utpu

t

A.

Insu

ffic

ient

line

gas

pre

ssur

e

B.

Gas

val

ve c

ontr

ol tu

rned

“O

FF”

C.

Insu

ffic

ient

man

ifol

d pr

essu

re, g

asva

lve

“ON

”

D.

No

spar

k at

ele

ctro

des

E.

Bur

ners

don

’t li

ght

F.B

urne

rs li

ght,

but e

xtin

guis

h af

ter

8se

cond

s or

less

A.

Flam

e se

nsor

con

tam

inat

ed

B.

Flam

e Se

nsor

impr

oper

ly m

ount

ed o

rgr

ound

ed

– 11 12

Inte

rnal

fau

lt

Faile

d Ig

nitio

n T

rial

1.C

heck

for

fun

ctio

n co

de 1

1 in

buf

fer.

See

sol

utio

ns f

or f

unct

ion

code

11.

2. C

heck

for

fun

ctio

n co

de 1

3 in

buf

fer.

See

sol

utio

ns f

or f

unct

ion

code

13.

Afu

rnac

e fa

ult h

as c

ause

d th

e co

ntro

ller

to e

xecu

te a

one

-hou

r re

try

mod

e.

A.

Faile

d ig

nitio

n tr

ial f

our t

imes

(cod

e 11

)B

.L

ost f

lam

e se

nse

four

tim

es (c

ode

13)

rO

ne-H

our

Ret

ry

Solu

tion

sF

unct

ion

Cod

eD

escr

ipti

onR

espo

nse

Com

men

tsP

roba

ble

Cau

ses

67

TABLE 21FAULT CODE TROUBLESHOOTING CHART, CONT.

1.C

lean

fla

me

sens

or r

od

1.R

e-in

stal

l / r

epla

ce f

lam

e se

nsor

, che

ckw

irin

g an

d co

nnec

tions

.

1.C

heck

tha

t al

l bu

rner

ass

embl

y co

mpo

-ne

nts

are

prop

erly

ins

tall

ed.

2.C

heck

tha

t al

l se

als

betw

een

the

vest

ibul

e ar

ea a

nd t

he h

eat

exch

ange

rar

ea a

re t

ight

3.In

sure

tha

t th

e co

mbu

stio

n do

or g

aske

tis

in

plac

e an

d th

e do

or i

s pr

oper

lyin

stal

led.

1.R

epai

r m

is-w

irin

g to

rem

ove

cont

inu-

ous

24V

to v

alve

.2.

Gas

val

ve s

tuck

ope

n -

rem

ove

and

repl

ace.

1.R

epla

ce I

FC b

oard

1.C

heck

Fau

lt B

uffe

r fo

r E

CM

mot

orfa

ult

hist

ory

2.C

heck

EC

M m

otor

wir

ing

to th

e co

n-tr

ol b

oard

.3.

Test

EC

M m

otor

and

rep

lace

if f

aulty

.

1.C

heck

Fau

lt B

uffe

r fo

r E

CM

mot

or f

ault

hist

ory

2.C

heck

EC

M m

otor

wir

ing

to th

e co

ntro

lbo

ard.

3.Te

st E

CM

mot

or a

nd r

epla

ce if

fau

lty.

1.R

epla

ce L

imit

.

1.C

heck

Fau

lt B

uffe

r fo

r E

CM

mot

orfa

ult h

isto

ry2.

Che

ck f

ilter

s an

d du

ct w

ork

for

rest

ric-

tions

3.C

heck

rat

e an

d ou

tlet a

ir te

mpe

ratu

reat

100

%, a

nd 4

0%, c

ompa

re to

max

i-m

um o

n na

mep

late

4.R

un f

urna

ce c

alib

ratio

n an

d re

–che

ckou

tlet a

ir te

mpe

ratu

re

1.R

epla

ce li

mit

cont

rol

1.In

sure

pro

perl

y si

zed

orif

ices

inst

alle

d.2.

Che

ck m

anif

old

pres

sure

and

adj

ust a

sne

eded

.

1.R

epai

r ju

mpe

r be

twee

n pi

ns 5

& 1

1on

J1.

Flam

e se

nse

is b

elow

min

imum

oper

atin

g th

resh

old

duri

ng a

hea

ting

cycl

e. R

emai

ns u

ntil

a su

cces

sful

igni

tion

sequ

ence

, one

hou

r re

try

isst

arte

d or

the

heat

dem

and

isre

mov

ed.

Faul

t is

stor

ed in

buf

fer

afte

r fo

urig

nitio

n re

trie

s in

a s

ingl

e he

at c

all.

Flam

e se

nsed

whe

n ga

s va

lve

is o

ff.

Rem

ains

dis

play

ed u

ntil

flam

ese

nse

sign

al is

gon

e.

Hig

h lim

it ci

rcui

t is

open

. R

emai

nsdi

spla

yed

until

cir

cuit

is s

ense

dcl

osed

.

Aux

iliar

y lim

it ci

rcui

t is

open

.R

emai

ns d

ispl

ayed

unt

il ci

rcui

t is

sens

ed c

lose

d.

A.

Flam

e se

nsor

con

tam

inat

ed

B.

Flam

e se

nsor

impr

oper

ly m

ount

ed o

rgr

ound

ed

C.

Uns

tabl

e fl

ame

patte

rn

A.

Flam

e re

mai

ns li

t in

“OFF

” cy

cle

B.

Flam

e go

es o

ut in

“O

FF”

cycl

e

A.

No

airf

low

B.

Insu

ffic

ient

air

flow

C.

Faul

ty li

mit

cont

rol

D.

Inpu

t rat

e to

o hi

gh.

A.

On

upfl

ow f

urna

ces

jum

per

loos

e,br

oken

or

mis

sing

B.

On

dow

nflo

w f

urna

ce, f

aulty

HA

LC

.

C. O

n do

wnf

low

fur

nace

s, n

o ai

rflo

w

13 14 22 23

Los

t Fla

me

Sens

e

Impr

oper

Fla

me

Sens

e

Hig

h L

imit

Aux

iliar

y L

imit

(HA

LC

)

Solu

tion

sF

unct

ion

Cod

eD

escr

ipti

onR

espo

nse

Com

men

tsP

roba

ble

Cau

ses

68


C.

Abn

orm

ally

hig

h ne

gativ

e pr

essu

repr

esen

t on

vent

sys

tem

Low

pre

ssur

e sw

itch

circ

uit i

scl

osed

whe

n no

cal

l for

hea

t.R

emai

ns d

ispl

ayed

unt

il ci

rcui

top

ens

or h

eat d

eman

d is

rem

oved

.

44L

PS –

Con

tact

s C

lose

d

1.R

epla

ce li

mit

cont

rol.

1.C

heck

that

indu

cer

is o

pera

ting

atpr

oper

spe

ed a

nd R

PM.

2.In

sure

ven

ting

does

not

exc

eed

the

max

imum

leng

ths

spec

ifie

d in

the

vent

ing

inst

ruct

ions

.3.

Che

ck th

at a

ll ga

sket

s be

twee

n th

ein

duce

r an

d th

e ce

nter

pan

el /

heat

exch

ange

r ar

e pr

oper

ly in

stal

led

and

no le

aks

exis

t

1.C

heck

that

all

burn

er a

ssem

bly

com

-po

nent

s ar

e pr

oper

ly in

stal

led.

2.C

heck

that

all

seal

s be

twee

n th

e bu

rn-

er com

part

men

t and

the

heat

exc

hang

erar

ea a

re ti

ght.

3.In

sure

that

the

door

sea

ls a

re in

pla

cean

d th

e do

or is

pro

perl

y in

stal

led.

4.C

heck

that

the

heat

exc

hang

er h

as n

otbe

en d

amag

ed; i

e. c

rush

ed tu

bes,

brea

ched

col

lect

or b

oxes

1.C

heck

for

sho

rted

wir

es to

the

low

pres

sure

sw

itch

1.R

epla

ce lo

w p

ress

ure

switc

h

1.C

heck

for

pro

per

vent

ing

and

term

ina-

tion

as d

efin

ed in

the

furn

ace

inst

alla

-tio

n in

stru

ctio

ns

Ove

r–te

mpe

ratu

re li

mit

circ

uit i

sop

en. R

emai

ns d

ispl

ayed

unt

il ci

r-cu

it is

sen

sed

clos

ed.

A.

Faul

ty li

mit

cont

rol

B.

Insu

ffic

ient

com

bust

ion

air

C.

Uns

tabl

e fl

ame

patte

rn

A.

Faul

ty w

irin

g

B.

Faul

ty s

witc

h

33O

ver–

Tem

pera

ture

Lim

it

1.C

heck

for

leak

ing

hose

s or

leak

ing

gask

et a

t the

indu

ced

draf

t blo

wer

1.R

epla

ce L

ow P

ress

ure

Switc

h

Low

pre

ssur

e sw

itch

circ

uit i

s op

endu

ring

hig

h sp

eed

IDM

ope

ratio

n.R

emai

ns d

ispl

ayed

unt

il a

succ

ess-

ful i

gniti

on s

eque

nce

or th

e he

atde

man

d is

rem

oved

B.

Insu

ffic

ient

com

bust

ion

air

C.

Impr

oper

pre

ssur

e sw

itch

setti

ng

45L

PS –

Ope

n –

IDM

=H

I

Solu

tion

sF

unct

ion

Cod

eD

escr

ipti

onR

espo

nse

Com

men

tsP

roba

ble

Cau

ses

A.

Insu

ffic

ient

com

bust

ion

airf

low

69


Hig

h pr

essu

re s

witc

h ci

rcui

t is

open

duri

ng h

igh

spee

d ID

M o

pera

tion.

Rem

ains

dis

play

ed u

ntil

a su

cces

s-fu

l ign

ition

seq

uenc

e or

the

heat

dem

and

is r

emov

ed.

57H

PS –

Ope

n –

IDM

=H

I

1.C

heck

that

the

wir

es to

the

high

pre

s-su

re s

witc

h ha

ve n

ot b

een

shor

ted

toge

ther

1.R

epla

ce h

igh

pres

sure

sw

itch

1.C

heck

that

the

max

imum

ven

t len

gth

for

the

appl

icat

ion

has

not b

een

exce

eded

and

that

the

vent

is p

rope

rly

term

inat

ed2.

Che

ck th

at th

e co

mbu

stio

n ai

r in

let

and

vent

pip

es a

re n

ot r

estr

icte

d3.

Che

ck th

at th

e in

duce

d dr

aft m

otor

isop

erat

ing

at th

e pr

oper

spe

ed.

1.C

heck

dra

in li

nes

for

bloc

kage

, kin

ksor

dou

ble

trap

s2.

Insu

re d

rain

trap

has

bee

n fi

lled

with

wat

er b

efor

e op

erat

ion

1.C

heck

for

leak

ing

hose

s or

leak

ing

gask

et a

t the

indu

ced

draf

t blo

wer

1.R

epla

ce H

igh

Pres

sure

Sw

itch

1.R

epla

ce H

igh

Pres

sure

Sw

itch

Hig

h pr

essu

re s

witc

h ci

rcui

t is

clos

ed w

ith n

o ca

ll fo

r he

at.

Rem

ains

dis

play

ed u

ntil

circ

uit

open

s or

hea

t dem

and

is r

emov

ed.

A.

Faul

ty w

irin

g

B.F

aulty

sw

itch

A.

Insu

ffic

ient

com

bust

ion

airf

low

B.

Con

dens

ate

not d

rain

ing

from

hea

tex

chan

ger

C.

Insu

ffic

ient

pre

ssur

e se

nsed

at s

witc

h

D.

Impr

oper

pre

ssur

e sw

itch

setti

ng

E.

Faul

ty s

witc

h

55H

PS –

Con

tact

s C

lose

d

1.In

sure

ven

t sys

tem

has

min

imum

rec

om-

men

ded

vent

leng

ths.

2.In

sure

ven

t sys

tem

is p

rope

rly

term

inat

ed.

3.In

sure

com

bust

ion

com

part

men

t doo

r is

prop

erly

inst

alle

d.

1.If

hig

h al

titud

e pr

essu

re s

witc

h is

inst

alle

d an

d in

stal

latio

n si

te e

leva

tion

isne

ar 5

,000

fee

t, ch

eck

cold

pre

ssur

es o

nhi

gh s

peed

indu

cer

to in

sure

pre

ssur

esw

itch

chan

ge w

as n

eces

sary

.2.

Rep

lace

hig

h pr

essu

re s

witc

h as

nee

ded.

Hig

h pr

essu

re s

witc

h ci

rcui

t is

clos

ed d

urin

g lo

w s

peed

ID

M o

per-

atio

n.

Rem

ains

dis

play

ed u

ntil

heat

dem

and

is r

emov

ed

A.

Min

imum

ven

t req

uire

men

ts n

ot f

ol-

low

ed

B. I

mpr

oper

sw

itch

setti

ng

56H

PS -

Clo

sed

- ID

M =

LO

1.C

heck

that

the

max

imum

ven

t len

gth

for

the

appl

icat

ion

has

not b

een

exce

eded

and

that

the

vent

is p

rope

rly

term

inat

ed2.

Che

ck th

at th

e co

mbu

stio

n ai

r in

let a

ndve

nt p

ipes

are

not

res

tric

ted

3.C

heck

that

the

indu

ced

draf

t mot

or is

oper

atin

g at

the

prop

er s

peed

.1.

Che

ck d

rain

line

s fo

r bl

ocka

ge, k

inks

or d

oubl

e tr

aps

2.In

sure

dra

in tr

ap h

as b

een

fille

d w

ithw

ater

bef

ore

oper

atio

n

1.C

heck

for

leak

ing

hose

s or

leak

ing

gask

et a

t the

indu

ced

draf

t blo

wer

1.R

epla

ce L

ow P

ress

ure

Switc

h

1.R

epla

ce L

ow P

ress

ure

Switc

h

Low

pre

ssur

e sw

itch

circ

uit i

s op

endu

ring

low

spe

ed I

DM

ope

ratio

n.R

emai

ns d

ispl

ayed

unt

il a

succ

ess-

ful i

gniti

on s

eque

nce

or th

e he

atde

man

d is

rem

oved

A.

Insu

ffic

ient

com

bust

ion

airf

low

B.

Con

dens

ate

not d

rain

ing

from

hea

tex

chan

ger

C.

Insu

ffic

ient

pre

ssur

e se

nsed

at s

witc

h

D.

Impr

oper

pre

ssur

e sw

itch

setti

ng

E.

Faul

ty s

witc

h

46A

uxili

ary

Lim

itL

PS -

Ope

n -

IDM

= L

O

Solu

tion

sF

unct

ion

Cod

eD

escr

ipti

onR

espo

nse

Com

men

tsP

roba

ble

Cau

ses

70


1.C

heck

for

dir

ty f

ilter

2.C

heck

for

inad

equa

te r

etur

n ai

r su

pply

3.C

heck

for

und

er–s

ized

duc

t wor

k4.

Che

ck f

or lo

ose

blow

er w

heel

5.U

nit i

nsta

llatio

n is

at e

nvir

onm

enta

l lim

-its

of:

alti

tude

, sys

tem

sta

tic p

ress

ures

,hi

gh e

ffic

ienc

y ai

r fi

lters

, etc

. Blo

wer

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FIGURE 65WIRING DIAGRAM

72 CM 1204

THERMOSTAT INSTRUCTIONS

SE

CT

ION

2

92-24321-05-02SUPERCEDES 92-24321-05-01

INSTALLATION INSTRUCTIONSPROGRAMMABLE MODULATING THERMOSTAT(PART # 41-24312-04)

NON-PROGRAMMABLE THERMOSTAT(PART #41-25347-01)

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!!

DO NOT DESTROY THIS MANUALPLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPERINSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.READ THESE INSTRUCTIONS THOROUGHLY BEFOREATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL-LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPERINSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCEPOSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING!

2

INSTALLING YOUR THERMOSTATINTRODUCTIONThis thermostat is an electronic 24-VAC, wall-mounted thermostat. Ituses two set points to maintain andcontrol room temperature in both theheating and cooling modes. Nobatteries are required: temperature,fan, mode, and installer configurationsettings are preserved if there is aloss of power.

IMPORTANT: THE 41-24312-04THERMOSTAT REPLACES ALLPAST THERMOSTATS WITH PARTNUMBERS 41-24312-02 AND 41-24312-03 THAT ARE NO LONGERAVAILABLE.

THIS THERMOSTAT IS INTENDEDFOR USE WITH THE MODULATINGHEAT 90 PLUS GAS FURNACE.THIS THERMOSTAT CANNOT BEUSED IN HEAT PUMPAPPLICATIONS.

INSTALLATIONCONSIDERATIONSYou should prepare ahead if you areinstalling any of the optionsmentioned in other sections of thismanual.

If this is a new installation or areplacement, verify:

• the size of wire needed or installed

• length of wire needed (distancefrom the thermostat and theequipment, and optionalequipment)

• if installing any remotetemperature sensing equipment(please read the installationinstructions packaged with theseunits before proceeding anyfurther)

The thermostat is to be connectedusing unshielded (18 AWG minimum)thermostat wire.

LOCATIONThe most important consideration ininstalling your electronic thermostatis where to locate the unit. Thelocation can radically affect theoperation of the thermostat. Toensure proper operation, thethermostat should be mounted on aninside wall, in a frequently occupiedarea of the building. In addition, itsposition must be at least 18 inches(46cm) from any outside wall, andapproximately 5 feet (1.5m) abovethe floor in a location with freelycirculating air of an averagetemperature.

BE SURE TO AVOID THEFOLLOWING LOCATIONS:

• behind doors or in corners wherefreely circulating air is unavailable

• where direct sunlight or radiantheat from appliances might affectcontrol operation

• on an outside wall

• adjacent to, or in line with,conditioned air discharge grills,stairwells, or outside doors

• where its operation may beaffected by steam or water pipesor warm air stacks in an adjacentpartition space, or by an area notheated or cooled behind thethermostat

• where its operation will be affectedby the supply air of an adjacentunit

• near sources of electricalinterference such as arcing relaycontacts

! CAUTIONEQUIPMENT DAMAGE HAZARDBefore connecting the powersupply to finished installation,make all wiring connections andVERIFY all connections. Short-circuited or improperlyconnected wires will result inpermanent damage to the unitand void the warranty.

! WARNINGSHOCK HAZARDDisconnect the power supplybefore any wiring connections orchanges are made to preventelectrical shock or possibledamage to the equipment. Followall local electrical codes duringinstallation. All wiring mustconform to local and nationalelectrical codes. Improper wiringor installation may damage thisproduct, electrical shock,property damage or death.

3

THERMOSTATINSTALLATIONIMPORTANT: WHEN REPLACING ANEXISTING THERMOSTAT, USE WIRETAGS TO IDENTIFY TERMINALDESIGNATIONS AS YOUDISCONNECT THE UNIT.

NOTE: Before you start, you will needthe following supplies:

• Drill

• 3/16 inch (4.7mm) drill bit

• 1/8 inch (3mm) flat blade screwdriver

• Hammer

• Marking pencil

• Wire stripper

1. Turn OFF power to the unit.

2. If an existing thermostat is beingreplaced:

a. Remove the existing thermostatfrom wall.

b. Disconnect wires from the existingthermostat, one at a time,recording wire color and terminalmarking as you go.

c. Discard or recycle old thermostat.

NOTE: Mercury is a hazardouswaste and MUST be disposed ofproperly. Consult local codes forproper disposal methods.

3. Separate the front plastic assemblyof the thermostat from the subbase.

4. Route the thermostat wires throughthe wire opening in the subbase.Mark the location of the mountingholes you will be using.

5. Drill two 3/16-in. mounting holes inthe marked locations.

6. Secure the subbase to the wall withthe 2 anchors and screws providedwith the thermostat. Make sure thatall wires extend through the wireopening in the subbase.

7. Connect wires to the proper terminallocations on the subbase (see Table1 and Figures 2 & 3).

8. Push any excess wire back into thewall and seal the hole to prevent airleaks. Leaks can affect thermostatoperation.

9. Snap the thermostat together,making sure assembly is secure.

10. Turn ON power to the unit.

FIGURE 1THERMOSTAT SUBBASE

TABLE 1WIRING INFORMATION

MOUNTING HOLES

WIRE OPENING WIRE TERMINALS

! WARNINGSHOCK HAZARDDisconnect the power supplybefore any wiring connections orchanges are made to preventelectrical shock or possibledamage to the equipment.

LANIMRET NOITCNUF

2Y )ECANRUFOTLANRETXE(GNILOOCEGATS-DNOCES

V42 DESUTON

)C(V42 NOMMOCV42REMROFSNART.DRAOBCFI,LANIMRET"C"OT

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FIGURE 3WIRING CONFIGURATION FOR REMOTE SENSORS

4

FIGURE 2WIRING CONFIGURATION FOR MODULATING 90 PLUS GAS FURNACES (MODULATING HEAT / 1-STAGE COOL)

THERMOSTAT WIRINGJUMPER “JW1 TWIST OFF”FEATURE"Twist off" is written on the thermostatprinted circuit board subbase, above andto the right of the thermostat vertical 24volt control wiring terminals. Nearby, is aone-time removable wiring jumper that isONLY removed when using 2 separate24-volt control transformers forindependent thermostat heating andcooling functions.

IMPORTANT: DO NOT REMOVE ORTWIST OFF THIS JUMPER WHENTHERMOSTAT IS USED WITH THEMODULATING 90% FURNACE.

If the twist off jumper is inadvertentlyremoved. The thermostat can continueto be used by placing a jumper wirebetween the thermostat subbase "24V"and "R" terminals. This will restore thethermostat back to its original wiringconfiguration for use with a single-control transformer.

REMOTE INDOOR/OUTDOORTEMPERATURE SENSOR(PART # 41-25300-04)The remote indoor/outdoor sensor isdesigned for use with your electronicthermostat. It is easy to install andprovides accurate digital communicationof space temperature back to thecontrolling thermostat from up to 300feet, using 2-wire, 18-gauge cable wireddirectly to the thermostat subbase.When a remote sensor is installed, theon-board temperature sensor isdisabled. The thermostat detects theremote sensor connection and controlstemperature based on the data received.Up to four (4) remote locations can bemonitored. See Figure 3 for wiringinformation.

IMPORTANT: USE ONLY THEINDOOR/OUTDOOR SENSORDESIGNED FOR THIS THERMOSTAT(PART # 41-25300-04). ANY REMOTEOUTDOOR OR INDOOR SENSORSUSED WITH PREVIOUSLY INSTALLEDSYSTEMS OR DESIGNED FOR USEWITH OTHER THERMOSTATS ARENOT COMPATIBLE AND CANNOT BEUSED WITH THIS THERMOSTAT.

THERMOSTAT ADAPTERPLATE (PART # 41-25300-06)The thermostat adapter plate is used tomount your electronic thermostat over alarge hole, or to cover other holes left bythe previous thermostat if you arereplacing an old thermostat.

1 INDOOR SENSOR 1 OUTDOOR SENSORSN(R)

SN(G) SN(G)

SN(O)

MULTIPLE LOCATIONSIf using sensors in multiple locations, 4 sensors must be used.

Sensors may be grouped in one cover if only 2 or 3 locations are required.NOTE: Wiring schematic remains the same no matter how many locations are used.

SN(R) SN(G)

5

THERMOSTATCONFIGURATIONEDITING SETTINGS(REFER TO FIGURE 4)1. Enter Configuration Mode by

pressing and holding the FAN buttonfor 10 seconds.

2. Use the UP and DOWN buttons tochange the Settings SelectionDisplay to the correct setting number.

3. Press the TIME/TEMP button toswitch to the Preferences Displayarea.

4. Use the UP and DOWN buttons tochange your preferences as listed inthe detailed settings instructions thatfollow.

5. If no further changes are needed,press the HOLD/END button. Iffurther settings changes are needed,press TIME/TEMP to toggle back tothe Setting Selection Display tochoose another setting. If no button ispressed for 3 minutes, the thermostatwill exit Configuration Mode andreturn to normal operation.

CONFIGURATION OPTIONSSetting 1: Sensitivity adjustment

Setting 3: Fahrenheit or Celsius

Setting 7: Local or remote sensorselection

Setting 8: setpoint anticipator

Setting 9: Programming periods per day

Setting 10: Off-Cycle dehumidification

Setting 13: Local sensor offset

Setting 16: Remote sensor offset

Setting 19: Outdoor sensor offset

NOTE: Settings 2, 4, 5, 6, 11, 12, 14,15, 17, and 18 are not used on thismodel.

SETTING 1SENSITIVITY ADJUSTMENTThis adjustment controls the coolingsensitivity. Factory default setting forcooling sensitivity is 8. The sensitivityoptions are:

FIRST STAGE SECOND STAGE

5 = 0.5° 5 = 1.0°8 = 0.8° 8 = 1.6°

12 = 1.2° 12 = 2.4°

SETTING 3FAHRENHEIT/CELSIUSThis setting operates the thermostat ineither Fahrenheit or Celsius mode.Factory default is Fahrenheit

SETTING 7LOCAL OR REMOTE SENSORThis selection determines whether thethermostat uses the local on-boardtemperature sensor or an optionalremote room temperature sensor.Factory default is LS.

The sensor options are:

LS = Local SensorRS = Remote Sensor

SETTING 8SETPOINT ANTICIPATORThis selection determines when theprogram schedule time takes effect. Ifset to ON the thermostat will look ahead60 minutes into the program scheduleand slowly ramp the setpoint to satisfydemand before the program period. Ifthis setting is OFF the program schedulewill switch to the scheduled temperatureat the scheduled time without rampingthe setpoint. The factory default is ON.

The setpoint anticipator options are:

ON = Anticipate setpoint change OFF = Do not anticipate setpoint change

SETTING 9PROGRAM SCHEDULE PERIODSThis setting determines the number ofprogram periods in the programschedule (2 or 4). Factory default 4.

SETTING 10OFF-CYCLE DEHUMIDIFICATION (OCD)This setting enables or disables OCD.Factory default is ON.

The OCD feature allows the unit to runwhen there has been no call for coolingand high humidity is present. It does thisby sensing the space temperature andcomparing that to the set pointtemperature. It also uses the timeelapsed since the last cooling callended.

OCD activates if the last call for coolingended at least 75 minutes ago and thespace temperature is below the setpoint. The thermostat calls for coolingand runs the blower at 85% of itsnormal cooling CFM. This cools anddehumidifies the space air. Theequipment runs for 15 minutes thenstops.

OCD will be canceled if the spacetemperature drops 2.5°F below setpoint, the thermostat mode is changed,or if a call for cooling occurs. Thisfeature will not be turned on at thefactory. The homeowner must turn thefeature on for it to become active.Check instructions supplied with thethermostat to determine how to do this.

SETTING 13LOCAL SENSOR OFFSETThis setting allows the roomtemperature display to be adjusted by+/- 5 degrees. The factory default is 0.

NOTE: Do not adjust for 30 minutesafter installation because the board maybe heated by handling. The selectednumber is the number of degrees, plusor minus, which will be added to theactual temperature. The numbers canrange between -5 and +5.

SETTING 16REMOTE SENSOR OFFSETThis setting allows the roomtemperature display to be adjusted by+/- 5 degrees. The factory default is 0.

SETTING 19OUTDOOR SENSOR OFFSETThis setting allows the outdoortemperature display to be adjusted by+/-5 degrees. The factory default is 0.

FIGURE 4THERMOSTAT - CONFIGURATION MODE

1 2

3

4

1. Setting Selection Display2. Preferences Display3. UP/DOWN Selection Buttons

4. HOLD/END Button5. TIME/TEMP button6. FAN button

6

5

6

FIGURE 5THERMOSTAT LCD DISPLAY

1

6

10

2

3

4

5789

1. Set Temperature2. Program Period3. Days of Week4. Time of Day5. Programming Mode

6. Set Time of Day7. Temperature Display8. Hold Status9. Fan Status

10. Mode Setting

THERMOSTAT OPERATION (REFER TO FIGURE 5)

POWER UPWhen power is first applied, “rh” willappear for 5 seconds in theTemperature Display area of the LCDscreen while the thermostat initializes.

SETTING CURRENT TIME1. Press the TIME/TEMP button. SET

TIME will flash on the display.

2. Press the UP or DOWN buttons untilthe correct time is displayed. Holdingeither button down will allow thevalue to scroll in the display.

3. When the correct time appears onthe display, press the HOLD/ENDbutton. (NOTE: If you choose not topress the HOLD/END button, thethermostat will automatically exit thetime setting mode after 10 seconds).

SETTING CURRENT DAYPress the DAY button to advance to thecorrect day.

MANUAL OPERATIONTo operate the thermostat manuallywithout a pre-programmed comfortschedule, press the HOLD/END button.The HOLD icon will appear in the LCDDisplay and the clock will be hidden toindicate that you are no longer followinga programmed schedule.

TO SELECT THE MODE:Use the mode button to movebetween the choices. OFF, AUTO,HEAT, or COOL will appear on thedisplay.

TO SELECT THE FAN OPERATIONUse the FAN button to movebetween continuous fan (indicated bythe FAN ON icon) and auto fanoperation.

TO READ ROOM TEMPERATURE:The large display reads roomtemperature until a button is pressed.

TO ADJUST SETPOINT:Pressing either the UP or DOWNbuttons once will show the currentsetpoint. The current setpoint will bedisplayed for a period of 5 seconds.Successive press within 5 secondswill adjust the setpoint. The SETTEMP icon will flash on the LCDDisplay while setpoint adjustmentsare being made. Five seconds ofinactivity will return the thermostat toroom temperature display mode.

AUTO MODEThis product can control heating/coolingset points simultaneously using Automode. Auto mode will switch betweenheating and cooling as required. Theminimum difference between theheating and cooling set points is 2degrees.

PROGRAMMED OPERATIONThe thermostat provides 2 or 4 periodsper day (MORNING, DAY, EVE, NIGHT,or DAY, NIGHT) as configured by yourinstaller. Seven schedules per week(one for each day) are available. Aseparate time, heat setpoint, and coolsetpoint can be set for each period andschedule. Set point can be set for eachperiod and schedule.

The first press of the PROGRAM buttonwill bring up the programming modeand place you at the current day.Successive presses will switch betweenthe four daily periods.

WHILE PROGRAMMING

• The TIME/TEMP button will togglebetween the SET TIME and SETTEMP modes.

• The MODE button toggles betweenHEAT and COOL setpoints. Thesethree numbers can be programmedfor each of the periods.

• The DAY button changes the day ofthe week.

• Exit programming at any time bypressing the HOLD/END button.

PROGRAMMING A COMFORTSCHEDULE

1. Press the PROGRAM button. Theword PROGRAMMING will appearon the display and the words SETTIME will flash on the display. theday of the week and the presentperiod icons will appear on thedisplay. The current mode (HEATor COOL) will also show. Use theDAY button to select the desiredday and the PROGRAM button toselect MORNING.

2. Press the UP or DOWN button toselect the cooling temperaturesetpoint.

3. Press the MODE button untilCOOL is displayed. PressTIME/TEMP until SET TEMPflashes on the display.

4. Press the UP or DOWN button toselect the cooling temperaturesetpoint.

5. Press the MODE button untilHEAT is displayed. PressTIME/TEMP until SET TEMPflashes on the display.

6. Press the Up or DOWN buttons toselect the heating temperaturesetpoint.

7

7. Press the PROGRAM button toadvance to the next time period. Enterthe remaining time and temperaturesettings for the periods DAY, EVE,and NIGHT by following steps 2through 6 above.

8. Press the DAY button to changebetween days. To set another daysschedule, repeat steps 2 through 7.

9. Press HOLD/END to exit theprogramming mode.

COPY PREVIOUS DAYWhen the last period parameters for thecurrent day have been programmed, theuser can press the DAY and UP buttonssimultaneously to copy the current dayschedule into the next day.

MODIFYING YOUR WEEKLYCOMFORT SCHEDULEIf you choose to change any of theschedule settings, press PROGRAM atany time. You will enter the programmingschedule at the present day, presentmode, in the morning period. You areready to set the new starting time for themorning period. Follow the steps listedabove to change the schedule values.

OVERRIDING YOUR COMFORTSCHEDULEThere are two ways to override yourcomfort schedule:

METHOD 1—MANUAL OPERATIONPressing the HOLD/END button will turnon the HOLD icon. The thermostat willmaintain the current temperaturesettings and ignore the comfort schedulefor an indefinite period of time. The wordHOLD will appear in the display and theclock digits will be hidden. Press theHOLD/END button a second time andthe thermostat will return thetemperature settings to the programmedcomfort schedule and display the clock.Pressing HOLD/END will not alter yourprogrammed comfort schedule.

METHOD 2—TEMPORARY OVERRIDEAt the first press of the UP or DOWNbutton, the current temperature settingwill appear on the display. Pressing theUP or DOWN button again willtemporarily change the setpoint asneeded. At the next programmed time,the programmed comfort schedule willbe used.

ADVANCEDTHERMOSTATOPERATIONREFER TO FIGURE 5

TEMPERATURE DISPLAYThe thermostat will display roomtemperature until either the UP orDOWN button is pressed. The wordsSET TEMP will appear when thesebuttons are pressed. The currentsetpoint will be displayed. If no buttonsare pressed for 5 seconds, the displaywill return to room temperature displaymode.

IF OPTIONAL OUTDOOR SENSOR ISINSTALLED: To display the outdoortemperature, press and hold the UP andDOWN keys at the same time. Displaywill return to normal after 4 seconds.

TIMEGUARD TIMERA 5-minute timeguard is built into thethermostat and is initiated automaticallyupon power up, and any time thecompressor turns off. The compressorwill not turn on until the timeguard hasexpired. The timeguard affects onlycompressor operation. Pressing the UPand FAN buttons simultaneouslyoverrides the timeguard for 1 cycle.

CYCLE TIMERIn normal heating and coolingoperation, the thermostat will not allowmore than 4 equipment cycles per hour(or 1 cycle every 15 minutes). Both theY and W outputs have a 15-minutetimer that begins to count down whenthe output is turned on. Pressing the UPand FAN buttons simultaneously orchanging the setpoint will override thetimer for 1 cycle.

MINIMUM-ON TIMEROnce the equipment has turned on, itwill remain on for a minimum of 3minutes regardless of demand.However, the equipment can turn off inless than 3 minutes if a change insetpoint or a change in mode occurs.

STAGING TIMERThere is a 15-minute delay between thefirst and second stages of cool (i.e. Y1to Y2).

ERROR MESSAGESE4 will be displayed if the thermostathas an internal memory failure. If E4appears, replace thermostat.

-- (dashes) will be displayed if thethermostat cannot properly readtemperature. If -- appears, replaceeither the thermostat or the sensor inerror (remote or outdoor air).

CHECKINGTHERMOSTATOPERATIONREFER TO FIGURE 5

FAN OPERATION1. Press FAN button. This will start

continuous fan operation. FAN ONicon will be displayed.

2. Press FAN button again. This willstop continuous fan operation. TheFAN ON icon will turn off.

HEATING OPERATION1. Press MODE button until HEAT is

displayed.

2. Press UP button until LCD displayreads 3° above room temperature.Press UP and FAN buttonssimultaneously to defeat timers.Heating system should begin tooperate immediately.

COOLING OPERATION1. Press the MODE button until COOL

is displayed.

2. Press the DOWN button until theLCD display reads 3° below roomtemperature. Press UP and FANbuttons simultaneously to defeattimers. Cooling system should beginto operate immediately.

FIRING RATEThis thermostat mode indicates themodulating furnace heating capacity in5% firing rate increments ranging from35% to 95%.

The furnace will fire at 40% capacity ifthe thermostat indicates 35%, 40% or45% heating capacity.

Beginning at the 50% firing rate, thefurnace fires in 5% increments up to95% heating capacity.

The furnace fires at 90% heatingcapacity at the thermostat-indicated90% heating capacity. The furnace firesat 100% heating capacity at thethermostat-indicated 95% heatingcapacity.

NOTE: Although the furnace is actuallyfiring at 100% capacity, the thermostatwill not indicate over 95% heatingcapacity.

1. Place thermostat in heating mode.

2. Press and hold the TIME/TEMPbutton for 10 seconds until displayreads 35. Though the thermostatmay read 35%, the furnace will notfire below 40% heating capacity.

3. To raise or lower the firing rate,press the up or down arrows.

4. To exit, press the HOLD/END button.

8

TABLE 2PROGRAMMABLE THERMOSTAT TROUBLESHOOTING TABLE

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION1- No display / 1a- Supply voltage incorrect 1a- Use a voltmeter to check between the 24V andfaint display 24V(c) terminals located on the thermostat subbase.

Voltage should read between 20VAC to 30VAC. If thevoltage is less than 20VAC, disconnect the thermostat andverify the voltage between 24V and the other equipmentwires; see possible causes 1b and 1c. If voltage is greaterthan 30VAC, troubleshoot the power source and replacethe thermostat.

1b- System transformer 1b- Check and / or replace with a suitable 24 Voltweak or overloaded transformer1c- Thermostat damaged because 1c- Replace with new thermostat, and ensure newsystem voltage was greater than thermostat is isolated from the system using suitable30VAC relays and a transformer of the proper rating.

3 - LCD display has 3a- LCD failure 3a- Replace the thermostatmissing or extrasegments displayed4 - Temperature 4a- The thermostat is set 4a- Verify whether the thermostat is set to display °Cdisplay is incorrect in either F or C display or °F.

4b- Poor thermostat location 4b- Relocate the thermostat to a better location.4c- Local Sensor Offset is too high 4c- Modify Setting 13 per the instructions in this manual.

5 - Fan does not 5a- Fan failure 5a- Place a jumper between terminal blocks R and G.activate with the Fan should activate. If it does not, troubleshoot the fansystem equipment system; if fan does activate, replace the thermostat.6 - Fan does not 6a- The thermostat is in continuous 6a- Press the Fan key to deactivate the continuous fanturn off fan mode mode. Fan will now activate only with equipment.7 - Thermostat will 7a- Compressor delay still in progress 7a- Wait . . . equipment short cycle protectionnot call for heat in progress. To override, press the UP and FAN buttons.

7b- Thermostat temperature setpoint 7b- Raise the heating temperature setpointis satisfied using the up arrow button.

8 - Thermostat will 8a- Compressor delay still 8a- Wait . . . equipment short cycle protectionnot call for cooling in progress in progress. To override, press the UP and FAN buttons.

8b- Thermostat temperature 8b- Lower the cooling temperature setpointsetpoint is satisfied using the down arrow button.

9 - Room 11a- Off-Cycle Dehumidification 11a- Deactivate Off-Cycle Dehumidification by following the Temperature too feature activated instructions in this manualcool when set tocooling

PROGRAMMABLE THERMOSTAT TROUBLESHOOTING GUIDETable 2 does not list all thesymptoms and probable causes, onlythose most probable. Variouscombinations of malfunctions arealso possible.

This chapter is devoted totroubleshooting various operatingproblems that may occur. It suggestsactions that may be taken to correctproblems and return the thermostat tooperational status.

To start the troubleshootingprocedure, a thorough visualinspection must be made todetermine if the malfunction iscaused by some obvious defect (i.e.,damaged component, loose wireconnection, etc ...).

9

The non-programmable thermostatcomplements the programmablethermostat, but is less costly and hasfewer features. Its location, mounting,installation, and wiring are the same asthe programmable thermostat.However, it only displays the roomtemperature, the operating mode, andif heating or cooling is currentlyoperating (see Figure 6).

This thermostat also can use remoteindoor and outdoor sensors. No batteryis needed. It can display temperaturesin either °F or °C. It can run the blowercontinuously or intermittently. The usercan select off-cycle dehumidificationand multistaging features as desired.

The user can select differenttemperatures for day and nightsettings. However, the thermostat mustbe manually changed from one to theother.

This thermostat has five DIP switcheson the subbase. Only three of whichare functional. The subbase andswitch selections are illustrated (seeFigure 7).

FIGURE 7NON-PROGRAMMABLE SUBBASE DIP SWITCH SETTINGS

HEAT/COOL AUTO-CHANGEOVER NON-PROGRAMMABLETHERMOSTAT (PART #41-25347-01)

FIGURE 6NON-PROGRAMMABLETHERMOSTAT

A

SWITCH # OFF ON

1 6 Minute Minimum On 4 Minute Minimum On

2 NOT USED NOT USED

3 Humidity Control Off Humidity Control On

4 NOT USED NOT USED

5 Single-Stage Multistage

DETAIL A

IMPORTANT: WHEN REPLACINGAN EXISTING THERMOSTAT, USEWIRE TAGS TO IDENTIFYTERMINAL DESIGNATIONS AS YOUDISCONNECT THE UNIT.

1. Lift the thermostat access coverand insert a coin (or a large flatblade screwdriver) into the slotlocated in the bottom center of thecase and twist 1/4 turn. Beextremely careful not insert intothe casing, as this may damagethe circuit board. Grasp the lowercorner of the thermostat body andseparate from the thermostatbackplate. Swing the thermostatout from the bottom, and lift upand out of the base.

2. Place the rectangular opening onthe thermostat backplate over theequipment control wires protrudingfrom the wall. Using the base as atemplate, mark the location of thetwo (2) mounting holes. Noleveling is required.

3. Use the supplied anchors andscrews for mounting on thedrywall or plaster. Drill two (2)3/16” (5mm) holes at the markedlocations, tap nylon anchors flushto the wall surface. Fasten thebackplate to the wall.

4. Connect the wires from yourequipment to the thermostatterminal blocks as shown in Table2 and Figures 8 and 9.

10

NON-PROGRAMMABLETHERMOSTATINSTALLATIONCONSIDERATIONSYou should prepare ahead if you areinstalling any of the options mentionedin other sections of this manual.

If this is a brand new installation or areplacement, verify:

• what kind of wire is needed or ispresent

• how much (distance from thethermostat and the equipment, andoptional equipment )

• are you installing any remote sensingequipment (please read theinstallation instructions packagedwith these units before proceedingany further)

The thermostat is to be connectedusing unshielded 18 AWG minimumthermostat wire.

LOCATIONThe most important consideration ininstalling your electronic thermostat iswhere to locate the unit. The locationcan radically affect the operation of thethermostat. To ensure proper operation,the thermostat should be mounted onan inside wall, in a frequently occupiedarea of the building. In addition, itsposition must be at least 18 inches(46cm) from any outside wall, andapproximately 5 feet (1.5m) above thefloor in a location with freely circulatingair of an average temperature.

BE SURE TO AVOID THEFOLLOWING LOCATIONS:

• behind doors or in corners wherefreely circulating air is unavailable

• where direct sunlight or radiant heatfrom appliances might affect controloperation

• on an outside wall

• adjacent to, or in line with,conditioned air discharge grills,stairwells, or outside doors

• where its operation may be affectedby steam or water pipes or warm airstacks in an adjacent partition space,or by an area not heated or cooledbehind the thermostat

• where its operation will be affectedby the supply air of an adjacent unit

• near sources of electricalinterference such as arcing relaycontacts

THERMOSTATINSTALLATION

! CAUTIONEQUIPMENT DAMAGE HAZARDBefore connecting the powersupply to finished installation,make all wiring connections andVERIFY all connections. Short-circuited or improperlyconnected wires will result inpermanent damage to the unitand void the warranty.

! WARNINGSHOCK HAZARDDisconnect the power supplybefore any wiring connections orchanges are made to preventelectrical shock or possibledamage to the equipment. Followall local electrical codes duringinstallation. All wiring mustconform to local and nationalelectrical codes. Improper wiringor installation may damage thisproduct, electrical shock,property damage or death.

TABLE 3OUTPUT TERMINAL DESIGNATIONS

TERMINAL FUNCTION

Y2 Energizes on a call for 2nd stage cooling

V Modulating heat output

W Energizes on a call for heat

Y1 Energizes on a call for cooling

G Fan is energized with a call for heating or cooling, or pressing the Fan key onthe thermostat

R * Independent switching voltage (Typically jumpered to 24V)

24V * 24VAC from equipment transformer

24V(c) 24VAC Common from equipment transformer

RS2 Use to connect outdoor temperature sensor (SL-ODT) option and / or indoorRS1 remote sensor(s) (SL-IDS) option. Refer to the instructions included with the

RS+V sensors.

11

FIGURE 8WIRING DIAGRAM FOR MODULATING HEAT / 1 STAGE COOL

FIGURE 9WIRING DIAGRAM FOR MODULATING HEAT / 2 STAGE COOL

12

RE-ASSEMBLING THETHERMOSTAT BODY ANDACCESS PANEL TO THEINSTALLED BACKPLATEBefore the thermostat is re-assembledto the backplate, install the optionalindoor/outdoor remote sensors, if used.Refer to the installation instructionssupplied with each option. Also, verifythe positions of the DIP switches on theback of the thermostat body.

1. Position the thermostat inside theaccess panel. See Figure 10.

2. Position the assembly on the hingedtabs located at the top of theinstalled backplate.

3. Gently swing the thermostat andaccess cover downwards and presson the bottom center edge until itsnaps into place.

TEMPERATUREACCURACYFull temperature accuracy will only berealized after the thermostat has beeninstalled and powered for at least one(1) hour.

FIGURE 10RE-ASSEMBLING THERMOSTAT TO BACKPLATE

NOTE: If you haveinstalled the optionallock pin, you willnotice the clearplastic tab snap intothe slot located on theaccess panel.

YOUR THERMOSTAT KEYSThe thermostat normally displaysroom temperature (°F or °C), modeof operation, and whether the fan isin use or not. The six keys on thefront of the unit allow completecontrol of your heating and coolingequipment. This document will gointo detail on the function of each ofthe ten keys. If you are alreadyfamiliar with the thermostat, youneed only refer to the pad-printedinstructions located on the inside ofthe thermostat door.

You may select different heating andcooling setpoints for the system tomaintain, e.g. 70° in heating and 75°in cooling. Raising or lowering thesetpoints in heating or cooling is assimple as pushing a button. Thissection will describe the function ofeach of the keys which make up thethermostat’s keyboard and walk youthrough setting up when (and why)you want your heating and coolingequipment to be activated.

THE OUTDOOR KEYThis key allows the thermostat todisplay the outdoor temperature, ifyour thermostat has been installedwith an optional electronic outdoorremote temperature sensor.

THE MODE KEYThis key allows to select betweenthe four (4) modes available: Heat ,Cool , Auto , Off. The words(accompanied by their appropriatesymbols) Heat, Cool, and Auto aredisplayed for five seconds. Thewords HEAT and Off remain visible.

THE FAN KEYThis key allows to select betweencontinuous fan mode or auto fanmode. The continuous fan modeconstantly displays the symbol;auto fan mode refers that the fan(and symbol) only activates (isdisplayed) when your heating orcooling equipment has beenactivated.

THE DAY/NIGHT KEYThis key switches the thermostatbetween day and night temperaturesettings.

THE AND KEYSWhen used with a combination ofother keys, are used to scrollbackward or forward throughtemperature setpoints). They canalso choose between °C or °F. Press the or keys at the sametime to change the temperaturevalue from Celsius (°C) to Fahrenheit(°F), and vice versa.

><

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13

FIGURE 11THERMOSTAT ADAPTER PLATE

OPTIONAL FEATURES ANDEQUIPMENT FOR NON-PROGRAMMABLETHERMOSTATSThe following are some of the optionsavailable for your electronic thermostat,to further enhance and expand itscapabilities.

THERMOSTAT ADAPTER PLATE(PART # 41-25300-01)The thermostat adapter plate (SeeFigure 11) is used to mount yourelectronic thermostat over a large hole,or to cover other holes left by theprevious thermostat if you are replacingan old thermostat. Simply drill out theholes marked “A”, line the thermostatbackplate holes with those alreadydrilled out, and follow the standardinstallation instructions.

REMOTE INDOORTEMPERATURE SENSOR (PART# 41-25300-02)The remote indoor sensor (See Figure12) is designed for use with yourelectronic thermostat. It is easy toinstall and provides accurate digitalcommunication of space temperatureback to the controlling thermostat fromup to 300 feet, using 3-wire unshieldedcable (maximum of 100 feet if usingshielded cable) wired directly to thethermostat (RS2, RS1, and RS+V).When a remote indoor sensor isinstalled, the on-board temperaturesensor is disabled. The thermostatdetects the remote sensor connectionand controls temperature based on thedata received. You may connect up tosix (6) (and a optional remote outdoortemperature sensor) in daisy-chain fortemperature averaging.

OUTDOOR TEMPERATURESENSOR (PART # 41-25300-03)The remote outdoor sensor package(See Figure 13) is designed for usewith the Contour Comfort Controlthermostat. The sensor package iscomprised of two (2) pieces: the indoorthermostat interface and the outdoorprobe. It is easy to install and providesaccurate digital communication ofoutdoor temperature back to thecontrolling thermostat from up to 300feet, using 3-wire unshielded cable(maximum of 100 feet, if using shieldedcable). There are no switches to set.The sensor may be connected directlyto the electronic thermostat or wireddirectly to one of up to six optionalindoor remote sensors.

FIGURE 13REMOTE OUTDOOR TEMPERATURE SENSOR PACKAGE

FIGURE 12REMOTE INDOOR TEMPERATURE SENSOR

14

TABLE 4NON-PROGRAMMABLE TROUBLESHOOTING TABLE

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION1- No display / 1a- Supply voltage incorrect 1a- Use a voltmeter to check between the 24V andfaint display 24V(c) terminals located on the thermostat backplate.

Voltage should read between 20VAC to 30VAC. If thevoltage is less than 20VAC, disconnect the thermostat andverify the voltage between 24V and the other equipmentwires; see possible causes 1b and 1c. If voltage is greaterthan 30VAC, troubleshoot the power source and replacethe thermostat.

1b- System transformer 1b- Check and / or replace with a suitable 24 Vweak or overloaded transformer1c- Thermostat damaged because 1c- Replace with new thermostat, and ensure newsystem voltage was greater than thermostat is isolated from the system using suitable30VAC relays (INT-43) and a transformer of the proper rating.

2- “AC” is 2a- 20 - 30VAC absent from R and 2a- Using a voltmeter, measure the voltage betweenon the LCD display C terminals, located on the the 24V and 24V(c) terminal blocks. If the reading is

thermostat backplate less than 20VAC, check system transformer. If the voltageis between 20 and 30VAC, replace the thermostat.

3- LCD display has 3a- LCD failure 3a- Replace the thermostatmissing or extrasegments displayed4- Temperature 4a- The thermostat is set 4a- Verify whether the thermostat is set to display °Cdisplay is incorrect in either F or C display or °F.

4b- Poor thermostat location 4b- Relocate the thermostat to a better location.5- Fan does not 5a- Fan failure 5a- Place a jumper between terminal blocks R and G.activate with the Fan should activate. If it does not, troubleshoot the fansystem equipment system; if fan does activate, replace the thermostat.6- Fan does not 6a- The thermostat is in continuous 6a- Press the Fan key to deactivate the continuous fanturn off fan mode mode. Fan will now activate only with equipment.7- Thermostat will 7a- Compressor delay still in progress 7a- Wait . . . equipment short cycle protectionnot call for heat in progress.

7b- Thermostat temperature setpoint 7b- Raise the heating temperature setpointis satisfied using the key.

8- Thermostat will 8a- Compressor delay still 8a- Wait . . . equipment short cycle protectionnot call for cooling in progress in progress.

8b- Thermostat temperature 8b- Lower the cooling temperature setpointsetpoint is satisfied using the … key.

9- Minimum 9a- DIP switch #2 is in 9a- Place DIP switch #2 to the ON equipment ON time the ON position position. This will decrease minimum too long, causing (manufacturer’s default) equipment ON time from 6 minutes to 4 overshoot minutes.*10- Minimum 10a- DIP switch #2 is in 10a- Place DIP switch #2 to the OFF position.equipment ON time the OFF position This will increase minimum equipment ONtoo short time from 4 minutes to 6 minutes.*11- Room 11a- Off-cycle dehumidification 11a- Place DIP switch #4 to the OFF position.Temperature too feature activatedcool when set tocooling

This chapter is devoted totroubleshooting various operatingproblems that may occur. It suggestsactions that may be taken to correctproblems and return the thermostat tooperational status.

To start troubleshooting procedure,a thorough visual inspection must bemade to determine if the malfunction

is caused by some obvious defect(i.e., damaged component, loosewore connection, etc.)

Table 4 does not list all thesymptoms and probable causes, onlythose most probable. Variouscombinations of malfunctions arealso possible. The procedures arecomplete only up to beingcorrectable.

NON-PROGRAMMABLE THERMOSTAT TROUBLESHOOTING GUIDE

SE

CT

ION

3

USER’S INFORMATION MANUAL

FOR YOUR SAFETY!

IF THE INFORMATION IN THESE INSTRUCTIONSIS NOT FOLLOWED EXACTLY, A FIRE OR EXPLO-SION MAY RESULT, CAUSING PROPERTY DAM-AGE, PERSONAL INJURY OR DEATH.

USER’S INFORMATION MANUALFOR MODULATING CONDENSING GAS FURNACES

92-20802-71-06SUPERSEDES 92-20802-71-05

Recognize this symbol as an indication of Important Safety Information!!

— Do not store or use gasoline or other flammablevapors and liquids, or other combustible materialsin the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch; do not use

any phone in your building.• Immediately call your gas supplier from a neigh-

bor’s phone. Follow the gas supplier’s instruc-tions.

• If you cannot reach your gas supplier, call thefire department.

• Do not rely on smell alone to detect leaks. Dueto various factors, you may not be able to smellfuel gases.

• U.L. recognized fuel gas and CO detectors arerecommended in all applications, and theirinstallation should be in accordance with themanufacturer’s recommendations and/or locallaws, rules, regulations, or customs.

— Installation and service must be performed bya qualified installer, service agency or the gassupplier.

WARNING!

PROPOSITION 65: THIS PRODUCT CONTAINSCHEMICALS KNOWN TO THE STATE OF CALI-FORNIA TO CAUSE CANCER, BIRTH DEFECTSOR OTHER REPRODUCTIVE HARM.

WARNING!

NOTE TO INSTALLER: REVIEW THISMANUAL WITH THE USER AND LEAVEIT WITH THE EQUIPMENT.

DO NOT DESTROY. PLEASE READCAREFULLY AND KEEP IN A SAFEPLACE FOR FUTURE REFERENCE.

INTRODUCTION TO YOUR FURNACEThank you for the purchase of your new modulating gas fur-nace! This furnace is designed to be the ultimate in heatingcomfort and is the only true modulating gas furnace availableon the market today.

The modulating gas furnace provides a superior level ofcomfort due to the interaction of seven basic components:

• Variable Output Thermostat - Whereas conventional ther-mostats only send an On/Off signal to the furnace, the ther-mostat for the modulating furnace system is speciallydesigned to indicate the exact heating requirements of theconditioned space. This is accomplished by a logic controlroutine that accurately senses the space load, minimizesrecovery times, reduces temperature swings and optimizessystem efficiency and performance.

• Modulating Gas Valve - The gas valve has the convention-al redundant solenoid valves for inherent safety, but also hasa third operator for capacity control. This operator is actually

a servo valve which varies the input rate of the furnace pro-portionally to the signal from the controller. The modulatingfurnace can operate anywhere from 40% to 100% of thenameplate input of the furnace.

• Furnace Controller - The furnace controller provides all ofthe ignition and safety functions of the typical IFC as well asinterpreting the signals from the thermostat. The furnacecontroller will optimize furnace performance by monitoring allthermostat and temperature inputs and insuring the stableoperation of the inducer, gas valve and indoor blower motor.

• ECM Variable Speed Blower - The airflow through the ductwork is varied to meet the load demand. Airflow as low as300 CFM is achieved by the response of a brushless perma-nent magnet variable speed blower motor.

• Two Speed Draft Inducer - To insure clean combustionand peak efficiency, the induced draft motor speed is adjust-ed based on the gas valve setting to provide the properamount of combustion air to the burners.

2

FIGURE 2DOWNFLOW FURNACE

FIGURE 1UPFLOW FURNACE

I678

ITEMNO. PART NAME

1 CONDENSATE TRAP

2 DOOR SWITCH

3 JUNCTION BOX

4 TRANSFORMER




8 CONNECTOR

9 MAIN LIMIT

10 EXHAUST AIR PIPE

11 VENT CAP PLUG

12 FLAME SENSOR


ITEMNO. PART NAME

14 TOP PLATE

15 BURNER

16 IGNITER


18 GAS VALVE

19 CAPACITOR



22 IGNITION CONTROL

23 INTEGRATED FURNACE CONTROL

24 BLOWER MOTOR

25 R/A SENSOR

26 BLOWER HOUSING

ITEMNO. PART NAME

1 GAS VALVE

2 CAPACITOR



5 BLOWER HOUSING


7 BLOWER MOTOR

8 DOOR SWITCH

9 JUNCTION BOX


11 HALC

12 TOP PLATE

13 RETURN AIR SENSOR

ITEMNO. PART NAME

14 VENT CAP PLUG

15 EXHAUST AIR PIPE16 INTEGRATED FURNACE CONTROL

17 TRANSFORMER

18 IGNITION CONTROL


20 CONNECTOR


22 MAIN LIMIT

23 CONDENSATE TRAP

24 IGNITER


26 BURNER

27 FLAME SENSOR

SAFETY PRECAUTIONSSIGNAL WORDSThere are some safety precautionswhich must be understood and fol-lowed by all users of equipment suchas your furnace, where flames, gas,electricity and rotating parts are pre-sent. To alert you to the above poten-tial hazards, we use the signal words“WARNING” and “CAUTION” through-out this manual and safety labelsattached to the furnace.

Read carefully and pay special atten-tion to all warnings and cautions in thismanual. They are defined anddesigned as follows to help you recog-nize and avoid the potential hazards ofoperating this furnace:

Indicates a potentially hazardoussituation which, if not avoided,could result in property damage,serious injury or death.

INSTALLATION INFORMATION

Date Installed

Dealer Name

Address

City

State Zip

Telephone No.

FURNACE

Model No.

Serial No.

AC SYSTEM

Model No.

Serial No.

INDOOR COIL

Model No.

Serial No.

fied installer, service agency or thegas supplier immediately if you haveproblems turning the knob.

• Should overheating occur, or the gasvalve fail to shut off the gas supply,turn off the manual gas valve to thefurnace before turning off the electri-cal supply.

• Soot buildup indicates a serious com-bustion problem that requires immedi-ate correction. Turn the gas supply“OFF” until the furnace is repaired.Contact a qualified installer, serviceagency or the gas supplier immedi-ately to inspect the furnace.

• Do not place, store or use gasoline orother flammable vapors and liquidson, against, or around the furnacejacket.

• Do not store combustible materialsnear the furnace. The furnace musthave adequate clearances from allcombustible materials such as cloth-ing, paper, cardboard, wood or clean-ing materials to prevent them fromigniting.

• Keep any furnace installed in an atticor other insulated space free andclear of insulating material. Examinethe furnace area when installing thefurnace or adding insulation. Somematerials may be combustible.

• Any additions, changes or conver-sions required in order for the furnaceto satisfactorily meet the applicationneeds should be made by a qualifiedinstaller, service agency or the gassupplier, using factory specified or

3

POSSIBILITY OF FIRE OREXPLOSION

• Do not test for gas leaks with a matchor flame.

• Do not use this furnace with any othergas than the one listed on the ratingplate.

• Follow the furnace lighting instruc-tions carefully to be sure all gasfumes are cleared before lighting thefurnace.

• Check carefully for gas before lightinga furnace. Do not rely on smell aloneto detect gas. Use a UL recognizedfuel gas detector and a soap andwater solution on the pipes to checkfor gas leaks.

• A damaged gas control knob cancause gas to leak. Do not hit or dam-age the knob. Do not force the knobwith tools. Use only your hand to turnit to “ON” or “OFF”. Call the a quali-

THIS FURNACE OPERATES BYBURNING GAS INSIDE YOURHOME. THIS CREATES THE POS-SIBILITY OF FIRE OR AN EXPLO-SION WHICH CAN RESULT INPROPERTY DAMAGE, PERSONALINJURY OR DEATH. YOU MUSTREAD AND FOLLOW ALL OFTHESE SAFETY PRECAUTIONSTO HELP ENSURE SAFE OPERA-TION OF YOUR FURNACE.

WARNING!

Indicates a potentially hazardoussituation which, if not avoided,could result in property damage,or minor or moderate injury.

CAUTION!

• Return and Supply Air Sensors - These two thermisterassemblies, a factory installed return air sensor and a fieldinstalled air probe, communicate the furnace temperaturerise to the integrated furnace control. The integrated furnacecontrol uses this information to calculate field conditions dur-ing calibration to insure optimal efficiency and comfort duringnormal operation.

This furnace has been designed to give you many years ofefficient, dependable home comfort. With regular mainte-

nance, this furnace will operate superbly year after year.Please take the time to fill out the information below andread this manual to familiarize yourself with operation, main-tenance schedule, and safety operation.

IMPORTANT: READ THESE INSTRUCTIONS THOR-OUGHLY BEFORE ATTEMPTING TO OPERATE THISFURNACE.

WARNING!

4

approved parts. Read your Warranty.Contact the WARRANTOR for con-version information. This furnace wasequipped at the factory for use onNATURAL GAS ONLY. Conversionto LP GAS requires a special kit sup-plied by the WARRANTOR.

DANGER FROMASPHYXIATION

• Do not operate this furnace withoutprovisions for an adequate combus-tion air supply.

• Do not allow snow, ice, or any otherdebris to accumulate in or around theexhaust and intake terminations ofthis furnace. These are extendedthrough the roof or horizontallythrough the sidewall of the structure.See Figures 3 & 4. Blockage of theintake and exhaust can result in inad-

equate combustion air as well asinadequate unit performance or nui-sance tripping.

• Prevent flue gases from escaping intoyour residence. Deterioration of theventing system, or soot build-up cancause leaks into the system. Have aqualified installer, service agency or thegas supplier replace damaged parts orrepair obstructions in a deterioratedvent system immediately.

• Do not use this furnace if any part hasbeen under water. A flood-damagedfurnace is extremely dangerous.Attempts to use the furnace can resultin fire or explosion. A qualified serviceagency should be contacted to inspectthe furnace and to replace all gas con-trols, control system parts, electricalparts that have been wet or the furnace,if deemed necessary.

• To prevent carbon monoxide poisoning,all blower doors and compartment cov-ers must be replaced after the furnaceis serviced. Do not operate the unitwithout all panels and doors securely inplace.

SYSTEM OPERATIONINFORMATION• Keep the air filters clean. Your heating

system will operate more efficiently andprovide better heating, more economi-cally.

• Arrange your furniture and drapes sothat the supply air registers and returnair grilles are unobstructed.

• Close doors and windows. This willreduce the heating load on your sys-tem.

• Avoid excessive use of exhaust fans.

• Do not permit the heat generated bytelevision, lamps, or radios to influencethe thermostat operation.

• If you desire to operate your systemwith constant air circulation, consultyour thermostat manual or please askadvice from a qualified installer, serviceagency or the gas supplier.

IMPORTANT: FOR COMPLETEOPERATION AND SET UP OF YOURTHERMOSTAT REFER TO THE MAN-UAL INCLUDED IN THE LITERATUREPACKET SHIPPED WITH THIS FUR-NACE.

STARTING YOURFURNACELIGHTING INSTRUCTIONS

This appliance is equipped with a directspark ignition device. This device lightsthe main burners each time the roomthermostat calls for heat. DO NOT try tolight the burner by hand. See lightinginstructions on the furnace.

1. Remove the burner access door.

2. Set the thermostat to the lowest set-ting.

3. Turn the gas control knob counter-clockwise to the “ON” position.

4. Replace the burner access door.

5. Turn on the electrical power.

6. Set the room thermostat to a pointabove the room temperature to lightthe main burners. After the burners arelit, set the room thermostat to a desiredtemperature.

7. If the appliance will not operate, followthe instructions “To Turn Off Gas ToThe Appliance” and call your servicetechnician or gas supplier.

BE SURE THAT THE MANUAL GASCONTROL HAS BEEN IN THE “OFF”POSITION FOR AT LEAST FIVEMINUTES. DO NOT ATTEMPT TOMANUALLY LIGHT THE MAINBURNERS. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE AFIRE OR AN EXPLOSION RESULT-ING IN PROPERTY DAMAGE, PER-SONAL INJURY OR DEATH.

WARNING!

THIS FURNACE OPERATES BYBURNING GAS INSIDE YOURHOME. IMPROPER OR INCOM-PLETE BURNING OF THIS GASCAN RESULT IN THE FORMATIONOF CARBON MONOXIDE. IFINTRODUCED INTO THE LIVINGSPACE, THIS CAN CAUSE DIZZI-NESS, NAUSEA, OR DEATH BYASPHYXIATION. YOU MUSTREAD AND OBSERVE THE SAFE-TY RULES BELOW TO PREVENTOXYGEN DEPLETION ORUNBURNED GAS OR COMBUS-TION FROM ESCAPING INTO THELIVING SPACE OF YOUR RESI-DENCE.

WARNING!

FIGURE 3STANDARD VERTICALDIRECT VENTING

FIGURE 4STANDARD HORIZONTALDIRECT VENTING

I407

I407

5

TO TURN OFF GAS TO THEAPPLIANCE

IMPORTANT: SHUT OFF THE MANUALGAS VALVE LOCATED IN THE GASSUPPLY PIPING OUTSIDE THE FUR-NACE CASING.

1. Set the thermostat to the lowest set-ting.

2. Turn off all electric power to the appli-ance on which service is to be per-formed.

3. Remove the burner access door.

4. Turn the gas control knob to the “OFF”position.

5. Replace the burner access door.

SEQUENCE OFOPERATIONHeating Cycle Initiation

The heating cycle is always initiated by a24 volt signal on W of the thermostat.When the controller senses 24 volts onW, the following sequence occurs:

• High and low pressure switches arechecked to insure contacts are open.

• Inducer is powered on high speed for athirty (30) second prepurge.

• Pressure switches are monitored asthe inducer creates the vacuum toclose the contacts.

• The servo valve on the gas valve isenergized with ~180 milliamps current.(No flow yet.)

• The controller sends 120 volts to theignition control, which sparks acrossthe electrodes.

• The main solenoids on the gas valveare energized allowing gas to flow tothe burners.

• When flame is proven, the ignition con-trol is de-energized - 8 second maxi-mum trial time.

• The gas valve maintains 100% ratethrough the warm-up period - 20 sec-onds.

Heating Cycle Response

The heating cycle is always initiated by a24 volt signal on W1. When the controllersenses 24 volts on W1, the followingsequence occurs:

MODULATING FUNCTION:(“W” and “V” signal inputs)

After the warm-up period, the furnace willrespond to the thermostat demand byadjusting the gas valve pressure andblower speed anywhere between 40% to100% heating capacity.

TWO-STAGE FUNCTION:(“W” and “W2” inputs)

After the warm-up period, the furnace willrespond to the thermostat demand byadjusting the gas valve pressure andblower heating speeds to the W signalvalues. “W” only = 40% gas valve pres-sure and blower heating speed. “W” and“W2” = 100% gas valve pressure andblower heating speed.

SINGLE-STAGE(“W” signal only)

After the warm-up period, the furnace willrespond to the thermostat demand bymaintaining the gas valve pressure andblower speed at 100%.

Heating Cycle TerminationWhen the 24 volt signal is removed fromW1, the heating cycle will end and the fur-nace will shut down and return to the properoff cycle operation.

IMPORTANT: IT IS RECOMMENDEDTHAT AN ANNUAL INSPECTION OFYOUR FURNACE BE MADE BY AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIER.DURING THE ANNUAL INSPECTION,IT IS RECOMMENDED THAT 120VACPOWER BE TURNED OFF, THENBACK TO THE ON POSITION.REAPPLYING120VAC INITIATES ACALIBRATION CYCLE TO ENSUREOPTIMUM SYSTEM OPERATION.

MAINTENANCE

THIS FURNACE CONTAINS MOV-ING/ROTATING COMPONENTSAND USES HOUSEHOLD ELEC-TRICAL CURRENT. FOLLOW THESAFETY RULES BELOW TOAVOID CUTS, BURNS OR ELEC-TRICAL SHOCK WHICH CANRESULT IN SEVERE PERSONALINJURY OR DEATH.

WARNING!

POSSIBILITY OF BURNSOR ELECTRICAL INJURY• Do not perform any service or mainte-

nance on the furnace while it is oper-ating. Read and follow the serviceinstructions provided with this furnacebefore beginning any service or main-tenance work.

• Do not open the blower compartment,disassemble, or remove any compo-nents while the furnace is operating.This may expose sharp edges orpoints which could cause cuts, hotsurfaces which could cause burns,and electrical circuits which couldcause shocks.

• Instruct children on the safety haz-ards associated with furnaces. Keepchildren away from the furnace at alltimes.

FILTER MAINTENANCE

DO NOT OPERATE YOUR SYS-TEM FOR EXTENDED PERIODSWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED INTHE AIR MAY TEMPORARILYLODGE IN THE AIR DUCT RUNSAT THE SUPPLY REGISTERS.ANY RECIRCULATED DUST WILLBE HEATED AND CHARRED BYCONTACT WITH THE FURNACEHEAT EXCHANGER. THISRESIDUE WILL SOIL CEILINGS,WALLS, DRAPES, CARPETS ANDOTHER HOUSEHOLD ARTICLES.

CAUTION!

SHOULD OVERHEATING OCCUROR THE GAS SUPPLY FAIL TOSHUT OFF, SHUT OFF THE MANU-AL GAS VALVE TO THE APPLI-ANCE BEFORE SHUTTING OFFTHE ELECTRICAL SUPPLY. FAIL-URE TO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE, PERSON-AL INJURY OR DEATH.

WARNING!

CHECK THE VENT PIPE SECTIONSFOR DETERIORATION AND CHECKJOINT FITTINGS FOR THEIRINTEGRITY. IF IT HAS BECOMEDISCONNECTED TOXIC FUMESCAN ENTER THE HOME ANDCAUSE CARBON MONOXIDE POI-SONING OR DEATH. DO NOTOPERATE THIS FURNACE. APPRO-PRIATE SERVICE MUST BEAPPLIED.

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Have your qualified installer, serviceagency or the gas supplier instruct youon how to access your filters for regu-lar maintenance.

• Keep air filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air dry thor-oughly and reinstall.

• After filters are cleaned and returnedto the furnace, be sure doors areproperly reinstalled. If you are nottotally sure of this procedure, consultqualified installer, service agency orthe gas supplier.

REMOVING FILTERS

FILTER IN BOTTOM OR SIDELOCATION1. Remove the blower compartment

access door.

2. Disengage the filter retaining rod andpull filter out.

3. Clean filter and reinstall.

4. Replace the blower compartmentaccess door.

LUBRICATIONThe blower motor and induced draftmotor are permanently lubricated by themanufacturer and do not require furtherattention.

IMPORTANT: DO NOT ATTEMPT TOLUBRICATE THE BEARINGS ON THEBLOWER MOTOR OR THE INDUCED

DRAFT BLOWER MOTOR. ADDITIONOF LUBRICANTS CAN REDUCE THEMOTOR LIFE AND VOID THE WAR-RANTY.

The blower compartment and motorshould be inspected and cleaned peri-odically by your qualified installer, ser-vice agency or the gas supplier to pre-vent the possibility of overheating dueto an accumulation of dust and dirt onthe windings or on the motor exterior.And, as suggested elsewhere in theseinstructions, keep the air filters cleanbecause dirty filters can restrict airflowand the motor depends on sufficient airflowing across and through it to keep itfrom overheating.

COMBUSTION AIR ANDVENT SYSTEM1. It is recommended that an annual

inspection of your furnace’s combus-tion air and vent system be done bya qualified installer, service agencyor the gas supplier.

2. Turn OFF the electrical supply to thefurnace and remove the accessdoors.

3. Inspect the gas burners for dirt, rustor scale and clean as necessary.

4. Inspect the flue connection area andvent pipe. Be sure that the vent con-nector is in place and slopes upwardand is physically sound, withoutholes or excessive corrosion.

5. Be sure that the return air duct con-nections are physically sound, aresealed to the furnace casing and ter-minate outside the space containingthe furnace.

FIGURE 5UPFLOW SIDE FILTER LOCATION

I332

FIGURE 6UPFLOW BOTTOM FILTER INSTALLATION

ADS-5422-01

WARNING!

IF DIRT, RUST, SOOT OR SCALEACCUMULATIONS ARE PRESENT,DO NOT OPERATE THE FURNACE.INSPECT THE HEAT EXCHANGERFOR LEAKS. LEAKS CAN CAUSETOXIC FUMES TO ENTER THEHOME AND CAUSE CARBONMONOXIDE POISONING OR DEATH.

WARNING!

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FIGURE 7DOWNFLOW FILTER INSTALLATION

A087001.S01

6. Be sure the physical support of thefurnace is sound, without sags, cracks,etc. around the base so as to providea seal between the support and thebase.

7. Look for the obvious signs of deterio-ration of the furnace.

8. If the furnace is free of the above con-ditions, replace the access doors andrestore electrical power to the fur-nace.

9. Start the furnace and observe its oper-ation. Watch the burner flames to seeif they are bright blue. If a suspectedmalfunction is observed, or the burnerflames are not bright blue, call forappropriate service.

CONDENSATEThis furnace is equipped with a pressureswitch which will shut off the main burn-ers if the condensate drain line becomesblocked.

Be sure this condensate drain line doesnot become blocked or plugged. Visualinspection of the condensate flow caneasily be made while the furnace is inoperation. Use a flashlight to illuminatethe discharge end placed in the seweropening. See Figures 8 & 9.

Clean and flush the condensate tube tomake sure condensate flows freely whilethe furnace is in operation.

IMPORTANT: IT IS RECOMMENDEDTHAT AT THE BEGINNING OF THEHEATING SEASON, THE CONDEN-SATE TRAP BE INSPECTED BY AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIER FORDEBRIS OR BLOCKAGE. A BLOCKEDCONDENSATE TRAP CAN CAUSEWATER TO BACK UP INTO THE PRI-MARY HEAT EXCHANGER AND LEADTO NUISANCE TRIPPING OF THEOVER TEMPERATURE SWITCHES ORPRESSURE SWITCHES.

IMPORTANT: IT IS RECOMMENDEDTHAT AT THE BEGINNING OF THEHEATING SEASON THE CONDENSATENEUTRALIZER, IF USED, BEREPLACED BY A QUALIFIEDINSTALLER, SERVICE AGENCY ORTHE GAS SUPPLIER.

MARKINGSIt is recommended that an annualinspection and cleaning of all furnacemarkings be made to assure legibility.Attach a replacement marking, which canbe obtained through the distributor, if anyare found to be illegible or missing.

FIGURE 8UPFLOW CONDENSATE DRAIN

AO51601

REFER TOINSTALLATIONMANUAL.

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FIGURE 9DOWNFLOW CONNECTION

A0850-01

REFER TO INSTALLATIONMANUAL


INSTALLATION AND OPERATION INSTRUCTIONS - … · 2017-11-26 · section 3 user’s information...

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