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8031 Hunter Pl_BLD3065_2026
CITY OF ARLINGTON 238 N. OLYMPIC AVE - ARLINGTON,WA. 98223 PHONE; (360)403-3551 BUILDING PERNIIT Address:8031 Hunter Place Permit#:3065 Parcel#:00974800003300 Valuation:.00 OWNER APPLICANT CONTRACTOR Name:WILSTEIN CHRISTINE R Name:Kings Heating Inc Name:Kings Heating,Inc Address:8031 HUNTER PL Address:18933 Hwy 99 Address: 18933 Hwy 99 City,State Zip:ARLINGTON,WA 98223-5063 City,State Zip:Lynwood,WA 98036 City,State Zip:Lynnwood,WA 98036 Phone: Phone:425-275-5153 Phone:425-275-5153 LIC: EXP: MECHANICAL CONTRACTOR PLUMBING CONTRACTOR Name:Kings Heating,Inc Name: Address:19933 Hwy 99 Address: City,State,Zip:Lynnwood,WA 98036 City,State,Zip: Phone:425-275-5153 Phone: LIC#:KINGSH10441A EXP: 03/10/2Q22 LIC#: EXP: JOB DESCRIPTION PERMIT TYPE: Residential Mechanical CODE YEAR: 2015 STORIES: 2 CONST.TYPE: `IB DWELLING UNITS: I OCC GROUP: R3 BUILDINGS: I OCC LOAD: PERMIT APPROVAL I AGREE TO COMPLY WITH CITY AND STATE LAWS REGULATING CONSTRUCTION AND IN DOING THE WORK AUTHORIZED THEREBY; NO PERSON WILL BE EMPLOYED IN VIOLATION OF THE LABOR CODE OF THE STATE OF WASHINGTON RELATING TO WORKMEN'S COMPENSATION INSURANCE AND RCW 18.27. THIS APPLICATION IS NOT A PERMIT UNTIL SIGNED BY THE BUILDING OFFICIAL OR HIS/HER DEPUTY AND ALL FEES ARE PAID. IT IS UNLAWF L T USE OR CC PY A BUILDING OR STRUCTURE UNTIL.A FINAL INSPF '10 •IAS BEEN MADE AND APPROVAL OR A ER'IFIC EO OC' A Y AS FNGPANTED. IBCIIO/IRC110. fit. I'A• N( ''1 S x lath constriction and construction materials in the City a :\trli M in he port on your sales tax return form nd ed i y o -fit it it 10 ,/?/� 11'J J 2•WZA2 Si r Print Name Date el"_ l YI By Date CONDITIONS APPROVED AS SUBMITTED. ADHERE TO THE INSTALLATION OF THE APPROVED APPLIANCE. CALL FOR INSPECTIONS. T111S PGRMIT AUTHORIZES ONLY THE.WORK NOTED.THIS PERMIT COVERS WORK TO BE DONE ON PRIVATE PROPERTY ONLY. ANY CONSTRUCTION ON THE PUBLIC DOMAIN(CURBS,SIDEWALKS,DRIVEWAYS,MARQUEES,ETC.)WILL REQUIRE SEPARATE PERMISSION. PERMIT FEES Date Description Fee Amount 03/03/2020 Forced Air Heat $25.00 03/03/2020 Mechanical Residential Base $25.00 03/03/2020 Processing/Technology Fee $25.00 03Y03/2020 Inspection/Re-Inspection $75.00 Total Due: $150.00 Total Payment: $0.00 Balance Due: $150.00 CALL FOR INSPECTIONS BUILDING(360)403-3417 When calling for an inspection please leave the following information: Permit Number,Type of Inspection being requeNted,and whether you prefer morning or afternoon it i� CITY OF ARLINGTON s 238 N. OLYMPIC AVE - ARLINGTON, WA. 98223 PHONE; (360) 403-3551 BUILDING PERMIT Address:8031 Hunter Place Permit#:3065 Parcel#:00874800003300 Valuation:.00 OWNER APPLICANT CONTRACTOR __ Name:WILSTEIN CHRISTINE R Name:Kings Heating Inc Name:Kings Heating,Inc Address:8031 HUNTER PL Address:18933 Hwy 99 Address: 18933 Hwy 99 City,State Zip:ARLINGTON,WA 98223-5063 City,State Zip:Lynwood,WA 98036 City,State Zip:Lynnwood,WA 98036 Phone: Phone:425-275-5153 Phone:425-275-5153 LIC: EXP: MECHANICAL CONTRACTOR PLUMBING CONTRACTOR Name:Kings Heating,Inc Name: Address: 18933 Hwy 99 Address: City,State,Zip:Lynnwood,WA 98036 City,State,Zip: Phone:425-275-5153 Phone: LIC#:KINGSH1044JA EXP: 03/10/2022 LIC#: EXP: JOB DESCRIPTION PERMIT TYPE: Residential Mechanical CODE YEAR: 2015 STORIES: 2 CONST.TYPE: VB DWELLING UNITS: I OCC GROUP: R3 BUILDINGS: I OCC LOAD: PERMIT APPROVAL I AGREE TO COMPLY WITH CITY AND STATE LAWS REGULATING CONSTRUCTION AND IN DOING THE WORK AUTHORIZED THEREBY; NO PERSON WILL BE EMPLOYED IN VIOLATION OF THE LABOR CODE OF THE STATE OF WASHINGTON RELATING TO WORKMEN'S COMPENSATION INSURANCE AND RCW 18.27. THIS APPLICATION IS NOT A PERMIT UNTIL SIGNED BY THE BUILDING OFFICIAL OR HIS/HER DEPUTY AND ALL FEES ARE PAID. IT IS UNLAWFUL TO USE OR OCCUPY A BUILDING OR STRUCTURE UNTIL A FINALZ. Arli h—n AS BEEN MADE AND APPROVAL OR A CERTIFICATE OF OCCUPANCY HAS BEEN GRANTED. IBCl10/IRC110. SALES TAX NOTICE:Sales tax relating to construction and construction materials in the CityZbcpotrton your sales tax return form and coded City of Arlington#3101. Signature Print Name Date el d By Date CONDITIONS APPROVED AS SUBMITTED. ADHERE TO THE INSTALLATION OF THE APPROVED APPLIANCE. CALL FOR INSPECTIONS. THIS PERMIT AUTHORIZES ONLY THE WORK NOTED.THIS PERMIT COVERS WORK TO BE DONE ON PRIVATE PROPERTY ONLY. ANY CONSTRUCTION ON THE PUBLIC DOMAIN(CURBS,SIDEWALKS,DRIVEWAYS,MARQUEES,ETC.)WILL REQUIRE SEPARATE PERMISSION. PERMIT FEES Date Description Fee Amount 03/03/2020 Forced Air Heat $25.00 03/03/2020 Mechanical Residential Base $25.00 03/03/2020 Processing/Technology Fee $25.00 03/03/2020 Inspection/Re-Inspection $75.00 Total Due: $150.00 Total Payment: $0.00 Balance Due: $150.00 CALL FOR INSPECTIONS BUILDING(360)403-3417 When calling for an inspection please leave the following information: Permit Number,Type of Inspection being requested,and whether you prefer morning or afternoon ti 1 y 1 i Permit#: 3065 Permit Date: 03/02/20 Project Name: Wilstein Site Address: 8031 Hunter Place Company/Applicant Name: Kings Heating Inc Company/Applicant Address: 18933 Hwy 99 City, State, Zip: Lynwood, WA 98036 Contact: Michaela Pollard Phone: 425-275-5153 Email: michaelap@kingsheating.com Permit Type: Residential Mechanical Valuation: 0.00 Square Feet: 2149 Number of Stories: 2 Type of Construction: VB Occupancy Type: R-3 Proposed Use: Like for like furnace replacement MIC/Opportunity Zone: Permit Issued: Permit Expires: DNU: Status: IN PROCESS Property Parcel# Address Legal Description Owner Name Owner Phone Zoning WILSTEIN 111 Single Family 00874800003300 8031 HUNTER PL Residence- CHRISTINE R Detached Contractors Contractor Primary Contact Phone Address Contractor Type License License# Kings Heating,Inc Gary Pollard 425-275-5153 18933 Hwy 99 CONTRACTOR KINGSHI044JA Fees Fee Description Notes Amount Forced Air Heat fee per Btu $25.00 Mechanical Residential Base Permit Fee $25.00 Processing/Technology Fee $25.00 i Inspection/Re-Inspection $75.00 Total $150.00 Uploaded Files Date File Name 03/02/2020 0305830-3065 Furnace Specs.pdf 03/02/2020 6305831-3065 Application.pdf Signature: Date: RESIDENTIAL MECHANICAL PERMIT APPLICATION Department of Community& Economic Development City of Arlington • 18204 59th Ave NE• Arlington,WA 98223• Phone(360) 403-3551 THIS APPLICATION IS TO BE USED WHEN APPLYING FOR NEW MECHANICAL INSTALLATION AND OR GAS PIPING FOR EXISTING RESIDENCES. PLEASE FILL OUT ALL PAGES OF THIS APPLICATION AND INCLUDE ALL INFORMATION. Project Address:8031 Hunter PI Project Description:Replacing furnace like-for-like Owner: Christine Wilstein Address: 17910 Marine Dr City: Stanwood State WA Zip Code: 98292 Phone: 425-299-5030 Email:chriscarenursing@gmail.com Applicant: See Contractor Address: 18933 HWY 99 City: LYNNWOOD StateYVA Zip Code: 98036 Phone: 425-275-5153 Email: MichaelaP@KingsHeating.com CONTRACTOR INFORMATION Contractor Name:Kings Heating Inc Address: 18933 HWY 99 City: Lynnwood State WA Zip Code: 98036 License Number:KINGSH1044JA Expiration: 3/10/2022 Phone:425-275-5153 Email:MichaelaP @ KingsH eating.com STAFF US(by: Received Permit #: �l'J Accepted - Date: 6/16LP Page 1 of 2 X.. "'` RESIDENTIAL MECHANICAL PERMIT APPLICATION Department of Community& Economic Development City of Arlington • 18204 59th Ave NE• Arlington,WA 98223• Phone(360) 403-3551 SELECT ALL PROPOSED APPLIANCES Furnace (80+) Model #PG8MAA AFUE ❑: Heat Pump Model # AFUE HSPE U! AC Unit Model # SEER 01 Freestanding Stove Lj Fire Place Insert 0; Outdoor BBQ ❑ Gas Piping ❑ Solid-Fuel Appliance ❑ Other Gas Piping Information Not Applicable: ❑' Pipe Material: Pipe Size: Distance from Meter to Furthest Appliance: Total BTU's of all Appliances: • New gas piping requires a pressure test hooking to any appliance • Sediment traps (drips) are required on all gas lines • Gas lines are required to be supported/secured every 6 to 8 feet • Proper Combustion air and venting required for all appliances • A shut-off valve is required within 6 feet of all appliances Applicant Signature: ` � .....,M.K. .. Date: 03/02/2020 Applicant Printed Name: Michaela Pollard I hereby certify that the above information is correct and that the construction, installation for the above mentioned property will be in accordance with the applicable laws of the City of Arlington and the State of Washington. 6/16LP Page 2 of 2 wv...se.wu ua.,,n..i labor&Industriers(https://Ini.wa.gQy) KING'S HEATING INC Owner or tradesperson 18933 HIGHWAY 99 Principals LYNNWOOD,WA 98036-5203 POLLARD,GARY BROOKS,MEMBER 425-275-5153 SNOHOMISH County POLLARD,ERIN KELLY,MEMBER POLLARD,GARY B (End:02/20/2018) POLLARD,ERIN K (End:02/20/2018) Doing business as KING'S HEATING INC WA UBI No. Business type 601 682 595 Corporation Governing persons ERIN KELLY POLLARD GARY BROOKS POLLARD; License Verify the contractor's active registration/license/certification(depending on trade)and any past violations. Construction Contractor Active Meets current requirements. License specialties GENERAL License no. KINGSH1044JA Effective—expiration 04/01/1996—03/10/2022 Bond Developers Surety&Indem Co $12,000.00 Bond account no 674511C Received by L&I Effective date 02/26/2018 03/07/2018 Expiration date Until Canceled CBIC $12,000.00 Bond account no. SA1782 Received by L&I Effective date 03/05/2002 03/07/2002 Expiration date Until Canceled Bond history Insurance Austin Mutual Ins Co $1,000,000.00 Policy no. BP1734403 Received by L&I Effective date 03/21/2019 04/01/2018 Expiration date i 04/01/2020 Insurance history Savings No savings accounts during the previous 6 year period. Lawsuits against the bond or savings No lawsuits against the bond or savings accounts during the previous 6 year period. L&I Tax debts No L&I tax debts are recorded for this contractor license during the previous 6 year period,but some debts may be recorded by other agencies. License Violations No license violations during the previous 6 year period. Certifications & Endorsements OMWBE Certifications No active certifications exist for this business. ApprenticeTraining Agent No active Washington registered apprentices exist for this business.Washington allows the use of apprentices registered with Oregon or Montana.Contact the Oregon Bureau of Labor&Industries or Montana Department of Labor &Industry to verify if this business has apprentices. Workers' Comp Do you know if the business has employees?If so,verify the business is up-to-date on workers'comp premiums. L&I Account ID Account is current. 841,812-01 Doing business as KINGS HEATING INC Estimated workers reported Quarter 4 of Year 2019"11 to 20 Workers" L&I account contact T5/NATHAN KOZAK(360)902-6243-Email:KOZN235@lni.wa.gov Public Works Requirements Verify the contractor is eligible to perform work on public works projects. Required Training—Effective July 1,2019 Exempt from this requirement. Contractor Strikes No strikes have been issued against this contractor. Contractors not allowed to bid No debarments have been issued against this contractor. Workplace Safety & Health Check for any past safety and health violations found on jobsites this business was responsible for. No inspections during the previous 6 year period. �_y Q. RESIDENTIAL MECHANICAL PERMIT APPLICATION Department of Community & Economic Development City of Arlington • 18204 59th Ave NE • Arlington, WA 98223 • Phone (360) 403-3551 THIS APPLICATION IS TO BE USED WHEN APPLYING FOR NEW MECHANICAL INSTALLATION AND OR GAS PIPING FOR EXISTING RESIDENCES. PLEASE FILL OUT ALL PAGES OF THIS APPLICATION AND INCLUDE ALL INFORMATION. Project Address: 8031 Hunter PI Project Description:Replacing furnace like-for-like Owner: Christine Wilstein Address: 17910 Marine Dr City: Stanwood State.WA Zip Code: 98292 Phone: 425-299-5030 Email:chriscarenursing@gmail.com Applicant: See Contractor Address. 18933 HWY 99 City. LYNNWOOD StateYVA Zip Code: 98036 Phone. 425-275-5153 Email. MichaelaP@KingsHeating.com CONTRACTOR INFORMATION Contractor Name:Kings Heating Inc Address: 18933 HWY 99 City: Lynnwood State WA Zip Code: 98036 License Number: KINGSH1044JA Expiration: 3/10/2022 Phone- 425-275-5153 Email:MichaelaP@KingsHeating.com STAFF USE ONLY Permit #: Accepted by: Date: 6/16LP Page 1 of 2 RESIDENTIAL MECHANICAL PERMIT APPLICATION Department of Community& Economic Development City of Arlington • 18204 59th Ave NE• Arlington, WA 98223• Phone(360) 403-3551 SELECT ALL PROPOSED APPLIANCES Furnace (80+) Model # PG8MAA AFUE ❑ Heat Pump Model # AFUE HSPE ❑ AC Unit Model # SEER ❑ Freestanding Stove ❑ Fire Place Insert ❑ Outdoor BBQ ❑ Gas Piping ❑ Solid-Fuel Appliance ❑ Other Gas Piping Information Not Applicable: ❑ Pipe Material: Pipe Size: Distance from Meter to Furthest Appliance: Total BTU's of all Appliances: • New gas piping requires a pressure test hooking to any appliance • Sediment traps (drips) are required on all gas lines • Gas lines are required to be supported/secured every 6 to 8 feet • Proper Combustion air and venting required for all appliances • A shut-off valve iis required cwithin 6 feet of all appliances Low �C,-o����� Applicant Signature: tl5a51c3bba4a9294ftlaeBn b41eb Date: 03/02/2020 Applicant Printed Name: Michaela Pollard I hereby certify that the above information is correct and that the construction, installation for the above mentioned property will be in accordance with the applicable laws of the City of Arlington and the State of Washington. 6/16LP Page 2 of 2 PG8M/PG8J PAYNE S Installation, Start-up, Operating, and Service and Maintenance Instructions -Series C 00 00 °Oo 4 0 OD OD OD Op The Payne PG8M/PG8J 80% AFUE Gas Furnaces feature 4- O®OD OD pp way multipoise design and through-the-furnace downflow OD OD ®®O® O®O® ppo� venting. The PG8M/PG8J furnaces are approved for use with OD OD ODO® natural or propane gas and the PG8J is also approved for use in 0000 pp 60 Low Nox Air Quality Management Districts. STANDARD FEATURES Four-position furnace: upflow, horizontal right, horizontal left, downflow Electronic control center Adjustable heating air temperature rise LED diagnostics and self test feature Hot surface ignition (HSI) Twinning in Upflow, Downflow and Horizontal LIMITED WARRANTY • 20-year warranty on "Super STM" heat exchanger • 5-year parts warranty on all other components Catalog No: 53PG-8J5 Form No. IM-PG8J-05 5-05 Single-Stage Induced-Combustion 4-Way Multiaoise Furnace Cancels: 11 310A-45-4/1 M-PG8J-04 11310A-45-5/1 M-PG 8J-0 Installation, Start-up, Operating, and Service and Maintenance Instructions Series 120/C NOTE: Read the entire instruction manual before starting the installation. EFFICIENCY RATNG CERTIFIED This symbol—> indicates a change since the last issue. � Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2002©, Q SIG ra ama N with permission of National Fire Protection Association, Quincy,NIA 02269 and American Gas Association,Washington DC 20001.This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject,which S e ISO 9001:2000 (#CR is represented only by the standard in its entirety.TABLE OF CONTENTS SAFETY CONSIDERATIONS.....................................................2 FR T 1 0� R 1 INTRODUCTION..........................................................................4 REGISTERED CODES AND STANDARDS........................................................4 Safety.........................................................................................5 General Installation...................................................................5 Combustion and Ventilation Air..............................................5 DuctSystems............................................................................5 Acoustical Lining and Fibrous Glass Duct..............................5 Gas Piping and Gas Pipe Pressure Testing..............................5 Electrical Connections..............................................................5 ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS PROCEDURE................................................................................5 LOCATION....................................................................................5 24-V Wiring.......................................................................22 General......................................................................................5 Accessories........................................................................22 Location Relative to Cooling Equipment................................7 Venting....................................................................................22 AIR FOR COMBUSTION AND VENTILATION......................7 General Venting Requirements.........................................23 Masonry Chimney Requirements......................................23 INSTALLATION.........................................................................10 Appliance Application Requirements...............................24 Upflow Installation.................................................................10 Additional Venting Requirements.....................................26 Bottom Return Air Inlet....................................................10 Sidewall Venting 26 Side Return Air Inlet.........................................................10 Leveling Legs (If Desired)................................................10 START-UP,ADJUSTMENT,AND SAFETY CHECK............27 Downflow Installation............................................................10 General....................................................................................27 Bottom Return Air Inlet....................................................II Start-Up Procedures................................................................27 Horizontal Installation............................................................I I Adjustments.............................................................................31 Suspended Furnace Support..............................................11 Check Safety Controls............................................................34 Platform Furnace Support.................................................I I Checklist..................................................................................35 Roll-Out Protection............................................................I I SERVICE AND MAINTENANCE PROCEDURES..................35 Bottom Return Air Inlet....................................................11 Introduction.............................................................................35 SideReturn Air Inlet.........................................................11 General...............................................................................35 Filter Arrangement..................................................................I I Electrical Controls and Wiring.........................................36 Air Ducts.................................................................................11 Care and Maintenance............................................................37 General Requirements.......................................................11 Cleaning and/or Replacing Air Filter...............................37 Ductwork Acoustical Treatment.......................................12 Blower Motor and Wheel..................................................37 Supply Air Connections....................................................12 Cleaning Heat Exchanger..................................................40 Return Air Connections.....................................................14 Sequence of Operation............................................................44 GasPiping...............................................................................15 Wiring Diagrams.....................................................................45 Electrical Connections............................................................19 Troubleshooting......................................................................45 115-V Wiring.....................................................................19 J-Box Relocation...............................................................20 Electrical Connection to J-Box.........................................21 Power Cord Installation in Furnace J-Box.......................21 BX Cable Installation in Furnace J-Box..........................22 Manufacturer reserves the right to discontinue,or change at any time,specifications or designs without notice and without incurring obligations. BookI 11 4 PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-13SI Pg 1 5-05 Replaces: 58ST-12SI Tab 16a I 8a 26-1/8" 28-7/8" (FLUE COLLAR) 25-1/4" 2-7/16" 22-9/16" 1-5/16" AIRFLOW JUNCTION BOX 19" 13/16" LOCATION D 13/16" 1-118• 5-15/16" F 4-13/16" OUTLET I o00o i 1/2"DIA.K.O.THERMOS TAT , WIRE ENTRY 11/16" 7/8"DIA o000 8-9/16" 1-3/4"DIA.RIGHT HAND 7-3/4" ACCESSORY o000 GAS ENTRY 1/2"DIA THERMOSTAT o000 11-1/2" WIRE ENTRY o000 BBBB 3-15/16" LEFT HAND GAS 7/8"DIA.K.O.WIRE ENTRY ENTRY ALTERNATE 33-5/16" P---------------- 24-7I8" JUNCTION BOX P----------------- I LOCATIONS(TYP) VENT OUTLET I 5 PLACES(TYP) 1 14-7/8" 7/8"DIA.ACCESSORY I 7/8"DIA.ACCESSORY 11/16" 5-1/2" E 11/16" 3-3/4' -1-1/2" H-1 ... 21-5/8" 1-11/16" BOTTOM INLET 22-1/16" 24" SIDE INLET CASING A04037 NOTES: 1.Two additional 7/8-in.diameter holes are located in the top plate. 2.Minimum return-air openings ar furnace,based on metal duct. If flex duct is used,see flex duct manufacturer's recommendations for equivalent diameters. a.For 800 CFM-16-in.round or 14 1/2 x 12-in.rectangle. b.For 1200 CFM-20-in.round or 14 1/2 x 19 1/2-in.rectangle. c.For 1600 CFM-22-in.round or 14 1/2 x 22-in.rectangle. d.For airflow requirements above 1800 CFM,see Air Delivery table in Product Data literature for specific use of single side inlets.The use of both side inlets,a combination of 1 side and the bottom,or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM. ---� Fig. 1—Dimensional Drawing SAFETY CONSIDERATIONS These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residen- FIRE, EXPLOSION, ELECTRICAL SHOCK, AND tial construction practices. We require these instructions as a CARBON MONOXIDE POISONING HAZARD minimum for a safe installation. Failure to follow this warning could result in dangerous operation, serious injury, death, or property damage. • Improper installation,adjustment,alteration,service,mainte- CUT HAZARD nance, or use can cause carbon monoxide poisoning, explo- Failure to follow this caution may result in personal injury. sion, fire, electrical shock, or other conditions which may Sheet metal parts may have sharp edges or burrs.Use care and cause personal injury or property damage.Consult a qualified wear appropriate protective clothing, safety glasses and service agency, local gas supplier, or your distributor or gloves when handling parts and servicing furnaces. branch for information or assistance. The qualified service agency must use only factory-authorized and listed kits or Wear safety glasses and work gloves. Have fire extinguisher accessories when modifying this product. available during start-up and adjustment procedures and service calls. This is the safety-alert symbol .When you see this symbol on • the furnace and in instructions or manuals,be alert to the potential FURNACE RELIABILITY HAZARD for personal injury. Improper installation or misapplication of furnace may re- Understand the signal words DANGER, WARNING, and CAU- quire excessive servicing or cause premature component TION. These words are used with the safety-alert symbol. DAN- failure. GER identifies the most serious hazards which will result in severe Application of this furnace should be indoors with special personal injury or death. WARNING signifies a hazard which attention given to vent sizing and material,gas input rate,air could result in personal injury or death. CAUTION is used to temperature rise,unit leveling, and unit sizing. identify hazards which may result in minor personal injury or product and property damage.NOTE is used to highlight sugges- Installing and servicing heating equipment can be hazardous due to tions which will result in enhanced installation, reliability, or gas and electrical components. Only trained and qualified operation. personnel should install,repair,or service heating equipment. Untrained personnel can perform basic maintenance functions 1. Use only with type of gas approved for this furnace. Refer to such as cleaning and replacing air filters.All other operations must the furnace rating plate. be performed by trained service personnel. When working on 2. Install this furnace only in a location and position as specified heating equipment, observe precautions in literature, on tags, and in the"Location" section of these instructions. on labels attached to or shipped with furnace and other safety precautions that may apply. 2 INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW,DOWNFLOW, and natural gas at altitudes 0-10,000 ft(0-3,050m). HORIZONTAL installations. An accessory kit, supplied by the Cette foumaise est approuvee pour('installation HORIZONTALE manufacturer,shall be used to convert to propane et la circulation d'air VERS LE HAUT et VERS LE BAS. gas use or may be required for some natural gas applications. Clearance arrows 1(If Les f 6ches de degagement This furnace is for indoor installation in a do not change with a ne change pas avec building constructed on site. furnace orentation. I'orientation de la fournaise. Z m This furnace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combusible 0" 00 0" material. A B A c of This furnace may be used with a Type B-1 Vent R R I E and may be vented in common with other gas R E fired appliances. Foy Nj 0 Cette foumaise a air pulse est equipee FP PN� s E pour utilisation avec gaz naturel e )t altitudes S\o� F R ENT c E comprisesntre 0-3,050m(0-10,000 p Utiliser une trousse de conversion,foumie par aj A v N r EN 24' le fabricant,pour passer au gaz propane ou pour *0" o N T 3"M1 M1 certaines installations au gaz naturel. 0 Cette foumaise est prevue pour titre k s installee clans un batiment construit sur place. °� Clearance in inches Cette foumaise peut titre installee sur Degagement(po). un plancher combustible clans une aloove ou t0 dans un garde-robe en respectant le minimum d'espace libre des materiaux combustibles,tel Vent Clearance to combustibles: qu"indique sur le diagramme. For Single Wall vents 6 inches(6 po). Cette foumaise peut titre utilisee avec un For Type B-1 vent type 1 inch(1 po). conduit d'evacuation de Type B 1 ou connectee Degagement de 1'event avec combustibles: au conduit ommun d'autres appareils a gaz. Type Pour conduit d"evacuation a simple 6 po( inches). Pour conduit d"evacuation de T e 6-1 1 inch). nch. MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS: t Installation on non-combusibible floors only. For Installation on combustible flooring only when installed on special base,Part No.KGASB0201ALL, Coil Assembly,Part No.CD5 or CK5,or Coil Casing,Part No.KCAKC. 0 18 inches front clearance required for alcove. * Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible between lines formed by intersections of the Top and two Sides of the fumace jacket,and building joists, studs or framing. DEGAGEMENT MINIMUM EN POUCES AVEC ELEMENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT: t Pour 1"installation sur plancher non combustible seulement. Pour 1"installation sur un plancher combustible seulement quand on utilise la base speciale,piece n° KGASBO201ALL, 1'ensemble serpentin,piece n° CD5 ou CK5,ou le carter de serpentin,piece n° KCAKC. 0 Dans une alcove,on doit maintenir un degagement a I'avant de 18 po(450mm). * La poistion indiquee conceme le cote d'entree ou de retour quand la foumaise est dans la position horizontale. Le contact nest permis qu'entre les lignes formees par les intersections du dessus et des deux cotes de la chemse de la foumaise et les solives,montant sous cadre de charpente. 327590-101 REV. C A04123 —> Fig. 2—Clearances to Combustibles 3 ---> Table 1—Dimensions (IN.) D E F L.TOP AND FLUE FURNACE A SUPPLY-AIR RETURN-AIR C.L. COLLAR" SHIP WT. (LB) SIZE CABINET WIDTH WIDTH WIDTH (IN.) (IN.) FLUE COLLAR (IN.) (IN.) 045-08/024045 14-3/16 12-9/16 12-11/16 9-5/16 4 104 045-12/036045 14-3/16 12-9/16 12-11/16 9-5/16 4 107 070-08/024070 14-3/16 12-9/16 12-11/16 9-5/16 4 ill 070-12/036070 14-3/16 12-9/16 12-11/16 9-5/16 4 115 070-16/048070 17-1/2 15-7/8 16 11-9/16 4 126 090-14/042090 17-1/2 15-7/8 16 11-9/16 4 127 090-16/048090 21 19-3/8 19-1/2 13-5/16 4 140 090-20/060090 21 19-3/8 19-1/2 13-5/16 4 146 110-12/036110 17-1/2 15-7/8 16 11-9/16 4 135 110-16/048110 21 19-3/8 19-1/2 13-5/16 4 146 110-22/066110 21 19-3/8 19-1/2 13-5/16 4 152 135-16/048135 21 19-3/8 19-1/2 13-5/16 4 149 135-22/066135 24-1/2 22-7/8 23 15-1/16 4 163 155-20/060155 1 24-1/2 1 22-7/8 1 23 1 15-1/16 1 4 1 170 *5"or 6"vent connector may be required in some cases. 3. Provide adequate combustion and ventilation air to the furnace 13. These furnaces SHALL NOT be installed directly on carpet- space as specified in "Air for Combustion and Ventilation" ing, tile, or any other combustible material other than wood section. flooring. In downflow installations, factory accessory floor 4. Combustion products must be discharged outdoors. Connect base MUST be used when installed on combustible materials this furnace to an approved vent system only, as specified in and wood flooring. Special base is not required when this the"Venting" section of these instructions. furnace is installed on manufacturer's Coil Assembly Part No. 5. Never test for gas leaks with an open flame. Use a commer- CD5 or CK5,or when Coil Box Part No.KCAKC is used.See cially available soap solution made specifically for the detec- Fig. 2 for clearance to combustible construction information. tion of leaks to check all connections,as specified in the"Gas INTRODUCTION Piping" section. This Series 120/C 4—way multipoise Category I fan-assisted 6. Always install furnace to operate within the furnace's intended furnace is CSA design-certified.A Category I fan-assisted furnace temperature-rise range with a duct system which has an is an appliance equipped with an integral mechanical means to external static pressure within the allowable range, as speci- either draw or force products of combustion through the combus- fied in the"Start-Up,Adjustments,and Safety Check"section. tion chamber and/or heat exchanger. The furnace is factory- See furnace rating plate. shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) 7. When a furnace is installed so that supply ducts carry air listed gas conversion kit is required to convert furnace for use with circulated by the furnace to areas outside the space containing propane gas. This furnace is not approved for installation in the furnace, the return air shall also be handled by duct(s) mobile homes, recreational vehicles, or outdoors. sealed to the furnace casing and terminating outside the space This furnace is designed for minimum continuous return-air containing the furnace. See "Air Ducts"section. temperature of 60°F db or intermittent operation down to 55°F db 8. A gas-fired furnace for installation in a residential garage must such as when used with a night setback thermostat. Return-air be installed as specified in the warning box in the"Location" temperature must not exceed 85°F db. Failure to follow these section. return-air temperature limits may affect reliability of heat exchang- ers,motors, and controls. (See Fig. 3.) � 9. The furnace is not to be used for temporary heating of buildings or structures under construction. See page 7 caution For accessory installation details,refer to the applicable instruction box regarding the heating of buildings under construction. literature. 10. These Multipoise Gas-Fired Furnaces are CSA (formerly NOTE: Remove all shipping brackets and materials before oper- A.G.A. and C.G.A.) design-certified for use with natural and ating the furnace. propane gases(see furnace rating plate)and for installation in CODES AND STANDARDS alcoves,attics,basements,closets,utility rooms,crawlspaces, Follow all national and local codes and standards in addition to and garages. The furnace is factory-shipped for use with these instructions.The installation must comply with regulations natural gas. A CSA listed gas conversion kit is required to of the serving gas supplier,local building,heating,plumbing,and convert furnace for use with propane gas. other codes. In absence of local codes, the installation must 11. See Fig.2 for required clearances to combustible construction. comply with the national codes listed below and all authorities 12. Maintain a 1-in. clearance from combustible materials to having jurisdiction. supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements. 4 °F Step 8—Venting I L MAX 857 • US: NFGC; chapters 10 and 13 • CANADA:NSCNGPIC Part 7 and Appendix C ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE FRONT nm t • FURNACE RELIABILITY HAZARD RETURN = Improper installation or service of furnace may cause prema- AIR MIN60°F ture furnace component failure. Electrostatic discharge can affect electronic components. _ = Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will pre- A02055 vent electrostatic discharges from personnel and hand tools Fig. 3—Return Air Temperature which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace,the control,and the person at the same electrostatic potential. In the United States and Canada,follow all codes and standards for 1. Disconnect all power to the furnace.Multiple disconnects may the following: be required. DO NOT TOUCH THE CONTROL OR ANY Step 1—Safety WIRE CONNECTED TO THE CONTROL PRIOR TO DIS- • US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI CHARGING YOUR BODY'S ELECTROSTATIC CHARGE Z223.1-2002 and the Installation Standards,Warm Air Heating TO GROUND. and Air Conditioning Systems ANSI/NFPA 90B 2. Firmly touch the clean,unpainted,metal surface of the furnace • CANADA: CSA B149.1-00 National Standard of Canada chassis which is close to the control.Tools held in a person's Natural Gas and Propane Installation Codes(NSCNGPIC) hand during grounding will be satisfactorily discharged. Step 2—General Installation 3. After touching the chassis, you may proceed to service the • US: Current edition of the NFGC and the NFPA 90B. For control or connecting wires as long as you do nothing to copies, contact the National Fire Protection Association Inc., recharge your body with static electricity (for example; DO Batterymarch Park, Quincy, MA 02269 (www.NFPA.org); or NOT move or shuffle your feet, do not touch ungrounded for only the NFGC,contact the American Gas Association,400 objects, etc.). N. Capitol Street,N.W.,Washington, DC 20001 4. If you touch ungrounded objects(and recharge your body with (www.AGA.org). static electricity), firmly touch a clean, unpainted metal • CANADA: NSCNGPIC. For a copy, contact Standard Sales, surface of the furnace again before touching control or wires. CSA International, 178 Rexdale Boulevard, Etobicoke (Tor- 5. Use this procedure for installed and uninstalled(ungrounded) onto), Ontario, M9W 1R3 Canada furnaces. Step 3—Combustion and Ventilation Air 6. Before removing a new control from its container, discharge • US: Section 8.3 of the NFGC, Air for Combustion and your body's electrostatic charge to ground to protect the Ventilation control from damage. If the control is to be installed in a • CANADA: Part 7 of NSCNGPIC, Venting Systems and Air furnace,follow items 1 through 4 before bringing the control Supply for Appliances or yourself in contact with the furnace. Put all used and new Step 4—Duct Systems controls into containers before touching ungrounded objects. 7. An ESD service kit(available from commercial sources)may • US and CANADA: Air Conditioning Contractors Association also be used to prevent ESD damage. (ACCA) Manual D, Sheet Metal and Air Conditioning Con- tractors National Association(SMACNA), or American Soci- LOCATION ety of Heating,Refrigeration,and Air Conditioning Engineers (ASHRAE)2001 Fundamentals Handbook Chapter 34 or 2000 GENERAL HVAC Systems and Equipment Handbook Chapters 9 and 16. Step 5—Acoustical Lining and Fibrous Glass Duct Some assembly and modifications are required when used in any of the four applications shown in Fig. 4. • US and CANADA: current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts This furnace must: Step 6—Gas Piping and Gas Pipe Pressure Testing • be installed so the electrical components are protected from water. • US: NFGC; chapters 5, 6, 7, and 12 and National Plumbing Codes not be installed directly on any combustible material other than wood flooring(refer to SAFETY CONSIDERATIONS). • CANADA: NSCNGPIC Parts 3,4, and 5, and Appendices A, B, E and H. be located close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section. Step 7—Electrical Connections • be provided ample space for servicing and cleaning. Always • US: National Electrical Code (NEC)ANSI/NFPA 70-2002 comply with minimum fire protection clearances shown on the • CANADA: Canadian Electrical Code CSA C22.1 furnace clearance to combustible construction label. 5 AIRFLOW 4 THE BLOWER IS LOCATED BELOW THE BURNER SECTION,AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED uFFLow TO THE RIGHT OF THE BURNER SECTION,AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. aHORIZONTAL LEFT HORIZONTAL RIGHT E> AIRFLOW IRFLOW DOWNFLOW THE BLOWER IS THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION,AND OF THE BURNER SECTION, CONDITIONED AIR IS �/ AND CONDITIONED AIR IS DISCHARGED DOWNWARD AIRFLOW DISCHARGED TO THE RIGHT. A02097 Fig. 4—Multipoise Orientations All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative CARBON MONOXIDE POISONING HAZARD pressure in the equipment room or space.A positive seal must be Failure to follow this warning could result in personal injury made between the furnace cabinet and the return-air duct to or death, and unit component damage. prevent pulling air from the burner area and from draft safeguard Corrosive or contaminated air may cause failure of parts opening. containing flue gas,which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances. The following types of furnace installations may require OUT- DOOR AIR for combustion due to chemical exposures: �D • Commercial buildings • Buildings with indoor pools O • Laundry rooms • Hobby or craft rooms, and • Chemical storage areas 18-IN. MINIMUM If air is exposed to the following substances,it should not be used TO BURNERS A93044 for combustion air, and outdoor air may be required for combus- tion: Fig. 5—Installation in a Garage • Permanent wave solutions • Chlorinated waxes and cleaners • Chlorine based swimming pool chemicals • Water softening chemicals • De-icing salts or chemicals FIRE,INJURY OR DEATH HAZARD • Carbon tetrachloride Improper location or inadequate protection could result in fire • Halogen type refrigerants or explosion. • Cleaning solvents (such as perchloroethylene) When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches • Printing inks,paint removers,varnishes, etc. above the floor. The furnace must be located or protected to • Hydrochloric acid avoid damage by vehicles.When the furnace is installed in a • Cements and glues public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in • Antistatic fabric softeners for clothes dryers accordance with the NFGC or NSCNGPIC. (See Fig. 5.) • Masonry acid washing materials 6 ZX \PERSONAL INJURY AND/OR PROPERTY DAMAGE FRONT HAZARD Improper use or installation of this furnace may cause premature furnace component failure. This gas furnace may be used for heating buildings under B construction provided that: A C -The furnace is permanently installed with all electrical K wiring, piping, venting and ducting installed according to BACK these installation instructions. A return air duct is provided, v sealed to the furnace casing,and terminated outside the space containing the furnace. This prevents a negative pressure FRONT condition as created by the circulating air blower,causing a a flame rollout and/or drawing combustion products into the Ao2054 structure. Fig. 6—Prohibit Installation on Back -The furnace is controlled by a thermostat.It may not be"hot wired"to provide heat continuously to the structure without AIR FOR COMBUSTION AND VENTILATION thermostatic control. Provisions for adequate combustion, ventilation, and dilution air -Clean outside air is provided for combustion. This is to must be provided in accordance with: minimize the corrosive effects of adhesives,sealers and other • U.S.installations: Section 8.3 of the NFGC,Air for Combus- construction materials. It also prevents the entrainment of tion and Ventilation, and applicable provisions of the local drywall dust into combustion air, which can cause fouling building codes. and plugging of furnace components. • Canadian installations: Part 7 of the NSCNGPIC, Venting -The temperature of the return air to the furnace is main- Systems and Air Supply for Appliances, and all authorities tained between 55°F (13°C) and 80'F (27C), with no having jurisdiction. evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermit- ! tent operation per our installation instructions. FURNACE CORROSION HAZARD -The air temperature rise is within the rated rise range on the Failure to follow this caution may result in furnace damage. furnace rating plate, and the firing rate has been set to the Air for combustion must not be contaminated by halogen nameplate value. compounds, which include fluoride, chloride, bromide, and -The filters used to clean the circulating air during the iodide. These elements can corrode heat exchangers and construction process must be either changed or thoroughly cleaned prior to occupancy. shorten furnace life. Air contaminants are found in aerosol -The furnace, ductwork and filters are cleaned as necessary sprays, detergents, bleaches, cleaning solvents, salts, air to remove drywall dust and construction debris from all fresheners, and other household products. HVAC system components after construction is completed. -Verify proper furnace operating conditions including igni- tion, gas input rate, air temperature rise, and venting —4 CARBON MONOXIDE POISONING HAZARD according to these installation instructions. Failure to follow this warning could result in personal injury or death. A WARNING The operation of exhaust fans, kitchen ventilation fans, FIRE,INJURY OR DEATH HAZARD clothes dryers, attic exhaust fans or fireplaces could create a Failure to follow this warning could result in unsafe furnace NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices,in operation. addition to that required by the furnace. Refer to Carbon DO NOT install the furnace on its back or hang furnace with Monoxide Hazard warning in venting section of these instruc- control compartment facing downward. Safety control opera- tions to determine if an adequate amount of make-up air is tion will be adversely affected.Never connect return-air ducts available. to back of furnace. (See Fig. 6.) LOCATION RELATIVE TO COOLING EQUIPMENT The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume The cooling coil must be installed parallel with, or on the of at least 50 cubic feet per 1,000 Btuh input rating for all gas downstream side of the unit to avoid condensation in the heat appliances installed in the space. exchangers. When installed parallel with the furnace, dampers or . Spaces having less than 50 cubic feet per 1,000 Btuh require other flow control must prevent chilled air from entering the the OUTDOOR COMBUSTION AIR METHOD. furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the Spaces having at least 50 cubic feet per 1,000 Btuh may use the KNOWN- damper is in the full-heat or full-cool position. INDOOR COMBUSTION AIR,STANDARD or KNOWN- AIR INFILTRATION METHOD. 7 Table 2-Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS FURNACE (1 SQ. IN./2,000 BTUH)(1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH)(550 SQ. MM/KW) INPUT Free Area of Free Area of Free Area of (B (in Dia) (in Dia) (BTUH) Opening and Duct Round Duct Opening and Duct Round Duct Opening and Duct Round Duct (Sq. In.) . (sq In.) . (Sq In.) (In. Dia) 44,000 22 6 14.7 5 11 4 66,000 33 7 22 6 16.5 5 88,000 44 8 29.3 7 22 6 110,000 55 9 36.7 7 27.5 6 132,000 66 10 44 8 33 7 154,000 77 10 51.3 9 38.5 8 EXAMPLES: Determining Free Area FURNACE WATER HEATER TOTALINPUT 110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In.for each two Vertical Ducts or Openings 66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In.for a Single Duct or Opening 88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In.for each of two Horizontal Ducts Table 3-Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL ACH (1,000'S BTUH GAS INPUT RATE) (1,0005S BTUH GAS INPUT RATE) 30 40 50 44 66 88 110 132 154 Space Volume(ft3) 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850 0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620 0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775 0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700 0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550 0.10 6,300 8,400 1 10,500 1 6,600 9,900 13,200 1 16,500 1 19,800 1 23,100 0.00 NP NP NP NP NP NP NP NP NP NP=Not Permitted Outdoor Combustion Air Method b. Not less than the sum of the areas of all vent connectors in 1. Provide the space with sufficient air for proper combustion, the space. ventilation, and dilution of flue gases using permanent hori- The opening shall commence within 12"(300 mm)of the ceiling. zontal or vertical duct(s) or opening(s) directly communicat- Appliances in the space shall have clearances of at least 1" (25 ing with the outdoors or spaces that freely communicate with mm)from the sides and back and 6"(150 mm)from the front.The the outdoors. opening shall directly communicate with the outdoors or shall 2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN- communicate through a vertical or horizontal duct to the outdoors INGS,one inlet and one outlet combustion and ventilation air or spaces (crawl or attic) that freely communicate with the opening,to the outdoors. outdoors. a. One opening MUST commence within 12" (300 mm) of Indoor Combustion Air©NFPA&AGA the ceiling and the second opening MUST commence --->Standard and Known-Air-Infiltration Rate Methods within 12"(300 mm) of the floor. Indoor air is permitted for combustion,ventilation, and dilution, b. Size openings and ducts per Fig. 7 and Table 2. if the Standard or Known-Air-Infiltration Method is used. c. TWO HORIZONTAL DUCTS require 1 square inch of free area per 2,000 Btuh (1,100 mmz/kW) of combined input for all gas appliances in the space per Fig.7 and Table CARBON MONOXIDE POISONING HAZARD 2. Failure to supply outdoor air via grilles or ducts could result d. TWO OPENINGS OR VERTICAL DUCTS require 1 in death and/or personal injury. square inch of free area per 4,000 Btuh(550 mm2/kW)for Many homes require air to be supplied from outdoors for combined input of all gas appliances in the space per Fig. furnace combustion,ventilation, and dilution of flue gases. 7 and Table 2. The furnace combustion air supply must be provided in 3. ONE OUTDOOR OPENING requires: accordance with this instruction manual. a. 1 square inch of free area per 3,000 Btuh (734 mmz/kW) for combined input of all gas appliances in the space per Table 2 and 8 1 SO IN. DUCTS PER4000 CIRCULATING AIR VENT THROUGH ROOF TO BTUH` DUCTS OUTDOORS r r" i l 12"MAX D 12" 1 SQ IN. O VENT 12"MAX PER B Zv THROUGH F _ MAXM� z0 BTUH' ?o ROOF z - 1 SO IN. 1 SO IN. U) PER 1000 U¢ 40 co� BTUH'IN DOOR OR WALL BTUH' O F INTERIOR LLOa UNCONFINED DUCTS l_o w HEATED F SPACE TO 0 Q m o SPACE zO Q OUTDOORS z'z ry= 6"MIN LLOQM O LL[0 (FRONT)t zU)U)F 1 SO IN. z(D C7 U) PER Om�w 4 00 Uz 1 SQ IN. z�z-i BTUH" zw PER 1000 1 SQIN. �Oz� �LL = BTUH'IN DOOR PER 2000 A W a a E G - 12 w 0 = OR WALL BTUH` v O O " U 12 MAX C MAX 12"MAX 12"MAX CIRCULATING AIR DUCTS DUCT 1 SO IN. CIRCULATING AIR DUCTS TO PER 4000 OUTDOORS BTUH` Minimum opening size is 100 sq in.with 'Minimum dimensions of 3 in. minimum dimensions of 3 in. NOTE: Use any of the following tMinimum of 3 in.when type-B1 vent is used. combinations of openings: A03175 A&B C&D D&E F&G A03174 -> Fig. 8—Air for Combustion, Ventilation and Dilution from Indoors Fig. 7—Air for Combustion, Ventilation and Dilution for Outdoors The Standard Method: 2. For fan-assisted appliances such as this furnace: 1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2. The air infiltration rate is not known to be less than 0.40 air Volume,., = 15ft3 l ACH 1000 Btuft changes per hour(ACH). A04003 The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be: 1. Less than 0.40 ACH and 2. Equal to or greater than 0.10 ACH If: Infiltration rates greater than 0.60 ACH shall not be used. The I.,_ = combined input of all other than fan-assisted appli- minimum required volume of the space varies with the number of ances in Btu/hr ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the I fe =combined input of all fan-assisted appliances in Btu/hr space and add the volumes together to get the total minimum ACH=air changes per hour(ACH shall not exceed 0.60.) required volume for the space. Table 3-Minimum Space Volumes were determined by using the —4 The following requirements apply to the Standard Method and to following equations from the National Fuel Gas Code ANSI the Known Air Infiltration Rate Method. Z223.1-2002INFPA 54-2002,8.3.2.2: 1. Adjoining rooms can be considered part of a space if. 1. For other than fan-assisted appliances, such as a draft a. There are no closable doors between rooms. hood-equipped water heater: b. Combining spaces on same floor level.Each opening shall have free area of at least 1 in.2/1,000 Btuh(2,000 mm2/kW) Volume = 21ft3(TO-0-0 I 1 of the total input rating of all gas appliances in the space, ome ACH Btuihr) but not less than 100 in.2 (0.06 m2). One opening shall A04002 commence within 12" (300 mm) of the ceiling and the second opening shall commence within 12" (300 mm) of the floor.The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig. 8.) 9 c. Combining space on different floor levels.The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more perma- nent openings in doors or floors having free area of at least 2 in.2/1,000 Btuh(4,400 mm2/kW)of total input rating of all gas appliances. 2. An attic or crawlspace may be considered a space that freely I communicates with the outdoors provided there are adequate I J I j r permanent ventilation openings directly to outdoors having I I I I free area of at least 1-in.2/4,000 Btuh of total input rating for I I I all gas appliances in the space. I I 3. In spaces that use the Indoor Combustion Air Method, °� I infiltration should be adequate to provide air for combustion, j BOTTOM CLOSURE permanent ventilation and dilution of flue gases.However,in BOTTOM FILLER PANEL buildings with unusually tight construction, additional air PANEL oil' A02098 MUST be provided using the methods described in the Outdoor Combustion Air Method section. Fig. 9—Removing Bottom Closure Panel Unusually tight construction is defined as Construction with: NOTE: Side return-air openings can be used in UPFLOW and a. Walls and ceilings exposed to the outdoors have a continu- most HORIZONTAL configurations. Do not use side return-air ous, sealed vapor barrier. Openings are gasketed or sealed openings in DOWNFLOW configuration. and b. Doors and openable windows are weatherstripped and Leveling Legs (If Desired) In upflow position with side return inlet(s), leveling legs may be C. Other openings are caulked or sealed.These include joints used. (See Fig. 10.)Install field-supplied, 5/16 X 1-1/2 in. (max) around window and door frames,between sole plates and corrosion-resistant machine bolts,washers and nuts. floors,between wall-ceiling joints,between wall panels,at penetrations for plumbing, electrical and gas lines, etc. NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel Combination of Indoor and Outdoor Air to install leveling legs.To remove bottom closure panel,see Item 1. Indoor openings shall comply with the Indoor Combustion 1. in Bottom Return Air Inlet section. Air Method below and, To install leveling legs: 2. Outdoor openings shall be located as required in the Outdoor 1. Position furnace on its back. Locate and drill a hole in each Combustion Air Method mentioned previously and, bottom corner of furnace. (See Fig. 10.) 3. Outdoor openings shall be sized as follows: 2. For each leg,install nut on bolt and then install bolt and nut in a. Calculate the Ratio of all Indoor Space volume divided by hole. (Install flat washer if desired.) required volume for Indoor Combustion Air Method 3. Install another nut on other side of furnace base. (Install flat below. washer if desired.) b. Outdoor opening size reduction Factor is 1 minus the 4. Adjust outside nut to provide desired height,and tighten inside Ratio in a. above. nut to secure arrangement. c. Minimum size of Outdoor openings shall be the size 5. Reinstall bottom closure panel if removed. required in Outdoor Combustion Air Method above multiplied by reduction Factor in b.above.The minimum DOWNFLOW INSTALLATION dimension of air openings shall be not less than 3 in. (80 NOTE: For downflow applications, this furnace is approved for mm). use on combustible flooring when any one of the following 3 accessories are used: INSTALLATION • Special Base, KGASB UPFLOW INSTALLATION • Cased Coil Assembly Part No. CD5 or CKS Bottom Return Air Inlet • Coil Box Part No. KCAKC These furnaces are shipped with bottom closure panel installed in 1. Determine application being installed from Table 3. bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, 2. Construct hole in floor per Table 3 and Fig. 11. perform the following: 3. Construct plenum to dimensions specified in Table 3 and Fig. 1. Tilt or raise furnace and remove 2 screws holding bottom filler 11. panel. (See Fig. 9.) 4. If downflow subbase,KGASB is used,install as shown in Fig. 2. Rotate bottom filler panel downward to release holding tabs. 12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part 3. Remove bottom closure panel. No. KCAKC is used, install as shown in Fig. 13. 4. Reinstall bottom filler panel and screws. NOTE: It is recommended that the perforated supply-air duct flanges be completely folded over or removed from furnace when Side Return Air Inlet installing the furnace on a factory-supplied cased coil or coil box. These furnaces are shipped with bottom closure panel installed in To remove the supply-air duct flange,use wide duct pliers or hand bottom return-air opening. This panel MUST be in place when seamers to bend flange back and forth until it breaks off.Be careful only side return air is used. of sharp edges. (See Fig. 14.) 10 5/16 Platform Furnace Support Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in. i 5/16 clearance requirement on side, set furnace on non-combustible 3/4, blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists,the ground under- neath furnace must be level and the furnace set on blocks or bricks. Roll-Out Protection 1 3/4" Provide a minimum 17-3/4"X 22"piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12-in. to joists. The sheet metal MUST extend 5/16.. underneath the furnace casing by 1 in. with the door removed. The bottom closure panel on furnaces of widths 17-1/2 in. and larger may be used for flame roll-out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper cv • 5/16,. orientation of roll-out shield. 3/4 Bottom Return Air Inlet 1 3/4 1 I� These furnaces are shipped with bottom closure panel installed in �? A02071 bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, Fig. 10—Leveling Legs perform the following: Bottom Return Air Inlet 1. Tilt or raise furnace and remove 2 screws holding bottom filler These furnaces are shipped with bottom closure panel installed in panel. (See Fig. 9.) bottom return-air opening. Remove and discard this panel when 2. Rotate bottom filler panel downward to release holding tabs. bottom return air is used. To remove bottom closure panel, 3. Remove bottom closure panel. perform the following: 4. Reinstall bottom filler panel and screws. 1. Tilt or raise furnace and remove 2 screws holding bottom filler Side Return Air Inlet panel. (See Fig. 9.) These furnaces are shipped with bottom closure panel installed in 2. Rotate bottom filler panel downward to release holding tabs. bottom return-air opening.This panel MUST be in place when side 3. Remove bottom closure panel. return air inlet(s) is used without a bottom return air linlet. 4. Reinstall bottom filler panel and screws. Not all horizontal furnaces are approved for side return air HORIZONTAL INSTALLATION connections (See Fig. 20.) FILTER ARRANGEMENT A WARNING —4 FIRE,EXPLOSION,AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous FIRE,CARBON MONOXIDE AND POISONING operation, serious injury, death or property damage. HAZARD Do not install the furnace on its back or hang furnace with Failure to follow this warning could result in fire, personal control compartment facing downward. Safety control opera- injury, or death. tion will be adversely affected.Never connect return-air ducts Never operate a furnace without a filter or with filter access to the back of the furnace. door removed. The furnace can be installed horizontally in an attic or crawl space There are no provisions for an internal filter rack in these furnaces. on either the left-hand(LH)or right-hand(RH)side. The furnace A field-supplied accessory external filter rack is required. can be hung from floor joists, rafters or trusses or installed on a This furnace requires KGAFR0301ALL 1"external filter rack or a non-combustible platform,blocks,bricks or pad. suitable field-supplied substitute, such as the Media Cabinet. Suspended Furnace Support Refer to the instructions supplied with external filter rack for The furnace may be supported under each end with threaded rod, assembly and installation options. angle iron or metal plumber's strap as shown.(See Fig. 15 and 16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge AIR DUCTS sheet metal straps(plumber's straps)may be used to suspend the General Requirements furnace from each bottom corner.To prevent screws from pulling The duct system should be designed and sized according to out,use 2#8 x'/4-in. screws into the side and 2#8 x 3/4-in.screws accepted national standards such as those published by: Air in the bottom of the furnace casing for each strap.(See Fig. 15 and Conditioning Contractors Association (ACCA), Sheet Metal and 16.) Air Conditioning Contractors National Association(SMACNA)or If the screws are attached to ONLY the furnace sides and not the American Society of Heating,Refrigerating and Air Conditioning bottom, the straps must be vertical against the furnace sides and Engineers (ASHRAE) or consult The Air Systems Design Guide- not pull away from the furnace sides, so that the strap attachment lines reference tables available from your local distributor. The screws are not in tension(are loaded in shear)for reliable support. duct system should be sized to handle the required system design 11 Table 4—Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B C D Upflow Applications on Combustible or Noncombustible 12-11/16 21-5/8 13-5/16 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 12-9/16 19 13-3/16 19-5/8 (KGASB subbase not required) 14-3/16 Downflow applications on combustible flooring (KGASB 11-13/16 19 13-7/16 20-5/8 subbase required) Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box(KGASB subbase 12-5/16 19 13-5/16 20 not required) Upflow Applications on Combustible or Noncombustible 16 21-5/8 16-5/8 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 15-7/8 19 16-1/2 19-5/8 (KGASB subbase not required) 17-1/2 Downflow applications on combustible flooring (KGASB 15-1/8 19 16-3/4 20-5/8 subbase required) Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box(KGASB subbase 15-1/2 19 16-1/2 20 not required) Upflow Applications on Combustible or Noncombustible 19-1/2 21-5/8 20-1/8 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 19-3/8 19 20 19-5/8 (KGASB subbase not required) 21 Downflow applications on combustible flooring (KGASB 18-5/8 19 20-1/4 20-5/8 subbase required) Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box(KGASB subbase 19 19 20 20 not required) Upflow Applications on Combustible or Noncombustible 23 21-1/8 23-5/8 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 22-7/8 19 23-1/2 19-5/8 (KGASB subbase not required) 24-1/2 Downflow applications on Combustible flooring (KGASB 22-1/8 19 23-3/4 20-5/8 subbase required) Downflow Applications on Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC coil box(KGASB subbase 22-1/2 19 23-1/2 20 not required) CFM at the design external static pressure. The furnace airflow Both acoustical lining and fibrous ductwork shall comply with rates are provided in Table 5-AIR DELIVERY-CFM(With Filter). NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air When a furnace is installed so that the supply ducts carry air ducts. circulated by the furnace to areas outside the space containing the Supply Air Connections furnace,the return air shall also be handled by a duct(s)sealed to For a furnace not equipped with a cooling coil,the outlet duct shall the furnace casing and terminating outside the space containing the be provided with a removable access panel.This opening shall be furnace. accessible when the furnace is installed and shall be of such a size Secure ductwork with proper fasteners for type of ductwork used. that the heat exchanger can be viewed for possible openings using Seal supply- and return-duct connections to furnace with code light assistance or a probe can be inserted for sampling the air approved tape or duct sealer. stream. The cover attachment shall prevent leaks. NOTE: Flexible connections should be used between ductwork Upflow and Horizontal Furnaces and furnace to prevent transmission of vibration. Ductwork pass- Connect supply-air duct to flange on furnace supply-air outlet. ing through unconditioned space should be insulated and sealed to Bend flange upward to 90' with wide duct pliers. (See Fig. 14.) enhance system performance. When air conditioning is used, a The supply-air duct must be connected to ONLY the furnace vapor barrier is recommended. supply-outlet-air duct flanges or air conditioning coil casing(when Maintain a 1-in.clearance from combustible materials to supply air used).DO NOT cut main furnace casing side to attach supply air ductwork for a distance of 36 in.horizontally from the furnace.See duct, humidifier, or other accessories. All accessories MUST be NFPA 90B or local code for further requirements. connected external to furnace main casing. Ductwork Acoustical Treatment NOTE: For horizontal applications, the top-most flange may be bent past 90 degrees to allow the evaporator coil to hang on the NOTE: Metal duct systems that do not have a 90 degree elbow flange temporarily while the remaining attachment and sealing of and 10 ft of main duct to the first branch take-off may require the coil are performed. internal acoustical lining.As an alternative,fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. 12 FURNACE (OR COIL CASING WHEN USED) A PLENUM OPENING COMBUSTIBLE B D FLOORING FLOOR �� DOWNFLOW O C SUBBASE SHEET METAL /l PLENUM 1 FLOOR OPENING A96283 Fig. 11—Floor and Plenum Opening Dimensions A96285 Fig. 12—Furnace, Plenum, and Subbase Installed on a Combustible Floor FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING J� 2 SHEET METALS PLENUM X FLOOR L OPENING A04140 Fig. 13—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor Downflow Furnaces proved air conditioning coil casing. DO NOT cut main furnace Connect supply-air duct to supply-air outlet on furnace. Bend casing to attach supply side air duct,humidifier,or other accesso- flange inward past 90' with wide duct pliers. (See Fig. 14.) The ries. All accessories MUST be connected external to furnace supply-air duct must be connected to ONLY the furnace supply- casing. outlet or air conditioning coil casing(when used).When installed on combustible material, supply-air duct must be connected to ONLY the accessory subbase, KGASB0201ALL, or factory ap- 13 UPFLOW DOWNFLOW HORIZONTAL 90- -90' r I PREFERRED PREFERRED PREFERRED 1-- PREFERRED 120' PREFERRED 12p� PREFERRED MIN MIN MIN PERMITTED PERMITTED PERMITTED A02329 Fig. 14—Duct Flanges 1/a"THREADED ROD /4 REQ. I I I I I OUTER DOOR / r ASSEMBLY / SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3#8 x 3/4"SCREWS TYPICAL FOR 2 SUPPORTS 8"MIN FOR DOOR REMOVAL 1"SQUARE,11/4"x 1'A"x 1/8"ANGLE IRON OR UNI-STRUT MAY BE USED (2)HEX NUTS,(2)WASHERS&(2)LOCK WASHERS REQ.PER ROD A05027 Fig. 15—Horizontal Unit Suspension Return Air Connections horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. Upflow and Horizontal Furnaces The return-air duct must be connected to bottom, sides (left or FIRE HAZARD right), or a combination of bottom and side(s) of main furnace Failure to follow this warning could cause a fire, personal casing as shown in Fig. 18 and 20. Bypass humidifier may be injury, or death. attached to unused side return air side of the furnace casing. (See Never connect return-air ducts to the back of the furnace. Fig. 18 and 20.) Follow instructions below. Not all horizontal furnaces are approved for side return air Downflow Furnaces connections. (See Fig. 20.) The return-air duct must be connected to return-air opening (bottom inlet)as shown in Fig. 19.DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most 14 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS AIR OPENING OUTER DOOR ASSEMBLY \ F III I III I USE(2)#8 x 3/4 SHEET METAL SCREWS TYPICAL FOR ALL III I STRAPS I I III li / / / / / BACK OF / FURNACE / FOLD ALL STRAPS / UNDER FURNACE AND / SECURE W(2)#8 x 3/4 SHEET METAL SCREWS AIR OPENING A02014 Fig. 16—Horizontal Suspension with Straps LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS,OR FRAMING. 17 3/4" OVERALL 4 3/4" UNDER DOOR 1"UNDER FURNACE GAS TYPE-B ENTRY VENT EXTEND OUT 12"OUT FROM FACE OF DOOR p00�0 30-IN.MIN WORK AREA 'WHEN USED WITH �p000 SINGLE WALL VENT CONNECTIONS AnWl 17 3/4" SHEET METAL 22" MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP A02164 Fig. 17—Typical Attic Installation GAS PIPING A WARNING FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION HAZARD Failure to follow this warning coud result in personal injury, Failure to follow this warning could result in personal injury, death, and/or property damage. Use proper length of pipe to avoid stress on gas control death and/or property damage. manifold and a gas leak. Never purge a gas line into a combustion chamber.Never test for gas leaks with an open flame. Use a commercially Gas piping must be installed in accordance with national and local available soap solution made specifically for the detection of codes.Refer to current edition of NFGC in the U.S.,the NSCNG- leaks to check all connections. PIC in Canada. 15 Table 5—Air Delivery - CFM (With Filter)* FURNACE RETURN-AIR SPEED EXTERNAL STATIC PRESSURE(IN.WC) SIZE INLET 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Bottom High 1085 1035 975 915 845 770 675 565 390 195 024045 or Med-High 920 875 830 770 710 640 555 440 250 -- Side(s) Med-Low 820 775 730 680 620 555 470 360 190 - Bottom High 1440 1375 1305 1240 1160 1070 975 870 730 560 036045 or Med-High 1360 1300 1240 1175 1115 1040 950 850 725 575 Side(s) Med-Low 1250 1210 1160 1100 1040 965 885 790 1 670 520 Bottom High 1030 1010 980 945 900 845 775 680 490 335 024070 or Med-High 835 815 790 760 720 675 610 490 375 265 Side(s) Med-Low 725 1 700 675 645 600 555 1 475 390 300 Bottom High 1425 1375 1320 1265 1200 1125 1035 940 830 655 036070 or Med-High 1320 1280 1240 1205 1140 1075 995 905 790 620 Side(s) Med-Low 1200 1175 1145 1105 1050 990 920 840 725 555 Bottom High 1805 1740 1670 1600 1530 1445 1360 1280 1180 1075 048070 or Med-High 1630 1585 1530 1470 1405 1330 1255 1170 1080 990 Side(s) Med-Low 1460 1420 1385 1325 1280 1220 1155 1080 995 910 Bottom High 1650 1600 1535 1465 1385 1285 1175 1055 895 645 042090 or Med-High 1515 1485 1440 1380 1300 1220 1115 990 830 600 Side(s) Med-Low 1385 1 1360 1320 1260 1195 1120 1 1025 915 1 710 565 Bottom High 2060 1985 1915 1820 1720 1610 1490 1340 1135 925 048090 or Med-High 1790 1765 1715 1645 1560 1470 1345 1195 1010 820 Side(s) Med-Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740 Bottom High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350 Only Med-High 2225 2155 2080 1995 1895 1785 1675 1565 1420 1260 Med-Low 2020 1955 1880 1805 1 1730 1630 1535 1420 1275 1135 Both Sides or High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505 060090 1 Side&Bottom Med-High 2285 2215 2150 2075 1985 1890 1780 1660 1525 1360 Med-Low 1995 1945 1900 1840 1770 1685 1600 1480 1350 1180 High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425 1 Side Only Med-High 2260 2190 2110 2035 1940 1845 1735 1620 1475 1325 Med-Low 1950 1910 1855 1795 1730 1650 1555 1445 1310 1150 Bottom High 1625 1575 1515 1445 1355 1260 1165 990 785 -- 036110 or Med-High 1510 1470 1415 1355 1285 1185 1070 890 725 -- Side(s) Med-Low 1360 1335 1295 1250 1 1180 1100 985 810 -- - Bottom High 2035 1965 1880 1790 1680 1495 1365 1215 1075 875 048110 or Med-High 1745 1710 1650 1560 1450 1340 1205 1090 955 750 Side(s) Med-Low 1530 1515 1470 1400 1310 1215 1095 990 830 670 Bottom High 2530 2470 2400 2320 2220 2115 2000 1865 1730 1590 Only Med-High 2230 2205 2165 2110 2035 1950 1855 1740 1615 1485 Med-Low 1920 1900 1880 1845 1795 1730 1 1650 1555 1460 1340 Bottom Sides or High -- 2415 2350 2250 2145 2015 1875 1715 1560 066110 1 Side& Bottom Med-High 2235 2200 2155 2100 2040 1955 1850 1740 1595 1470 Med-Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340 High 2540 2495 2430 2355 2265 2175 2065 1935 1785 1650 1 Side Only Med-High 2125 2120 2105 2060 2010 1940 1840 1730 1615 1485 Med-Low 1795 1790 1765 1720 1650 1585 1500 1390 1280 *A filter is required for each return-air inlet. Airflow performance included 1-in.washable filter media such as contained in factory-authorized accessory filter rack. To determine airnow performance without this filter,assume an additional 0.1 in.we available external static pressure. Indicates unstable operating conditions. 16 Table 5—Air Delivery - CFM (With Filter)* (Continued) FURNACE RETURN-AIR SPEED EXTERNAL STATIC PRESSURE (IN.WC) SIZE INLET 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Bottom High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835 048135 or Med-High 1790 1755 1705 1640 1550 1465 1360 1210 945 785 Side(s) Med-Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670 Bottom High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355 Only Med-High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255 Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Bottom, Sides or High -- 2385 2305 2195 2085 1960 1825 1670 1465 066135 1 Side&Bottom Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325 Med-Low 1 1880 1850 1820 1780 1715 1635 1540 1 1415 1290 1 1160 High - 2245 2155 2055 1940 1825 1695 1555 1385 1 Side Only Med-High 2135 2085 2035 1975 1895 1795 1685 1565 1445 1265 Med-Low 1880 1850 1820 1780 1715 1 1635 1540 1415 1290 1160 Bottom High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545 Only Med-High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225 Both Sides Or High -- 2375 2285 2200 2105 1995 1870 1730 1570 060155 1 Side&Bottom Med-High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400 Med-Low 1800 1790 1 1770 1 1735 1695 1640 1570 1465 1345 1225 High -- 2260 2180 2085 1975 1865 1740 1605 1455 1 Side Only Med-High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325 Med-Low 1800 1790 1770 1735 1 1695 1 1640 1570 1465 1345 1 1225 *A filter is required for each return-air inlet.Airflow performance included 1-in.washable filter media such as contained in factory-authorized accessory filter rack.To determine airflow performance without this filter,assume an additional 0.1 in.we available external static pressure. -- Indicates unstable operating conditions. Installations must be made in accordance with all authorities installed immediately upstream of gas supply connection to having jurisdiction. If possible, the gas supply line should be a furnace and downstream of manual equipment shutoff valve. separate line running directly from meter to furnace. NOTE: The gas valve inlet pressure tap connection is suitable to NOTE: In the state of Massachusetts: use as test gauge connection providing test pressure DOES NOT 1. Gas supply connections MUST be performed by a licensed exceed maximum 0.5 psig(14-in.wc)stated on gas control valve. plumber or gas fitter. (See Fig. 46.) 2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm). Some installations require gas entry on right side of furnace (as 3.When lever handle type manual equipment shutoff valves are viewed in upflow). (See Fig. 21 a.) used, they shall be T-handle valves. Install a sediment trap in riser leading to furnace as shown in Fig 4.The use of copper tubing for gas piping is NOT approved by 21b.Connect a capped nipple into lower end of tee.Capped nipple the state of Massachusetts. should extend below level of furnace gas controls.Place a ground Refer to Table 6 for recommended gas pipe sizing.Risers must be joint union between furnace gas control valve and exterior manual equipment gas shutoff valve. A 1/8-in. NPT plugged tapping, used to connect to furnace and to meter. Support all gas piping i with appropriate straps,hangers,etc.Use a minimum of 1 hanger accessible for test gauge connection,MUST be installed immedi- eve 6 ft.Joint compound(pipe dope)should be applied sparingly ately upstream of gas supply connection to furnace and down- every (p p p ) pp stream of manual equipment shutoff valve. and only to male threads of joints. Pipe dope must be resistant to the action of propane gas. Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada, local, and national plumbing and gas codes before the furnace has been connected.After all connections have been made,purge lines and � FIRE OR EXPLOSION HAZARD check for leakage at furnace prior to operating furnace. Failure to follow this warning could result in death,personal injury and/or property damage. If pressure exceeds 0.5 psig(14-in. wc), gas supply pipe must be If local codes allow the use of a flexible gas appliance disconnected from furnace and capped before and during supply connector, always use a new listed connector. Do not use a pipe pressure test.If test pressure is equal to or less than 0.5 psig connector which has previously served another gas appliance. (14-in.wc),turn off electric shutoff switch located on furnace gas Black iron pipe shall be installed at the furnace gas control control valve and accessible manual equipment shutoff valve valve and extend a minimum of 2-in. outside the furnace. before and during supply pipe pressure test.After all connections have been made,purge lines and check for leakage at furnace prior t to operating furnace. • The gas supply pressure shall be within the maximum and FURNACE OVERHEAT HAZARD minimum inlet supply pressures marked on the rating plate with Failure to follow this caution may result in property damage. the furnace burners ON and OFF. Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls. An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace.A 1/8-in.NPT plugged tapping, accessible for test gauge connection, MUST be 17 SUPPLY 1 AIR UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS - - - AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR - - - - CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS - - - - ONLY ONLY ONLY OF 1,2,AND 3 066.060,-22 AND YES YES YES YES -20 MODELS ALL OTHER MODELS YES YES YES YES 02 O RETURN RE RN AIR AIR UFF- R AgRN 1 7Q RESTRICTIOINS Fig. 18—Upflow Return Air Configurations and Restrictions A02075 1 O RETURN AIR RETURN RETU AIR AIR SIDE RETURN SIDE RETURN NOT PERMITTED NOT PERMITTED FOR ANY MODEL FOR ANY MODEL DOWNFLOW RETURN AIRCONFIGURATIONSAND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR - - CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1,2,AND 3 066.060,-22 AND YES NO NO NO -20 MODELS ALL OTHER MODELS YES NO NO NO SUPPLY AIR Fig. 19—Downflow Return Air Configurations and Restrictions A02163 � U RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066,060,-22-20 AIR FLOW MODELS IIIIIII o IIIIIII 6AIRLY IIIIIII R RN AIR SIDE RETURN AIR NOT PERMITTED FOR 066,060,.2.20 AIR FLOW MODELS RETURN R HORIZONAL URN AIR ET NOTE:RESTRICTION SAME FOR AIR RESTRICTIONS HORIZONAL LEFT O HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1,2,AND 3 066.060,-22 AND YES NO NO NO -20 MODELS ALL OTHER MODELS YES YES YES YES A02162 Fig. 20—Horizontal Return Air Configurations and Restrictions 18 Table 6—Maximum Capacity of Pipe* NOMINAL ELECTRICAL SHOCK AND FIRE HAZARD IRON INTERNAL LENGTH OF PIPE (FT) Failure to follow this warning could result in serious injury, PIPE DIAMETER death, or property damage. SIZE (IN.) 10 20 30 40 50 The cabinet MUST have an uninterrupted or unbroken round (IN.) p g 1/2 0.622 175 120 97 82 73 according to NEC ANSI/NFPA 70-2002 and Canadian Elec- 3/4 0.824 360 250 200 170 151 trical Code CSA C22.1 or local codes to minimize personal 1 1.049 680 465 375 320 285 injury if an electrical fault should occur.This may consist of 1-1/4 1.380 1400 950 1 770 1 660 580 electrical wire, conduit approved for electrical ground or a 1-1/2 1.610 2100 1460 1 1180 1 990 900 listed,grounded power cord(where permitted by local code) Cubic ft of natural gas per hr for gas pressures of 0.5 psig(14—in.wc)or less When installed in accordance with existing electrical codes. and a pressure drop of 0.5—in we(based on a 0.60 specific gravity gas). Refer to the power cord manufacturer's ratings for proper Ref:Table 12.2 ANSI Z223-2002/NFPA 54-2002. wire gauge. Do not use gas piping as an electrical ground. TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY t —4 FURNACE MAY NOT OPERATE Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather. 90'Elbows o o Furnace control must be grounded for proper operation or control will lock out. Control is grounded through To Gas green/yellow wire routed to gas valve and manifold bracket 6T�� Supply screw. 2"Nipple 115-V Wiring Verify that the voltage, frequency, and phase correspond to that 90'Elbow specified on unit rating plate. Also, check to be sure that service Close Nipple Gas Valve A02327 provided by utility is sufficient to handle load imposed by this equipment.Refer to rating plate or Table 7 for equipment electrical Fig. 21a—Right Side Gas Entry Example specifications. U.S. installations: Make all electrical connections in accordance GAS — — with National Electrical Code (NEC) ANSI/NFPA 70-2002 and SUPPLY — — any local codes or ordinances that might apply. MANUAL — — Canadian installations: Make all electrical connections in accor- SHUTOFF VALVE — — dance with Canadian Electrical Code CSA C22.1 or authorities (REQUIRE having jurisdiction. SEDIMENT TRAP UNION � FIRE HAZARD Failure to follow this warning could result in serious injury, death, or property damage. Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. Use a separate,fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size A02035 and fuse specifications. A readily accessible means of electrical Fig. 21 b—Typical Gas Pipe Arrangement disconnect must be located within sight of the furnace. NOTE: Proper polarity must be maintained for 115-v wiring. If ELECTRICAL CONNECTIONS polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate. WARNING J-BOX RELOCATION ELECTRICAL SHOCK HAZARD NOTE: If factory location of J-Box is acceptable, go to next Failure to follow this warning could result in serious personal section(Electrical Connection to J-Box). injury or death. NOTE: On 14" wide casing models, the J-Box shall not be Blower access panel door switch opens 115-v power to relocated to other side of furnace casing when the vent pipe is control.No component operation can occur.Do not bypass or routed within the casing. close switch with panel removed. 1. Remove and save two screws holding J-box. (See Fig. 22.) See Fig. 25 for field wiring diagram showing typical field 115-v NOTE: The J-Box cover need not be removed from the J-Box in wiring. Check all factory and field electrical connections for order to move the J-Box. Do NOT remove green ground screw tightness. inside J-Box. The ground screw is not threaded into the casing Field-supplied wiring shall conform with the limitations of 63°F flange and can be lifted out of the clearance hole in casing while (33°C)rise. swinging the front edge of the J-Box outboard of the casing. 19 -> Table 7-Electrical Data VOLTS- OPERATING MAXIMUM FURNACE SIZE HERTZ- VOLTAGE RANGE MAXIMUM UNIT MAXIMUM FUSE OR CKT BKR MINIMUM PHASE Maximum* Minimum* UNIT AMPS AMPACITY# WIRE LENGTH (FT)$ AMPSt WIRE GAUGE 045-08/024045 115-60-1 127 104 5.4 7.54 49 15 14 045-12/036045 115-60-1 127 104 7.0 9.50 39 15 14 070-08/024070 115-60-1 127 104 5.0 7.06 52 15 14 070-12/036070 115-60-1 127 104 6.8 9.22 40 15 14 070-16/048070 115-60-1 127 104 9.5 12.60 29 15 14 090-14/042090 115-60-1 127 104 8.2 10.83 34 15 14 090-16/048090 115-60-1 127 104 10.0 13.13 28 15 14 090-20/060090 115-60-1 127 104 13.6 17.61 32 20 12 110-12/036110 115-60-1 127 104 8.2 10.75 34 15 14 110-16/048110 115-60-1 127 104 10.1 13.12 28 15 14 110-22/066110 115-60-1 127 104 1 14.8 1 18.99 1 30 1 20 12 135-16/048135 115-60-1 127 104 10.2 13.27 27 15 14 135-22/066135 115-60-1 127 104 14.4 18.55 30 20 12 155-20/060155 115-60-1 127 104 15.0 19.33 29 20 12 *Permissible limits of the voltage range at which the unit operates satisfactorily. #Unit ampacity=125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components'(EAC,humidifier,etc.)full load amps. t Time-delay type is recommended. $Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. FACTORY INSTALLED LOCATION O U TWO ALTERNATE FIELD o e LOCATION 11 O ' O O O A02099 O Fig. 22-Relocating J-Box 2. Cut wire tie on loop in furnace wires attached to J-Box. 3. Move box to desired location. 4. Fasten J-Box to casing with two screws removed in Step 1. O 5. Route J-Box wires within furnace away from sharp edges, rotating parts, and hot surfaces. A03221 ELECTRICAL CONNECTION TO J-Box Fig. 23-Field-Supplied Electrical Box on Field-Supplied Electrical Box on Furnace J-Box Bracket Furnace Casing See Fig. 23. 4. Route and secure field ground wire to green ground screw on 1. Remove cover from furnace J-Box. J-Box bracket. 2. Attach electrical box to furnace J-Box bracket with at least 5. Connect line voltage leads as shown in Fig. 25. two field-supplied screws through holes in electrical box into 6. Reinstall cover to J-Box. Do not pinch wires between cover holes in bracket. Use blunt-nose screws that will not pierce and bracket. wire insulation. 3. Route furnace power wires through holes in electrical box and J-Box bracket, and make field-wire connections in electrical box. Use best practices (NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc. 20 TWINNING AND/OR BLOWER OFF-DELAY COMPONENTTEST TERMINAL J2 JUMPER BLOWER OFF-DELAY o o HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT " 0 TERMINALS 0 �3 TRANSFORMER 24-VAC < � TEST/TWIN CONNECTIONS y A � HUeM .5 AC 3-AMP FUSE y FUSE P SEC-2 SEC-1 n O 0 n LED OPERATION& m EAC-2 L2 n DIAGNOSTIC LIGHT o o A o o o4 PL1-LOW VOLTAGE MAIN 115-VAC(L2)NEUTRAL o o HARNESS CONNECTOR CONNECTIONS o 0 o COOL o H EAT 1-A @ _ SPAREA SPARE-2 EAC-1 115VAC PR-1 ��1 SPARE-1 O 115 VAC(L1)LINE PL2-HOT SURFACE BLOWER SPEED SPARE-2 VOLTAGE CONNECTION IGNITER&INDUCER SELECTION TERMINALS MOTOR CONNECTOR EAC-1 TERMINAL (115-VAC 1.0 AMP MAX.) A02100 Fig. 24—Furnace Control Electrical Box on Furnace Casing Side 9. Route field ground wire through holes in electrical box and See Fig. 23. casing, and into furnace J-Box. 10. Reattach furnace J-Box to furnace casing with screws re- A WARNING moved in Step 4. FIRE OR ELECTRICAL SHOCK HAZARD 11. Secure field ground wire to J-Box green ground screw. Failure to follow this warning could result in personal injury, 12. Complete electrical box wiring and installation. Connect line death, or property damage. voltage leads as shown in Fig.25.Use best practices(NEC in If field-supplied manual disconnect switch is to be mounted U.S. and CSA C22.1 in Canada) for wire bushings, strain on furnace casing side, select a location where a drill or relief, etc. fastener cannot damage electrical or gas components. 13. Reinstall cover to J-Box. Do not pinch wires between cover 1. Select and remove a hole knockout in the casing where the and bracket. electrical box is to be installed. POWER CORD INSTALLATION IN FURNACE J-BOX NOTE: Check that duct on side of furnace will not interfere with NOTE: Power cords must be able to handle the electrical require- installed electrical box. ments listed in Table 5. Refer to power cord manufacturer's 2. Remove the desired electrical box hole knockout and position listings. the hole in the electrical box over the hole in the furnace 1. Remove cover from J-Box. casing. 2. Route listed power cord through 7/8-inch diameter hole in 3. Fasten the electrical box to casing by driving two field- J-Box. supplied screws from inside electrical box into casing steel. 3. Secure power cord to J-Box bracket with a strain relief 4. Remove and save two screws holding J-Box. (See Fig. 22.) bushing or a connector approved for the type of cord used. 5. Pull furnace power wires out of 1/2-inch diameter hole in 4. Secure field ground wire to green ground screw on J-Box J-Box. Do not loosen wires from strain-relief wire-tie on bracket. outside of J-Box. 5. Connect line voltage leads as shown in Fig. 25. 6. Route furnace power wires through holes in casing and 6. Reinstall cover to J-Box. Do not pinch wires between cover electrical box and into electrical box. and bracket. 7. Pull field power wires into electrical box. 8. Remove cover from furnace J-Box. 21 ---- FIELD 24-V WIRING ---- FIELD 115-,208/230-,460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE WIRE w c Q Q Q TERMINALS FIELD-SUPPLIED THREE-WIRE I I DISCONNECT HEATING-ONLY I I BLOWER DOOR SWITCH --- 460-V 0-OR I 208/2 I THREE BLK� BL V O i i _ __ PHASE __ I I - - --�-- - C I I Q I I -- --�___-- N i i -- •---1 208/230-V =GND GND R G --_L-------j t— __ ---l SINGLE 115-V FIELD- AUXILIARY Q ♦ __ Jr PHASE SUPPLIED 3-BOX L co ------------ i I r17— — --- GND--- DISCONNECT ----NOTE CONDENSING ns --------------- UNIT 24-V TWO TERMINAL WIRE BLOCK FURNACE NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation. 2. Some thermostats require a"C"terminal connection as shown. 3. If any of the original wire,as supplied,must be replaced,use same type or equivalent wire. A99440 Fig. 25—Heating and Cooling Application Wiring Diagram with 1—Stage Thermostat BX CABLE INSTALLATION IN FURNACE J-BOX 2. Humidifier(HUM) 1. Remove cover from J-Box. Connect an accessory 24 VAC,0.5 amp maximum humidifier (if used)to the 1/4-in male quick-connect HUM terminal and 2. Route BX cable into 7/8-inch diameter hole in J-Box. CoM-24V screw terminal on the control board thermostat strip. 3. Secure BX cable to J-Box bracket with connectors approved The HUM terminal is energized when pressure switch(PRS) for the type of cable used. closes. (See Fig. 24.) 4. Secure field ground wire to green ground screw on J-Box NOTE: A field-supplied, 115-v controlled relay connected to bracket. EAC terminals may be added if humidifier operation is desired 5. Connect line voltage leads as shown in Fig. 25. during blower operation. 6. Reinstall cover to J-Box. Do not pinch wires between cover NOTE: DO NOT connect furnace control HUM terminal to HUM and bracket. (humidifier)terminal on ThermidistatTM,Zone Controller or simi- 24-V WIRING lar device. See ThermidistatTM, Zone Controller, thermostat, or Make field 24-v connections at the 24-v terminal strip. (See Fig. controller manufacturer's instructions for proper connection. 24.) Connect terminal Y as shown in Fig. 25 for proper cooling operation.Use only AWG No. 18,color-coded,copper thermostat VENTING wire. The furnace shall be connected to a listed factory built chimney or The 24-v circuit contains an automotive-type, 3-amp fuse located vent or a clay-tile lined masonry or concrete chimney.Venting into on the control. Any direct shorts during installation, service, or an unlined masonry chimney or concrete chimney is prohibited. maintenance could cause this fuse to blow. If fuse replacement is required,use ONLY a 3-amp fuse of identical size. �When an existing Category I furnace is removed or replaced,the original venting system may no longer be sized to properly vent ACCESSORIES the attached appliances. An improperly sized Category I venting 1. Electronic Air Cleaner(EAC) system could cause the formation of condensate in the furnace and Connect an accessory Electronic Air Cleaner (if used) using vent,leakage of condensate and combustion products,and spillage 1/4-in female quick connect terminals to the two male 1/4-in of combustion products into the living space. quick-connect terminals on the control board marked EAC-1 and EAC-2. The terminals are rated for 115 VAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 24.) 22 The following information and warning must be considered in addition to the requirements defined in the NFGC and the CARBON MONOXIDE POISONING HAZARD NSCNGPIC. Failure to follow the steps outlined below for each appliance 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 CARBON MONOXIDE POISONING HAZARD connected to the venting system being placed into operation, Failure to follow this warning could result in a build-up of while all other appliances connected to the venting system are carbon monoxide and lead to personal injury or death. not in operation: Do not bypass the draft safeguard switch, as an unsafe 1. Seal any unused openings in venting system. condition could exist which must be corrected. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI 1. If a vent(common or dedicated)becomes blocked,the furnace Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and will be shut off by the draft safeguard switch located on the Propane Installation Code and these instructions. Deter- vent elbow. mine that there is no blockage or restriction, leakage, 2. Do not connect this Category I furnace into a single-wall corrosion and other deficiencies, which could cause an dedicated or common vent. The dedicated or common vent is unsafe condition. considered to be the vertical portion of the vent system that 3. As far as practical, close all building doors and windows terminates outdoors. and all doors between the space in which the appliance(s) 3. Vent connectors serving Category I furnaces shall not be connected to the venting system are located and other connected into any portion of a mechanical draft system spaces of the building. operating under positive pressure. 4. Close fireplace dampers. 4. In the U.S.: Do not vent this appliance with any solid fuel 5.Turn on clothes dryers and any appliance not connected to burning appliance. the venting system. Turn on any exhaust fans, such as In Canada: Check with the authority having jurisdiction for range hoods and bathroom exhausts, so they are operating approval on use with solid fuel burning appliance. at maximum speed.Do not operate a summer exhaust fan. 6.Follow the lighting instructions.Place the appliance being 5. Category I furnaces must be vented vertically or nearly inspected into operation. Adjust the thermostat so appli- vertically unless equipped with a listed power ventor. ante is operating continuously. 6. Do not vent this appliance into an unlined masonry chimney. 7.Test for spillage from draft hood equipped appliances at the Refer to Chimney Inspection Chart,Fig. 26. draft hood relief opening after 5 minutes of main burner MASONRY CHIMNEY REQUIREMENTS operation. Use the flame of a match or candle. 8. If improper venting is observed during any of the above NOTE: These furnaces are CSA design-certified for use in tests, the venting system must be corrected in accordance exterior clay tile-lined masonry chimneys with a factory accessory with the National Fuel Gas Code,ANSI Z223.IINFPA 54 Chimney Adapter Kit.Refer to the furnace rating plate for correct and/or CSA B149.1,Natural Gas and Propane Installation kit usage. The Chimney Adapter Kits are for use with ONLY Code. furnaces having a Chimney Adapter Kit number marked on the 9.After it has been determined that each appliance connected furnace rating plate. to the venting system properly vents when tested as If a clay tile-lined masonry chimney is being used and it is exposed outlined above, return doors, windows, exhaust fans, to the outdoors below the roof line, relining might be required. fireplace dampers and any other gas-fired burning appli- Chimneys shall conform to the Standard for Chimneys,Fireplaces, ante to their previous conditions of use. Vents,and Soild Fuel Burning Appliances ANSI/NFPA 211-2003 in the United States and to a Provincial or Territorial Building Vent system or vent connectors may need to be resized. Vent Code in Canada (in its absence, the National Building Code of systems or vent connectors must be sized to approach minimum Canada) and must be in good condition. size as determined using appropriate table found in the NFGC or NSCNGPIC. U.S.A.-Refer to Sections 13.1.9 and 13.2.20 of the NFGC or the authority having jurisdiction to determine whether relining is GENERAL VENTING REQUIREMENTS required. If relining is required,use a properly sized listed metal Follow all safety codes for proper vent sizing and installation liner, Type-B vent, or a listed alternative venting design. requirements, including local building codes, the National Fuel NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative Gas Code ANSI Z223.1-2002/NFPA 54-2002 (NFGC), Parts 10 and 13 in the United States or the National Standard of Canada, venting design and the exception,which cover installations such as Natural Gas and Propane Installation Code CSA-B149.1-00 the Chimney Adapter Kits KGACA02014FC and KGACA02015FC,which are listed for use with these furnaces. (NSCNGPIC), Section 7, Appendix C in Canada, the local building codes,and furnace and vent manufacturers' instructions. The Chimney Adapter Kit is listed alternative venting system for These furnaces are design-certified as Category I furnaces in these furnaces. See the kit instructions for complete details. accordance with ANSI Z21.47-2003/CSA 2.3-2003 and operate Canada(and U.S.A.)-This furnace is permitted to be vented into with a non-positive vent static pressure to minimize the potential a clay tile-lined masonry chimney that is exposed to the outdoors for vent gas leakage. Category I furnaces operate with a flue loss below the roof line,provided: not less than 17 percent to minimize the potential for condensation 1. Vent connector is Type-B double-wall, and in the venting system. These furnaces are approved for common 2. This furnace is common vented with at least 1 draft hood- venting and multistory venting with other fan assisted or draft equipped appliance, and hood equipped appliances in accordance with the NFCG or the NSCNGPIC, the local building codes and furnace and vent 3. The combined appliance input rating is less than the maximum capacity given in Table A, and manufacturers' instructions. 23 4. The input rating of each space heating appliance is greater Table B—Minimum Alowable Input Rating of than the minimum input rating given in Table B for the local 99% Winter Design Temperature. Chimneys having internal Space-Heating Appliance in areas greater than 38 square inches require furnace input Thousands of BTU per Hour ratings greater than the input ratings of these furnaces. See INTERNAL AREA OF CHIMNEY footnote at bottom of Table B, and VENT (SQ. IN.) HEIGHT(FT) 5. The authority having jurisdiction approves. 12 I 19 1 28 38 Local 99%Winter Design If all of these conditions cannot be met, an alternative venting Temperature: 17 to 26 degrees F* design shall be used, such as the listed chimney adapter kit with 6 0 55 99 141 these furnaces listed for use with the kit, a listed chimney-lining u- 8 52 74 111 154 system, or a Type-B common vent. N 10 NR 90 125 169 Inspections before the sale and at the time of installation will � 15 NR NR 167 212 determine the acceptability of the chimney or the need for repair 20 NR NR 212 258 and/or(re)lining.Refer to Fig.26 to perform a chimney inspection. 30 NR NR NR 362 If the inspection of a previously used tile-lined chimney: Local 99%Winter Design Temperature:5 to 16 degrees F* a. Shows signs of vent gas condensation,the chimney should 6 NR 78 121 166 be relined in accordance with local codes and the authority u 8 NR 94 135 182 having jurisdiction. The chimney should be relined with a Io 10 NR 111 149 198 listed metal liner,Type-B vent,or a listed chimney adapter $ 15 NR NR 193 247 kit shall be used to reduce condensation. If a condensate 0 20 NR NR NR 293 drain is required by local code,refer to the NFGC,Section 30 NR NR NR 377 10.9 for additional information on condensate drains. Local 99%Winter Design b. Indicates the chimney exceeds the maximum permissible Temperature: -10 to 4 degrees F* 6 NR NR 145 196 size in the tables,the chimney should be rebuilt or relined LL 8 NR NR 159 213 to conform to the requirements of the equipment being 4 10 NR NR 175 231 installed and the authority having jurisdiction. w 0 15 NR NR NR 283 A chimney without a clay tile liner, which is otherwise in good 20 NR NR NR 333 condition, shall be rebuilt to conform to ANSI/NFPA 211 or be 30 NR NR NR NR lined with a UL listed(ULC listed in Canada)metal liner or UL Local 99%Winter Design listed Type-B vent. Relining with a listed metal liner or Type-B Temperature:-11 degrees F or lower* vent is considered to be a vent-in-a-chase. Not recommended for any vent configuration If a metal liner or Type-B vent is used to line a chimney,no other o appliance shall be vented into the annular space between the 0 chimney and the metal liner. ;L Exterior Masonry Chimney FAN + NAT Installations with T e-B Double-Wall Vent *The 99%Winter Design Dry-Bulb(db)temperatures are found in the 1993 yp ASHRAE Fundamentals Handbook,Chapter 24,Table 1 (United States)and Connectors©NFPA&AGA 2(Canada),or use the 99.6%heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook,Climatic Design Information chap- Table A—Combined Appliance Maximum Input ter,Table 1A(United States)and 2A(Canada). Rating in Thousands of BTU per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT(FT) (SQ. IN.) tioning Contractors of America(Manual J); American Society of 12 19 28 38 Heating, Refrigerating, and Air-Conditioning Engineers; or other 6 74 119 178 257 approved engineering methods. Excessive oversizing of the fur- 8 80 130 193 279 nace could cause the furnace and/or vent to fail prematurely. 10 84 138 207 299 When a metal vent or metal liner is used,the vent must be in good 15 NR 152 233 334 condition and be installed in accordance with the vent manufac- 20 NR NR 250 368 turer's instructions. 30 NR NR I NR 404 To prevent condensation in the furnace and vent system, the following precautions must be observed: APPLIANCE APPLICATION REQUIREMENTS 1. The return-air temperature must be at least 60°F db except for Appliance operation has a significant impact on the performance brief periods of time during warm-up from setback at no lower of the venting system. If the appliances are sized, installed, than 55°F db or during initial start-up from a standby adjusted, and operated properly, the venting system and/or the condition. appliances should not suffer from condensation and corrosion.The 2. Adjust the gas input rate per the installation instructions.Low venting system and all appliances shall be installed in accordance gas input rate causes low vent gas temperatures, causing with applicable listings, standards, and codes. condensation and corrosion in the furnace and/or venting The furnace should be sized to provide 100 percent of the design system.Derating is permitted only for altitudes above 2000 ft. heating load requirement plus any margin that occurs because of 3. Adjust the air temperature rise to the midpoint of the rise range furnace model size capacity increments. Heating load estimates or slightly above.Low air temperature rise can cause low vent can be made using approved methods available from Air Condi- gas temperature and potential for condensation problems. 24 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces,Vents, and Solid Fuel Burning Appliances in the U.S.A.or to the Canadian installation Code CSA-B149.1 in Canada. Crown condition: Yes Rebuild Missing mortar crown. or brick? No Is chimney No property lined with clay tile liner? Yes Is Repair liner and top No liner or top seal Reline seal in good or reline chimney as 01 condition? necessary. Yes Repair Debris in cleanout? Yes Mortar Yes Remove mortar Mortar,tile,metal vent, or tile and tile debris 0 fuel oil residue? debris? No Remove metal vent No or liner. Clay tile misalignment, Yes missing sections, gaps? Consult Part B of Not Suitable No chimney adapter venting No instructions for application Is chimney suitability. Condensate lined with properly Suitable Line chimney with property drainage at bottom sized,listed liner or sized,listed flexible metal of chimney? Yes liner orType-B vent per Type-B vent? NFGC or NSCNGPIC Vent Yes Install chimney Sizing Tables and liner or adapter per vent manufacturer's No Yes instructions. Not Suitable Installation instructions. Consult Chimney Is chimney No Part C of exposed to to be dedicated to chimney adapter venting Suitable outdoors below a single instructions for roof line? Yes furnace? application suitability No Install chimney adapter per instructions. Chimney is acceptable for use. Fig. 26—Chimney Inspection Chart A03206 25 4. Set the thermostat heat anticipator or cycle rate to reduce short III Jill III iiiiiiiiiiii� cycling. Air for combustion must not be contaminated by halogen com- CUT HAZARD pounds which include chlorides,fluorides,bromides,and iodides. Failure to follow this caution may result in personal injury. These compounds are found in many common home products such Sheet metal parts may have sharp edges or burrs.Use care and as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, wear appropriate protective clothing, safety glasses, and salt, and air freshener, and can cause corrosion of furnaces and gloves when handling parts and servicing furnaces. vents. Avoid using such products in the combustion-air supply. 3. Orient the door to determine the correct location of the door Furnace use during construction of the building could cause the cutout to be removed. furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion. 4. Use aviation-type tin snips to remove the correct U-shaped cut-out in door. Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not --->NOTE: If this furnace is equipped with knockouts in the door for use vent dampers on appliances common vented with this furnace. the vent, a number of techniques can be used to remove these ADDITIONAL VENTING REQUIREMENTS knockouts as seen in Fig. 27 through 31. The knockout in the bottom of the door is unique due to its flanging and is not easily A 4"round vent elbow is supplied with the furnace.A 5-inch or 6- removed by first cutting the two tie points at the edge of the door, inch vent connector may be required for some model furnaces.A using aviation-type tin snips. (See Fig. 27.) A sharp blow to the field-supplied 4-inch-to-5-inch or 4-inch-to-6-inch sheet metal rounded end of the knockout(See Fig.28.)will separate more tie increaser fitting is required when 5-inch or 6-inch vent connector points and allow the knockout to be pulled loose. (See Fig. 29.) is used. See Fig. 32-44 Venting Orientation for approved vent Remove all burrs and sharp edges. configurations. For the knockouts in the other locations on the door (top and NOTE: Vent connector length for connector sizing starts at sides),tin snips can also be used along the door edges; however, furnace vent elbow. The 4-inch vent elbow is shipped for upflow the preferred method is to use a hammer and screwdriver to strike configuration and may be rotated for other positions. Remove the a sharp blow(See Fig. 30.) directly to the knockout tie points or 3 screws that secure vent elbow to furnace, rotate furnace vent use a hammer in the upper left corner of the desired knockout.(See elbow to position desired,re-install screws. The factory-supplied Fig. 31.)Remove all burrs and sharp edges. vent elbow does NOT count as part of the number of vent An accessory Vent Guard Kit,KGAVG0l0lDFG is REQUIRED connector elbows. for downflow applications for use where the vent exits through the The vent connector can exit the door through one of 5 locations on lower portion of the furnace casing door.Refer to the Vent Guard the door. Kit Instructions for complete details. 1. Attach the single wall vent connector to the furnace vent The horizontal portion of the venting system shall slope upwards elbow,and fasten the vent connector to the vent elbow with at not less than 1/4-in.per linear ft(21mm/m)from the furnace to the least two field-supplied, corrosion-resistant, sheet metal vent and shall be rigidly supported every 5 ft or less with metal screws located 180' apart. hangers or straps to ensure there is no movement after installation. NOTE: An accessory flue extension KGAFE0112UPH is avail- SIDEWALL VENTING able to extend from the furnace elbow to outside the furnace This furnace is not approved for direct sidewall horizontal venting. casing. If flue extension is used, fasten the flue extension to the In the U.S.:Per section 10.3.4 of the NFGC,any listed mechanical vent elbow with at least two field-supplied, corrosion-resistant, venter may be used, when approved by the authority having sheet metal screws located 1800 apart.Fasten the vent connector to jurisdiction. the flue extension with at least two field-supplied, corrosion- In Canada: Per section 7.24.2 of the NSCNGPIC, any listed resistant sheet metal screws located 180' apart. venters may be used, when approved by the authority having 2. Vent the furnace with the appropriate connector as shown in jurisdiction. Fig. 32-44. Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer's installation re- quirements for venting and termination included with the listed mechanical venter. A04127 Fig. 27—Using Tin Snips to Cut Tie Points 26 01 O \ C A04131 0 Fig. 31—Remove Knockout with Hammer 0 START-UP, ADJUSTMENT, AND SAFETY CHECK Step 1—General A04128 ---> Fig. 28—Rounded End of Knockout ! FIRE HAZARD Failure to follow this warning could result in a fire and lead to property damage,personal injury, or death. This furnace is equipped with manual reset limit switches in the gas control area.The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area.DO NOT bypass the switches. Correct inadequate combustion air supply problem and reset the switches. CUT HAZARD Failure to follow this caution may result in personal injury. A04129 Sheet metal parts may have sharp edges or burrs.Use care and Fig. 29—Knockout Pulled Loose wear appropriate protective clothing, safety glasses, and gloves when handling parts and servicing furnaces. \ 1. Maintain 115-v wiring and ground. Improper polarity will \ result in rapid flashing LED and no furnace operation. 2. Make thermostat wire connections at the 24-v terminal block on the furance control. Failure to make proper connections �O will result in improper operation. (See Fig. 25.) 3. Gas supply pressure to the furnace must be greater than 4.5-in. we(0.16 psig)but not exceed 14-in. we (0.5 psig). 4. Check all manual-reset switches for continuity. 5. Install blower compartment door. Door must be in place to operate furnace. 6. Replace outer door. Step 2—Start-Up Procedures A04130 Fig. 30—Hammer and Screwdriver Used for ! Knockout FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause property damage, personal injury, or death. Never purge a gas line into a combustion chamber.Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. 1. Purge gas lines after all connections have been made. 2. Check gas lines for leaks. 27 LULLLL 11L1L1LL O O O •O• SEE NOTES:1,2,4,7,8,9 SEE NOTES:1,2,4,5,7,8,9 on the page following on the page following these figures these figures A03208 A03211 Fig. 32—Upflow Application-Vent Elbow Up Fig. 35—Downflow Application-Vent Elbow Up lllllJ!I'!I e e e I I 1 I Ili — 1 I I II II C1 I / II F3 I I .p. I I O II e e � I a m I I I O I I I I I I SEE NOTES:1,2,4,5,6,7,8,9,10 SEE NOTES:1,2,3,4,7,8,9 on the page following these figures on the pages following these figures Fig. 36—DownflowApplication- th A03209 Vent Elbow Left then Up A03207 Fig. 33—Upflow Application-Vent Elbow Right I `� I II II II C7 I II II II P1 I O O o• o• SEE NOTES:1,2,3,4,5,7,8,9 SEE NOTES:1,2,3.........9 on the page following on the page following these figures A03210 these figures. A03212 Fig. 34—Downflow Application- Fig. 37—Downflow Application- Vent Elbow Up then Left Vent Elbow Up then Right 28 I11 W W 0 p O SEE NOTES:1,2,4,7,8,9 on the page following these figures SEE NOTES:1,2,4,5,7,8,9 on the page A03213 following these figures Fig. 38—Horizontal Left Application-Vent Elbow Left Fig. 40—Horizontal Left Application-Vent Elbows uOd3gp WWW o o SEE NOTES:1,2,4,5,7,8,9 on the page SEE NOTES:1,2,4,5,7,8,9 on the page A03214 following these figures A03216 following these figures Fig. 39—Horizontal Left Application- Fig.41—Horizontal Left Application-Vent Elbow Right Vent Elbow Right then Up ULLL O II F Ii III II II i 0, I° SEE NOTES:1,2,4,7,8,9 on the page A03218 following these figures SEE NOTES:1,2,4,5,7,8,9 on the page Fig. 42—Horizontal Right Application- following these figures A03219 Vent Elbow Right Fig. 43—Horizontal Right Application- Vent Elbow Left then Up 29 o° --- o Ed II � I III 00 SEE NOTES:1,2,4,5,7,8,9 A02068 Fig. 44—Horizontal Right Application-Vent Elbow Left Venting Notes for Figures 32-44 1. For common vent,vent connector sizing and vent material: United States--use the NFGC Canada--use the NSCNGPIC 2. Immediately increase to 5-inch or 6-inch vent connector outside furnace casing when 5-inch vent connector is required,refer to Note 1 above. 3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when KGAVG0101DFG, Downflow Vent Guard Kit, is used in the downflow position. 4. Type-B vent where required,refer to Note 1 above. 5. Four-inch single-wall(26 ga.min.)vent must be used inside furnace casing and when the KGAVG010lDFG Downflow Vent Guard Kit is used external to the furnace. 6. Accessory Downflow Vent Guard Kit, KGAVG0l0IDFG required in downflow installations with lower vent configuration. 7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC or KGACA02015FC, for sizing and complete application details. 8. Secure vent connector to furnace elbow with(2) corrosion-resistant sheet metal screws, spaced approximately 180' apart. 9. Secure all other single wall vent connector joints with(3) corrosion resistant screws spaced approximately 120' apart. Secure Type-B vent connectors per vent connector manufacturer's recommendations. 10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 36.) Caution!! For the following applications, use the minimum vertical vent heights as specified below. For all other applications, follow exclusively the National Fuel Gas Code. FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR) MINIMUM MINIMUM VERTICAL VENT HEIGHT(FT)** VENT DIAMETER(IN.)* Vent elbow left,then up 154,000 Downflow Fig.36 132,000 5 12 110,000(036/-12 only) Vent elbow right, 154,000 Horizontal Left then up 132,000 5 7 Fig.39 Horizontal Left Vent Elbow up 154,000 5 7 Fig.40 132,000 Horizontal Left Vent elbow right 154,000 5 7 Fig.41 Downflow Vent elbow up then left 110,000 5 10 Fig.34 (036/-12 only) Downflow Vent elbow up,then right 110,000 5 10 Fig.37 (036/-12 only) NOTE:All vent configurations must also meet National Fuel Gas Code venting requirements NFGC *4 in.inside casing or vent guard **Including 4 in.vent section(s) 30 1. Determine the correct gas input rate. In the U.S.A.: ELECTRICAL SHOCK HAZARD The input rating for altitudes above 2,000 ft.must be reduced Failure to follow this warning could result in electrical shock, by 4 percent for each 1,000 ft. above sea level. For installa- personal injury, or death. tions below 2000 ft., refer to the unit rating plate. For Blower access door switch opens 115-v power to control.No installations above 2000 ft., multiply the input on the rating component operation can occur unless switch is closed. plate by the de-rate multiplier in Table 8 for the correct input Caution must be taken when manually closing this switch for rate. service purposes. In Canada: The input rating must be derated by 10 percent for altitudes of � 3. To Begin Component Self-Test:Remove blower access door.Disconnect the thermostat R lead 2,000 ft. to 4,500 ft. above sea level by an authorized GasConversion Station or Dealer.To determine correct input rate from furnace control board. Manually close the blower door for altitude, see example 1 and use 0.90 as derate multiplier switch.Short(jumper)the CoM-24V terminal on control to the factor. TEST/TWIN 3/16-inch quick connect terminal on control until LED goes out (approximately 2 sec). Gas valve and EXAMPLE II: humidifier will not be turned on. (See Fig. 24.) 88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. NOTE: The furnace control allows all components,except the gas Derate - Furnace Input Rate valve, to be run for short period of time. This feature helps Furnace Input Rate X Multiplier - at Installation diagnose a system problem in case of a component failure. at Sea Level Factor Altitude Component test feature will not operate if any thermostat signal is 88,000 X 0.90 = 79,200 present at the control. 2. Determine the correct orifice and manifold pressure adjust- ment.There are two different orifice and manifold adjustment Component test sequence is as follows: tables.All models in all positions,except Low NOx models in Refer to service label attached to furnace or see Fig. 49. downflow or horizontal positions, use Table 12 (22,000 a. LED will display previous status code 4 times. BTUH/Burner) b. Inducer motor starts and continues to run until Step f of Low NOx models in the downflow or horizontal positions component test sequence. must use Table 13(21,000 BTUH/Bumer).See input listed on rating plate. c. Hot surface igniter is energized for 15 sec., then off. a. Obtain average yearly gas heat value(at installed altitude) d. Blower motor operates on HEAT speed for 10 sec. from local gas supplier. e. Blower motor operates on COOL speed for 10 sec. b. Obtain average yearly gas specific gravity from local gas f. Inducer motor stops. supplier. g. Reconnect R lead to furnace control board,release blower c. Find installation altitude in Table 12 or 13. door switch and re-install blower door. d. Find closest natural gas heat value and specific gravity in 4. Operate furnace per instruction on door. Table 12 or 13. 5. Verify furnace shut down by lowering thermostat setting e. Follow heat value and specific gravity lines to point of below room temperature. intersection to find orifice size and manifold pressure 6. Verify furnace restarts by raising thermostat setting above settings for proper operation. room temperature. £ Check and verify burner orifice size in furnace. NEVER Step 3—Adjustments ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY. A WARNING g. Replace orifice with correct size if required by Table 12 or FIRE HAZARD 13. Use only factory-supplied orifices. See EXAMPLE 2. Failure to follow this warning could result in reduced furnace life,property damage, injury and death. For 22,000 BTUH burner applications use Table 12 DO NOT bottom out gas valve regulator adjusting screw. EXAMPLE 2: (0-2000 ft altitude) This can result in unregulated manifold pressure and result in Heating value= 1000 Btu/cu ft excess overfire and heat exchanger failures. Specific gravity=0.62 Therefore: Orifice No. 43* A CAUTION Manifold pressure: 3.7-in. we *Furnace is shipped with No. 43 orifices. In this example FURNACE DAMAGE HAZARD all main burner orifices are the correct size and do not need Failure to follow this caution may result in reduced furnace to be changed to obtain proper input rate. life. DO NOT redrill orifices. Improper drilling (burrs, out-of- 3. Adjust manifold pressure to obtain correct input rate. round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame a. Turn gas valve ON/OFF switch to OFF. impingement of heat exchangers, causing failures. (See Fig. b. Remove manifold pressure tap plug from gas valve. (See 47) Fig. 46.) c. Connect a water column manometer or similar device to Furnace gas input rate on rating plate is for installations at altitudes manifold pressure tap. UP to 2000 ft. Furnace input rate must be within f2 percent of furnace rating plate input. d. Turn gas valve ON/OFF switch to ON. -4 e. Manually close blower door switch. 31 9'AgM LOL-699LZE iv?u 13N Z T W r- p Li W w p Q Q ❑ �uZ (.�Z LL1 l� WE Z F a ¢a z g m d a e 00 m o a Hd C3�W LL o f -� o c g LU 5 E Es �'8 0��ya�mT0'aLa��mU$$'�$' �a9ao wdbdafoC80iS o.9O any�UNEJJ1 yt�>a°tm�mC`go?ii 00 C. LON�Y-mmN2 16 -C S LO .'oy_acni CD(Eoa p 3aN78 Ftm S10 4-M smc E w9- - E -g Z O - �3 wNC .mE oisa 2 QLo a ` y EE g Z 2 F � PRINTED CIRCIUT BOAR g Ni ri�,i�6 r.6 oi o -------,�9 w� ..0 OKW ❑ �K V� w K z W Z L fa, ` � wzJIaz^o z o w -- --- tnpCi zd, Z V Vg mxiI i 8pOpZe QazFV Imzz ,�13J.- �p,. pz;ozoz-'= <; � apw z 0 m U � I�i I I �zA opoUN� N � � w❑ ow I-�-- -r-' ¢z mz3 w ~ z_ z_ N z I I I =-�Va00w o z z c� c� z = c� "' LL p F¢r¢K UxWW ❑ m 3 3 Z Z pZ ~�LL' �FFz zO o Y Z WF ¢ ° 00 ❑Uz V W W OC,ISHV LL LL ZLL T� m�N.hmmz , e��l m LL' m U C W K H I I m V D U u� fww� U ci Z m N U¢ N W Z \ zFL C9 w u~i¢�U z� X ai¢? I ` O �ww L 131JN210❑ a N a (7 7d wgw,Zu ¢ H��2ZK O❑FK co O z a i^zm.Q�¢W .UR.¢ ZwNU �_OZF xF2im p=F O L wu}OmW 0 m Wzczz7 m= 321 F. O-Z UFzza�jwys z�W wN� z0� qYq FO nis G❑LLz1 UwmWd •8i• •.n• • F' ]x 1 •mN O•p •S ' • ' NVa' m O O m=wo.gm3m3��m>�Ugmga❑iww w¢w`mo� gLLw 0j»LL jLL Ozm ca7 wu'w�VZOZo�z.Y oHp w�w ���N yyo Ow❑�❑ umoT w N roj z LOl68L9568Z1 O¢ F 2. zy�zr0 00oz mo--0>¢ —RWzwwm WLL❑ zV m 0. UW LLxpz 00�> U p O2m ZzoK� O�w z O ❑ 0 zz zwOzm z-w ZV J � » 0 o0 va» wW0rp0 uiw WzmZm U w<m ?Z --0 J2� 0 B06 C 0v 3 y zvanA mF- V y n z»mm¢aa8#3iON PRINTED CIRCIUT BOARz W U U>0=ix ❑ m� J W C7 W 01 32 Table 8—Altitude Derate Multipler for U.S.A. SEALCAPOR ALTITUDE PERCENT DERATE MULTIPLIER REGULATOR (FT) OF DERATE FACTOR` ADJUSTMENT 0-2000 0 1.00 SCREW ON/OFF SWITCH 2001-3000 8-12 0.90 3001-4000 12-16 0.86 4001-5000 16-20 0.82 p REGULATOR SPRING 5001-6000 20-24 0.78 1/2"NPT INLET 6001-7000 24-28 0.74 GAS PRESSURE 7001-8000 28-32 0.70 REGULATOR INLET ADJUSTMENT 8001-9000 32-36 0.66 PRESSURETAP 9001-10,000 36-40 0.62 *Derate multiplier factors are based on midpoint altitude for altitude range. MANIFOLD PRESSURE TAP f. Set thermostat to call for heat. vr'NPT OUTLET A04166 g. Jumper R and W thermostat connections on furnace control board to start furnace. Fig. 46—Gas Control Valve h. Remove regulator seal cap and turn regulator adjusting radiant heat from heat exchangers. Radiant heat affects screw counterclockwise (out) to decrease input rate of temperature rise readings. This practice is particularly clockwise (in)to increase input rate. important with straight-run ducts. i. Install regulator seal cap. b. When thermometer readings stabilize, subtract return-air j. Leave manometer or similar device connected and proceed temperature from supply-air temperature to determine air to Step 4. temperature rise. NOTE: DO NOT set manifold pressure less than 3.2-in we or NOTE: Blower access door must be installed for proper tempera- more than 3.8-in. we for natural gas at sea level. If manifold ture rise measurement. pressure is outside this range,change main burner orifices or refer NOTE: If the temperature rise is outside this range, first check: to Table 12 or 13. 1.) Gas input for heating operation. NOTE: If orifice hole appears damaged or it is suspected to have 2.)Derate for altitude if applicable. been redrilled, check orifice hole with a numbered drill bit of 3.)Return and supply ducts for excessive restrictions causing static correct size. Never redrill an orifice. A burr-free and squarely pressures greater than 0.50-in. wc. aligned orifice hole is essential for proper flame characteristics. 4.)Dirty filter. 4. Verify natural gas input rate by clocking meter. NOTE: Gas valve regulator adjustment cap must be in place for proper input to be clocked. ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury a. Turn off all other gas appliances and pilots served by the or death. meter. Disconnect I I5-v electrical power before changing speed tap. b. Run furnace for 3 minutes in heating operation. c. Adjust air temperature rise by adjusting blower speed. c. Measure time(in sec)for gas meter to complete 1 revolu- Increase blower speed to reduce temperature rise.Decrease tion and note reading.The 2 or 5 cubic feet dial provides a blower speed to increase temperature rise. more accurate measurement of gas flow. d. Refer to Table 10 for cubic ft of gas per hr. e. Multiply gas rate (cu ft/hr)by heating value(Btu/cu ft)to obtain input. If clocked rate does not match required input from Step 1,increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through a until correct input is achieved. Reinstall regulator seal cap on gas valve. 5. Set temperature rise. (S The furnace must operate within the temperature rise ranges specified on the furnace rating plate.Do not exceed tempera- ture rise range specified on unit rating plate. Determine the temperature rise as follows: BURNER ORIFICE NOTE: Blower access door must be installed when taking tem- perature rise reading.Leaving blower access door off will result in incorrect temperature measurements. A93059 a. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see Fig. 47—Orifice Hole 33 Table 9—Speed Selection THERMOSTAT SUBBASE TERMINALS WITH COLOR SPEED AS SHIPPED THERMOSTAT REMOVED (ANITICIPATOR,CLOCK, ETC., White Common BLW MUST BE OUT OF CIRCUIT.) Black High COOL HOOK-AROUND Yellowt Med-High SPARE AMMETER Blue* Med-Low SPARE Red* Low HEAT *1/5 HP motor models:BLUE to HEAT,RED to SPARE. ® Y G t Not available on 1/5 HP motors. NOTE:Continuous blower is the HEAT speed. d. Turn thermostat down below room temperature and re- move blower access door. e. To change motor speed selection for heating, remove blower motor lead from control HEAT terminal (See Fig. 24.)Select desired blower motor speed lead from one of the 10 TURNS other terminals and relocate it to the HEAT terminal (See Table 9 for lead color identification). Reconnect original FROM UNIT 24 V lead to SPARE terminal. CONTROL TERMINALS f. Repeat steps a through e. EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT g. When correct input rate and temperature rise is achieved, 10 TURNS AROUND JAWS ANTICIPATOR SETTING turn gas valve ON/OFF switch to OFF. A96316 h. Remove manometer or similar device from gas valve. Fig. 48—Amp Draw Check With Ammeter i. Reinstall manifold pressure tap plug in gas valve. ! furnace control board. (See Fig. 24.) —4 FIRE HAZARD To change the blower off delay setting,move the jumper from Leaking gas could be ignited and cause fire, explosion, one set of pins on the control to the pins used for the selected personal injury,property damage or death. blower off delay. Factory off delay setting is 120 sec. Reinstall manifold pressure tap plug in gas valve to prevent 8. Set airflow CFM for cooling gas leak. Select the desired blower motor speed lead for cooling airflow. See Table 5-Air Delivery-CFM (With Filter). See j. Reinstall blower access door if removed. Table 9 for lead color identification. k. Turn gas valve ON/OFF switch to ON. Step 4—Check Safety Controls III lI The flame sensor,gas valve,and pressure switch were all checked in the Start-up procedure section as part of normal operation. —4 FURNACE OVERHEATING HAZARD 1. Check Main Limit Switch(es) Failure to properly set temperature rise may cause excessive This control shuts off combustion control system and ener- furnace temperatures and shorten furnace life. gizes air-circulating blower motor, if furnace overheats. By Recheck temperature rise. It must be within limits specified using this method to check limit control,it can be established on the rating plate. Recommended operation is at the mid- point of rise range or slightly above. that limit is functioning properly and will operate if there is a restricted duct system or motor failure. If limit control does 6. Set thermostat heat anticipator. not function during this test, cause must be determined and a. Mechanical thermostat—Set thermostat heat anticipator to corrected. match the amp draw of the electrical components in the a. Run furnace for at least 5 minutes. R-W circuit.Accurate amp draw readings can be obtained b. Gradually block off return air with a piece of cardboard or at the wires normally connected to thermostat subbase sheet metal until the limit trips. terminals, R and W. The thermostat anticipator should c. Unblock return air to cause normal circulation. NOT be in the circuit while measuring current. d. Burners will re-light when furnace cools down. (1.) Remove thermostat from subbase or from wall. 2. Check draft safeguard switch. (2.) Connect an amp meter as shown in Fig.48 across the The purpose of this control is to cause the safe shutdown of the R and W terminals or R and W wires at wall. furnace during certain blocked vent conditions. (3.) Record amp draw across terminals when furnace is in a. Verify vent pipe is cool to the touch. heating and after blower starts. b. Disconnect power to furnace and remove vent connector (4.) Set heat anticapator on thermostat per thermostat from furnace vent elbow. instructions and install on subbase or wall. c. Restore power to furnace and set room thermostat above b. Electronic thermostat: Set cycle rate for 4 cycles per hr. room temperature. 7. Adjust blower off delay d. After normal start-up, allow furnace to operate for 2 The blower off delay has 4 adjustable settings from 90 sec to minutes, then block vent elbow in furnace 80 percent of 180 sec. The blower off delay jumpers are located on the vent area with a piece of flat sheet metal. 34 Table 10—GAS RATE (CU FT/HR) status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately. SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL e. Determine reason pressure switch did not function properly FOR 1 1 2 5 FOR 1 1 2 5 REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft and correct condition. 10 360 720 1800 50 72 144 360 f. Turn off 115-v power to furnace. 11 327 655 1636 51 71 141 355 g. Reconnect inducer motor wires, replace outer door, and 12 300 600 1500 52 69 138 346 turn on 115-v power. 13 277 665 1385 53 68 136 340 14 257 514 1286 54 67 133 333 h. Blower will run for 90 sec before beginning the call for 15 240 480 1200 55 65 131 327 heat again. 16 225 450 1125 56 64 129 321 i. Furnace should ignite normally. 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 Step 5—Checklist 19 189 379 947 59 61 122 305 1. Put away tools and instruments. Clean up debris. 20 180 360 900 60 60 120 300 2. Check that blower OFF-DELAY time is selected as desired. 21 171 3 8 62 58 11 290 3. Verify that blower and burner access doors are properly 22 164 32727 818 18 64 56 112 281 installed. 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 4. Cycle test furnace with room thermostat. 25 144 288 720 70 51 103 257 5. Check operation of accessories per manufacturer's instruc- 26 138 277 692 72 50 100 250 tions. 27 133 267 667 74 48 97 243 6. Review User's Guide with owner. 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 7. Attach literature packet to furnace. 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 SERVICE AND MAINTENANCE PROCEDURES 32 113 225 1 563 84 43 86 214 33 109 218 545 86 1 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 FIRE,INJURY,OR DEATH HAZARD 36 100 200 500 92 39 78 1 196 Failure to follow this warning could result in possible damage 37 97 195 486 94 38 76 192 to this equipment, serious personal injury, or death. 38 95 189 474 96 38 75 188 The ability to properly perform maintenance on this equip- 39 92 185 1 462 98 37 74 184 ment requires certain knowledge,mechanical skills,tools,and 40 90 180 450 100 36 72 180 equipment. If you do not possess these, do not attempt to 41 88 176 439 102 35 71 178 perform any maintenance on this equipment other than those 42 86 172 429 104 35 69 1 173 1 procedures recommended in the User's Manual. 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 1 400 110 33 65 164 46 78 157 391 112 32 64 161 —� ELECTRICAL SHOCK,FIRE, OR EXPLOSION 47 76 153 383 116 31 62 155 HAZARD 48 75 150 375 120 30 60 150 Failure to follow this warning could result in personal injury, 49 1 73 147 367 1 1 death, or property damage. Before servicing, disconnect all electrical power to furnace. e. Furnace should cycle off within 2 minutes.If gas does not Verify proper operation after servicing. shut off within 2 minutes,determine reason draft safeguard switch did not function properly and correct condition. t • f. Remove blockage from furnace vent elbow. ELECTRICAL OPERATION HAZARD g. Switch will auto-reset when it cools. Failure to follow this caution may result in improper furnace h. Re-install vent connector. operation or failure of furnace. NOTE: Should switch remain open longer than 3 minutes, Label all wires prior to disconnection when servicing con- furnace control board will lockout the furnace for 3 hours.To reset trols. Wiring errors can cause improper and dangerous furnace control board,turn thermostat below room temperature or operation. from HEAT to OFF and turn 115v power OFF,then back ON. Step 1—Introduction 3. Check Pressure Switch This control proves operation of the draft inducer blower. GENERAL a. Turn off 115-v power to furnace. These instructions are written as if the furnace is installed in an b. Disconnect inducer motor lead wires from wire harness. upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the c. Turn on 115-v power to furnace. furnace, and conditioned air is discharged upward. Since this d. Set thermostat to"call for heat"and wait 1 minute. When furnace can be installed in any of the 4 positions shown in Fig.4, pressure switch is functioning properly,hot surface igniter you must revise your orientation to component location accord- should NOT glow and control diagnostic light flashes a ingly. 35 SERVICE If status code recall is needed,briefly repave then reconnect one main limit wire to display stored status code.On RED LED boards do not repave power or blower door before initiating status code recall.After status code recall is completed component test Wil occur. LED CODE STATUS CONTINUOUS OFF-Check for 115VAC at L1 and L2,and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON-Control has 24VAC power. RAPID FLASHING -Line voltage(115VAC)polarity reversed.If twinned,refer to twinning kit instructions. EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG RASHES. 11 NO PREVIOUS CODE-Stored status code is erased automatically after 72 hours.On 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED-If open longer than five minutes, RED LED boards stored status codes can also be erased when power inducer shuts off for 15 minutes before retry. Check for: -Excessive wind (115 VAC or 24 VAC)to control is interrupted. -Proper vent sizing -Defective inducer motor 12 BLOWER ON AFTER POWER UP(115 VAC or 24 VAC) -Blower runs for 90 seconds, -Low inducer voltage(115VAC) -Defective pressure switch if unit is powered up during a call for heat(R-W closed)or R-W opens during blower -Inadequate combustion air supply -Disconnected or obstructed pressure tubing on-delay. -Low inlet gas pressure(if LGPS used) -Restricted vent 13 LIMIT CIRCUIT LOCKOUT-Lockout occurs if the limit,draft safeguard,flame rollout,or If it opens during blower on-delay period,blower will come on for the selected blower blocked vent switch(if used)is open longer than 3 minutes. off-delay. -Control will auto reset after three hours. -Refer to#33. 33 LIMIT CIRCUIT FAULT-Indicates a limit,draft safeguard,Flame rollout,or blocked vent 14 IGNITION LOCKOUT-Control will auto-reset after three hours.Refer to#34. switch(!fused)is open. Blower will run for 4 minutes or until open switch remakes 21 GAS HEATING LOCKOUT-Control will NOT auto reset. whichever is longer. If open longer than 3 minutes,code changes to lockout#13. Check for:-Mis-wired gas valve -Defective control(valve relay) If open less than 3 minutes status code#33 continues to flash until blower shuts off. 22 ABNORMAL FLAME-PROVING SIGNAL-Flame is proved while gas valve is de- Flame rollout switch and BVSS require manual reset. Check for: -Restricted vent energized. Inducer will run until fault is cleared. Check for: -Leaky gas valve -Proper vent sizing -Loose blower wheel. -Excessive wind -Stuck-open gas valve -Dirty filter or restricted duct system. 23 PRESSURE SWITCH DID NOT OPEN Check for: -Defective blower motor or capacitor. -Defective switch or connections. -Obstructed pressure tubing. -Pressure switch stuck closed. -Inadequate combustion air supply(Flame Roll-out Switch open). 24 SECONDARY VOLTAGE FUSE IS OPEN Check for: 34 IGNITION PROVING FAILURE-Control will try three more times before lockout#14 -Short circuit in secondary voltage(24VAC)wiring. occurs.If flame signal lost during blower on-delay period,blower will come on for the selected blower off-delay. Check for: -Flame sensor must not be grounded COMPONENT TEST Oxide buildup on Flame sensor(clean with fine steel wool). To initiate the component test sequence,shut OFF the room thermostat or disconnect the"R" -Proper Flame sense microamps(.5 microamps D.C.min.,4.0-6.0 nominal). thermostat lead.Brieflyshort the TESTITWIN terminal to the"Com 24V"terminal.Status LED -Gas valve defective or gas valve turned off -Manual valve shut-off -Defective Hot Surface Ignitor -Control ground continuity will flash code and then turn ON the inducer motor.The inducer motor will run for the entire -Low inlet gas pressure -Inadequate flame carryover or rough ignition component test.The hot surface ignitor,blower motor fan speed(on AMBER LED boards -Green/Yellow wire MUST be connected to furnace sheet metal only)blower motor-heat speed,and blower motor-cool speed will be turned ON for 10-15 45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to; seconds each. Gas Valve and Humidifier will not be turned on. -Gas valve relay stuck open -Flame sense circuit failure -Software check error Reset power to clear lockout. Replace control if status code repeats. 327596-101 REV. B A04223 -� Fig. 49—Service Label ELECTRICAL CONTROLS AND WIRING For Controls With a Red LED The stored status codes WILL be erased from the control memory, if 115- or 24-v power is interrupted. ELECTRICAL SHOCK HAZARD 1. To retrieve the status code,proceed with the following: Failure to follow this warning could result in personal injury or death. NOTE: NO thermostat signal may be present at control, and all There may be more than one electrical supply to the furnace. blower-OFF delays must be completed. Check accessories and cooling unit for additional electrical a. Leave 115-v power to furnace turned on. supplies that must be shut off during furnace servicing. b. Remove outer access door. The electrical ground and polarity for 115-v wiring must be c. Look into blower access door sight glass for current LED properly maintained.Refer to Fig.25 for field wiring information status. DO NOT remove blower access door or terminate and to Fig. 45 for furnace wiring information. 115-v power to control or status code will be lost. NOTE: If the polarity is not correct, the STATUS LED on the d. BRIEFLY remove insulated terminal wire from the draft control will flash rapidly and prevent the furnace from heating. safeguard switch (DSS) until LED goes out (1 to 2 sec), The control system also requires an earth ground for proper then reconnect it. operation of the control and flame-sensing electrode. 2. When above items have been completed, the LED flashes The 24-v circuit contains an automotive-type, 3-amp fuse located status code 4 times. Record this status code for further on the control.(See Fig.24.)Any shorts of the 24-v wiring during troubleshooting. installation,service,or maintenance will cause this fuse to blow.If 3. Component self-test will begin. Refer to COMPONENT fuse replacement is required,use ONLY a 3-amp fuse.The control TEST section for complete test sequence. LED will display status code 24 when fuse needs to be replaced. 4. Check LED status. Proper instrumentation is required to service electrical controls. T 5. Refer to the SERVICE label on the front of the blower access The control in this furnace is equipped with a Status Code LED (Light-Emitting Diode) to aid in installation, servicing, and door for more information. troubleshooting.It can be viewed through the sight glass in blower 6. Check LED status. If no previous fault is in history, control access door. The furnace control LED is either ON continuously, will flash status code 11. rapid flashing,or a code composed of 2 digits.The first digit is the 7. If LED status indicates proper operation, RELEASE number of short flashes, the second digit is the number of long BLOWER ACCESS DOOR SWITCH, reattach wire to "R" flashes. terminal on furnace control board,replace blower access door, For an explanation of status codes,refer to service label located on and replace burner access door. blower access door or Fig.49,and the troubleshooting guide which can be obtained from your distributor. The furnace control will store 1 status code for 72 hours. See Fig. 53, a brief Troubleshooting Guide. 36 Table 11—FILTER SIZE INFORMATION (IN.) 4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have FURNACE FILTER QUANTITY AND SIZE FILTER furnace and burner serviced by a qualified service agency. CASING WIDTH Side Return Bottom Return TYPE 5. Inspect the vent pipe/vent system before each heating season 14-1/2 (1) 16 X 25 X 1 (1) 14 X 25 X 1 Cleanable* for rust, corrosion, water leakage, sagging pipes or broken 17-1/2 (1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable* fittings. Have vent pipes/vent system serviced by a qualified 21 (1) 16 X 25 X 1 (1)20 X 25 X 1 Cleanable* service agency. 24** (1) 16 X 25 X 1 (1)24 X 25 X 1 Cleanable* 6. Inspect any accessories attached to the furnace such as a *Recommended **Some furnaces may have 2 filters humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the acces- sory instructions. Step 2—Care and Maintenance CLEANING AND/OR REPLACING AIR FILTER A WARNING The air filter arrangement will vary depending on the application. FIRE OR EXPLOSION HAZARD The filter is exterior to the furnace casing. Failure to follow this warning could result in corrosion of heat NOTE: If the filter has an airflow direction arrow,the arrow must exchanger, fire,personal injury, or death. point towards the blower. Never store anything on,near,or in contact with the furnace, such as: r • 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum CUT HAZARD cleaners, or other cleaning tools. 2. Soap powders, bleaches, waxes or other cleaning com- Failure to follow this caution may result in personal injury. pounds, plastic or plastic containers, gasoline, kerosene, Sheet metal parts may have sharp edges or burrs.Use care and cigarette lighter fluid,dry cleaning fluids,or other volatile wear appropriate protective clothing, safety glasses, and gloves when handling parts and servicing furnaces. fluids. 3. Paint thinners and other painting compounds,paper bags, Media cabinet filter procedures: or other paper products. NOTE: Media cabinet or 1"Filter Rack are accessories and are For continuing high performance and to minimize possible equip- not included from the factory with the standard furnace model. ment failure, periodic maintenance must be performed on this 1. Turn off electrical supply to furnace before removing filter equipment. Consult your local dealer about proper frequency of access door. maintenance and the availability of a maintenance contract. 2. Remove filter cabinet door. A WARNING 3. Slide filter out of cabinet. ELECTRICAL SHOCK HAZARD 4. If equipped with permanent,washable 1-inch filter,clean filter Failure to follow this warning could result in personal injury, by spraying cold tap water through filter in opposite direction death or product damage. of airflow. Rinse filter and let dry. Oiling or coating of the Turn off the gas and electrical supplies to the unit before filter is not recommended. See Table 11 for size information. performing any maintenance or service.Follow the operating 5. If equipped with factory-specified disposable media filter, instructions on the label attached to the furnace. replace only with media filter having the same part number and size. For expandable replacement media, refer to the A WARNING instructions included with the replacement media.If equipped with KGAFR0301ALL external filter rack, See Table It. CARBON MONOXIDE POISONING AND FIRE 6. Slide filter into cabinet. HAZARD Failure to follow this warning could result in fire, personal 7. Replace filter cabinet door. injury, or death. 8. Turn on electrical supply to furnace. Never operate unit without a filter or with filter access door BLOWER MOTOR AND WHEEL removed. r t • ELECTRICAL SHOCK HAZARD CUT HAZARD Failure to follow this warning could result in personal injury Failure to follow this caution may result in personal injury. or death. Sheet metal parts may have sharp edges or burrs.Use care and Blower access door switch opens 115-v power to control.No wear appropriate protective clothing, safety glasses, and component operation can occur unless switch is closed. gloves when handling parts and servicing furnaces. Caution must be taken when manually closing this switch for The minimum maintenance on this furnace is as follows: service purposes. 1. Check and clean air filter each month or more frequently if NOTE: The blower wheel should not be dropped or bent as required. Replace if torn. balance will be affected. 2. Check blower motor and wheel for cleanliness each heating The following steps should be performed by a qualified service and cooling season. Clean as necessary. agency. 3. Check electrical connections for tightness and controls for To ensure long life and high efficiency,clean accumulated dirt and proper operation each heating season. Service as necessary. grease from blower wheel and motor annually. 37 TABLE 12-Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 900 42 3.5 42 3.6 42 3.7 41 3.5 925 42 3.3 42 3.4 42 3.5 42 3.7 R 950 43 3.8 42 3.3 42 3.4 42 3.5 v 0 975 43 3.6 43 3.8 42 3.2 42 3.3 to 1000 43 3.5 43 3.6 43 3.7 43 3.8 2000 1025 43 3.3 43 3.4 43 3.5 43 3.6 Q vi 1050 44 3.6 43 3.2 43 3.4 43 3.5 1075 44 3.4 44 3.5 43 3.2 43 3.3 1100 44 3.3 44 3.4 44 3.5 43 3.2 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62 0.64 (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure U.S.A. 800 42 3.4 42 3.5 42 3.6 42 3.7 Altitudes 825 42 3.2 42 3.3 42 3.4 42 3.5 2001 to 850 43 3.7 43 3.8 42 3.2 42 3.3 v 3000 875 43 3.5 43 3.6 43 3.7 43 3.8 or 900 43 3.3 43 3.4 43 3.5 43 3.6 Canada Altitudes 925 43 3.1 43 3.2 43 3.3 43 3.4 d C6 2000 950 43 2.9 43 3.0 43 3.1 43 3.2 to 975 43 2.8 43 2.9 43 3.0 43 3.1 4500 1000 43 2.6 43 2.7 43 2.8 43 2.9 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 775 42 3.2 42 3.3 42 3.4 42 3.5 800 43 3.6 43 3.8 42 3.2 42 3.3 3001 825 43 3.4 43 3.5 43 3.7 43 3.8 U.S.A. Only to 850 43 3.2 43 3.3 43 3.4 43 3.6 4000 875 43 3.0 43 3.1 43 3.3 43 3.4 900 43 2.9 43 3.0 43 3.1 43 1 3.2 925 43 2.7 43 2.8 1 43 2.9 43 3.0 950 43 2.6 43 2.7 1 43 2.8 43 2.8 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 750 43 3.6 43 3.8 42 3.2 42 3.3 21 775 43 3.4 43 3.5 43 3.6 43 3.8 r_ 4001 800 43 3.2 43 3.3 43 3.4 43 3.5 to 825 43 3.0 43 3.1 43 3.2 43 3.3 a 5000 850 43 2.8 43 2.9 43 3.0 43 3.1 875 43 2.7 43 2.8 43 2.9 43 2.9 900 43 2.5 43 2.6 43 2.7 43 2.8 925 43 2.4 43 2.5 43 2.6 43 2.6 Orifice numbers 43 are factory installed The inducer and blower motors are pre-lubricated and require no 3. For downflow or horizontal furnaces having vent pipes within additional lubrication. These motors can be identified by the the furnace that pass in front of the blower access door: absence of oil ports on each end of the motor. a. Disconnect vent connector from furnace vent elbow. Clean blower motor and wheel as follows: b. Disconnect and remove short piece of vent pipe from 1. Turn off electrical supply to furnace. within furnace. 2. Loosen the thumbscrew on outer door and remove outer door. 38 Table 12-Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 725 43 3.4 43 3.5 43 3.6 43 3.7 750 43 3.2 43 3.3 43 3.4 43 3.5 p 5001 775 43 3.0 43 3.1 43 3.2 43 3.3 to 800 43 2.8 43 2.9 43 3.0 43 3.1 (16 a 6000 825 43 2.6 43 2.7 43 2.8 43 2.9 850 43 2.5 43 2.5 43 2.6 43 2.7 875 43 2.3 43 2.4 43 2.5 43 2.6 900 43 2.2 43 2.3 43 2.3 43 2.4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 675 43 3.4 43 3.5 43 3.6 43 3.7 700 43 3.1 43 3.3 43 3.4 43 3.5 p 6001 725 43 2.9 43 3.0 43 3.1 43 3.2 to 750 43 2.7 43 2.8 43 2.9 43 3.0 a 7000 775 43 2.6 43 2.7 43 2.7 43 2.8 800 43 2.4 43 2.5 43 2.6 43 2.7 825 43 2.3 43 2.3 43 2.4 43 2.5 850 43 2.1 43 2.2 43 2.3 43 2.4 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 650 43 3.1 43 3.2 43 3.4 43 3.5 21 675 43 2.9 43 3.0 43 3.1 43 3.2 a 7001 700 43 2.7 43 2.8 43 2.9 43 3.0 to 725 43 2.5 43 2.6 43 2.7 43 2.8 a 8000 750 43 2.4 43 2.4 43 2.5 43 2.6 775 43 2.2 43 2.3 43 2.4 43 2.4 800 43 2.1 43 2.1 43 2.2 43 2.3 825 48 3.7 43 2.0 43 2.1 43 2.2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 625 43 2.9 43 3.0 43 3.1 43 3.2 2, 650 43 2.7 43 2.8 43 2.9 43 3.0 r- 8001 675 43 2.5 43 2.6 43 2.7 43 2.8 a to 700 43 1 2.3 43 1 2.4 1 43 1 2.5 43 1 2.6 uj 9000 725 Et48 2.2 43 2.2 43 2.3 43 2.4 750 2.0 43 2.1 43 2.2 43 2.2 775 3.6 48 3.7 432.1 Orifice numbers 43 are factory installed 4. Remove 2 screws from blower access door and remove blower 8. Remove 2 screws holding blower assembly to blower deck access door. and slide blower assembly out of furnace. 5. Disconnect blower leads from furnace control. Record wire 9. Clean blower wheel and motor using a vacuum with soft brush color and location for reassembly.All other factory wires can attachment.Blower wheel blades may be cleaned with a small be left connected,but field thermostat connections may need paint or flux brush.Do not remove or disturb balance weights to be disconnected depending on their length and routing. (clips) on blower wheel blades. 6. Remove 2 screws holding control box to blower shelf. 10. Vacuum any loose dust from blower housing, wheel and 7. Hang control box from front of furnace casing and away from motor. blower compartment. 39 Table 12-Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 600 43 2.7 43 2.8 43 2.9 43 3.0 p 9001 625 43 2.5 43 2.6 43 2.6 43 2.7 to 650 43 2.3 43 2.4 43 2.4 43 2.5 q 10,000 675 43 2.1 43 2.2 43 2.3 43 2.3 700 48 3.7 43 2.0 43 2.1 43 2.2 725 48 3.5 48 3.6 1 48 3.7 43 2.0 *Orifice numbers 43 are factory installed 11. If a greasy residue is present on blower wheel,remove wheel A WARNING from the blower housing and wash it with an appropriate degreaser. To remove wheel: ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock, NOTE: Before disassembly, mark blower motor, and blower personal injury, or death. housing so motor and each arm is positioned at the same location Blower access door switch opens 115-v power to furnace during reassembly. control. No component operation can occur unless switch is a. Disconnect capacitor wires and ground wire attached to closed. Exercise caution to avoid electrical shock from blower housing. exposed electrical components when manually closing this b. Remove screws securing cutoff plate and remove cutoff switch for service purposes. plate from housing. b. Manually close blower access door switch. c. Loosen set screw holding blower wheel on motor shaft NOTE: If thermostat terminals are jumpered at the time blower (160+/-20 in-lb when reassembling). access door switch is closed, blower will run for 90 sec before d. Remove bolts holding motor to blower housing and slide beginning a heating or cooling cycle. motor out of wheel(40+/-20 in-lb when reassembling). c. Perform component self-test as shown at the bottom of the e. Remove blower wheel from housing. SERVICE label,located on the front of blower access door. f. Clean wheel and housing. d. Verify blower is rotating in the correct direction. 12. Reassemble motor and blower by reversing steps 1 if through 19. If furnace is operating properly, RELEASE BLOWER AC- 1 la,finishing with 1 la.Be sure to reattach ground wire to the CESS DOOR SWITCH. Remove any jumpers or reconnect blower housing. any disconnected thermostat leads. Replace blower access 13. Verify that blower wheel is centered in blower housing and set door. screw contacts the flat portion of the motor shaft. Loosen set 20. Downflow or horizontal furnaces with vent pipe through screw on blower wheel and reposition if necessary. furnace only: 14. Spin the blower wheel by hand to verify that the wheel does a. Install and connect short piece of vent pipe inside furnace not rub on the housing. to existing vent. 15. Reinstall blower assembly in furnace. b. Connect vent connector to vent elbow. 16. Reinstall control box assembly in furnace. 21. Reinstall casing door. 22. Turn on gas supply and cycle furnace through one complete heating and cooling cycle.Verify the furnace temperature rise as shown in"Adjustments'Section.Adjust temperature rise as UNIT DAMAGE HAZARD shown in "Adjustments" Section. If outdoor temperature is Failure to follow this caution may shorten heat exchanger life. below 70°F, turn off circuit breaker to outdoor unit before Heating fan speed(s)MUST be adjusted to provide proper air running furnace in the cooling cycle. Turn outdoor circuit temperature rise as specified on the rating plate. Recom- breaker on after completing cooling cycle. mended operation is at the midpoint of the rise range or CLEANING HEAT EXCHANGER slightly above.Refer to"SET TEMPERATURE RISE"under START-UP,ADJUSTMENT, and SAFETY CHECK. The following steps should be performed by a qualified service agency: NOTE: Refer to Table 9 for motor speed lead relocation if leads NOTE: If the heat exchangers get a heavy accumulation of soot were not identified before disconnection. and carbon, they should be replaced rather than trying to clean 17. Reconnect blower leads to furnace control. Refer to furnace them thoroughly. A build-up of soot and carbon indicates that a wiring diagram, and connect thermostat leads if previously problem exists which needs to be corrected, such as improper disconnected. adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), 18. To check blower for proper rotation: improper gas,or a restricted heat exchanger.Action must be taken a. Turn on electrical supply. to correct the problem. 40 TABLE 13-Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 900 42 3.2 42 3.3 42 3.4 42 3.5 ca 925 43 3.7 43 3.8 42 3.2 42 3.3 950 43 3.5 43 3.6 43 3.7 43 3.8 v 0 975 43 3.3 43 3.4 43 3.5 43 3.7 to 1000 44 3.6 43 3.3 43 3.4 43 3.5 2000 1025 44 3.4 44 3.6 43 3.2 43 3.3 a ui 1050 44 3.3 44 3.4 44 3.5 43 3.2 1075 45 3.8 44 3.2 44 3.3 44 3.4 1100 46 3.8 45 3.7 44 3.2 44 3.3 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62 0.64 (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure U.S.A. 800 43 3.8 42 3.2 42 3.3 42 3.4 Altitudes 2001 825 43 3.5 43 3.7 43 3.8 42 3.2 @ to 850 43 3.3 43 3.5 43 3.6 43 3.7 v 3000 875 43 3.2 43 3.3 43 3.4 43 3.5 or 900 43 3.0 43 3.1 43 3.2 43 3.3 Canada 925 43 2.8 43 2.9 43 3.0 43 3.1 d Altitudes �? 2000 950 43 2.7 43 2.8 43 2.9 43 2.9 to 975 43 2.5 43 2.6 43 2.7 43 2.8 4500 1000 43 2.4 43 2.5 43 2.6 43 2.7 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 775 43 3.5 43 3.7 43 3.8 42 3.2 800 43 3.3 43 3.4 43 3.5 43 3.7 3001 825 43 3.1 43 3.2 43 3.3 43 3.4 U.S.A. Only to 850 43 2.9 43 3.0 43 3.1 43 3.2 4000 875 43 2.8 43 2.9 43 3.0 43 3.1 900 43 2.6 43 2.7 43 2.8 43 2.9 925 43 2.5 1 43 2.6 43 2.7 43 2.7 950 43 2.4 43 2.4 43 2.5 43 2.6 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE (FT) (BTU/CU FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold No. Pressure No. Pressure No. Pressure No. Pressure 750 43 3.3 43 3.4 43 3.5 43 3.6 21 775 43 3.1 43 3.2 43 3.3 43 3.4 a 4001 800 43 2.9 43 3.0 43 3.1 43 3.2 to 825 43 2.7 43 2.8 43 2.9 43 3.0 a 5000 850 43 2.6 43 2.7 43 2.8 43 2.8 875 43 2.4 43 2.5 43 2.6 43 2.7 900 43 2.3 43 2.4 43 2.5 43 2.5 925 43 2.2 43 2.2 43 2.3 43 2.4 *Orifice numbers 43 are factory installed If it becomes necessary to clean the heat exchangers because of 4. For downflow or horizontal furnace having an internal vent dust or corrosion,proceed as follows: pipe,remove internal vent pipe within the casing. 1. Turn OFF gas and electrical power to furnace. 5. Disconnect wires to the following components.Mark wires to 2. Remove outer access door. aid in reconnection of(be careful when disconnecting wires 3. Disconnect vent connector from furnace vent elbow. from switches because damage may occur): a. Draft safeguard switch. 41 Table 13-Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 725 43 3.1 43 3.2 43 3.3 43 3.4 21 750 43 2.9 43 3.0 43 3.1 43 3.2 r_ 5001 775 43 2.7 43 2.8 43 2.9 43 3.0 to 800 43 2.5 43 2.6 43 2.7 43 2.8 a 6000 825 43 2.4 43 2.5 43 2.5 43 2.6 850 43 2.2 43 2.3 43 2.4 1 43 2.5 875 43 2.1 43 2.2 43 2.3 43 2.3 900 43 2.0 43 2.1 43 2.1 43 2.2 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 675 43 3.1 43 3.2 43 3.3 43 3.4 21 700 43 2.9 43 3.0 43 3.1 43 3.2 - 6001 725 43 2.7 43 2.8 43 2.9 43 2.9 to 750 43 2.5 43 2.6 43 2.7 43 2.8 q rn 7000 775 43 2.3 43 2.4 43 2.5 43 2.6 800 43 2.2 43 2.3 43 2.3 43 2.4 825 43 2.1 43 2.1 43 2.2 43 2.3 850 48 3.7 43 2.0 43 2.1 43 2.1 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62 0.64 (FT) AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 650 43 2.9 43 3.0 43 3.1 43 3.2 T 675 43 2.7 43 2.7 43 2.8 43 2.9 - 7001 700 43 2.5 43 2.6 43 2.6 43 2.7 to 725 43 2.3 43 2.4 43 2.5 43 2.5 Q rn 8000 750 43 2.1 43 2.2 43 2.3 43 2.4 775 43 2.0 43 2.1 43 2.2 43 2.2 800 48 3.6 48 3.7 43 2.0 43 2.1 825 48 3.3 1 48 3.5 48 3.6 48 3.7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 625 43 2.7 43 2.7 43 2.8 43 2.9 T 650 43 2.5 43 2.5 43 2.6 43 2.7 0 8001 675 43 2.3 43 2.4 43 2.4 43 2.5 Q 9 o 700 43 2.1 43 2.2 43 2.3 43 2.3 N 725 48 3.7 43 2.0 43 2.1 43 2.2 750 48 3.5 48 3.6 48 3.7 43 2.0 775 49 3.8 48 3.4 48 3.5 48 3.6 *Orifice numbers 43 are factory installed b. Inducer motor. 6. Remove screws that fasten the collector box assembly to the c. Pressure switch(es). cell panel.Be careful not to damage the collector box.Inducer d. Limit overtemperatare switch. assembly and elbow need not be removed from collector box. e. Gas valve. 7. Disconnect gas line from gas manifold. 8. Remove the 5 screws that attach the burner assembly to the £ Hot surface igniter. cell panel. The gas valve and individual burners need not be g. Flame-sensing electrode. removed from support assembly. h. Flame rollout switches. NOTE: Be very careful when removing burner assembly to avoid i. Remove NOx baffles on low NOx models. breaking igniter. See Fig. 50 and 51 for correct igniter location. 42 Table 13-Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 RANGE AT ALTITUDE (FT) Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure 600 43 2.4 43 2.5 43 2.6 43 2.7 p 9001 625 43 2.3 43 2.3 43 2.4 43 2.5 to 650 43 2.1 43 2.2 43 2.2 43 2.3 a 10,000 675 48 3.6 48 3.8 43 2.1 43 2.1 700 48 3.4 48 3.5 48 3.6 48 3.7 725 49 3.7 49 3.8 48 3.4 48 3.5 *Orifice numbers 43 are factory installed 9/32• (2.) Insert brush end of cable into the outlet opening of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell.(See Fig. 5/16•• 52.) (3.) Work cable in and out of cell 3 or 4 times to obtain i sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out. (4.) Insert brush end of cable in burner inlet opening of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass. (5.) Repeat foregoing procedures until each cell in furnace has been cleaned. (6.) Using vacuum cleaner,remove residue from each cell. (7.) Using vacuum cleaner with soft brush attachment, clean burner assembly. A05025 (8.) Clean flame sensor with fine steel wool. Fig. 50-Igniter Position-Side View � (9.) Install NOx baffles, if removed. (10.) Reinstall burner assembly. Center burners in cell openings. 1-7/8 10. Remove old sealant from cell panel and collector box flange. 11. Spray releasing agent on the heat exchanger cell panel where p collector box assembly contacts cell panel. NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant A05026 (G.E. 162, 6702,or Dow-Corning 738)are needed before starting installation. DO NOT substitute any other type of RTV sealant. Fig. 51-Igniter Position-Top View G.E. 162 (P771-9003) is available through RCD in 3-oz tubes. 12. Apply new sealant to flange of collector box and attach to cell panel using existing screws,making sure all screws are secure. 9. Using field-provided 25-caliber rifle cleaning brush, 36-in. 13. Reconnect wires to the following components(Use connection long, 1/4" diameter steel spring cable, a variable speed, diagram on wiring label, if wires were not marked for reversible electric drill, and vacuum cleaner, clean cells as reconnection locations.): follows: a. Draft safeguard switch. a. Remove metal screw fitting from wire brush to allow b. Inducer motor. insertion into cable. c. Pressure switch(es). b. Insert the twisted wire end of brush into end of spring d. Limit overtemperature switch. cable, and crimp tight with crimping tool or crimp by e. Gas valve. striking with ball-peen hammer. TIGHTNESS IS VERY IMPORTANT. f. Hot surface igniter. NOTE: The materials needed in item 9 can usually be purchased g• Flame-sensing electrode. at local hardware stores. h. Flame rollout switches. (L) Attach variable-speed, reversible drill to the end of i. Install NOx baffles (if removed). spring cable (end opposite brush). 14. Reinstall internal vent pipe, if applicable. 43 b. Igniter Warm-Up-At the end of the prepurge period,the Hot-Surface Igniter HSI is energized for a 17-second o igniter warm-up period. ° ° ° o o c. Trial-for-Ignition Sequence- When the igniter warm-up period is completed the main gas valve relay contacts GVR ° ° o close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners where it is ignited by the HSI.Five seconds after the GVR closes,a 2-second flame proving period begins.The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins. n d. Flame-Proving- When the burner flame is proved at the A91252 flame-proving sensor electrode FSE, the furnace control Fig. 52—Cleaning Heat Exchanger Cell CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not 15. Reinstall vent connector on furnace vent elbow. Securely proved within two seconds,the control CPU will close the fasten vent connector to vent elbow with 2 field-supplied, gas valve GV,and the control CPU will repeat the ignition corrosion-resistant, sheet metal screws located 180' apart. sequence for up to three more Trials-For-Ignition before 16. Replace blower access door only, if it was removed. going to Ignition-Lockout. Lockout will be reset auto- matically after three hours, by momentarily interrupting 17. Set thermostat above room temperature and check furnace for 115 vac power to the furnace, or by interrupting 24 vac proper operation. power at SEC or SEC2 to the furnace control CPU(not at 18. Verify blower airflow and speed changes between heating and W, G,R, etc.) cooling. If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode ! and operate the inducer motor IDM until flame is no longer FIRE OR EXPLOSION HAZARD proved. Failure to follow this warning could result in fire, personal e. Blower-On Delay- If the burner flame is proven, the injury, or death. blower motor is energized on HEAT speed 25 seconds after Never use a match or other open flame to check for gas leaks. the gas valve GV is energized. Use a soap-and-water solution. Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower 19. Check for gas leaks. motor BLWM is energized. 20. Replace outer access door. £ Blower-Off Delay- When the thermostat is satisfied, the Step 3—Sequence of Operation R-to-W circuit is opened,de-energizing the gas valve GV, NOTE: Furnace control must be grounded for proper operation or stopping gas flow to the burners, and de-energizing the control will lock out. Control is grounded through green/yellow humidifier terminal HUM. The inducer motor IDM will wire routed to gas valve and manifold bracket screw. remain energized for a 5-second post-purge period. The Using the schematic diagram in Fig. 45, follow the sequence of blower motor BLWM and air cleaner terminal EAC-1 will operation through the different modes.Read and follow the wiring remain energized for 90, 120, 150,or 180 seconds(depend- diagram very carefully. ing on the blower-OFF delay selection). The furnace control CPU is factory-set for a 120-second blower-OFF NOTE: If a power interruption occurs during a call for heat(W), delay. the control will start a 90-second blower-only ON period two seconds after power is restored,if the thermostat is still calling for 2. Cooling Mode gas heating. The red LED light will flash code 12 during the (See Fig. 25 for thermostat connections) 90-second period,after which the LED will be ON continuous,as The thermostat closes the R-to-G-and-Y circuits. The R-to-Y long as no faults are detected. After the 90-second period, the circuit starts the outdoor unit, and the R-to-G and Y circuits furnace will respond to the thermostat normally. start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with The blower door must be installed for power to be conducted 115 vac when the blower motor BLWM is operating. through the blower door interlock switch ILK to the furnace When the thermostat is satisfied,the R-to-G-and-Y circuits are control CPU, transformer TRAN, inducer motor IDM, blower opened. The outdoor unit will stop, and the furnace blower motor BLWM,hot-surface igniter HSI, and gas valve GV. motor BLWM will continue operating on the COOL speed for 1. Heating an additional 90 seconds.Cut jumper J2 to reduce the cooling (See Fig. 25 for thermostat connections.) off-delay to 5 seconds. (See Fig. 24.) The wall thermostat "calls for heat', closing the R to W 3. Continuous Blower Mode circuit.The furnace control performs a self-check,verifies the When the R-to-G circuit is closed by the thermostat, the pressure switch contacts PRS is open, and starts the inducer blower motor BLWM will operate on continuous-blower motor IDM. speed(same as HEAT speed).Terminal EAC-1 is energized as a. Inducer Prepurge Period- As the inducer motor IDM long as the blower motor BLWM is energized. comes up to speed,the pressure switch contacts PRS close, During a call for heat, the blower BLWM will stop during 24 vac power is supplied for a field installed humidifier at igniter warm-up(17 seconds),ignition,and blower-ON delay the HUM terminal and the control begins a 15-second (25 seconds),allowing the furnace heat exchangers to heat up prepurge period. more quickly,then restarts at the end of the blower-ON delay 44 period at HEAT speed. the blower switches to COOL speed after a 3 second delay.If When the thermostat "calls for cooling', the blower motor the R-to-W-and-Y-and-G signals disappear at the same time, BLWM will operate at COOL speed. When the thermostat is the blower motor BLWM will remain on for the selected satisfied,the blower motor BLWM will operate an additional blower-OFF delay period.If the R-to-W-and-Y signals disap- 90 seconds on COOL speed before reverting back to pear, leaving the G signal, the blower motor BLWM will continuous-blower speed. continue running the blower motor BLWM at HEAT speed When the R-to-G circuit is opened,the blower motor BLWM after the selected blower-OFF delay period is completed. will continue operating for an additional 5 seconds,if no other function requires blower motor BLWM operation. Step 4—Wiring Diagrams 4. Heat Pump Refer to Fig. 25 and 45 for wiring diagrams. When installed with a heat pump, the furnace control auto- Step 5—Troubleshooting matically changes the timing sequence to avoid long blower Refer to the service label. (See Fig. 49—Service Label.) off times during demand defrost cycles. When the R-to-W- and-Y or R-to-W-and-Y-and-G circuits are energized the The Troubleshooting Guide can be a useful tool in isolating furnace control CPU will continue to turn on the blower motor furnace operation problems. Beginning with the word "Start," BLWM at HEAT speed, and begin a heating cycle. The answer each question and follow the appropriate arrow to the next blower motor BLWM will remain on until the end of the item. prepurge period,then shut off for 24 seconds then come back The Guide will help to identify the problem or failed component. on at HEAT speed. 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OLYMPIC AVE - ARLINGTON, WA. 98223 PHONE; (360)403-3551 BUILDING PERMIT Address:8031 Hunter Place Permit#:3065 Parcel#:00874800003300 Valuation:.00 OWNER APPLICANT CONTRACTOR Name:WILSTEIN CHRISTINE R Name:Kings Heating Inc Name:Kings Heating,Inc Address:8031 HUNTER PL Address:18933 Hwy 99 Address: 18933 Hwy 99 City,State Zip:ARLINGTON,WA 98223-5063 City,State Zip:Lynwood,WA 98036 City,State Zip:Lynnwood,WA 98036 Phone: Phone:425-275-5153 Phone:425-275-5153 LIC: EXP: MECHANICAL CONTRACTOR PLUMBING CONTRACTOR Name:Kings heating,Inc Name: Address: 18933 Hwy 99 Address: City,State,Zip:Lynnwood,WA 98036 City,State,Zip: Phone:425-275-5153 Phone: LIC#:KINGSH1044JA EXP: 03/10/2Q22 LIC#: EXP: JOB DESCRIPTION PERMIT TYPE: Residential Mechanical CODE YEAR: 2015 STORIES: 2 CONST.TYPE: ` B DWELLING UNITS: I OCC GROUP: R3 BUILDINGS: I OCC LOAD: PERMIT APPROVAL I AGREE TO COMPLY WITH CITY AND STATE LAWS REGULATING CONSTRUCTION AND IN DOING THE WORK AUTHORIZED THEREBY; NO PERSON WILL BE EMPLOYED IN VIOLATION OF THE LABOR CODE OF THE STATE OF WASHINGTON RELATING TO WORKMEN'S COMPENSATION INSURANCE AND RCW 18.27. THIS APPLICATION IS NOT A PERMIT UNTIL SIGNED BY THE BUILDING OFFICIAL OR HIS/HER DEPUTY AND ALL FEES ARE PAID. IT S UNLAWF L T USE OR CC PY A BUILDING OR STRUCTURE UNTIL A FINAL INSP 10 4AS BEEN MADE AND APPROVAL OR A ER IFIiN E O O A Y AS EN GRANTED. IBCI IO/IRC1 I O. . 1L TA 1 S x Iati construction and construction materials in the City ti Arli iY lie Pon on your safes tax return fonn nd Ped i o i gt n 10 . � /,6 2,0 Si r Print Name Date et d By Date CONDITIONS APPROVED AS SUBMITTED. ADHERE TO THE INSTALLATION OF THE APPROVED APPLIANCE. CALL FOR INSPECTIONS. THIS PERMIT AUTHORIZES ONLY THE WORK NOTED.THIS PERMIT COVERS WORK TO BE DONE ON PRIVATE PROPERTY ONLY. ANY CONSTRUCTION ON THE PUBLIC DOMAIN(CURBS,SIDEWALKS,DRIVEWAYS,MARQUEES,ETC.)WILL REQUIRE SEPARATE PERMISSION. PERMIT FEES Date Description Fee Amount 03/03/2020 Forced Air Heat $25.00 03/03/2020 Mechanical Residential Base $25.00 03/03/2020 Processing/Technology Fee $25.00 03/03/2020 Inspection/Re-Inspection $75.00 Total Due: $150.00 Total Payment: $0.00 Balance Due: $150.00 CALL FOR INSPECTIONS BUILDING(360)403-3417 When calling for an inspection please leave the following information: Permit Number,Type of Inspection being requested,and whether you prefer morning or afternoon CITY OF ARLINGTON 238 N. OLYMPIC AVE - ARLINGTON, WA. 98223 PHONE; (360) 403-3551 BUILDING PERMIT Address:8031 Hunter Place Permit#:3065 Parcel#:00874900003300 Valuation:.00 OWNER APPLICANT CONTRACTOR Name:WILSTEIN CHRISTINE R Name:Kings Heating Inc Name:Kings Heating,Inc Address:8031 HUNTER PL Address:18933 Hwy 99 Address: 18933 Hwy 99 City,State Zip:ARLINGTON,WA 98223-5063 City,State Zip:Lynwood,WA 98036 City,State Zip:Lynnwood,WA 98036 Phone: Phone:425-275-5153 Phone:425-275-5153 LIC: EXP: MECHANICAL CONTRACTOR PLUMBING CONTRACTOR Name:Kings Heating,Inc Name: Address: 18933 Hwy 99 Address: City,State,Zip: Lynnwood,WA 98036 City,State,Zip: Phone:425-275-5153 Phone: LIC#:KINGSHI044JA EXP: 03/10/2022 LIC#: EXP: JOB DESCRIPTION PERMIT TYPE: Residential Mechanical CODE YEAR: 2015 STORIES: 2 CONST.TYPE: `IB DWELLING UNITS: 1 OCC GROUP: R3 BUILDINGS: 1 OCC LOAD: PERMIT APPROVAL I AGREE TO COMPLY WITH CITY AND STATE LAWS REGULATING CONSTRUCTION AND IN DOING THE WORK AUTHORIZED THEREBY; NO PERSON WILL BE EMPLOYED IN VIOLATION OF THE LABOR CODE OF THE STATE OF WASHINGTON RELATING TO WORKMEN'S COMPENSATION INSURANCE AND RCW 18.27. THIS APPLICATION IS NOT A PERMIT UNTIL SIGNED BY THE BUILDING OFFICIAL OR HIS/HER DEPUTY AND ALL FEES ARE PAID. IT IS UNLAWFUL TO USE OR OCCUPY A BUILDING OR STRUCTURE UNTIL A FINALZINSPAn S BEEN MADE AND APPROVAL OR A CERTIFICATE OF OCCUPANCY HAS BEEN GRANTED. IBCI l0/IRCI l0. SALES TAX NOTICE.:Sales tax relating to construction and construction materials in the Citybe port on your sales tax return form and coded City of Arlington#3101. Signature Print Name Date el d By Date CONDITIONS APPROVED AS SUBMITTED. ADHERE TO THE INSTALLATION OF THE APPROVED APPLIANCE. CALL FOR INSPECTIONS. THIS PERMIT AUTHORIZES ONLY THE WORK NOTED.THIS PERMIT COVERS WORK TO BE DONE ON PRIVATE PROPERTY ONLY. ANY CONSTRUCTION ON THE PUBLIC DOMAIN(CURBS,SIDEWALKS,DRIVEWAYS,MARQUEES,ETC.)WILL REQUIRE SEPARATE PERMISSION. PERMIT FEES Date Description Fee Amount 03/03/2020 Forced Air Heat $25.00 03/03/2020 Mechanical Residential Base $25.00 03/03/2020 Processing/Technology Fee $25.00 03/03/2020 Inspection/Re-Inspection $75.00 Total Due: $150.00 Total Payment: $0.00 Balance Due: $150.00 CALL FOR INSPECTIONS BUILDING(360)403-3417 When calling for an inspection please leave the following information: Permit Number,Type of Inspection being requested,and whether you prefer morning or afternoon Permit#: 3065 Permit Date: 03/02/20 Permit Type: RESIDENTIAL MECHANICAL Project Name: Wilstein Applicant Name: Kings Heating Inc Applicant Address: 18933 Hwy 99 Applicant, City, State, Zip: Lynwood, WA 98036 Contact: Michaela Pollard Phone: 425-275-5153 Email: michaelap@kingsheating.com Scope of Work: Like for like furnace replacement Valuation: 0.00 Square Feet: 2149 Number of Stories: 2 Construction Type: VB Occupancy Group: R-3; Residential ID Code: Permit Issued: 03/03/2020 Permit Expires: Form Permit Type: Status: COMPLETE Assigned To: Kristin Foster Property Parcel# Address Legal Description Owner Name Owner Phone Zoning 00874800003300 8031 HUNTER PL WILSTEIN 111 Single Family CHRISTINE R Residence-Detached Contractors Contractor Primary Contact Phone Address Contractor Type License License# Kings Heating,Inc Michaela CONSTRUCTION COA Pollard 425-275-5153 18933 Hwy 99 CONTRACTOR L Business icense 601682595 Kings Heating,Inc Michaela Pollard 425-275-5153 18933 Hwy 99 CONSTRUCTION Construction KINGSHI044JA CONTRACTOR Contractor Fees Fee Description Notes Amount Forced Air Heat fee per Btu $25.00 Mechanical Base Permit Fee $25.00 Processing/Technology $25.00 Inspection $75.00 Credit Card Service $4.50 Total $154.50 Attached Letters Date Letter Description 03/02/2020 Building Permit Payments Date Paid By Description Payment Type Accepted By Amount 03/03/2020 Gary Pollard 79322610 $150.00 03/03/2020 79322610 CC Surcharge Raelynn Jones $4.50 Outstanding Balance $0.00 Uploaded Files Date File Name 03/03/2020 6309050-3065 Issued Permit.pdf 03/02/2020 6305830-3065 Furnace Specs.pdf 03/02/2020 6305831-3065 Application.pdf