International comfort products Induced Combustion Gas Furnace Owner's manual

Specifications subject to change without notice. 441 02 2401 01 June 2011
HOME OWNER’S INFORMATION
Induced Combustion Gas Furnace
NOTE TO INSTALLER:
This manual must be left with the equipment user.
USER: Please read all instructions in the manual and
retain all manuals for future reference.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in injury, death, or
property damage.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
−Do not try to light any appliance.
−Do not touch any electrical switch; do not use any
phone in your building.
−Leave the building immediately.
−Immediately call your gas supplier from a near by
phone. Follow the gas supplier’s instructions.
−If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
!WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury and/or death.
Carbon Monoxide is invisible, odorless, and toxic! Install
a carbon monoxide alarm in your home, even if you do
not own a gas appliance. Locate the carbon monoxide
alarm in the living area of your home and away from gas
appliances and doorways to attached garages. Follow
the alarm manufacturer’s instruction included with the
alarm.
!WARNING
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org .
Illustrations and photographs are only representative. Some product models may vary.
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not use this furnace if any part has been under
water. A flood−damaged furnace is extremely
dangerous. Attempts to use the furnace can result in fire
or explosion. A qualified service agency should be
contacted to inspect the furnace and to replace all gas
controls, control system parts, electrical parts that have
been wet or the furnace if deemed necessary.
!WARNING
TABLE OF CONTENTS
FURNACE COMPONENTS 2............................
GENERAL FURNACE SAFETY 2........................
IMPORTANT FACTS 2..................................
SAFETY CONSIDERATIONS 3..........................
BEFORE STARTING YOUR FURNACE 3.................
STARTING YOUR FURNACE 3..........................
Steps for Starting Your Furnace 3.......................
SHUTTING DOWN YOUR FURNACE 5...................
PERFORMING ROUTINE MAINTENANCE 5..............
Filtering Out Trouble 5.................................
COMBUSTION AREA AND VENT SYSTEM 6..............
BEFORE YOU REQUEST A SERVICE CALL 7............
REGULAR DEALER MAINTENANCE 7...................
INSTALLATION DATA 8................................

2Specifications subject to change without notice. 441 02 2401 01
GENERAL FURNACE SAFETY
1. Combustible Materials, Gasoline Warning. 1.......
2. Flood Damage Warning 1.......................
3. Fire or Explosion Hazard Warning 1..............
4. Carbon Monoxide Warning 1.....................
5. Furnace Must be Kept Free and Clear of Insulating
Material Warning. 3.............................
6. Starting (Lighting) and Shutting Down the
Furnace Warning 3.............................
7. Furnace Needs Air for Combustion and Ventilation
Warning 5.....................................
8. Proper Furnace Shutdown Procedures 5..........
9. Sharp Edges Caution 5.........................
10. No Filter Caution 5.............................
11. Service and Maintenance Electrical Hazard Warning 5
12. Draft Safeguard Switch Caution 6................
13. Improper Vent Warning 6........................
14. Filter Rod Modification Caution 6.................
15. Dirt, Rust, or Accumulation Caution 7.............
FURNACE COMPONENTS
(Furnace shown in upflow position; may be used in downflow
or horizontal orientation or applications. Vent Elbow may be
turned to a different position, depending on type of
installation)
Figure 1 −80% AFUE Single Stage Furnace Components
INDUCER MOTOR
ASSEMBLY
PRESSURE
SWITCH
FLUE COLLECTOR
BOX
GAS VALVE
HOT SURFACE
IGNITOR
BLOWER
DOOR SAFETY
SWITCH
FURNACE
CONTROL
BOARD
VENT
ELBOW
MAIN LIMIT SWITCH
(BEHIND GAS VALVE)
BLOCKED VENT
SWITCH
FLAME
SENSOR
GAS MANIFOLD
GAS BURNER
BLOWER AND
MOTOR
MANUAL RESET
LIMIT SWITCHES
CAPACITOR/
POWER CHOKE
RATING PLATE NOT SHOWN
(LOCATED ON BLOWER DOOR)
Figure 2 −80% AFUE Two−Stage Furnace Components
INDUCER MOTOR
ASSEMBLY
PRESSURE
SWITCHES
FLUE COLLECTOR
BOX
GAS VALVE
HOT SURFACE
IGNITOR
BLOWER DOOR
SAFETY SWITCH
FURNACE CONTROL
BOARD
VENT
ELBOW
MAIN LIMIT SWITCH
(BEHIND GAS VALVE)
BLOCKED VENT
SWITCH
FLAME
SENSOR
GAS MANIFOLD
GAS BURNER
BLOWER AND
MOTOR
MANUAL RESET
LIMIT SWITCHES
CAPACITOR/
POWER CHOKE
RATING PLATE NOT SHOWN
(LOCATED ON BLOWER DOOR)
IMPORTANT FACTS (DO’S AND DON’TS)
SDO: READ AND UNDERSTAND THIS MANUAL.
SDO: Have your furnace and vent system inspected annually
by a qualified service technician.
SDO: Inspect your filter monthly and clean or replace when
needed.
SDO: Provide adequate airflow to the furnace for efficient
combustion and safe ventilation.
SDO: Keep your furnace free and clear of insulating material.
Some materials may be combustible. Examine the furnace
area when the furnace is installed or when insulation is
added.
SDO NOT: Enclose your furnace in an airtight room or seal it
behind solid doors.
SDO NOT: Keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
SDO NOT: Cover your furnace in any manner.
SDO NOT: Store anything (including trash or debris) near your
furnace.
SDO NOT: In any way block or restrict airflow around your
furnace.
SDO NOT: In any way block or restrict airflow to your supply air
and return air grills.
SDO NOT: Use your furnace room as a broom closet or a place
to store any kind of chemical or cleaner.
SDO NOT: Contaminate the air used for combustion of your
furnace with any kind of chemical or fumes. This could also
cause heat exchangers, metal vent systems or components
to deteriorate.
NOTE: These chemicals or fumes are present in many
products around the home, such as: water softener salts, any
type of household cleaning product, any type of laundry
product, adhesives, paints, varnishes, paint strippers, waxes
and plastics, etc.
During remodeling be sure the combustion air is fresh and
uncontaminated. If these compounds are burned in your
furnace, the heat exchangers and metal vent system may
deteriorate.

3
Specifications subject to change without notice.
441 02 2401 01
NOTE: The qualified installer or agency must use only
factory−authorized replacement parts, kits, and accessories
when modifying this product.
This furnace contains safety devices which must be manually
reset. If the furnace is left unattended for an extended period
of time, have it checked periodically for proper operation. This
precaution will prevent problems associated with no heat,
such as frozen water pipes, etc. See “Before You Request a
Service Call” section in this manual.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in personal
injury, death, or property damage.
Keep insulation clear of furnace and maintain
clearances shown on unit clearance label.
!WARNING
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous
due to gas and electrical components. Only trained and
qualified personnel should install, repair, or service heating
equipment.
Untrained personnel can perform basic maintenance
functions such as cleaning or replacing air filters. All other
operations must be performed by trained service personnel.
Observe safety precautions in this manual, on tags, and on
labels attached to the furnace, and other safety precautions
that may apply.
Recognize safety information. This is the safety−alert symbol
. When you see this symbol on the furnace and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety−alert
symbol. DANGER identifies the most serious hazards which
will result in severe personal injury or death. WARNING
signifies hazards which could result in personal injury or
death. CAUTION is used to identify unsafe practices which
would result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability or operation.
BEFORE STARTING YOUR FURNACE
Examine the furnace installation to determine that:
1. All flue gas carrying areas external to the furnace (i.e.
chimney, vent connector) are clear and free of
obstructions.
2. The vent connector is in place, slopes upward and is
physically sound without holes or excessive corrosion.
3. The return−air duct connection(s) is physically sound, is
sealed to the furnace casing, and terminates outside the
space containing the furnace.
4. The physical support of the furnace is sound without
sagging cracks, gaps, etc. around the base.
5. There are no obvious signs of deterioration of the
furnace.
STARTING YOUR FURNACE
Your furnace uses an automatic, hot surface ignition system
to light the burners each time the thermostat signals the
furnace to start.
Follow these important safeguards:
SNever attempt to manually light the burners with a
match or other source of flame.
Figure 3 −Do Not Light Burner with Match
A92319
SRead and follow the operating instructions on inside
of main furnace door, especially the item that reads
as follows:
“Wait 5 minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas, STOP!
Follow “B” in the safety information above on this
furnace label. If you don’t smell gas, go to the next
step.”
SIf a suspected malfunction occurs with your gas
control system, such as the burners do not light
when they should, refer to the shutdown procedures
on inside of main furnace door, or in the “Shutting
Down Your Furnace” section and call your dealer as
soon as possible.
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Should the gas supply fail to shut off or if overheating
occurs, turn off the manual gas valve to the furnace
BEFORE turning off the electrical supply and install
lockout tag.
!WARNING
SCHECK AIR FILTER: Before attempting to start your
furnace, be sure the furnace filter is clean and in
place. See “Performing Routine Maintenance”
section in this manual. Do not run the furnace
without a filter in place. Then proceed as follows:
STEPS FOR STARTING YOUR FURNACE
1. Set your room thermostat to the lowest temperature
setting.

4Specifications subject to change without notice. 441 02 2401 01
Figure 4 −Lowest Temperature Setting
A08175
2. Close the external manual gas valve.
Figure 5 −Close Valve
C
L
O
S
E
A06188
3. Turn OFF electrical supply to the furnace.
Figure 6 −Turn Off Electrical Supply
A92185
4. Remove the outer door by turning knobs clockwise and
lift door upward, then pull door forward.
Figure 7 −Remove Furnace Door
UNLOCK UNLOCK
5. Turn the control switch on the gas control to the OFF
position and wait 5 minutes. See Figure 7. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow “B” on furnace label. If you don’t smell gas, go to
next step.
Figure 8 −Control Switch to OFF
ON
OFF
OR
A02266
6. After waiting 5 minutes, if you still smell gas, STOP!
Follow the safety information on the cover of this manual.
If you do not smell gas, go to the next step.
7. Turn the control switch to ON.
Figure 9 −Control Switch to ON
ON
OFF
OR
A02267
8. Replace the outer door by placing flange inside casing,
push door firmly against casing and turn knobs
counterclockwise to tighten.
Figure 10 −Furnace Door Replaced
LOCK LOCK
9. Turn ON the electrical supply to the furnace.

5
Specifications subject to change without notice.
441 02 2401 01
Figure 11 −Turn On Electrical Supply
A92359
10. Open the external manual gas valve.
Figure 12 −Open Valve
O
P
E
N
A06189
11. Set the room thermostat to a temperature slightly above
the room temperature. This will automatically signal the
furnace to start. The inducer motor will start and the hot
surface igniter will energize. When hot, the igniter will
have an orange glow.
12. After about 17 seconds, the gas valve permits gas to flow
to the main burners where it is ignited. Hot flames begin
to warm the furnace’s heat exchanger. After a time delay
of approximately 25−45 seconds the furnace blower is
switched on.
NOTE: If the main burners fail to ignite, the furnace control
system will go through three more ignition cycles. Then if
burners fail to ignite, the system will lockout. If lockout occurs or
the blower does not come on, shut down your furnace and call
your dealer for service.
13. Set your thermostat to the temperature that satisfies your
comfort requirements. SUGGESTION: Setting the
thermostat back a few degrees—and compensating for
the difference with warmer clothing—can make a big
difference in your fuel consumption on extremely cold
days. The few degrees at the top of your thermostat
“comfort level” are the most costly degrees to obtain.
When the room temperature drops below the temperature
selected on the thermostat, the furnace will switch on
automatically. When the room temperature reaches the setting
selected on the thermostat, the furnace will be automatically
switched off.
Continuous Fan Operation −Some thermostats have a
“FAN” switch with two selections: AUTO and ON. When
thermostat is set on AUTO, the furnace blower cycles on and
off, controlled by the thermostat. In ON position, the furnace
blower runs continuously except for a 42−62 sec delay at the
“call for heat.” Continuous fan keeps the temperature level in
your home more evenly balanced. It also continuously filters
the indoor air.
SHUTTING DOWN YOUR FURNACE
Should you ever suspect a malfunction in your furnace, you
will need to turn the furnace off. The following procedures
must be followed:
1. Set your room thermostat to the lowest temperature
setting. (See Figure 4)
2. Close the external manual gas valve (See Figure 5).
3. Turn off electrical supply to the furnace. (See Figure 6)
4. Remove outer furnace door. (See Figure 7)
5. Turn the switch on the gas control to the OFF position.
(See Figure 8)
6. Replace the outer furnace door. (See Figure 9)
7. If the furnace is being shut down because of a
malfunction, call your dealer as soon as possible.
PERFORMING ROUTINE MAINTENANCE
With proper maintenance and care, your furnace will operate
economically and dependably. Instructions for basic
maintenance are found on this and the following pages.
However, before beginning maintenance, follow these safety
precautions:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in
personal injury or death.
Turn off electrical power supply to your furnace
before removing the access doors to service or
perform maintenance.
!WARNING
CUT HAZARD
Failure to follow this caution may result in personal
injury.
Although special care has been taken to minimize
sharp edges, be extremely careful when handling
parts or reaching into the furnace. Wear safety
glasses, gloves, and appropriate protective clothing.
CAUTION
!
FILTERING OUT TROUBLE
UNIT PERFORMANCE HAZARD
Failure to follow this caution may result in product
damage.
Never operate your furnace without a filter in place.
Doing so may damage the furnace blower motor. An
accumulation of dust and lint on internal parts of your
furnace can cause a loss of efficiency.
CAUTION
!
A dirty filter will cause excessive stress on the furnace, heat
exchanger, and blower motor and can cause it to overheat
and automatically shut down. The furnace filter should be
checked every 4 weeks and cleaned or replaced if necessary.
If installed with factory specified disposable media filter, check
or replace filter before each heating and cooling season.
Replace disposable media filter at least twice a year.
If your furnace filter needs replacing, be sure to use the same
size and type of filter that was originally specified.
The air filter for the furnace may be located in a filter
cabinet/rack attached to the side or bottom of the furnace. If
air filter has been installed in another location, contact your

6Specifications subject to change without notice. 441 02 2401 01
dealer for instructions. To inspect, clean and/or replace the air
filter(s), follow these steps:
1. Turn off the electrical supply to the furnace.
Figure 13 −Turn Off Electrical Supply
A92185
2. Remove filter cabinet door/rack.
3. Slide air filter out of filter cabinet/rack. Keep dirty side up
(if dirty) to avoid spilling dirt.
4. Inspect the filter. If torn, replace it.
NOTE: If the filter is:
a. a factory specified disposable media filter — Do not
clean. If dirty, replace only with media filter having
the same part number and size. Install with airflow
direction arrow pointing towards blower.
b. an Electronic Air Cleaner (EAC) — Refer to EAC
Owner’s Manual for maintenance information.
c. a factory specified disposable filter do not clean,
replace it with a new filter of same size.
d. a washable filter, wash filter (if dirty) in sink, bathtub,
or outside with a garden hose. Always use cold tap
water. A mild liquid detergent may be used if
necessary. Spray water through filter in the opposite
direction of airflow. Allow filter to dry.
5. Reinstall clean air filter.
6. Replace filter cabinet door.
7. Turn on electrical supply to furnace (See Figure 11).
NOTE: If side return ducts are used, two filters may be
required in some models. The procedure listed above may be
used to remove side filters.
Filters may be field modified by cutting filter material and
support rods (3) in filters. Alternate sizes and additional filters
may be ordered from your dealer.
FURNACE
CASING WIDTH
in (mm)
FILTER QUANTITY AND SIZE *
** FILTER TYPE*
SIDE RETURN
in (mm)
BOTTOM RETURN
in (mm)
14-1/2 (368) (1) 16 x 25 (406 x 635) (1) 14 x 25 (356 x 635) 1” (25 mm) thick cleanable or 4-5/16” (110 mm)
thick media-type
17-1/2 (445) (1) 16 x 25 (406 x 635) (1) 16 x 25 (406 x 635) 1” (25 mm) thick cleanable or 4-5/16” (110 mm)
thick media-type
21 (533) (1) 16 x 25 (406 x 635) (1) 20 x 25 (508 x 635) 1” (25 mm) thick cleanable or 4-5/16” (100 mm)
thick media-type
24 (610) (1) 16 x 25 (406 x 635) (1) 24 x 25 (610 x 635) 1” (25 mm) thick cleanable or 4-5/16” (100 mm)
thick media-type
*Recommended
**Some furnaces may have 2 filters
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal
injury.
Use care when cutting support rods in filters to protect
against flying pieces and sharp rod ends. Wear safety
glasses, gloves, and appropriate protective clothing.
CAUTION
!
COMBUSTION AREA AND VENT SYSTEM
UNIT OPERATION HAZARD
Failure to follow this caution may result in personal
injury.
Failure to follow this warning could result in personal
injury or death.
For proper and safe operation the furnace needs air for
combustion and ventilation. Do not block or obstruct air
openings on the furnace, air opening to the area in
which the furnace is installed, and the space around the
furnace.
CAUTION
!
Inspect the combustion area and vent system before each
heating season. An accumulation of dirt, soot, or rust can
mean a loss of efficiency and improper performance. Buildups
on the main burners can cause faulty firing. This “delayed
ignition” is characterized by an alarmingly loud sound.
NOTE: If your furnace makes a loud noise when the main
burners are ignited, shut down the furnace and call your
servicing dealer.
Use your flashlight and follow these steps for inspecting the
combustion area and vent system of your furnace:
1. Turn off electrical supply to the furnace and remove the
access door. (See Figure 8 and Figure 9)
2. Carefully inspect the gas burner for dirt, rust, or scale.
Inspect the elbow, flue connection area, and the vent
pipe for rust.
Figure 14 −Burner Flame
A92330
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in
personal injury or death.
If dirt, rust, soot, or scale accumulations are
found, call your dealer. Do not operate your
furnace.
!WARNING

7
Specifications subject to change without notice.
441 02 2401 01
3. Inspect the vent pipe for a sag, holes, or a disconnection.
A horizontal vent pipe must slope upward away from
furnace. If rusty joints or seams, or signs of water
leakages are found, call your dealer for service.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
If holes are found or if the vent pipe is obstructed or is
not connected, toxic fumes can escape into your home.
DO NOT OPERATE YOUR FURNACE. Call your dealer
for service.
!WARNING
4. Restore electrical power to the furnace. (See Figure 9)
5. Start the furnace and observe its operation. If possible,
watch the burner flames. Are they burning bright blue? If
not or if you suspect some other malfunction, call your
servicing dealer.
6. Replace the access door. (See Figure 10)
BEFORE YOU REQUEST A
“SERVICE CALL”
Before you call for service, check for several easily
solved problems:
SCheck for sufficient airflow. Check the air filter for dirt. Check
for blocked return−air or supply−air grilles. Be sure they are
open and unobstructed. If this isn’t the cause of the problem,
call your servicing dealer. If your furnace isn’t operating at all,
check the following list for easily solved problems:
SIs your thermostat set above room temperature? Is the HEAT
mode selected?
SIs the electrical power supply switch on? Is the blower access
door firmly in place? Are any fuses blown? (There is a fuse
on the furnace control.) Has a circuit breaker tripped?
SIs the manual shut−off valve in the gas supply pipe leading to
the furnace open? Does the lever point in the same direction
that the pipe runs (open)? Or is it at a right angle to the pipe
(closed)? NOTE: Before proceeding with the next checks,
turn off the electrical power supply to the furnace. Remove
access door.
SIs the switch on the gas valve turned to the ON position? If
this or the preceding check shows an interruption in the gas
supply, make sure the gas has not been shut off for safety
reasons. If nothing else seems to be wrong, follow the
start−up procedures found on pages 4 and 5 of this booklet.
UNIT OPERATION HAZARD
Failure to follow this caution may result in personal
injury.
If for some reason the vent is blocked, the draft
safeguard switch will shut off the furnace. (See furnace
components for switch location.) The switch will
automatically reset after the furnace cools off. If the
furnace fails to operate, contact a qualified service
agency.
CAUTION
!
SCheck the manual reset limit switches located on the ends
of the burner enclosure (see Figure 1 and Figure 2). If the
furnace has experienced a high−temperature condition due
to inadequate combustion air, these switches will shut off
the furnace. Reset the switches by pushing the button on
the switch. If the switch trips a second time, turn off the
furnace and call for service.
SIf your furnace still fails to operate, call your servicing dealer
for troubleshooting and repairs. Tell your dealer the model
and serial numbers for your furnace. (You should have
them recorded on the last page of this booklet.) By knowing
exactly which furnace you have, the dealer may be able to
offer suggestions over the phone or save valuable time
through knowledgeable preparation for the service call.

8Specifications subject to change without notice. 441 02 2401 01
NOTE TO EQUIPMENT OWNER:
For your convenience, please record the model and serial numbers of your new equipment in the spaces
provided. This information, along with the installation data and dealer contact information will be helpful
should your system require maintenance or service.
FURNACE
Model # _____________________________________
Serial # ______________________________________
AIR CONDITIONER OR HEAT PUMP
Model # _____________________________________
Serial # _____________________________________
INDOOR COIL (Furnace Coil or Fan Coil)
Model # _____________________________________
Serial # _____________________________________
INSTALLATION INFORMATION:
Date Installed ________________________________
DEALERSHIP CONTACT INFORMATION:
Company Name_______________________________
Address______________________________________
_____________________________________________
Phone Number _______________________________
Technician Name _____________________________
_____________________________________________
_____________________________________________
NOTE TO INSTALLER:
This manual must be left with the equipment owner.
MAINTENANCE CHECKLIST
In addition to the type of routing maintenance you might be willing to perform; your furnace should be inspected regularly by a
properly trained service technician.
You should work with your dealer or service technician to assure your inspection includes the following at a minimum.
DESCRIPTION INSPECTION INTERVAL
Monthly Semiannually Annually
Furnace specific, external items:
Clean or replace air filters. X
Inspect cabinet for signs of damage. X
Inspect and clean door louvers if needed. X
Inspect electrical disconnect for proper function. Repair or replace as necessary. X
Inspect external wiring for damage. X
Inspect gas supply line and manual shutoff for leaks. X
Furnace specific, internal items:
Inspect and clean blower assembly (includes blower housing, blower wheel and
motor). X
Inspect gas valve and check for proper manifold gas pressure Adjust as needed. X
Inspect ignition system and safety controls. Clean and adjust as needed. X
Inspect control box, associated controls, wiring and connections. X
Check combustion blower housing for lint and debris and clean as necessary. X
Inspect burner assembly  clean as needed. X
Inspect heat exchanger  clean as needed. X
Inspect flue system—check for proper attachment to the furnace, any dislocated
sections, and for signs of corrosion. Replace if necessary. X
System:
Inspect airflow system (ductwork)—check for leaks and repair as needed. X
Inspect evaporator coil, drain pan and condensate drain lines as applicable.
Clean as needed. X
This list may not include all maintenance items, and inspection interval times may vary depending on operational conditions of the
furnace.
Ask your servicing dealer for further details about an economical service contract that covers seasonal inspections.
International Comfort Product, LLC SPO Box 128 SLewisburg, TN 37091 USA