Residential Gas Furnaces Installation Instructions *RA Full Size Series 80+ High Efficiency Upflow/Horizontal *RK Full Size Series 80+ High Efficiency Downflow EFFICIENCY RATING CERTIFIED ama *RA 80+ Upflow/Horizontal *RK 80+ Downflow /\ WARNING: WHAT TO DO IF YOU Improper installation, adjustment, al- SMELL GAS: teration, service, or maintenance can cause injury or property damage. Refer ¢ Do not try to light any appliance. to this manual. For assistance or additional information consult a quali- + Do not touch any electrical switch; do not fied installer, service agency, or the use any phone in your building. gas supplier. ¢ Immediately call your gas supplier from a neighbor’s phone. Follow the gassupplier’s instructions. /\ FOR YOUR SAFETY: ¢ If you cannot reach your gas supplier, call Do not store or use gasoline or other the fire department. flammable vapors and liquids in the vi- cinity of this or any other appliance. ¢ Extinguish any open flame. These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all instructions carefully before starting the installation. Table of Contents FUFMACE: SPeOCiTICAtlONS a. ccicccesere cia eeendecedeceec ste ecetuccedce ces ceeesenauceseecceudeacetsecdcoucusudwes cescesecwctecupesdteeeense 4-5 Uptlow/Herizonital IMOGGIS a csisescitet iat sucsteeuet Livan sa deddae uve vantceataivuiraadenstpeetuaduuvarvsdulotevtasielaawels 4 DoOwntlow IMOGGIS os tice cet cord. cect rvenecicectesnexhascsltv ctx senses basvogiow atte eacansecaueesedvas acres oeeseatecsemav an 5 Capacities-Furnace Airflow Data 0.0... ceecceesssecesseeeeeeceeeneeeesaeeesaeeeeaaeesesaeeeseeeeeaeeseneeeeeeees 6-7 Dalety IMfOrMatlO nei sacc cece ccscssececsue denn cteceiwesenwedetd cease ceceescedeadtessavedenewed sete detuvee stewdeceue cet ceue stawdeteetuenacen site 8 Installation: [REQUIFCIMGINGS 2: .icc50 ce sisec ccc cseseccene cee wed seesnccen su ceetaesceeaceexsecencastuscterescacueesctuccbevescaeecvees 8-9 Supply Air Plenum Installation ...........:ccccescceeseeeeeeeeeeseeeeseeeeeeeeeesseeeeneeeeeeeeeesseeesneenesseeeeseeeeeseeeeesenees 10 Installation On a Concrete Slab oe. cece cecceesceeceeeeeeeeeeceeeeeeeeeeeaeeeeeeeeseeeeeeeaeeseeaeeeeeeeeeas 10 Installation On a Combustible FlOOM ....... eee eceeeeeceeeeeeseeeeeeeeeeseeeeeeeeeeseeeeesesaeeeeaeeseaeeseaeeeeeas 10 Venting and Combustion Air Requirement .............::cceseecseceeseeeeeeeneeseeeeneeneeneneesseeeeneeeeeseneeesenees 11 GO Mera oerdceissiedvncedanetecteevsanutae Sienna daaesate vacated aecaee aueinecetccse hae uieaeenidaraheacindieiees 11 Installation in an Unconfined Space .........eccceeccesenceeeeeeeeeneeeseeeeeeeeeeseeeeseeeeseeeeeseaeeseeereees 11 Installation: ina: ComfinGd SPA Ce: yes ccseccacssdeees scvsendysesdeceeevsheecustydyegeeer syeenesty ltueeaerseanebeetayensces 12 Horizontal Furnace Installation ..........cceccecseceseeeeeeeeeeneeeceeeeeeeeseaeeseaeeeeeaeeseaeeseeeeeees 12 PAIE ERO RIV VIS IG Gis: os ict ance akec eu atad vane ctickes du aeac edna ct sac aaatee ces asain avaatal dee aatndengetataaeeaeed ee 13 Outdoor Air Using Vertical DUCtS 20.0... ccc eeeeceeeneeceneeeeeeeeeeaeeceaeeeeeaeeseaaeeeeaeeeeeeeeeaeeees 13 Air Directly Through an Exterior Wall .........ccecceeecceeeceesereeeeeeeeeeeeeesenaeeeeaeeeeeaeeseaeeeeeaes 13 Outdoor Air Using A Crawl Space and Ventilated Attic ...........0..:ccceeeeeeeeeeeeeeeeeees 14 Outdoor Air Through Horizontal Ducts 0.0.0... cece eeeeeeeeeeeeeeneeceeeeeeaeeeeaeeseaeeeeeeeeenaeeees 14 Venting REQUIFEMOIS .icuccceciiesiccenticccecccecnte cen cceecececeneceeencctensteceedceeesiedes siceesiteessnecesittenstieessnecersteees 14 GOMel al sccsoretcnct erence cines ctunld ines heoel inenlaaorehoeatensnmsioeedeteaietenieandins paar 14 Category | - COMMON VENTING ......... ceeeeceeeceeeeeeeeneeceaeeeeeaeeceaaeeeeaeeeesaeeseaeeeeeaeeseaeeeeieeeenaeeees 15 Category III - Horizontal Venting ........... eee ceeesceceseeeeeneeeesaeeceaeeeeeaeeceaaeeseaeeeeaaeeseaeeeseaeeseaaeees 16 Horizontal Venting for Upflow Models ..........cccceceseeeeeeeeeeeeeceeeeeeneeceaeeeeaeesenaeeseeereees 16 Horizontal Venting for Downflow Models .............::scceeseeceeeeeeeeeeeeaeeceaeeeeeneesenaeeeeneeenas 17 Horizontal Power Venting ........::cceccceceeeeeeeeeeeeeeeceeeeeeeeeeceeaeeeeaeeeesaeeseaeeeseaeesesaeseeaeesenaeesnteeeeas 18 Vent Termination Clearance is cictivtcnssoossevoet eiatiesoeeseteet sgnee une gure raeeelenaee neon eeaeeee 19 Location of Outdoor Terminations ............cceecceeeeeceeneeeeneeeeeeeceeeeeeeaeeseaaeeceaeeeeeaeesesaeeeeatesenas 20 Horizontal: Installation. ccctitiiscceavinctcagal stovundtenie domaedtevuntanecsaaadicvnedeceesdosecieiaeiegeedmeunnd 20 Flexible Vent SYSIOMS seccicecasseccsscevauds stacsecriscevandanrouasntsSencagdede teat aenenrtadetvoeth dadvnets Pevearnannte edt 21 Circulating) Air SUpply ---ccciscccistecces cece cet teeensccenceceeneteeeecctenc nce eneceecustreceseenencceueceeensecenenedsunseeeneseees 21 GOMe lal. cis ivesssevnsnataOiaes evra easib umn dvdeer tema davnaee auearrerdstas dealieeeeasaartaaadaeiias 21 PRO TUNICA east ada sashes Uren reed ed anteeeran aaa ct waits ad aaah ch Witacadant idpaklcch wuatidaierefeds detnniviratsanicne(ndceiaacina 21 Gas Supply and Piping ie ivseccccces ese cesccedsecceseceedeneces stgessceessncedsectenvecexsduuesie cued secevedeaesvestedeeden suedsdveieyis 22 GOMOM Al eticices teacnevecensdediG adds vegan gitdseG cdsndhegss vied ss teesnghikes votasvandand acs vidas yaead dl caees Ddensieaceecase tales 22 LG ak GO CK tat tai enact ager tosis casei stance acetic panact Guus casted cansceatuie cause naaid penta sagudenane pants aaauecaast naeas cs 22 COMVGSY SION sco, tose docnedcoslea dean eveatnvetionl ide enccinetn vans « deleeditensu dens Vetceuinechitbe ced vetted ued scot vation sce uaeeaays 23 High=Altitude Application ci..ccccccscscecsacetseecdeesteneenseteedcetuereedsnteedertornsteededtnedervcnuntendedeneeendcneers 23 Natural Gas High Altitude ConverSion ..........::ccccsceceseeeeeeeeeeneeeceeeeeeeaeesesaeeeeeeeeeeaeeseaeeeeneeeenas 23 LP/Propane Gas Sea Level and High Altitude Conversion .............ececcesseeeeeeeeeeteeeeees 23-24 Electrical: Wiring) siticccccectstedeedctetiek nec bee ccd athe cet eet ece ect heads at ecu enue Sib cab ecewses ee vacua wens cedsuenccueda weteeeeeveees 25 GOMOr all ass iootewc eects stennerseteuaseakeehveednlenersetnel endian sieeedeuale eon 25 LIME: VOI GS: WING sssesicttedaetitanctnctect. cued saueneraeuennetetseyutcaius undiaa fe vidantnereenasetutaneunavetyea atucauie 25 LOW ‘Volta 6: With AQticsetscceesndexvack aitens soncezeeet bl ctacechtascpaaundeneleadsa pease alec eet ae ee eee 26 Start-Up & AGJUStMONS unceccciccccceicccecccetie cecteeccnceence tenceteenee cececetenden cence setndsededeeenndeecendsecndcecundecencdere 27 GOMOP All ccsrncccedteeveveeansnecttere vceransteeuatoeaatd vera tates hed nteetev dee toe weap news aeeeateae 27 Slart=Up -PLOCCGULCS oes sacs accra cess teadastiens Gedehdacndsntaauceanstcenastens Ouedsctebstuteadiatodsndeathtaeseucames 27 Verifying and Adjusting Firing Rate ..........ceceecessceeeeeeenneeceneeeeeaeesesaeeeeaeeeeeaeeeeaeeeeeeeenaeeees 27 Verifying and Adjusting Temperature RiS@ ............cccececeseeeeeeeeeneeeceneeeeeaeeseaeeeeneeeeeneeeeea 27-28 Verifying: Burner :OPe ration rcceivcnce scene conc suceeknn woes cence cdcoee ecnee etait mevoes ernehenelt aecesbevameeeanensnceeere 29 Verifying Operation of Supply Air Limit Switch... eee eeeeeeeeeee centres eeeeeeaeeceeeeeeeeeenaeeees 29 Description Of COMPOMENES .........::cceseeceeeeeeseneeeeeeeseeneeeseeesneeneeseneeeeeeeseenaesseneseesuessenaeeeseeseeneeeeeneneenes 29 Wiring) Did Qra wisccccccceccccccwte sive rennet ccecces ence tecncnededcedcnustecnctdencci ence teceetvenddedende denccteende stance rencererndeedecceds 30 CEU UE: (0): ln 31 MOTI SY SLO Mea ste ecarsnuncarat ceseantcentatrascevezsicnst detente a teutetaputestatsdtahensadesnenitdauatenstentemttn ataawterane 31 PAUCTPUIG ES) cst csicee ta xee cease odes nape ic anit te ind cages anny se ins eatawalds ane nesae eae came cag rates aeantieaneateasecaamenes 31 LUDA CATL ON a sintscca wctauee tS weneron cc tasuc Madea iiendatlet ale eatie atau setulae anlpatada detbanle Roactel iia wettaalandtakieeieaeusaies 32 BIOWSr ‘COMP AIIM OME cecaticssteccats sensu cade nee aces aus pen udees lucevand seaweed in deuane sbeactate leaevane eee temnuteeyente 32 Heat Exchanger and Burner Maintenance ..............::cceceeceeseeeceeeeeeeeeeceseeeeeneeeeeeeseaeeeenterenas 32 Cleaning of Flue PaSSages .......eecesessceessceceseeeeseeeesaeeseaeeeseaeeeeaaeeseaeeeseaeeseaaeeeeaeeeeaaeeenaeenees 32 Cleaning Of BUPNGES: scicic.cocicccsccmiectonnecconecemnvctosnccusnviedons ectbenecuansiedenavciehs eceeesieconycior ecm vacenys 33 System Operation INFOrmation ..........cccccceseeceseeeeeeeeeeeseeeeeneeeeseeeesseeeeneeesseeaesseeesneeeesseeeesseeesneenenseeees 33 GOMOM Al baer scatnencctacncensnaatasnecastcdana tice tuts ceastcddatsCeaugu cabs tedeaw aes aucbdaaiesauctessbGedaulcasaetecaskGearatadeale 33 SEQUENCE: Of- OPSratiOM cacevescecsseeireanercseustaeeseceenaseeranes aeelardeedcmedauarsedetaeesaeerie Minded 33 Heating MOG Asti acaace sat siren Ccon etaiedead ce auceie tenant aeasaie ate ides ubiebac cea iaeatearte 33 GOOGLING: 'MOG6 svcceviicocntyscesteceenssieehieeanetearstieesiegeeeciie eee cie tae ee 34 Fail MOGC 23s. bisatasectuanes sdletaupuanestapeidte tangateteden sud tataewitreins suctecauet tanpaiereadetantutenmasaseaetaatetnacy 34 Furnace: Falls: 0 “OPCrate sseisisn:ccice chy. ccaake-caiae cagavdcaageccabocesnsdetaiae Canuaraaadelelesepaltenegdecueebcnmeeecs 34 TWINNING cicccsdceresagni Gees doasereecalliccck ota santo diink - opulscndbunieteteaasnslandstuelsdegarcbvus desta sgderddoasteduueeddaretesys 35 FURNACE SPECIFICATIONS - Upflow/Horizontal Models ‘ Unit Shown in Upflow << 23 3a Position Rotate 90° FLUE j OUTLET Clockwise or Counter Clockwise for Horizontal Application |<—__—"9 3i4 | 3/4 —>| 3/4 [ 1 jt 25 18 } Oa 12 X 32 Cut-out for Gas Connection | 112 X 31/2 Cut-out for Dina Connection oOo IA 7/8 Cut-out for Electric 7g Cut-out for Connection Electric Connection oOo- + 25 1/4 1 Return Air Opening (Side) L 11/4 » < D - =~ 11/4 14 Return Air Opening (Bottom) ~<a Figure 1A. Upflow Unit Dimensions FURNACE DIMENSIONS AND SHIPPING WEIGHTS Furnace | Ciimensions | Shipppi Model Input Weight *RA (Btuh) (in.) (in.) (in.) (in.) Note: (*) Can be C or N Table 1A. Upflow Furnace Dimensions and Shipping Weights FURNACE SPECIFICATIONS - Downflow Models 3/4 ea ajar 23 5/8" —S 19 3/4" $e Y 24 1/2" ° Cut-ouf for Electtic Connection Both sides 25" Cut-out for Gas Connection 1-1/2 x 3-1/2 (both sides) (_) —«g— Cut - out for U) e Gas Connection et 19 3/4" | +~<t—_— B Saal (Bottom Opening) (Bottom Opening) 27 7/8" Figure 1B. Downflow Unit Dimensions DOWNFLOW FURNACE MODELS FURNACE DIMENSIONS AND SHIPPING WEIGHTS Model Furnace|___——sdDimensions__| Shipping Number Input Cc Weights *RK Btuh inches Ibs Note: (*) Can be C or N Table 1B. Downflow Furnace Dimensions and Shipping Weights CAPACITIES —Furnace Airflow Data aQnalforr + RIS OR \ S : i) cr On ren) trv t+ nN — wo clu - O- RJD OR -nrl[or lo o[H o Oar re Kn aes) ol- om RJon OR (uwNjoyD 49}e\, SAYdu]) unssaig Bes jeusa}Xy KR = Le [s) = i [s) STAGOW AOVNENA IWLNOZIHOH/MOT4dN +08 MO] MO7-pay| «UBIH-POW « BIH MO] +x MO7-PaW yBIH-PaW, « 4BIH MOT] MO7-payl wx UBIH-P2N\ « YO! +x WNIPS| « 4BIH axnx MOT MO7-pe|\ YBIH-PeW, wee UBIH x MOT MO7-pe|\ yBIH-PaW » 4BIH x MOT wunipe|\| + 4BIH xx MOT wunipey| + 4BIH x MOT wunipe|\| « U6IH Lo ~~ ‘N40 -9 aq ueD 4 000'rrt 000‘021 000‘021 000‘96 Furnace Airflow Data 000‘96 000°96 000'22 000'¢2 000'22 000‘09 000‘Sr (unig) yndu| Bunesy 002-(4)0e1 agt-(4)oz1 agt-(1)960 azi-(4)960 vzt-(4)2z0 agi-(4)220 vzel-(4)220 “Vs Jequinn 1ePo¢N Table 2. PEPUSLULWODOY JON - psads Buljeay jes Auojoe4 ,, pseds buljoo9 jes Auojoe4 , "‘PSPUSWWLUODSJ JOU 1 SUO!}I|PUOCD asoy, ‘AJUO 9OUaIIJA1 JO} BU GQ UeY} Ja}ea916 Sainssaud O1}e}S JeEUII}X9 JO} SMO|pIe PUB SASI aunyesodwa! ‘¢ “Aen Aew SOsu ainyesodws] jenjoy “ajewixosdde ae ajqQe} oy} Ul Sas aunyesodwea| “Z *(S)J9}|y ULM UOITeJOdO JO} SI BYE “SUONOO9UUOD IIe UINJAJ OM) A4IND|J BJOW JO WD OOS] JO Sayed MOWHIVY “| :SSLON ‘N40 .9 9q URD } = O9El = OZEL = osel : O6El = SOvl OZ Slvl OZ Serl 69 Oerl MO1 s9 ossl v9 OZSI €9 ossl £9 S8sl €9 0091 eg OL9L (Ae) 0z9l 19 O€9t MO1-04W 000‘SEL SS Orel vS 098t €S OZ81 €S SZ8b €S 0681 es 0061 es Ol6L 1S 0261 ve «+HOIH-GAW aoz-(4)ser vv leleiarg ev cee ev Ove? ov ogee 44 Glee 4 S8ee 4 S6Ec ly Ove +HOIH 29 O9El 99 OZEL 99 Osel so O6EL v9 SOvl v9 Slvk v9 Sevl €9 oerl MOT 8S ossl 8S OZSI 2g osst 2g Ses} 2g 0091 9S OL9l 9S 0291 9S Oegl »MOTCAWN 000021 6p Orel 6p o98l 8v OZ81 8r SZ8L 8P 0681 8P 0061 lv O16L Lv 0z61 vie |HOIH-GaW a02-(4)0z1 = (elelore = cee = Ove? > ogee = Glee * gee > S6Ec * Ove «HOIH OLOL OL OEOl 89 0901 29 0801 s9 OLLL v9 Ovit CAS] SOLL 19 Ostt MO1 09 0021 6S Oe?t 8S osel 2S SZek 9S SOEl vS Geel €S O9El €S GZEL ««MOTCAN 000‘96 agt-(+)960 1S Oerl os osrl 6y OZvL 8r S6rl 87 Sesh Lv SSSI ov O8st Sv 0091 2e/t HOIH-dAaW ev OOZ1 ov OeZt LY OLZL Ov Sosl = Sesl . s98l = 0681 = OS61 «HOIH = 069 = OZ = 022 = sez : SGZ = OLL = Sez 2 S6Z MO1 s9 OLLE s9 OZ t v9 OviL £9 Slt eo SOL 19 Ostt 19 S6LL 09 0021 e/t «NNIGAW 000‘96 azt-(4)960 €S O9E1 es Osel es oorl 1S Olt LS Oerl 0s Srrl os o9rl 6v SZvl xHOIH 09 O16 8S 06 8S Ove 2g SS6 9S SZ6 ss S66 vS OLOL €S 0201 «MOT os 0601 6v OLLE 6p OZtL 8r Ovit Lv O9tt ov O8tt Sv S6LL Sv Olet MO1-04N 000‘%2 ly OZEl ly OvEl Ov O9el 6€ Osel 6€ oorl 8€ Ocrl 8e Serl = o9rl e/t HOIH-daW agt-(4)220 ig osgol - os9gl = OOZI 2 SeZh 7 SSZL .: SZLL = O6Z1 2 ossl «HOIH eZ osz IZ 092 IZ OLL OZ 082 89 S6Z 29 S08 29 018 s9 oes «MOT vS OLOL es OvOl IS 0901 os 0801 6v OLLE 87 OElt Lv SvLt ov Ostt g/t Wnidaw 000'%2 vai-(4)220 6v OZ E Lv O9LL ov O6LL > Oech = o9gcl * Oeel > SVEL = O8el xHDIH 09 osz 09 092 6S OZZ 8S 082 ZS S62 9S S08 9S 018 gs oes xxMOT Sv OLOL 44 OvOl ev 0901 ov osol ly OLLE Ov OElt Ov Svil 8€ O8tt g/L WnIdaW 000‘09 vat-(4)090 Ov OZLI 6€ O9Lt 8€ O6LL Ze lelaral 9€ o9zl = Oeel iy SVEL = O8el «HOIH 8sly Ws49 8sly W499 8sly W449 8sly W490 8sly W490 8sly W490 8sly W499 8sly WA dH qaads LNdNI ds 80 20 90 s0 v0 £0 20 xe) YOLOW YOLOW ONILVAH Y3AagWNN NWA109 YALVM AO SSHONI) SYNSS3Yd OILVLS TWNYALXS 7gq0N STAGOW ADVNYNA MOTANMOC +08 Furnace Airflow Data Table 2A. SAFETY INFORMATION 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. 2. Install this furnace only in alocation and position as specified on Table 3 of these instructions. 3. Provide adequate combustion and ventilation air to the furnace space as specified on Pages 11 through 18. 4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified on Pages 14 through 18. 5. Nevertestforgasleaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified on Page 21 of these instructions. 6. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as speci- fied on Table 2 of these instructions. See furnace rating plate. 7. Whena furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. 8. A gas-fired furnace for installation in a residential garage must be installed as specified on Page 9 of these instructions. 9. The furnace is not to be used for temporary heating of buildings or structures under con- struction. INSTALLATION REQUIREMENTS Requirements and Codes This furnace must be installed in accordance with these instructions, all applicable local build- ing codes, current revision of the National Fuel Gas Code (ANSI-Z223.1), and in Canada with the CAN/CGA - B149 installation code. The current revision of the National Fuel Gas Code is available from: American National Standards Institute, Inc. 14380 Broadway New York, New York 10018 Additional helpful publications are: NFPA-90A - Installation of Air Conditioning and Ventilating Systems NFPA-90B - Warm Air Heating and Air Conditioning Systems These publications are available from: National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts 02269 /\ WARNING: This furnace is not approved for installa- tion in mobile homes. _ Installation in a mobile home could cause fire, property damage, and/or personal injury. Location Upflow gas furnaces are shipped ready for installation in the upflow or horizontal right or left positions. The *RK gas furnace is for downflow operation only. The furnace must be installed on a level surface, located as close to the vent (or chimney) and as close to the center of the air distribution system as possible. See Table 1 for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the instal- lation point. The furnace must be installed so that all electrical components are protected from water. The furnace must be installed upstream from a refrigeration system. This furnace is not to be used for temporary heating of buildings or structures under construction. Clearances to Combustibles This furnace is Design Certified by CSA Inter- national for the minimum clearances to com- bustible material listed in Table 3. Refer to the furnace rating plate, located inside of the fur- nace cabinet, for the specific model number and clearance information. Access for positioning and servicing the unit must be considered when locating unit. 24 inches is the minimum required clearance from the front of the unit for servicing it. 30 inches is the minimum required clearance from the front of the unit for positioning it. 36 inches is the recommended clearance from the front of the unit. Please note that a panel or door can be located such that the minimum clearance on the rating plate is satisfied, but that panel or door must be removable and allow the appropriate clearance for your installation. This furnace is certified for use on wood floor- ing. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring. Downflow Warning (*RK Models): The design of the downflow furnace is certified for natural or propane gas and for installation on non-combustible flooring. A special combus- tible floor sub-base is required when installing onacombustible floor. Failure to install the sub- base may result in fire, property damage and personal injury. The special downflow sub- bases are factory supplied accessories, part number 904165. When the furnace is installed on a factory or site-built cased air conditioning coil, the sub-base is not necessary. However, Upflow Furnace Models UPFLOW APPLICATION BOTTOM INSTALLATION CLEARANCES Vent Connector | Standard Single Type B-1 Double Type Wall Metal Vent Wall Metal Vent LEFT SIDE RIGHT SIDE For Downflow furnace installations only, furnace mustbe installed on non-combustible flooring. Allow 24" minimum clearance for servicing. The recommended clearance is 36". the plenum attached to the coil casing must be installed such that its surfaces are at least 1" from combustible construction. /\ CAUTION: The downflow sub-base must not be installed directly on carpeting, tile, or any combustible material other than wood flooring. HORIZONTAL APPLICATION nnn SIDE Downflow Furnace Models TOP BOTTOM Table 3. Minimum Clearances to Combustible Material A gas-fired furnace installed in a residential Supply Air Plenum Installation garage must be installed so the burners and the igniter are located not less than 18 inches (457 —A_._ Installation on a concrete slab. - *RK mm) above the floor, and the furnace must be 1. Construct a hole in the floor per the located or protected to avoid physical damage dimension in Figure 2. by vehicles. 2. Place the plenum and the furnace as shown in Figure 3. /\ WARNING: B. Installation on a combustible floor. - *RK For downflow furnace installation, this fur- Do not place combustible material on or nace is approved for use on combustible against the furnace cabinet or within 6 flooring when NORDYNE combustible floor inches of the vent pipe. Do not place sub-base kit #904165 is used. combustible materials, including gaso- 1. Cut hole and frame the hole per the line and any other flammable vapors and dimensions in Figure 4. liquids, in the vicinity of the furnace. 2. Install the sub-base according to the installation instructions. (See Figure 5) Downflow Sub-base Furnace *RK 072-16; 096-12; *RK 060-12: 096-16; 120-20 072-12 z 135-20; ! eee Metal Plenum Figure 2. Opening for Concrete Slab Concrete Furnace Floor Figure 5. Downflow Sub-Base Dimensions Furnace Coil Wood Assembly Floor Sheet Metal Plenum Minimum *RK 072-16; *RK 060-12; 096-12; 096-16; 072-12 Figure 6. Furnace with Coil Assembly on 120-20; 135-20 a Wood Floor Figure 4. Opening in Wood Floor 10 3. When the furnace is installed on a fac- tory or site-built cased air conditioning coil, the sub-base is not necessary. However, the plenum attached to the coil casing must be installed such that its surface is at least 1” from combustible material in Figure 6. VENTING AND COMBUSTION AIR REQUIREMENTS General Provisions must be made in the installation of this furnace to provide an adequate supply of air for combustion. Detailed instructions for deter- mining the adequacy of an installation can be found in the current revision of the National Fuel Gas Code (ANSI 2223.1 / NFPA54) or in appli- cable local building codes. Consult local codes for special requirements. For Cana- dian installations consult Canadian Installations Codes and (CAN/CGA B149.1 or .2). If the furnace is operated with inadequate air for combustion one of the flame roll-out switches located in the burner compartment or the vent switch will open, turning off the gas supply to the burners. These safety devices are manually reset switches. DO NOT install jumper wires across these switches to defeat their function. DO NOT reset a switch without identifying and correcting the fault condition. Ifa switch must be replaced, use only the correct part specified in the Replacement Parts List. Air openings in the furnace door, warm air registers, and return air grilles must not be restricted. Combustion Air Quality To maximize heat exchanger life, the combus- tion air must be free of chemicals which form corrosive acidic compounds in the combustion gases. The recommended source of combus- tion air is to use the outdoor air supply. How- ever, the use of indoor air in most applications is acceptable except as follows: 1. Ifthe furnace is installed in a confined space it is recommended that the necessary combus- tion air come from the outdoors by way of attic, crawl space, air duct, or direct opening. 2. lfoutdoorcombustion air is used, there must be no exposure to the installations or substances listed in Item 3 below. 3. The following types of installation may require Outdoor Air for combustion, due to chemical exposures: * Commercial buildings ¢ Buildings with indoor pools ¢ Furnaces installed in laundry rooms e Furnaces installed in hobby or craft rooms ¢ Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply may also require Out- door Air for combustion: « Permanent wave solutions ¢ Chlorinated waxes and cleaners ¢ Chlorine based swimming pool chemicals ¢ Water softening chemicals ¢ De-icing salts or chemicals * Carbon tetrachloride ¢ Halogen type refrigerants * Cleaning solvents (such as perchloroethyl- ene) e Printing inks, paint removers, varnishes, etc. ¢ Hydrochloric acid * Cements and glues e Antistatic fabric softeners for clothes dryers ¢ Masonry acid washing materials /\\. CAUTION: Combustion air must not be drawn from a corrosive atmosphere. /\ WARNING: Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the furnace. Installation In An Unconfined Space An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1,000 Btuh of the combined input rates of all appliances which draw combustion air from that space. For example, aspace including a water heater rated at 45,000 Btuh input and a furnace rated at 75,000 Btuh requires a volume of 6,000 cubic feet [50 x (45 + 75) = 6,000] to be considered unconfined. If the space has an 8 foot ceiling, the floor area of the space must be 750 square 11 feet (6,000 / 8 = 750). In general, a furnace installed in an unconfined space will not require outside air for combustion. However, in “tight” buildings (with weather stripping and caulk to reduce infiltration), it may be necessary to provide outside air to ensure adequate com- bustion and venting, even though the furnace is located in an unconfined space. Installation In A Confined Space A confined space is an area with volume less than 50 cubic feet per 1,000 Btuh of the com- bined input rates of all appliances drawing combustion air from that space. Furnace clos- ets, small equipment rooms and garages are confined spaces. Furnaces installed in a con- fined space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace. A confined space must have two openings into the space for combustion air. One opening must be within 12 inches of the ceiling, and the other must be within 12 inches of the floor. The required sizing of these openings is determined by whether inside or outside air is used to support combustion, the method by which the air is brought to the space, and by the total input rate of all appliances in the space. Horizontal Furnace Installation The *RA series furnaces can be installed hori- zontally in an attic, basement, crawl space or alcove. Itcan be suspended from a ceiling ina basement or utility room in either a right to left airflow or left to right airflow. (See Figures 7 and 8.) If the furnace is to be suspended from the ceiling, it will be necessary to use steel straps around each end of the furnace. These straps should be attached to the furnace with sheet metal screws and to the rafters with bolts. The furnace could also be suspended by an angle iron frame bolted to the rafters. (See Figure 7.) Access for positioning and servicing must be considered when locating the unit. Refer to Table 3, Minimum Clearances to Combustible Material, for clearance specifications. Keep all insulating materials away from the louvered door. Insulating materials may be combustible. The *RA series furnace may be installed di- rectly on combustible wood flooring or sup- ports, if type "B-1" vent pipe is used (See Figure 8). It is recommended for further reduction of fire hazard that cement board or sheet metal be placed between the furnace and the combus- tible floor and extend 12 inches beyond the front of the louvered door. /A\ WARNING: Furnaces installed with combustion air drawn from a heated space which in- cludes exhaust fans, fireplaces, or other devices that may produce a negative pressure should be considered con- fined space installations. MITT | | Figure 7. *RA Horizontal Installation Suspended in Attic or Crawl Space Note: Line Contact is Permissible Gas Inlet Type “B” Vent ——— \_______ Combustible Platform Coil Plenum Bees Louver Door Connection Figure 8. *RA Horizontal installation on a Platform See the venting section for venting guidelines and specifications. Air From Inside (See Figure 9) If combustion air is taken from the heated space, the two openings must each have a free area of at least one square inch per 1,000 Btuh of total input of all appliances in the confined space, but not less than 100 square inches of free area. For example, if the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free area of at least 100 square inches. If the combined input rate of all appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches. Openings to adjacent space. Each opening must be at least 100 sq. in. or 1 sq. in. per 1000 Btuh of total input rating, whichever is greater. See minimum area per table. — Sion Max. ¥ = a) Furnace a El Oo I Ty Water Heater Minimum Total Input Free Area Rating (Btu/hr) (Each Opening) 40,000 100 sq. in. 60,000 100 sq. in. 80,000 100 sq. in. 100,000 100 sq. in. 120,000 120 sq. in. 140,000 140 sq. in. 160,000 160 sq. in. Figure 9. Equipment in a Confined Space with all Combustion Air Drawn from the Inside Round Duct Diameter Ventilation Louvers at A Cee each end of attic [| a Outlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. a Inlet and Outlet i Ducts must extend above ry attic insulation. Attic Insulation 77 a Pas \— Water Heater Inlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of | 2—~“‘total input rating. a. All Combustion Air from Ventilated Attic. Minimum Free Area Round Duct (Each Opening) Diameter Total Input Rating (Btu/hr) 40,000 10 sq. in. 60,000 15 sq. in. 80,000 20 sq. in. 100,000 120,000 140,000 25 sq. in. 30 sq. in. 35 sq. in. 160,000 40 sq. in. Figure 10. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Vertical Ducts Outdoor Air Using Vertical Ducts (See Figure 10) If combustion air is taken from outdoors through vertical ducts, the openings and ducts must have a minimum free area of one square inch per 4,000 Btuh of total appliance input. In instal- lations drawing combustion air from a ventilated attic, both air ducts must extend above the attic insulation. If the unit is installed in an area with an exhaust fan, provide sufficient ventilation to prevent negative pressures from occurring in the room. The combustion air openings must not be re- stricted in any manner. /\. CAUTION: Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure. Air Directly Through An Exterior Wall (See Figure 11) Vent or Chimney Each opening to outside must be at least 1s 7 Btuh of total input rating. Furnace U ier Max _ Water Heater Minimum Free Area Round Duct Rating (Btuh) (Each Opening) Diameter 40,000 10 sq. in. 4" 60,000 15 sq. in. " 80,000 20 sq. in. 100,000 25 sq. in. 120,000 30 sq. in. 140,000 35 sq. in. 160,000 40 sq. in. Total Input Figure 11. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Exterior Wall 13 If combustion air is provided directly through an exterior wall, the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input. Outdoor Air Using a Crawl Space and Ventilated Attic (See Figure 12) When directly communicating with the out- doors, each opening shall have a minimum free area of 1 square inch per 4,000 Btuh of total appliance input. The openings shall communi- cate directly, or by ducts, with the outdoor spaces (crawl or attic) that freely communicate with the outdoors. Outdoor Air Using Horizontal Ducts (See Fig- ure 13) If combustion air is taken from outdoors through horizontal ducts, the openings and ducts must have a minimum free area of one square inch per 2,000 Btuh of total appliance input. If the unit is installed in an area with an exhaust fan, provide sufficient ventilation to prevent negative pressures from occurring in the room. The combustion air openings must not be re- stricted in any manner. VENTING REQUIREMENTS General This furnace must be vented in compliance with, the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54), with the instructions provided below. Vent or Ventilation Louvers at “7 Chimney each end of attic Cutlet Air Duct | —— must be at least 1 3 . in. per 4000 Btuh of total input aaa rating. Must exten id Attic Ingulation above attic insulation. Water Heater, Inlet Air Duct must Oo IC _— Ventilation Louvers for unheated crawl space Crawl Space Figure 12. Equipment in a Confined Space with All Combustion Air Drawn from a Crawl Space and Ventilated Attic In Canada, venting shall conform to the require- ments of the current (CAN/CGA B149.1 or .2) installation codes. Consult local codes for special requirements. For Category | furnace installations, the fur- nace shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptance to the authority having jurisdiction. Venting into an unlined masonry chimney or concrete chim- ney is prohibited. This furnace must never be vented to a chim- ney flue servicing a fireplace or other appliance designed to burn solid fuel. If the furnace vent is to be connected to a chimney serving a fireplace, the fireplace must be sealed off from Vent or <7 Chimney, Each (opening to outside must be at least . in. per 2000 un of total input ing. FE] Air Duct . fam i ‘Water Heater E] Air Duct Minimum input Free Area Round Duct Rae (Btu/hr) (Each Opening) Diameter 40,000 20 sq. in. ” 60,000 30 sq. in. 80,000 40 sq. in. 100,000 50 sq. in. 120,000 60 sq. in. 140,000 70 sq. in. 160,000 80 sq. in. Figure 13. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Horizontal Ducts Pressure Switch -— Bleed Tube Bleed Tube Orifice - Pres: switch operat at high altituc can be made responsive b) Sensor Tubes covering blee orifice Collector c Pan *RA Bleed Tube Installation Figure 14. the chimney. Single wall metal vents shall not be used for Category | venting, Category | fur- naces must be vented vertically or near verti- cally. The furnace vent, if metal, may be insulated if local codes allow. Any part of the vent system, metal vent only, not exposed to weather, but which are exposed to ambient temperatures below 35° F must be insulated to prevent con- densation. Allventinsulation shall be foil backed fiberglass of one inch minimum thickness. Three sheet metal fasteners (field supplied) Category I - Common Venting When an existing furnace is removed from a venting system serving other appliances, the venting system is likely to be too large to properly vent the remaining appliances. An improperly sized venting system can result in the formation of condensate, leakage, spillage, etc. The steps outlined in the warning below shall be followed with each individual appliance con- nected to the vent system placed in operation, while all other appliances connected to the vent system are not in operation: should be used to secure the vent pipe to the furnace flue. These fasteners should be evenly spaced around the flue diameter, if possible. /\ WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI 2223. 1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Deter- mine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Close fireplace dampers. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI 2223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installa- tion Codes. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, win- dows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use. 15 The venting system should be designed to have the minimum number of elbows or turns. All horizontal runs shall be sloped upwards from the furnace at 1/4 inch per running foot of vent. Supports for the vent pipe must be installed a minimum of every five feet along the vent run to ensure no displacement after instal- lation. Under no circumstances shall any portion of the vent system extend into or pass through any return air duct, supply air duct, or plenum. If the furnace is operated with blocked or restricted venting, the blocked vent switch located in the vent plate will open, turning off the gas supply to the burners. The blocked vent switch is a manually reset device. DO NOT install a jumper wire across this switch to defeat its function. DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip. If this switch must be replaced, use only the part specified in the Replacement Parts List. /\\ WARNING: Upon completion of the furnace installa- tion, carefully inspect the entire flue sys- tem both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure of flue products, including carbon mon- oxide. Category Ill: Horizontal Venting NOTE: The reduced NOx models (eighth character N) are not approved as a Cat- egory Ill (Category III) furnace for use with horizontal venting. The furnaces are approved for use with 3" single wall AL29-4C stainless steel vent pipe in horizontal vent applications. This pipe is available from the following manufac- turers: Z-FLEX Inc. - vent brand name (Z-VENT) Heat-fab Inc. - vent brand name (Saf-T Vent) Flex-L International - vent brand name (Star- 34 Vent) This vent pipe must be used for the entire length of the vent run. The installation must be in accordance with all instructions supplied by the 16 vent manufacturer for use on Category Ill appliances. When venting horizontal, this is defined as a Category Ill furnace, the vent pressure is positive, and the venting system must be sealed in both horizontal and vertical runs. For horizontal venting installations in both the United States and Canada the transition as- sembly must be modified by adding ableed tube to the pressure switch tube and bypassing the vent switch. All model furnaces will require Vent Kit #903196 for horizontal venting. NOTE: No bleed tube is required for the *RA 045(C,N)-08 model. Horizontal Venting For Upflow Models: 1. Remove the rubber tubing from the pressure switch sensor tube and the collector pan sen- sortube. Cut 1/2 inch from one endofthe rubber sensor tube, fold in half and cut along the bend line. Discard the 1/2 inch long piece of tubing. Select the correct bleed tube using the table supplied with vent kit #903196 and place the other two pieces of tubing on both ends of the bleed tube. Do not cover the hole in the bleed tube. Place the assembly back on the pressure switch sensor tube and the collector pan sen- sor tube. (See Figure 14.) 2. Remove the nut and restrictor plate from the vent collar assembly and discard the restrictor plate. Selectthe appropriate dilution cover plate as noted with ventkit#903196. Fitthe clearance hole in the cover plate over the weld stud. The cover plate must cover the hole(s) on the vent collar assembly. Tighten the nut securely while holding the cover plate in position. (See Figure 15.) 3. Bypass the vent switch by removing both wires from the vent switch and attaching them to the wire nut. (See Figure 16.) Covered Vent Collar Hole Figure 15. Vent Collar Detail Switch Switch Limit Flame Roll-Out Wire Nut Figure 16. Limit Circuit Wiring Horizontal Venting: *RK Models: 1. By-pass the vent switch, located on blower compartment door, by removing both wires from the switch. Remove wire terminals, strip wires and tie together in a wire nut. (See Figure 16.) Remove the rubber tubing from the pressure switch sensor tube and the collector pan sen- sor tube. Cut the tubing approximately 3" from one end. Select the appropriate dilution cover plate as noted with vent kit #903196. Insert the bleed tube into the tubing. Do not cover the hole in the bleed tube. Place the tubing assembly back on the pressure switch sensor tube and collector pan sensor tube. (See Figure 17.) as To gain access to the restrictor plate, remove and discard the combustion tube from the transition assembly. Insure the seal between inducer and transition assembly is not broken. (See Figure 18.) = Remove and discard the restrictor plate and screw from the transition assembly. (See Fig- ure 18.) 2 Installandseala4"to 3" reducer to thetransition. (See Figure 19.) Attach the new high tempera- ture vent pipe to the reducer. /\ CAUTION: Do not drill holes through the vent pipe or fittings on a horizontal vented fur- nace. Do not use sheet metal screws, or rivets. Drilling, screws, or rivets will cause leaks. oe Collector Pan Pressure Bleed Tube ~l Switch Bleed Tube Orifice Figure 17. *RK Bleed Tube Installation The components of the horizontal vent system must not be penetrated with screws, rivets, or other devices, either when joining pipes and fittings or using support straps. All joints must be sealed with high temperature silicone before locking bands are installed. Ifthe lengths of pipe must be cut, the joint must still be sealed with silicone and the locking band used. When installing the condensate tube be sure to form a trap by means of a 3" loop filled with water. (See Figure 20.) Keep the number of pipe fittings to a minimum. Maintain a minimum of 6 inches of air space between the vent and combustibles at all times, this includes inside and outside the building. NOTE: The direction of the male-female joints from the drain tee to the termination tee is opposite to standard gas appliance venting. The male end of the pipes point towards the furnace. Combustion Tube == ae dg a= BeSMicior i Plate Transition Figure 18. *RK Horizontal Vent Modification Special 3" _— AL29-4C Stainless Steel Vent Pipe 4" to 3" Reducer Transition Figure 19. *RK Reducer Installation 17 1. Apply an adhesive bead around the outside of the pipe approximately 1/4" from the end of the pipe. This includes the first fitting or pipe attached to the furnace. 2: Push the pipe and fitting together while twisting the pipe or fitting. Twisting the pipe or fitting spreads the adhesive completely within the fitting socket. 3. | When the pipe is at the socket bottom, inspect the joint. Look for a complete, uninterrupted ring of adhesive material around the pipe at the fitting socket. Additional adhesive or rotation of the pipe or fitting may be required for a complete seal. The complete adhesive material ring provides the seal required for the positive pressure vent. 4. All vent systems must include a tee and drain plug for collection and disposal of condensate. The drain tee must be installed within the first 5 feet of vent run to protect the furnace. 5. All horizontal sections must have a slope toward the drain tee of not less than 1/4" per footto prevent the collection of condensate at any location other than at the tee. 6. Horizontal runs must be supported with 3/4" pipe strap at a maximum of 5 foot intervals and at each point where an elbow is used. 7. Maintain a6 inch minimum air space to combustibles from all sections of the stainless steel vent system, except when a wall thimble is used. Support Wall Thimble (For combustible wv wall material) Locking Band Locking 90 Elbow \ Tee ie i X\ ‘ Band PA Drain t Plug 1/4" Per Foot Rise Termination ee 3" Dia. Loop Outside Wall Figure 20. Typical Horizontal Vent Installation Horizontal Power Venting—The Tjerlund GPAK- 1TN horizontal kit is certified for use with this furnace. The kit includes a power venter, a side- wall vent hood and a barometric draft control. It has an electrical interlock to assure that the furnace will not operate when the power venter is off. The kit is for use only when exhaust is through an exterior wall, normally with horizontal vent piping. The power venter establishes negative pressure in the vent piping and the furnace operates as if connected to Category | vertical venting. Installation Instructions are provided with the kit. Installation must conform to those instruc- tions and applicable requirements of local codes. /\ WARNING: The entire vent system must be sealed with a high temperature sealant which will withstand temperatures of 450°F. Recommended sealants: Dow Corning Sealant 736 RTV; GE 106 RTV; High Tech Ind., High TEMP RED. Horizontal Venting Requirements Furnace Model Number | Pipe | Reducer} Maximum] Max. Feet *RA Size | Needed | # Elbows | Vent Pipe Note: Special 5" to 4" Reducer Kit, p/n 902249 required for model number *RA144C-20. Furnace Model Number | Pipe | Reducer} Maximum] Max. Feet *RK Size | Needed | # Elbows | Vent Pipe 0600-12 0720-12 Table 4. Horizontal Venting Requirements VENT TERMINAL (X) AIR SUPPLY INLET CMLL LLLLLLLLING Uf S AREA WHERE TERMINAL IS NOT PERMITTED — J ty, XG = {Clearance to permanentl = |Vertical clearance to ventilated soffit Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened closed window located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal = [Clearance to unventilated soffit = |Clearance to outside corner Clearance to inside corner Canadian Installations’ 12 inches (30 cm) 6 inches (15 cm) for appliances < 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and $ 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW) US Installations? 12 inches (30 cm) 4 feet (1.2 m) below or to side of opening; 1 foot (300 mm) above opening = |Clearance to each side of center line extended above meter/regulator assembl Clearance to service regulator vent outlet Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to a mechanical air supply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda, porch deck, or balcon' 3 feet (91 cm) within a height 15 feet above the meter/regulator assembl 3 feet (1.83 m) * 6 inches (15 cm) for appliances < 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and $ 100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW) 6 feet (1.83 m) 7 feet (2.13 m) t 4 feet (1.2 m) below or to side of opening; 1 foot (300 mm) above opening 3 feet (91 cm) above if within 10 feet (3 m) horizontally 7 feet (2.13 m) 12 inches (30 cm) + ‘ In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, one of the following statement shall be included: “Clearance in accordance with local installation codes, and the requirements of the gas supplier and the manufacturer’s installation instructions.” Figure 21. Vent Termination Clearances for Direct Vent Furnaces 19 Location of Outdoor Terminations Horizontal Installation The vent termination tee must be installed with the following minimum clearances. (See Figure 21.) Vent termination clearances shall be con- sistent with the National Fuel Gas Code, ANSI 2223.1/NFPA 54 and/or the CSA B149.1, Natural Gas and Propane Installation Code. All minimum clearances specified must be maintained to protect building materials from degradation by flue gases. 1. The termination tee must be 12 inches above snow level or grade level which ever is higher. See Figure 22 for alter- nate method to achieve 12" above snow level. When penetrating a noncombustible wall, the hole through the wall must be large enough to maintain the pitch, pipe clearance for passage, and provide for proper sealing. Penetrating a combus- tible wall requires the use of a wall thimble. (See Figure 22.) A 6-1/2 inch square framed opening is required to insert the thimble halves. The thimble is adjustable to varying wall thickness and isheldin place by applying sealant to the male sleeve before assembly. Also run a bead of sealant around the outer wall thimble. The vent pipe must extend 1-1/4 inches through the outer thimble half for a combustible wall. Be sure to check this carefully before cutting the vent pipe. Attach a3 inch coupling to the end of the 2. Avoid areas where condensate drainage pipe that extends through the wall or may cause problems such as above thimble. This prevents the vent pipe planters, patios, or adjacent to windows from being pushed inward. where the steam from the flue gases Cutan 8 inch minimum piece of vent pipe may cause fogging. Do not terminate and connect the coupling to the above any public walkway. termination tee. The inside of the tee 3. Select the point of wall penetration where must be a minimum of 12 inches from the minimum 1/4 inch per foot of upward slope can be maintained. Vent Points ! Use Wall Thimble at the outside of the wall. (See Figure 23.) = Termination Tee Support TIT Figure 22. Alternate Horizontal Vent Installation 20 Flexible Vent Systems Flexible gas vent is approved for use in vertical single vent or common vent installations only. The minimum distance to combustibles is 1" for type B insulated and 6" for single wall. The venting system must be installed in accordance with the local authorities, the vent manufacturer's instructions and the instructions listed below. The flexible vent must be installed in accor- dance with the venting tables for vertical or common venting only. The vent system must be supported in horizontal runs with 3/4" pipe strap at a maximum of 5 foot intervals. All horizontal sections must have a slope toward the furnace of not less than 1/4" per foot. The vent must not sag, or have any bends greater than 90 degrees. CIRCULATING AIRSUPPLY General Plenums and air ducts must be installed in accordance with the Standard for the Installa- tion of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Instal- lation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B). It is recommended that the outlet duct be pro- vided with a removable access panel. This opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover for the opening shall be attached in such a manner as to prevent leaks. If outside air is used as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air Inside Outer Overlapping Combustible Shield 67/2" Dia. Wall Wall Thimble Wall Thimble Outer Half (Inner Half) 3" Vent SS Pipe ¥ Locking Band 1 f M Protective Screen Inner Overlapping Shield 63/e" Dia. Termination Tee 12" Min Ore Outside Combustible Wall Inner Shield 41/2" Dia. Inside Combustible > Wall Figure 23. Typical Termination is notless than 50°F (10°C) during operation. If a combination of indoor and outdoor air is used, the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal, indoor return air applications. When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil, the coil must be installed down- stream (on the outlet side) of the furnace or in parallel with the furnace. If acooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and con- densing on the heat exchanger. If a manually operated damper is installed, it must be de- signed so that operation of the furnace is pre- vented when the damper is in the cooling posi- tion and operation of the cooling system is prevented when the damper is in the heating position. Return Air In applications where the supply ducts carry heated air to areas outside the space in which the furnace is installed, the return air must be delivered to the furnace by duct(s) sealed to the furnace casing, running full size and without interruption. /\\ WARNING: The solid base of the furnace must be in place when the furnace is installed with side return air ducts. Removal of all or part of the base could cause products of combustion to be circu- lated into the living space and create potentially hazardous conditions, in- cluding carbon monoxide poisoning that could result in personal injury or death. For upflow/horizontal installations: The return air ductwork may be connected to any or all of the following: left side return, right side return, or bottom return. NOTE: Do not use the back of the furnace for return air. Table 2 and 2a, in the front pages of these instructions, contains the airflow data for each furnace model. Where maximum airflow is 1800 CFM or more, two openings must be used for return air. /A\ WARNING: Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. All return ductwork must be secured to the furnace with sheet metal screws. For installations in confined spaces, all return ductwork must be adequately sealed and joints must be taped. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be air tight. The floor or platform on which the fur- nace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform. Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace in- sert, stove, etc. Doing so may result in fire, explosion, carbon monoxide poisoning, personal injury, or property damage. Upflow Models- Left Side Entry ee a Shuto Valve ities} aa IN YL ground Joint Union Dripleg_s* Downflow Models- Right Side Eniry Shut-Off Valve G 4 ™~ Some utilities r require Shut-Off 4st Automatic Gas Valve to be Valve (with manual 4to 5 feet TI shut-off) above floor 1 i Ground Joint Union ~ Burner Assembly \ ~<_Dripleg Manifold Figure 24. Typical Gas Service Connection 22 GAS SUPPLY AND PIPING General This furnace may be installed for either left or right side gas entry. A typical gas service hookup is shown in Figure 24. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace. All gas piping must be installed in compliance with local codes and utility regulations. Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements re- garding placement of the manual main gas shut- off. In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1) or (CAN/CGA B149.1 or .2) Installation Codes. An 1/8inch NPT tap mustbe installed in the gas line to the unit for use when measuring the gas supply pressure. The tap should be readily accessible for service use. A drip leg should be installed in the vertical pipe run to the unit. Table 5 lists gas flow capacities for standard pipe sizes as a function of length in typical applica- tions based on nominal pressure drop in the line. IMPORTANT NOTES: 1. Gas piping must not be run in or through air ducts, chimneys, gas vents, elevator shafts, etc. 2. Compounds used on threaded joints of gas piping must be resistant to the actions of lique- fied petroleum gases. 3. The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required. Leak Check After the gas piping to the furnace is complete, all connections must be tested for gas leaks. To check for leaks in gas piping systems, use only a soap and water solution or other approved method. /\. CAUTION: Do not use matches, lighters, candles, or other sources of open flame to check for gas leaks. IMPORTANT NOTE: When pressure testing the gas supply lines at pressures greater than 1/2 psig (14 inch W.C.), the furnace must be disconnected from the gas supply piping system to prevent damage to the gas control valve. If the test pressure is less than or equal to 1/2 psig (14 inch W.C.), the furnace must be isolated from the gas supply line by closing the manual shut-off valve. /\. WARNING: FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings ex- actly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detec- tion of leaks to check all connections. A fire or explosion may result causing prop- erty damage, personal injury or loss of life. CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60) NOMINAL LENGTH OF PIPE RUN BLACK IRON (feet) PIPE DIAMETER (in.) 10 20 30 40 50 60 70 80 1/2 130 90 75 65 55 50 45 40 3/4 280 190 150 130 115 105 95 90 11/4 1050 | 730 590 500 440 400 370 350 11/2 1600 | 1100 } 890 760 670 610 560 530 The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace. To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value of the gas: Cubic Feet Per Hour Required Input To Furnace (Btu/hr) Heating Value of Gas (Btu/Cu. Ft.) Table 5. Capacity of Black Iron Gas Pipe (cu. ft. per hour) for Natural Gas (specific gravity = .60) Conversion Conversion of this furnace to use LP/propane gas must be made by qualified service person- nel, using only approved parts. /\ WARNING: This furnace was equipped at the factory for use with natural gas only. A special kit, supplied by the manufacturer, is re- quired to convert the furnace to operate on LP/propane gas. Failure to use the proper conversion kit can cause fire, ex- plosion, property damage, carbon mon- oxide poisoning, personal injury, or death. High Altitude Application High altitude application with this furnace can be field performed by a simple adjustment of mani- fold pressure, and if necessary changing the orifices. The changes required depend on the installation altitude and the heating value of the gas. The gas heating value based on sea level can be obtained from your local gas utility. The heating value of gas at high altitude is always lower than the sea level heating value. The heating values used in Tables 6 & 7 are based on sea level values. Natural Gas High Altitude Conversion All factory shipped furnaces are ready to oper- ate between zero and 4999 ft. above sea level. For higher altitudes (between 5000 and 10,000 ft. above sea level), conversion can be achieved simply by adjusting the furnace manifold pres- sure as shown in Table 6. LP/Propane Gas Sea Level and High Alti- tude Conversion IMPORTANT NOTE: When converting a low NOx furnace from Natural gas to LP/pro- pane gas, it is necessary to remove the NOx Baffles from the furnace. Conversion of this furnace to utilize LP/propane gas must be made by qualified service person- nel, using factory authorized or approved parts. Conversion to LP/propane gas can be accom- plished by first replacing the natural gas orifices with the appropriate LP/propane orifices shown in Table 8 or 9. Note: for installations between zero and 5000 ft. above sea level, a, #53, #54 or #55 drill size orifice should be used depend- ing upon the rated firing rate of the unit (see 23 For a Natural Gas Sea Level Heating Value of 800 to 899 Biu/cu.ft. Elevation (feet above sea level zero to | 2000 to | 5000 to | 6000 to | 8000 to 1999 4999 5999 7999 10000 Manifold Pressure Setting (in WC) For a Natural Gas Sea Level Heating Value of 900 to 999 Biu/cu.ft. Elevation (feet above sea level zero to | 2000 to | 5000 to | 6000 to | 8000 to 1999 4999 5999 7999 10000 Manifold Pressure Setting (in WC) For a Natural Gas Sea Level Heating Value of 1,000 to 1,100 Btu/cu.ft. Elevation (feet above sea level zero to | 2000 to | 5000 to | 6000 to | 8000 to 1999 4999 5999 7999 10000 Manifold Pressure Setting (in WC) Table 6. Manifold Pressure (in WC) for Natural Gas at Various Altitudes Manifold Pressure in (WC) for an LP Gas Heating 10.0 Value of 2,500 Btu/hr. Elevation (feet above sea level 2,000 to | 5,000 to | 6,000 to | 8,000 to 1,999 | 4999 | 5999 | 7,999 | 10,000 8.5 8.5 10.0 Table 7. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes Furnace Rating Orifice Drill Size Plate Input (Btu/h) | Nat | LP | 45000 Table 8. Natural and LP Gas Orifice Sizes for Elevations between zero and 4999 ft. Above Sea Level Furnace Rating Orifice Drill Size Plate Input (Btu/h) | Nat | LP | 45000 60000 Table 9. Natural and LP gas Orifice Sizes for Elevations between 5000 and 10,000 ft. Above Sea Level Table 8 or 9). However for installations above 5000 ft. above sea level, a #55 or #56 drill size orifice should be used. After changing the orifices, use Table 7 to determine the appropri- ate manifold pressure for your installation. Conversion to LP/propane, sea level, and high altitude is detailed in the installation instructions provided with the conversion kit. Approved conversion kits are listed below. United States LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904090A This kit is for LP/propane conversion in the United States at altitudes between zero and 10,000 ft. above sea level. Follow the installa- tion instructions supplied with the kit for proper installation. 24 Canadian LP/Propane Gas Sea Level and High Altitude Conversion Kit - P/N 904091A This kit is for LP/propane conversions in Canada at altitudes between zero and 4500 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation. /A\ WARNING: To avoid electric shock, personal injury, or death, turn off the electric power at the disconnect or the main service panel before making any electrical connections. ELECTRICAL WIRING General Electrical connections must be made in accor- dance with all applicable local codes and ordi- nances, and with the current revision of the National Electric Code (ANSI/NFPA 70). For Canadian installations the electrical con- nections and grounding shall be done in accor- dance with the current Canadian Electrical Cabinet Width Furnace Input Furnace Model Number *RA,*RK (Btu/hr) | (in.) 45,000 60,000 72,000 72,000 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 72,000 96,000 96,000 96,000 120,000 120,000 135,000 144,000 Note: (t) can be C or N. *“Time-delay fuses or HACR-type circuit breakers are required. Nominal Maximum | Minimum | Maximum] Minimum Electrical | Operating | Operating | Furnace Wire Fuse or Circuit Supply Voltage Voltage | Amperes | Gauge | Breaker Amps** 5.6 14 14 Code (CSA C22.1, Part 1 and/or local codes). If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wire having a temperature rating of at least 105°C. Refer to the furnace nameplate and Table 10 for electrical requirements. Line Voltage Wiring The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. (See Table 10.) An electrical disconnect must be installed to be readily ac- cessible from and located within sight of the furnace. (See the Wiring Diagram label in the furnace and Figure 25.) /\. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous op- eration. Verify proper operation after servicing. Maximum 7.4 7.4 9.0 21.0 7.4 9.0 9.0 12.2 Recommended Thermostat Wire Length 2-wire 4 or 5-wire (heating) (cooling) Table 10. Electrical Data 25 The furnace cabinet must have an_ uninter- rupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this furnace require an earth ground to operate properly. Accept- able methods for grounding are electrical wire or conduit approved for electrical ground ser- vice. Do not use gas piping as an electrical ground. IMPORTANT NOTE: Proper line voltage polarity must be main- tained in order for the control system to operate correctly. Verify that the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. These furnaces will not operate unless the polarity and ground are properly connected. See Figure 25. Low Voltage Wiring Install the thermostat per the manufacturer’s instructions. The low voltage (24 volt) connec- tions from the thermostat are made at the terminal strip on the integrated control in the Field Supplied Fused Service Panel \ Black (Hot) | Field Supplied ___ Panel Connector (Ground) Ground Field Supplied Disconnect Within Sight of Furnace furnace. See Figure 26 for the proper connec- tions for heating only (two-wire) and heating/ cooling (four-wire) applications. The recom- mended minimum wire gauge for thermostat wiring is shown in Table 10. The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected. Adverse affects include radiant loading from fireplaces, sunlight, or lighting fixtures, and convective loading from warm air registers or electrical appliances. To determine the heat anticipator setting either: 1. Add the current draw of the system compo- nents; or 2. Measure the current flow on the thermostat R- W circuit after the circulating blower motor has started. Set the heat anticipator according to the ther- mostat manufacturer’s instructions for heat anticipator settings. Field Line Voltage Wiring —_—_ Factory Line | White Voltage Wiring Ground \ \ Junction Box (may be internal \ or external to the furnace). These connections can be made in the field supplied disconnect at the furnace. A/C Condensing Unit ie Condensing Unit Control Box oo Blower Off son0 Connect oS) R&W> Q. F Hastie ©. Only Room Thermostat NOTE: The "Y" terminal on the UTEC control board must be connected to the thermostat for proper cooling Timing [+e TWIN Flame Signal Light (Yellow) Status Light (Red) e mode operation. — Neutrals Unused Motor Leads FIELD WIRING xm Q Low Voltage z Connections l Figure 26. Low Voltage Field, Four-wire Heating/Cooling Applications 26 START-UP AND ADJUSTMENTS General Prior to start-up, verify that: 1. The line voltage power leads are securely connected, that the polarity of the connections is correct, and that the furnace is properly grounded. 2. The thermostat wires (R, W, Y, and G) are securely connected to the correct leads on the terminal strip of the circuit board. 3. The gas line service pressure does not exceed 10.0in. water column (0.36 psig), andis notless than 4.5 in. water column (0.16 psig) for natural gas. For LP gas the line service pressure must notexceed 14 in. water column (0.51 psig), and must not be less than 11.0 in. w.c. (0.40 psig). 4. The roll-out and vent safety manual reset switches are closed. If necessary, press the red button to reset a switch. DO NOT install a jumper wire across a switch to defeat its function. If a switch reopens on start-up, DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip. 5. The blower door is in place, closing the door switch in the line voltage circuit. 6. The gas line has been purged and all connec- tions are leak tight. Start-up Procedures After all of the above checks have been made: 1. Set the thermostat to the lowest setting. 2. Close the disconnect(s) to provide line voltage to the furnace. 3. Follow the procedures given on the operating instruction label attached to the furnace. 4. Set the thermostat above room temperature and verify the operating sequence. (See the Sequence of Operation). 5. After the furnace has run for approximately five minutes, set the thermostat below room tem- perature and verify steps (9) through (11) of the Sequence of Operation. Verifying and Adjusting Firing Rate The firing rate must be verified for each installation to prevent over-firing the furnace. IMPORTANT NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. At alti- tudes above 2000 feet it must not exceed that on the rating plate less 4% for each 1000 feet. Follow the procedure below to determine the firing rate. 1. Shut off all other gas fired appliances. Start the furnace and allow it to run for at least three minutes. 8. Measure the time (in seconds) required for the gas meter to complete one revolution. 4. Convert the time per revolution to cubic feet of gas per hour using Table 11. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour. Example: 2 ¢ Time for 1 revolution of a gas meter with a 1 cubic foot dial = 40 seconds. ¢ From Table 11 read 90 cubic feet per hour of gas. ¢ Heating value of the gas (obtained from gas supplier) = 1040 Btu per cubic foot. ¢ Firing rate = 1040 x 90 = 93,600 Btuh. 2 Adjustments to the firing rate can be made by adjusting the gas manifold pressure. See the High Altitude Application section for additional information of firing rate at elevations above 2000 ft. The manifold pressure must be set to the appropriate value for your installation. Refer to either Table 6 for natural gas or Table 7 for LP/ propane gas to verify the manifold pressure setting required for your particular installation. To adjust the manifold pressure, remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counter- clockwise to reduce pressure. Replace the regulator cap after adjustments are complete. /\. CAUTION: Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices. Verifying and Adjusting Temperature Rise Verify the temperature rise through the furnace is within the range specified on the furnace rating plate. | Temperature rises outside the specified range could result in premature heat exchanger failure. Place thermometers in the return and supply air stream as close to the furnace as possible. The 27 thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings. Adjust all registers and duct dampers to the desired position and run the furnace for ten to fifteen minutes before taking any temperature read- ings. The temperature rise is the difference between the supply and return air tempera- tures. For typical duct systems, the tempera- ture rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting. If the temperature rise measured is outside the range specified, it may be necessary to change the blower speed. Lower blower speeds will increase the tem- perature rise and higher blower speeds will decrease the temperature rise. The furnace is equipped with a multi-speed motor. Heating and cooling speed selection is made by moving the leads on the integrated control located in the furnace. The wiring diagram on the furnace and Figure 28 show the speed taps for adjusting motor speed. If itis desired that the blower operate at the same speed for heating and cooling, tape off the TIME FOR ONE REVOLUTION CUBIC FEET PER REVOLUTION OF METER SECONDS 10 Table 11. 28 GAS FLOW RATE (CUBIC FEET PER HOUR) unused blower lead and install the jumper wire found in the plastic instruction bag. Remove the desired blower tap, and install the jumper wire piggyback to the heating speed tap, and straight quick connect to the cooling speed tap. Recon- nect the desired blower tap to piggyback quick connect. The integrated control is factory set to start the circulating air blower 30 seconds after the gas valve is opened. The integrated control is factory wired to turn the blower motor off 120 seconds after the gas valve is closed. If necessary for comfort, the “off” time may be changed by adjusting the Blower Off jumper on the integrated control. See Figure 27 for blower on and off time adjustments. /\ WARNING: To avoid electric shock, personal in- jury, or death, disconnect the electric power before performing any mainte- nance. TIME FOR CUBIC FEET PER REVOLUTION OF ONE REVOLUTION METER SECONDS 1 5 10 66 55 273 545 68 53 265 529 70 51 257 514 72 50 250 500 74 49 243 486 76 47 237 474 78 46 231 462 80 45 225 450 82 44 220 439 84 43 214 429 86 42 209 419 88 41 205 409 90 40 200 400 92 39 196 391 94 38 191 383 96 38 188 375 98 37 184 367 100 36 180 360 102 35 176 353 104 35 173 346 106 34 170 340 108 33 167 333 110 33 164 327 112 32 161 321 114 32 158 316 116 31 155 310 118 31 153 305 120 30 150 300 Gas Flow Rate Verifying Burner Operation To verify operation of the burners, make sure that the furnace door is in place and that there is power to the furnace. Set the thermostat to a temperature above room temperature and observe the ignition sequence. The burner flame should carry over immediately between all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting off, curling, or floating. After verifying satisfactory flame characteristics, set the thermostat to a temperature below room temperature and verify that the burner flame extinguishes completely. Verify Operation of the Supply Air Limit Switch To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace. Block the return airflow to the furnace by installing a close- off plate in place of or upstream of the filter(s). Set the thermostat to a temperature above room temperature and verify that the Sequence of Operation is as described in these instruc- tions. The limit switch should function to turn off the gas valve within approximately four minutes (the exact time depending on the efficiency of the close-off in blocking the return air to the furnace). The circulating air and combustion blowers should continue to run when the limit switch opens. Remove the close-off immedi- ately after the limit switch opens. If the furnace operates for more than four minutes with no return air, set the thermostat to a temperature below room temperature, shut off the power to the furnace, and replace the limit switch. DESCRIPTION OF COMPONENTS Figure 29 shows the location of each of the functional components described below. Also, refer to the Sequence of Operation Section of this manual . If any component of the furnace must be replaced, use only factory authorized replacement parts. See the Replacement Parts List for the factory authorized replacement for each component. Flame Sensor The flame sensor acts to prove that flame has carried over from the igniter to the opposite end burner. If no flame is sensed, the furnace will shut down within 7 seconds of ignition. Flame Roll-Out Switch The flame roll-out switch verifies that the burner flames are drawn into the heat exchanger tubes. If the burner flames are not properly drawn into the heat exchanger, the flame roll- out switch will open. The circulating air blower (and combustion blower, if connected) will continue to operate if the flame roll-out switch opens. Bis Blower Off [1mm] Timing 3 Amp Fuse TWIN Flame Signal Light (Yellow) O Status Light (Red) @ Unused Motor Leads => 1V4H ==1000 OVA —=dNsAX [_——! La Figure 27. Be) o 24V (o) <|@ Q = Oxora DOO OO Common . | Leads Neutrals —|3 = Connect ~—— Neutral — é = © Lead of 5 Electronic © © Air Cleaner © ia and/or Humidifier Here. Humidifier Tap (.5A@ 120 VAC) __| L_Electronic Air Tap (.5A@ 120 VAC) These motor speed taps are ‘— not used for two-stage models Integrated Control 29 Gas Valve The gas valve controls the flow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold. Pressure Switch The pressure switch verifies that the inducer is drawing the combustion gases through the heat exchanger. Supply Air Limit Switch The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature. Vent Safety Switch The vent safety switch shuts the furnace down if the vent becomes blocked or restricted. For Upflow and Downflow Series Residential Furnaces Ss BLUE Ss BLUE Ss BLUE SS BLUE FLAME BLOWER SUPPLY AIR FLAME ROLL-OUT ROLL-OUT SWITCH — DECK SWITCH LIMIT SWITCH SWITCH (SELECT si (ALL MODELS) (ALL MODELS) (SELECT MODELS ONLY) MODELS ONLY) EP SAFETY SWITCH (SELEC’ PRESSURE SWITCH VENT PRESSURE SWITCH (93+ MODELS ONLY) (SELECT MODELS ONLY) BLUE BLUE ORANGE ORANGE WHITE (NEUTRAL). - ----------4-------- Ee ieee BLACK 120V -- - WHITE BLOWER DOOR ‘SWITCH TRANSFORMER WHITE W/ BLK STRIPES 2aVv BLK W/ WHITE STRIPES VENT SAFETY SWITCH (SELECT MODELS ONLY) AIRCONDITIONER | © | | Refer to the Installation ca) BLOWER OFF B BBB CO CONDENSING UNIT | | Instructions provided with the furnace for the proper heating and cooling speeds for your application. smuvis 3W¥14 3 OR 4 SPEED MOTOR YELLOW BROWN NEUTRALS c M Min x) <)=) 7 2029 5 Field Wiring —-—-—- — Factory Wiring: Low Voltage High Voltage RED FAULT CONDITION LIGHT Power On ON Limit Circuit Open or External Load On "W" 1 FLASH Pressure Switch is Open with Inducer On {2 FLASHES Pressure Switch is Closed with Inducer Off} 3 FLASHES Ignition Failure (Check Ground) 4 FLASHES 115 VAC & Neutral Reversed or no Ground [5 FLASHES False Flame or Gas Valve Relay Shorted Power Off STATUS Continuous OFF FLAME YELLOW LIGHT FAULT CONDITION Low Flame Sensor Signal Continuous Flash Flame Present ON Figure 28. These wires are not present on all models lf any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having atemperature rating of at least 105° C. Use copper conductors only. WD#710355-0 Wiring Diagram for Upflow and Downflow Models 30 MAINTENANCE It is recommended that the furnace be checked yearly. Ata minimum, this check should include the following items. /\\ WARNING: To avoid electrical shock, personal in- jury, or death, turn off the electric power at the disconnect or the main service panel before making any electrical con- nections. /\ WARNING: Products of combustion must not be allowed to enter the living space. Fail- ure to prevent products of combustion from being circulated into the living space can create potentially hazardous condi- tions including carbon monoxide poi- soning that could result in personal in- jury or death. Upflow Models 8 as 1 ET LT og Control Board 10 Blower Door Switch 1 Vent Assembly 12 (Upflow Models) 13 Vent Switch 14 Igniter Flame Sensor Gas Valve Roll-Out Switch(s) Pressure Switch Low Voltage 5 Transformer Burner Assembly Supply Air Limit Switch 46 Blower Assembly Inducer Vent System Check the vent pipe to ensure that it is not corroded or blocked by debris. Any corroded section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace. Air Filter(s) /\ WARNING: Never operate the furnace without a filter in place. Dust and lint in the return air can build up on internal components, result- ing in loss of efficiency, equipment dam- age, and possible fire. Air filter(s) are not supplied with the fur- nace as shipped from the factory. The installer must provide a high velocity filter and rack for a filter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. Filters should be changed or cleaned monthly during the heating season. New or Downflow —, Models 15 Combustion Tube w/insulation (Downflow Models) Vent Transition Assembly (Downflow Models) Figure 29. Location of Major Components 31 newly renovated homes may require more frequent changing until the construction dust has been removed. Filters for side return and bottom return appli- cations are available from your local distribu- tors. Lubrication The bearings in the circulating air blower motor and inducer blower used in these furnaces are pre-lubricated and sealed at the factory. No further oiling of the bearings is required for the life of the motor. Blower Compartment The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and short- ened service life. Heat Exchanger and Burner Maintenance The furnace should operate for many years without soot buildup in the flue passageways, however, the flue passageways, the vent sys- tem, and the burners should be inspected and cleaned (if required) by a qualified serviceman annually to ensure continued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources. /\ WARNING: Holes in the vent pipe or heat exchanger can cause products of combustion to enter the home. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. Cleaning Of Flue Passages If the flue passages must be cleaned, follow the steps below. See Figure 29 for component location and identification. 1. Shut off the gas supply to the furnace either at the meter or at the manual valve in the gas supply piping. 32 Ld Turn off all power to the furnace and set the thermostat to the lowest temperature setting. Remove the louvered door from the furnace. Turn the gas control lever to the OFF position. Disconnect the wires from the gas valve, igniter, flame sensor, combustion air motor, flame roll-out switch, blocked vent switch, over- temperature limit switch, pressure switch. Or /\ CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous op- eration. oe Remove the silicone rubber tube from the collector pan. For *RA upflow models: Remove the screws that hold the vent control assembly to the top panel. Remove the nuts that hold the combustion air motor to the collector pan, and remove the complete combustion air blower and combus- tion tube assembly. BE CAREFUL NOT TO BREAK THE SEALS AT EACH END OF THE COMBUSTION AIR TUBE. Remove the screws that hold the collector pan in place, and remove the collector pan from the furnace. 10. Using wrenches, separate the ground-joint union in the gas supply piping at the furnace. 11. Remove the piping between the gas valve and the ground-joint union, if necessary. 12. Remove the screws that hold the burner as- sembly in place and remove the burner assembly. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE RE- MOVING THE BURNER ASSEMBLY. 13. The furnace heat exchanger tubes can now be cleaned by the use of a round wire brush attached to alength of high grade stainless steel cable, such as drain cleanout cable. Attach variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drillandinsertitinto the top portion ofthe heat exchanger. While reversing the drill, work the cableinand outseveraltimes to obtain sufficient cleaning. Repeat this sequence for each heat exchanger tube. 14. When all heat exchanger tubes have been cleaned, any debris inside the tubes can be removed with the nozzle of a vacuum cleaner. 15. With alight, check the condition ofthe upper and lower sections of the heat exchanger tube. a ©0 © 16. Inspect the burners and clean them (if neces- sary) with a soft wire brush and/or the nozzle ofavacuum cleaner. BEEXTREMELY CARE- FUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER. 17. Replace all the parts in reverse order from which they were removed. 18. Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing. Cleaning of Burners If the burners must be cleaned, follow the steps below. See Figure 30 for component location and identification. 1. Shut off the gas supply to the furnace either at the meter or ata manual valve in the supply piping. 2. Turn off all power to the furnace and set the thermostat to the lowest temperature setting. 3. Remove the upper louvered door from the furnace. 4. Turn the gas control lever to the OFF position. 5. Disconnect the wires from the gas valve, igniter, and flame sensor. 6. Using wrenches, separate the ground-joint union in the gas supply piping at the furnace. 7. Remove the piping between the gas valve and the ground-joint union, if necessary. 8. Remove the screws that hold the burner as- sembly in place and remove the burner assem- bly. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE REMOVING THEBURNERASSEMBLY. 9. Inspect the burners and clean them (if neces- sary) with a soft wire brush and/or the nozzle ofavacuum cleaner. BEEXTREMELY CARE- FUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER. 10. Replace all the parts in reverse order from which they were removed. .Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing. 1 = SYSTEM OPERATION INFORMATION General Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation. 1. Donotplacecombustible materials onoragainst the furnace cabinet orwithin6 inches ofthe vent pipe. 2. Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace. Change or replace the air filters monthly during any period when the circulating blower is operating regularly. Always replace the doors on the furnace after servicing or cleaning/changing the filters. Do not operate the furnace without all doors and covers in place. Avoid operating the furnace when windows and doors are open. Be sure that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances. Sequence of Operation The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams; Figures 25, 26, 27 and 28. Heating Mode: ae On a call for heat the thermostat closes, apply- ing 24 VAC to the W terminal on the control board. The control board checks for continuity on the 24 VAC limit control circuit (over-temperature limit switch, flame rollout switches and blocked vent switch in series). Ifan open limit is detected the control board will energize the inducer and the conditioned air blower. All other system functions will be inoperable until the limit circuit closes. While the limit is open, the red LED will pulse at a rate of 1 blink per unit time. The furnace control checks for continuity across the pressure switch (24 VAC). If the pressure switch is closed the heat mode sequence will not continue. If it remains closed for 10 seconds the red LED will blink3 times repetitively untilthe fault condition clears. The inducer is energized. The pressure switch will close. If the pressure switch does not close after 10 seconds the fault LEDwillblink 2times repetitively and the inducer will continue to run until the switch is closed. The inducer will pre-purge for 30 seconds and then the igniter will start its warm-up as follows: Initial Power up: After 30 seconds of igniter warm-up the gas valve (24 VAC) will then open. The igniter circuit will stay energized for 3 seconds after the gas valve opens. 33 After Initial Power up: The control has a pro- grammed adaptive ignition feature which varies the warm-up period as follows: If ignition is successful the warm-up is reduced by 3- seconds on each subsequent call for heat until ignition failure occurs. Upon ignition failure, the warm-up is increased by 3-seconds on the next try. If successful, the timing remains fixed atthis level. In general, whenever ignition failure occurs the warm-up interval is increased by 3-seconds on the next try. And if successful, it remains there. Minimum and maximum warm- up time limits are set at 6 and 54-seconds, respectively. 7. The furnace control must prove flame via the flame sensor 5 seconds after the gas valve opens. If flame is sensed, all burners are on and the igniter cools off. Ifno flameis sensed, the gas valve closes immediately and the inducer con- tinues to run. A second trial for ignition (step 6) begins if no flame is sensed on the fifth try for ignition, the furnace controlis locked and the red LED will blink 4 times repetitively. The thermo- stat must be opened for at least ten seconds to reset the furnace control after a lock out. Otherwise, the furnace will attempt another ignition sequence in 1 hour. 8. The furnace control energizes the circulating air blower on the heating speed 30 seconds after the gas valve circuit is energized . 9. When the thermostat has been satisfied, gas valve is de-energized. 10. The inducer is de-energized after a 30-second postpurge. 11. The furnace control keeps the circulating air blower energized for 120 seconds (factory set) or 60, 90, or 180 seconds (field adjustable). (See Figure 27.) 12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is de- energized immediately. The blowers continue to operate until the limit closes. When the limit closes the inducer blower is de-energized immediately. The circulating air blower contin- ues to operate for the specified delay (factory set at 120 seconds). Cooling Mode: 1. Ona call for cooling the thermostat closes, applying 24 VAC tothe Gand Y terminals onthe 34 furnace control. This closes the compressor contactor. 2. The furnace control energizes the circulating blower (115 VAC) on the cooling speed. 3. When the thermostat is satisfied, the G and Y terminals onthe control board are de-energized opening the compressor contactor. 4. The circulating air blower is de-energized after a 90-second delay. Fan Mode: 1. On a call for fan operation, the thermostat applies 24 VAC to the G terminal on the furnace control board. 2. Thecirculating air blower is energized immedi- ately on the heating speed. 3. If the furnace is operated in the continuous ON position at the thermostat and is then switched to AUTO, the circulating blower will operate for a specified delay (factory set at 120 seconds). Furnace Fails to Operate If the furnace does not operate check the following: Is the thermostat operating properly? Are the blower compartment door(s) in place? Is the furnace disconnect closed? Has the circuit breaker tripped or the control board fuse burned open? Is the gas turned on? Are any manual reset switches open? Is the filter dirty or plugged? Is the flame sensor coated? (Remove and clean with emery cloth.) i a 07 Or} If the furnace locks out after 5 attempts for ignition, it will try again every hour ifacall for heat remains. If the inducer and circulating air blow- ers are operating, and items 1 through 8 have been checked, press the red reset button on the vent safety switch (See Figure 29). If the fur- nace operates after depressing the reset but- ton, contact a qualified serviceman to identify and repair the problem. If the furnace continues to not operate, depress the red reset buttons on the flame roll-out switches. (See Figure 29.) If the furnace oper- ates after depressing the reset buttons, contact a qualified servicemen to identify and repair the problem. Twinning The control board on these furnaces is capable of being twinned to another furnace of the same series. If using UTEC Control Boards, leave the fuses installed on each board. The thermostat wires and the 1/4 inch quick-connect terminals marked “TWIN” on the furnace controls must be wired for twinning. (See Figure 30.) ie) R Ble Ot . ol Terminal ie) Figure 30. Twinning 35 INSTALLATION/PERFORMANCE CHECK LIST LOCATION CITY INSTALLER CITY UNIT MODEL NUMBER UNIT SERIAL NUMBER Minimum Clearances per Table 3? Electrical Connections tight? Line Voltage Polarity correct? Supply Voltage: Volts Blower Motor HP: FUEL TYPE: Natural Gas LP/Propane Gas Piping Connections leak-tested? Gas Line Pressure: (in. water column, with furnace operating) Manifold Pressure: (in. water column, with furnace operating) Is there adequate fresh air supply for combustion and ventilation? Furnace Input: (Btuh) Supply Air Temperature: (°F Return Air Temperature: (°F Temperature Rise: (° F) STATE STATE Are Flue Connections tight? Is there Proper Draft? Is Vent free from restrictions? Is the Filter(s) secured in place? Is the Filter(s) clean? Has the Thermostat been calibrated? Is the Thermostat level? Is the Heat Anticipator Setting correct? Has the Owner's Information been reviewed with the homeowner? Has the Literature Package been left near the furnace? 708291B O'Fallon, MO NORDYNE 708291B (Replaces 708291A) Specifications and illustrations subject to change without notice andwithoutincurring obligations. Printedin U.S.A. (03/04)