International comfort products R80esn User manual

441 01 6200 00 3/20/2019

INSTALL

TION INSTRUCTIONS

80% Single Stage, ECM Motor

Category I, 33--1/3 in. Gas Furnace

R80ESN and R80ESL

(

Series

SAFETY CONSIDERATIONS 2.......................

INTRODUCTION 2.................................

CODES AND STANDARDS 5.........................

SAFETY 5.......................................

GENERAL INSTALLATION 5...........................

COMBUSTION AND VENTILATION AIR 5.................

DUCT SYSTEMS 5.................................

ACOUSTICAL LINING AND FIBROUS GLASS DUCT 5........

GAS PIPING AND GAS PIPE PRESSURE TESTING 5..........

ELECTRICAL CONNECTIONS 5........................

VENTING 5......................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE 5....................................

LOCATION 6......................................

AIR FOR COMBUSTION AND VENTILATION 8.........

OUTDOOR COMBUSTION AIR METHOD 8................

COMBINATION OF INDOOR AND OUTDOOR AIR 10...........

INSTALLATION 10..................................

UPFLOW INSTALLATION 10............................

DOWNFLOW INSTALLATION 11.........................

HORIZONTAL INSTALLATION 13.........................

FURNACE SUPPORT 13...............................

AIR DUCTS 13.....................................

GAS PIPING 16.....................................

ELECTRICAL CONNECTIONS 20.........................

115--V WIRING 20...................................

J--BOX RELOCATION 21...............................

24--V WIRING 21....................................

ACCESSORIES 22...................................

VENTING 25.......................................

GENERAL VENTING REQUIREMENTS 25...................

MASONRY CHIMNEY REQUIREMENTS 25..................

APPLIANCE APPLICATION REQUIREMENTS 26...............

ADDITIONAL VENTING REQUIREMENTS 28.................

SIDEWALL VENTING 28...............................

START--UP, ADJUSTMENT, AND SAFETY CHECK 32.....

START--UP PROCEDURES 32............................

ADJUSTMENTS 33..................................

CHECK SAFETY CONTROLS 35..........................

CHECKLIST 35.....................................

SERVICE AND MAINTENANCE PROCEDURES 41.......

INTRODUCTION 41..................................

GENERAL 41......................................

ELECTRICAL CONTROLS AND WIRING 41..................

CARE AND MAINTENANCE 42..........................

CLEANING AND/OR REPLACING AIR FILTER 43..............

BLOWER MOTOR AND WHEEL 43........................

CLEANING HEAT EXCHANGER 44........................

SEQUENCE OF OPERATION 45..........................

WIRING DIAGRAMS 46...............................

TROUBLESHOOTING 46...............................

PARTS REPLACEMENT INFORMATION GUIDE 50.......

Use of the AHRI Certified

Mark indicates a

manufacturer’s participation in the program. For

verification of certification for individual products,

go to www.ahridirectory.org.

NOTE: Read the entire instruction manual before starting the

installation.

Portions of the text and tables are reprinted from current edition

of NFPA 54/ANSI Z223.1E, with permission of National Fire

Protection Association, Quincy, MA 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 is represented only by the standard

in its entirety.

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous

operation, serious injury, death, or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use could cause carbon monoxide

poisoning, explosion, fire, electrical shock, or other

conditions which may cause personal injury or property

damage. Consult a qualified service agency, local gas

supplier, or your distributor or branch for information or

assistance. The qualified service agency must use only

factory--authorized and listed kits or accessories when

modifying this product.

!WARNING

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may

require excessive servicing or cause premature component

failure.

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate,

air temperature rise, unit leveling, and unit sizing.

CAUTION

Specifications are subject to change without notice.

2441 01 6200 00

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, personal injury, or

property damage. Consult a qualified installer, service agency, or

your distributor or branch for information or assistance. The

qualified installer or agency must use factory--authorized kits or

accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions

include in literature and attached to the unit. Consult local

building codes, the current editions of the current edition of

National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the

current edition of National Electrical Code (NEC) NFPA 70.

Recognize safety information. This is the safety--alert symbol .

When you see this symbol on the unit 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 may 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.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and

gloves when handling parts and servicing furnaces.

CAUTION

1. Use only with type of gas approved for this furnace. Refer

to the furnace rating plate.

2. Install this furnace only in a location and position as spe-

cified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the

furnace space as specified in “Air for Combustion and

Ventilation” section.

4. Combustion products must be discharged outdoors. Con-

nect this furnace to an approved vent system only, as spe-

cified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a com-

mercially available soap solution made specifically for the

detection of leaks to check all connections, as specified in

the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s in-

tended temperature--rise range with a duct system which

has an external static pressure within the allowable range,

as specified in the “Start--Up, Adjustments, and Safety

Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space con-

taining the furnace, the return air shall also be handled by

duct(s) sealed to the furnace casing and terminating out-

side the space containing the furnace. See “Air Ducts” sec-

tion.

8. A gas--fired furnace for installation in a residential garage

must be installed as specified in the warning box in the

“Location” section.

9. The furnace may be used for construction heat provided

that the furnace installation and operation complies with

the first CAUTION in the LOCATION section of these in-

structions.

10. These Multipoise Gas--Fired Furnaces are CSA (formerly

A.G.A. and C.G.A). design--certified for use with natural

and propane gases (see furnace rating plate) and for install-

ation in alcoves, attics, basements, closets, utility rooms,

crawlspaces, and garages. The furnace is factory--shipped

for use with natural gas. A CSA listed accessory gas con-

version kit is required to convert furnace for use with pro-

pane gas.

11. See Fig. 2 for required clearances to combustible construc-

tion.

12. Maintain a 1--in. (25 mm) clearance from combustible ma-

terials to supply air ductwork for a distance of 36 inches

(914 mm) horizontally from the furnace. See current edi-

tion of NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on car-

peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory access-

ory floor base MUST be used when installed on combust-

ible materials and wood flooring. Special base is not re-

quired when this furnace is installed on manufacturer’s

coil model numbers END4X, ENW4X or coil casing mod-

el number NAEA is used. See Fig. 2 for clearance to com-

bustible construction information.

INTRODUCTION

This 4--way multipoise Category I fan--assisted furnace is CSA

design--certified. A Category I fan--assisted furnace is an

appliance equipped with an integral mechanical means to either

draw or force products of combustion through the combustion

chamber and/or heat exchanger. The furnace is factory--shipped

for use with natural gas.

This furnace is not approved for installation in mobile homes,

recreational vehicles, or outdoors. This furnace is designed for

minimum continuous return--air temperature of 60_F(16_C)db

or intermittent operation down to 55_F(13_C) db such as when

used with a night setback thermostat. Return--air temperature

must not exceed 80_F(27_C) db. Failure to follow these

return--air temperature limits may affect reliability of heat

exchangers, motors, and controls. (See Fig. 3).

For accessory installation details, refer to the applicable

instruction literature.

NOTE: Remove all shipping brackets and materials before

operating the furnace.

Specifications are subject to change without notice. 3441 01 6200 00

A190084

NOTES:

1. Two additional 7/8---in. (22 mm) diameter holes are located in the top plate.

2. Minimum return---air openings at 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. (406 mm) round or 14 1/2 x 12---in. (368 x 305 mm) rectangle.

b. For 1200 CFM---20 ---in. (508 mm) round or 14 1/2 x 19 1/2---in. (368 x 495 mm) rectangle.

c. For 1600 CFM---22 ---in. (559 mm) round or 14 1/2 x 22 1/16---in. (368 x 560mm) rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Specification Sheet 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

Table1–Dimensions

FURNACE SIZE

CABINET WIDTH

OUTLET WIDTH

TOP AND

BOTTOM FLUE

COLLAR

BOTTOM

INLET WIDTH

VENT

CONNECTION

SIZE

SHIP WT.

LB. (KG)

0451412 14--- 3/16 (360) 12--- 9/16 (319) 9--- 5/16 (237) 12 ---11/16 (322) 4 (102) 104 (47)

0451712 17---1/2 (445) 15---7/8 (403) 11--- 9/16 (294) 16 (406) 4 (102) 119 (54)

0701412 14---3/16 (360) 12--- 9/16 (319) 9--- 5/16 (237) 12--- 11/16 (322) 4 (102) 114 (52)

0701712 17---1/2 (445) 15---7/8 (403) 11--- 9/16 (294) 16 (406) 4 (102) 120 (54)

0702116 21 (533) 19---3/8 (492) 13--- 5/16 (338) 19---1/2 (495) 4 (102) 142 (64)

0901714 17---1/2 (445) 15---7/8 (403) 11--- 9/16 (294) 16 (406) 4 (102) 131 (49)

0902116 21 (533) 19---3/8 (492) 13--- 5/16 (338) 19---1/2 (495) 4 (102) 137 (62)

0902120 21 (533) 19---3/8 (492) 13--- 5/16 (338) 19---1/2 (495) 4 (102) 140 (64)

0902420 24---1/2 (622) 22---7/8 (581) 15--- 1/16 (383) 23 (584) 4 (102) 146 (66)

1102120 21 (533) 19---3/8 (492) 13--- 5/16 (338) 19---1/2 (495) 4 (102) 146 (66)

1102420 24---1/2 (622) 22---7/8 (581) 15--- 1/16 (383) 23 (584) 4 (102) 161 (73)

1352420 24---1/2 (622) 22---7/8 (581) 15--- 1/16 (383) 23 (584) 4 (102) 167 (76)

*135 size furnace requires a 5 or 6---in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete

installation requirements.

Specifications are subject to change without notice.

4441 01 6200 00

A10269

Fig. 2 -- Clearances to Combustibles

Specifications are subject to change without notice. 5441 01 6200 00

A02055

Fig. 3 -- Return Air Temperature

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

these instructions. The installation must comply with regulations

of the serving gas supplier, local building, heating, plumbing, and

other codes. In absence of local codes, the installation must

comply with the national codes listed below and all authorities

having jurisdiction.

In the United States, follow all codes and standards for the

following:

Safety

SUSA: Current edition of National Fuel Gas Code

(NFGC) NFPA 54/ANSI Z223.1 and the Installation

Standards, Warm Air Heating and Air Conditioning

Systems ANSI/NFPA 90B

General Installation

SCurrent edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association

Inc., Batterymarch Park, Quincy, MA 02269;

(www.NFPA.org) or for only the NFGC, contact the

American Gas Association, 400 N. Capitol Street,

N.W., Washington, DC 20001 (www.AGA.org).

Combustion and Ventilation Air

SCurrent edition of NFGC NFPA54/ANSI Z223.1 Sec-

tion 9.3, Air for Combustion and Ventilation.

Duct Systems

SAir Conditioning Contractors Association (ACCA)

Manual D, Sheet Metal and Air Conditioning Contract-

ors National Association (SMACNA), or American

Society of Heating, Refrigeration, and Air Condition-

ing Engineers (ASHRAE) 2005 Fundamentals Hand-

book Chapter 35 or 2004 HVAC Systems and Equip-

ment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass Duct

SCurrent edition of SMACNA and NFPA 90B as tested

by UL Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure T

esting

SCurrent edition of NFGC NFPA54/ANSI Z223.1;

chapters 5, 6, 7, and 8 and National Plumbing Codes.

Electrical Connections

SCurrent edition of National Electrical Code (NEC) NF-

PA 70.

Venting

SCurrent edition of NFGC NFPA 54 / ANSI Z223.1;

Chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause

premature furnace component failure.

Electrostatic discharge can affect electronic components.

Follow the Electrostatic Discharge Precautions Procedure

listed below during furnace installation and servicing to

protect the furnace electronic control. Precautions will

prevent electrostatic discharges from personnel and hand

tools 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.

CAUTION

1. Disconnect all power to the furnace. Multiple disconnects

maybe required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR

TO DISCHARGING YOUR BODY’S

ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the fur-

nace chassis which is close to the control. Firmly touch

the clean, unpainted, metal surface of the furnace chassis

which is close to the control. Tools held in a person’s hand

during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the

control or connecting wires as long as you do nothing to

recharge your body with static electricity (for example;

DO NOT move or shuffle your feet, do not touch un-

grounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body

with static electricity), firmly touch a clean, unpainted

metal surface of the furnace again before touching control

or wires.

5. Use this procedure for installed and uninstalled (ungroun-

ded) furnaces.

6. Before removing a new control from its container, dis-

charge your body’s electrostatic charge to ground to pro-

tect the control from damage. If the control is to be in-

stalled in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the fur-

nace. Put all used and new controls into containers before

touching ungrounded objects.

7. An ESD service kit (available from commercial sources)

mayalsobeusedtopreventESDdamage.

Specifications are subject to change without notice.

6441 01 6200 00

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4 -- Multipoise Orientations

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any

of the four applications shown in Fig. 4.

This furnace must:

Sbe installed so the electrical components are protected

from water.

Snot be installed directly on any combustible material

other than wood flooring for upflow applications.

Downflow installations require use of a factory--ap-

proved floor base or coil assembly when installed on

combustible materials or wood flooring (refer to

SAFETY CONSIDERATIONS).

Sbe located as close to the chimney or vent and attached

to an air distribution system. Refer to Air Ducts section.

Sbe provided ample space for servicing and cleaning.

Always comply with minimum fire protection clear-

ances shown on the furnace clearance to combustible

label.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury or death, and unit component damage.

Corrosive or contaminated air may cause failure of parts

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.

!WARNING

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

SCommercial buildings

SBuildings with indoor pools

SLaundry rooms

SHobby or craft rooms, and

SChemical storage areas

If air is exposed to the following substances, it should not be used

for combustion air, and outdoor air may be required for

combustion:

SPermanent wave solutions

SChlorinated waxes and cleaners

SChlorine based swimming pool chemicals

SWater softening chemicals

SDe--icing salts or chemicals

SCarbon tetrachloride

SHalogen type refrigerants

SCleaning solvents (such as perchloroethylene)

SPrinting inks, paint removers, varnishes, etc.

SHydrochloric acid

SCements and glues

SAntistatic fabric softeners for clothes dryers

SMasonry acid washing materials

Specifications are subject to change without notice. 7441 01 6200 00

All fuel--burning equipment must be supplied with air for fuel

combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be

made between the furnace cabinet and the return--air duct to

prevent pulling air from the burner area and from draft safeguard

opening.

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

FIRE HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

When the furnace is installed in a residential garage, the

burners and ignition sources must be located at least 18

inches above the floor. The furnace must be located or

protected to avoid damage by vehicles. When the furnace is

installed in a public garage, airplane hangar, or other

building having a hazardous atmosphere, the furnace must

be installed in accordance with the NFGC.

!WARNING

PERSONAL INJURY AND/OR PROPERTY

DAMAGE HAZARD

Improper use or installation of this furnace may cause

premature furnace component failure.

This gas furnace may be used for heating buildings under

construction provided that:

--The furnace is permanently installed with all electrical

wiring, piping, venting and ducting installed according to

these installation instructions. A return air duct is provided,

sealed to the furnace casing, and terminated outside the

space containing the furnace. This prevents a negative

pressure condition as created by the circulating air blower,

causing a flame rollout and/or drawing combustion

products into the structure.

--The furnace is controlled by a thermostat. It may not be

“hot wired” to provide heat continuously to the structure

without thermostatic control.

--Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and

other construction materials. It also prevents the

entrainment of drywall dust into combustion air, which can

cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is

maintained between 55_F(13_C) and 80_F(27_C), with

no evening setback or shutdown. The use of the furnace

while the structure is under construction is deemed to be

intermittent operation per our installation instructions.

--The air temperature rise is within the rated rise range on

the furnace rating plate, and the gas input rate has been set

to the nameplate value.

--The filters used to clean the circulating air during the

construction process must be either changed or thoroughly

cleaned prior to occupancy.

--The furnace, ductwork and filters are cleaned as necessary

to remove drywall dust and construction debris from all

HVAC system components after construction is completed.

--Verify proper furnace operating conditions including

ignition, gas input rate, air temperature rise, and venting

according to these installation instructions.

CAUTION

Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

FURNACE

INPUT

(BTUH)

TWO HORIZONTAL DUCTS

(1 SQ. IN./2,000 BTUH)

(1,100 SQ. MM/KW)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

TWO OPENINGS OR VERTICAL

DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Free Area of Open-

ing and Duct

(sq.in./sq.mm)

Round Duct

Diameter

(in./mm)

Free Area of Open-

ing and Duct

(sq.In./sq.mm)

Round Duct

Diameter

(in. / mm)

Free Area of

Opening and Duct

(sq.In./sq.mm)

Round Duct

Diameter

(In./mm)

44,000 22 (14193) 6 (152) 14.7 (9484) 5 (127) 11 (7097) 4 (102)

66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)

132,000 66 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

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

Specifications are subject to change without notice.

8441 01 6200 00

Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors

ACH*

OTHER THAN FAN---ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE

FAN---ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132

SpaceVolume(ft.

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800

0.00 NP NP NP NP NP NP NP NP

*Air Changes/Hour

FIRE HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with

control compartment facing downward. Safety control

operation will be adversely affected. Never connect

return--air ducts to the back of the furnace. (See Fig. 6.)

!WARNING

A02054

Fig. 6 -- Prohibit Installation on Back

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

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.

CAUTION

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the

downstream side of the unit to avoid condensation in the heat

exchangers. When installed parallel with the furnace, dampers or

other flow control must prevent chilled air from entering the

furnace. If the dampers are manually operated, they must be

equipped with means to prevent operation of either unit unless

the damper is in the full--heat or full--cool position.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

SU.S. installations: Section 9.3 of the current edition of

NFGC NFPA54/ANSI Z223.1, Air for Combustion

and Ventilation, and applicable provisions of the local

building codes.

!WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury

or death.

The operation of exhaust fans, kitchen ventilation fans,

clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace.

Make--up air MUST be provided for the ventilation devices,

in addition to that required by the furnace. Refer to Carbon

Monoxide Poisoning Hazard warning in venting section of

these instructions to determine if an adequate amount of

make--up air is available.

The requirements for combustion and ventilation air depend upon

whether or not the furnace is located in a space having a volume

of at least 50 cubic feet per 1,000 Btuh input rating for all gas

appliances installed in the space.

SSpaces having less than 50 cubic feet per 1,000 Btuh

require the OUTDOOR COMBUSTION AIR

METHOD.

SSpaces having at least 50 cubic feet per 1,000 Btuh

may use the INDOOR COMBUSTION AIR,

STANDARD or KNOWN AIR INFILTRATION

METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combus-

tion, ventilation, and dilution of flue gases using perman-

ent horizontal or vertical duct(s) or opening(s) directly

communicating with the outdoors or spaces that freely

communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR

OPENINGS, one inlet and one outlet combustion and

ventilation air opening, to the outdoors.

e. One opening MUST commence within 12--in. (300 mm)

of the ceiling and the second opening MUST commence

within 12--in. (300 mm) of the floor.

f. Size openings and ducts per Fig. 7 and Table 2.

Specifications are subject to change without notice. 9441 01 6200 00

1 SQ IN.

PER

4000

BTUH*

DUCTS

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

CIRCULATING

AIR DUCTS

VENT

THROUGH

ROOF

1 SQ IN.

PER 4000

BTUH*

DUCT

OUTDOORS

CIRCULATING AIR DUCTS

1 SQ IN.

PER 2000

BTUH*

1 SQ IN.

PER 2000

BTUH*

DUCTS

OUTDOORS

12″MAX

12″

MAX

12″

MAX

OUTDOORS

1 SQ IN.

PER

4000

BTUH*

CLEARANCE IN FRONT

OF COMBUSTION AIR

OPENINGS SHALL BE

AT LEAST 3 IN.

(305mm)

(76mm)

*Minimum dimensions of 3 in. (76 mm).

NOTE: Use any of the following combinations of openings:

A&B, C&D, D&E, F&G

A03174

Fig. 7 -- Air for Combustion, Ventilation, and Dilution from

Outdoors

g. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm2/kW) of combined

input for all gas appliances in the space per Fig. 7 and

Table 2.

h. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm2/kW)

for combined input of all gas appliances in the space per

Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per

Table 2 and

b. Not less than the sum of the areas of all vent connectors

in the space.

The opening shall commence within 12” (300 mm) of the ceiling.

Appliances in the space shall have clearances of at least 1” (25

mm) from the sides and back and 6” (150 mm) from the front.

The opening shall directly communicate with the outdoors or

shall communicate through a vertical or horizontal duct to the

outdoors or spaces (crawl or attic) that freely communicate with

the outdoors.

Indoor Combustion Air -- NFPA & AGA

Standard and Known--Air--Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution,

if the Standard or Known--Air--Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or

personal injury.

Many homes require air to be supplied from outdoors for

furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in

accordance with this instruction manual.

!WARNING

CIRCULATING AIR

DUCTS

6" MIN

(FRONT)Ü

CIRCULATING AIR DUCTS

VENT THROUGH ROOF

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

12" MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

12" MAX

UNCONFINED

SPACE

INTERIOR

HEATED

SPACE

CLEARANCE IN FRONT OF COMBUSTION AIR

OPENINGS SHALL BE AT LEAST 3 IN.

(305mm)

(152mm)

(305mm)

*Minimum opening size is 100 in.2with minimum dimensions of 3 in. (76

mm).

*Minimum of 3 in. (76 mm), when type ---B1 vent is used.

A03175

Fig. 8 -- Air for Combustion, Ventilation, and Dilution from

Indoors

The Standard Method:

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 changes per hour (ACH).

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

Infiltration rates greater than 0.60 ACH shall not be used. The

minimum required volume of the space varies with the number of

ACH and shall be determined per Table 3 or Equations 1 and 2.

Determine the minimum required volume for each appliance in

the space and add the volumes together to get the total minimum

required volume for the space.

Table 3 -- Minimum Space Volumes were determined by using

the following equations from the current edition of National Fuel

Gas Code ANSI Z223.1/NFPA 54:

1. For other than fan--assisted appliances, such as a draft

hood--equipped water heater:

Volume

Other

=21ft

ACH

other

1000 Btu/hr

A04002

2. For fan--assisted appliances such as this furnace:

Volume

Fan

=15ft

ACH

fan

1000 Btu/hr

A004003

If:

Iother = combined input of all other than fan--assisted appliances

in Btuh/hr

Specifications are subject to change without notice.

10 441 01 6200 00

Ifan = combined input of all fan--assisted appliances in Btuh/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to

the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

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) of the total input rating of all gas appliances

in the space, but not less than 100 in.2(0.06 m2). One

opening shall commence within 12”(300 mm)of theceil-

ing 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.)

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 per-

manent 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 communicates with the outdoors provided there are

adequate permanent ventilation openings directly to out-

doors having free area of at least 1--in.2/4,000 Btuh of total

input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method,

infiltration should be adequate to provide air for combus-

tion, permanent ventilation and dilution of flue gases.

However, in buildings with unusually tight construction,

additional air MUST be provided using the methods de-

scribedintheOutdoor Combustion Air Method section.

Unusually tight construction is defined as construction with:

a. Walls and ceilings exposed to the outdoors have a con-

tinuous, sealed vapor barrier. Openings are gasketed or

sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole

plates and floors, between wall--ceiling joints, between

wall panels, at penetrations for plumbing, electrical and

gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus-

tion Air Method below and,

2. Outdoor openings shall be located as required in the Out-

door Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Meth-

od below.

b. Outdoor opening size reduction Factor is 1 minus the Ra-

tio in a. above.

c. Minimum size of Outdoor openings shall be the size re-

quired in Outdoor Combustion Air Method above multi-

plied by reduction Factor in b. above. The minimum di-

mension of air openings shall be not less than 3 in. (80

mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return--air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel,

perform the following:

1. Tilt or raise furnace and remove two screws holding bot-

tom filler panel. (See Fig. 9.)

Bottom

Closure Panel

Bottom Filler Panel

A10273

Fig. 9 -- Removing Bottom Closure Panel

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return--air opening. This panel MUST be in place when

only side return air is used.

NOTE: Side return--air openings can be used in UPFLOW and

most HORIZONTAL configurations. Do not use side return--air

openings in DOWNFLOW configuration.

Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 10.) Install field--supplied, 5/16 x 1--1/2 in. (8 x

38 mm) (max) corrosion--resistant machine bolts, washers and

nuts.

NOTE: Bottom closure must be used when leveling legs are

used. It may be necessary to remove and reinstall bottom closure

panel to install leveling legs. To remove bottom closure panel, see

Item 1. in Bottom Return Air Inlet section.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in

each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt and

nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install

flat washer if desired.)

Specifications are subject to change without notice. 11441 01 6200 00



(44mm)

(8mm)

(44mm)

(8mm)

(44mm)

A89014

Fig. 10 -- Leveling Legs

4. Adjust outside nut to provide desired height, and tighten

inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3

accessories are used:

SDownflow combustible floor subbase

SCased Coil numbers END4X, ENW4X

SCoil casing model number NAEA

1. Determine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Fig. 11.

3. Construct plenum to dimensions specified in Table 4 and

Fig. 11.

4. If downflow subbase is used, install as shown in Fig. 12. If

Coil model number END4X, ENW4X or Coil Casing

model number NAEA is used, install as shown in Fig. 13.

NOTE: It is required that the perforated supply--air duct flanges

be completely folded over or removed from furnace when

installing the furnace on a factory--supplied cased coil or coil box.

To remove the supply--air duct flange, use wide duct pliers or

hand seamers to bend flange back and forth until it breaks off. Be

careful of sharp edges. (See Fig. 14.)

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return--air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel,

perform the following:

1. Tilt or raise furnace and remove two screws holding bot-

tom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws

PLENUM

OPENING

FLOOR

OPENING

A96283

Fig. 11 -- Floor and Plenum Opening Dimensions

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

A96285

Fig. 12 -- Furnace, Plenum, and Subbase Installed

on a Combustible Floor

Specifications are subject to change without notice.

12 441 01 6200 00

APPROVED

COIL ASSEMBLY

COIL BOX

FURNACE

SHEET METAL

PLENUM

FLOOR

OPENING

COMBUSTIBLE

FLOORING

A08556

Fig. 13 -- Furnace, Plenum, and Coil Assembly or

Coil Box Installed on a Combustible Floor

Table 4 – Opening Dimensions -- In. (mm)

FURNACE

CASING

WIDTH

APPLICATION PLENUM OPENING FLOOR OPENING

A B C D

14–3/16

(360)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

12--11/16

(322)

21--5/8

(549)

13--5/16

(338)

22--1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

12--9/16

(319)

(483)

13--3/16

(335)

19--5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

11--13/16

(284)

(483)

13--7/16

(341)

20--5/8

(600)

Downflow Applications on Combustible Flooring with Cased

Coil (subbase not required)

12--5/16

(319)

(483)

13--5/16

(338)

(508)

17–1/2

(445)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

(406)

21--5/8

(549)

16--5/8

(422)

22--1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

15--7/8

(403)

(483)

16--1/2

(419)

19--5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

15--1/8

(384)

(483)

16--3/4

(425)

20--5/8

(600)

Downflow Applications on Combustible Flooring with Cased

Coil (subbase not required)

15--1/2

(394)

(483)

16--1/2

(419)

(508)

(533)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

19--1/2

(495)

21--5/8

(549)

20--1/8

(511)

22--1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

19--3/8

(492)

(483)

(508)

19--5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

18--5/8

(473)

(483)

20--1/4

(514)

20--5/8

(600)

Downflow Applications on Combustible Flooring with Cased

Coil (subbase not required)

(483)

(508)

24--1/2

(622)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

(584)

21--1/8

(537)

23--5/8

(600)

22--1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

22--7/8

(581)

(483)

23--1/2

(597)

19--5/8

(498)

Downflow Applications on Combustible flooring

(subbase required)

22--1/8

(562)

(483)

23--3/4

(603)

20--5/8

(600)

Downflow Applications on Combustible Flooring with Cased

Coil (subbase not required)

22--1/2

(572)

(483)

23--1/2

(597)

(508)

Specifications are subject to change without notice. 13441 01 6200 00

HORIZONTAL INSTALLATION

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

Do not install the furnace on its back or hang furnace with

control compartment facing downward. Safety control

operation will be adversely affected. Never connect

return--air ducts to the back of the furnace.

!WARNING

The furnace can be installed horizontally in an attic or crawl space

on either the left--hand (LH) or right--hand (RH) side. The furnace

can be hung from floor joists, rafters or trusses or installed on a

non--combustible platform, blocks, bricks or pad.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod,

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 sheet metal straps (plumber’s straps) may be used

to suspend the furnace from each bottom corner. To prevent

screws from pulling out, use 2 #8 x 3/4--in. (19 mm) screws into

the side and 2 #8 x 3/4--in. (19 mm) screws in the bottom of the

furnace casing for each strap. (See Fig. 15 and 16.) If the screws

are attached to ONLY the furnace sides and not the bottom, the

straps must be vertical against the furnace sides and not pull away

from the furnace sides, so that the strap attachment screws are not

in tension (are loaded in shear) for reliable support.

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.

(25 mm) clearance requirement on side, set furnace on

noncombustible blocks, bricks or angle iron. For crawl space

installations, if the furnace is not suspended from the floor joists,

the ground underneath furnace must be level and the furnace set

on blocks or bricks.

Roll--Out Protection

Provide a minimum 17--3/4 in. x 22 in. (451 mm x 559 mm)

piece of sheet metal for flame roll--out protection in front of

burner area for furnaces closer than 12 inches (305 mm) above

the combustible deck or suspended furnaces closer than 12 inches

(305 mm) to joists. The sheet metal MUST extend underneath the

furnace casing by 1 in. (25 mm) with the door removed.

The bottom closure panel on furnaces of widths 17--1/2 in. (445

mm) 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 orientation of roll--out shield.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return--air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel,

perform the following:

1. Tilt or raise furnace and remove two screws holding bot-

tom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding

tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws. Side Return Air

Inlet

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in

bottom return--air opening. This panel MUST be in place when

side return air inlet(s) is used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air

connections. (See Fig. 21.)

FILTER ARRANGEMENT

CARBON MONOXIDE AND POISONING

HAZARD

Failure to follow this warning could result in personal

injury, or death.

Never operate a furnace without a filter or with filter access

door removed.

!WARNING

There are no provisions for an internal filter rack in these

furnaces.

A field--supplied accessory external filter is required.

Refer to the instructions supplied with the external filter rack for

assembly and installation options.

AIR DUCTS

General Requirements

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA)

or American Society of Heating, Refrigerating and Air

Conditioning Engineers (ASHRAE) or consult The Air Systems

Design Guidelines reference tables available from your local

distributor. The duct system should be sized to handle the

required system design CFM at the design external static pressure.

The furnace airflow rates are provided in Table 5 -- AIR

DELIVERY--CFM (With Filter).

When a furnace is installed so that the supply ducts carry air

circulated by the furnace to areas outside the space containing the

furnace, the return air shall also be handled by duct(s) sealed to

the furnace casing and terminating outside the space containing

the furnace.

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply-- and return--duct connections to furnace with code

approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork

and furnace to prevent transmission of vibration. Ductwork

passing through unconditioned space should be insulated and

sealed to enhance system performance. When air conditioning is

used, a vapor barrier is recommended.

Maintain a 1--in. (25 mm) clearance from combustible materials

to supply air ductwork for a distance of 36 in. (914 mm)

horizontally from the furnace. See NFPA 90B or local code for

further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. (3 M) of main duct to the first branch take--off may

require 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. Both acoustical lining and fibrous ductwork

shall comply with NFPA 90B as tested by UL Standard 181 for

Class 1 Rigid air ducts.

Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with a removable access panel. This opening

shall be accessible when the furnace is installed and shall be of

such a size that the heat exchanger can be viewed for possible

openings using light assistance or a probe can be inserted for

sampling the airstream. The cover attachment shall prevent leaks.

Specifications are subject to change without notice.

14 441 01 6200 00

Upflow and Horizontal Furnaces

Connect supply--air duct to flanges on furnace supply--air outlet.

Bend flange upward to 90_with wide duct pliers. (See Fig. 14.)

The supply--air duct must be connected to ONLY the furnace

supply--outlet--air duct flanges or air conditioning coil casing

(when used). DO NOT cut main furnace casing side to attach

supply air duct, humidifier, or other accessories. All accessories

MUST be connected to duct external to furnace main casing.

NOTE: For horizontal applications, the top--most flange may be

bent past 90 degrees to allow the evaporator coil to hang on the

flange temporarily while the remaining attachment and sealing of

the coil are performed.

Downflow Furnaces

Connect supply--air duct to supply--air outlet on furnace. Bend

flange inward past 90_with wide duct pliers. (See Fig. 14.) The

supply--air duct must be connected to ONLY the furnace supply

outlet or air conditioning coil casing (when used). When installed

on combustible material, supply--air duct must be connected to

ONLY the factory--approved accessory subbase or a factory--

approved air conditioning coil casing. DO NOT cut main furnace

casing to attach supply side air duct, humidifier, or other

accessories. All accessories MUST be connected to duct external

to furnace casing.

UPFLOW DOWNFLOW HORIZONTAL

YES

NO NO

YES

120

MIN

YES 120

MIN

YES

120

MIN

9090

A02020

Fig. 14 -- Duct Flanges

4" (6mm) THREADED ROD

4 REQ.

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x

" (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS

1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD

8" (203mm)

MIN

FOR DOOR REMOVAL

OUTER DOOR

ASSEMBLY

A10130

Fig. 15 -- Horizontal Unit Suspension

Specifications are subject to change without notice. 15441 01 6200 00

METHOD 2

USE (4) #8 x 3/4 (19 mm) SHEET

METAL SCREWS FOR EACH

STRAP. THE STRAPS

SHOULD BE VERTICAL

AGAINST THE FURNACE

SIDES AND NOT PULL AWAY

FROM THE FURNACE

SIDES.

METHOD 1

FOLD ALL STRAPS UNDER

FURNACE AND SECURE WTH

(4) #8 x 3/4 (19 mm) SHEET METAL SCREWS

(2 SCREWS IN SIDE AND 2 SCREWS

IN BOTTOM).

A10131

Fig. 16 -- Horizontal Suspension with Straps

30-IN. (762mm)

MIN WORK AREA

6″ MIN

TYPE-B

VENT

″

SHEET

METAL

SEDIMENT

TRAP

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

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.

GAS

ENTRY

″

(451mm)

OVERALL

″

(121mm)

UNDER DOOR

1″

(25mm)

UNDER FURNACE

EXTEND OUT 12″

(305mm)

FROM FACE OF DOOR

* WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

UNION

(152mm)

(451mm)

(559mm)

A10164

Fig. 17 -- Typical Attic Installation

Specifications are subject to change without notice.

16 441 01 6200 00

Return Air Connections

FIRE HAZARD

Failure to follow this warning could cause personal injury,

death and/or property damage.

Never connect return--air ducts to the back of the furnace.

Follow instructions below

!WARNING

Downflow Furnaces

The return--air duct must be connected to return--air opening

(bottom inlet) as shown in Fig. 20. DO NOT cut into casing sides

(left or right). Side opening is permitted for only upflow and most

horizontal furnaces. (See Fig. 20.) 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

right), or a combination of bottom and side(s) of main furnace

casing as shown in Fig. 19 and 21. Bypass humidifier may be

attached into unused return air side of the furnace casing. (See

Fig. 19 and 21.)

Not all horizontal furnaces are approved for side return air

connections. (See Fig. 21.)

GAS PIPING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never

test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection

of leaks to check all connections.

!WARNING

FIRE OR EXPLOSION HAZARD

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

manifold and a gas leak.

!WARNING

FURNACE OVERHEAT HAZARD

Failure to follow this caution may result in property

damage.

Connect gas pipe to gas valve using a backup wrench to

avoid damaging gas controls and burner misalignment.

CAUTION

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death, and/or property damage.

If local codes allow the use of a flexible gas appliance

connector, always use a new listed connector. Do not use a

connector which has previously served another gas

appliance. Black iron pipe shall be installed at the furnace

gas control valve and extend a minimum of 2 in.(51 mm)

outside the furnace.

!WARNING

Gas piping must be installed in accordance with national and

local codes. Refer to current edition of NFGC.

Installations must be made in accordance with all authorities

having jurisdiction. If possible, the gas supply line should be a

separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a li-

censed plumber or gas fitter.

2. When flexible connectors are used, the maximum length

shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves

are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved

by the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing. Risers must be

used to connect to furnace and to meter. Support all gas piping

with appropriate straps, hangers, etc. Use a minimum of 1 hanger

every 6 ft. (2 M). Joint compound (pipe dope) should be applied

sparingly and only to male threads of joints. Pipe dope must be

resistant to the action of propane gas.

An accessible manual equipment shutoff valve MUST be

installed external to furnace casing and within 6 ft. (2 M) of

furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for

test gauge connection, MUST be installed immediately upstream

of gas supply connection to furnace and downstream of manual

equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap

connection is suitable to use as test gauge connection providing

test pressure DOES NOT exceed maximum 0.5 psig (14--In.

W.C.) stated on gas control valve. (See Fig. 41.)

Some installations require gas entry on right side of furnace (as

viewed in upflow.) (See Fig. 22.)

Install a sediment trap in riser leading to furnace as shown in Fig.

18. Connect a capped nipple into lower end of tee. Capped nipple

should extend below level of furnace gas controls. Place a ground

joint union between furnace gas control valve and exterior

manual equipment gas shutoff valve. A 1/8--in. (3 mm) NPT

plugged tapping, accessible for test gauge connection, MUST be

installed immediately upstream of gas supply connection to

furnace and downstream of manual equipment shutoff valve.

Specifications are subject to change without notice. 17441 01 6200 00

Table 5 – Air Delivery -- CFM (With Filter)*

Furnace

Wire

Lead

Color

Function Test Airflow Delivery @ Various External Static Pressures

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0451412

Gray Cooling. Do not use for heating. 1230 1190 1155 1120 1080 1045 1010 975 935 895

Yellow Alt Cooling or alt Heating 980 945 920 890 855 815 770 735 690 645

Orange Alt Cooling or alt Heating 770 720 685 640 600 560 520 475 430 385

Blue Heating or alt Cooling 710 660 620 580 540 490 455 415 375 335

Red AltCooling.Donotuseforheating. 600 540 500 455 415 385 345 305 235 ---

0451712

Gray Cooling. Do not use for heating. 1370 1335 1295 1255 1215 1175 1135 1095 1055 1020

Yellow Alt Cooling or alt Heating 1130 1085 1040 995 955 910 865 825 780 730

Orange Alt Cooling or alt Heating 930 885 835 795 745 700 655 600 545 495

Blue Heating or alt Cooling 760 720 670 625 580 515 460 410 355 300

Red AltCooling.Donotuseforheating. 610 500 445 375 320 260 200 135 --- ---

0701412

Gray Cooling. Do not use for heating. 1205 1170 1143 1105 1070 1035 1000 960 925 885

Blue Heating or alt Cooling 1095 1060 1030 995 960 925 885 840 800 735

Yellow Alt Cooling or alt Heating 920 880 845 805 765 730 685 620 560 510

Orange AltCooling.Donotuseforheating. 715 650 610 575 520 465 410 380 305 245

Red AltCooling.Donotuseforheating. 635 490 445 375 315 270 205 230 190 140

0701712

Gray Cooling. Do not use for heating. 1610 1565 1525 1475 1435 1395 1350 1305 1260 1215

Yellow Alt Cooling or alt Heating 1385 1335 1290 1250 1205 1165 1125 1075 1025 980

Blue Heating or alt Cooling 1215 1165 1120 1075 1035 985 940 895 845 840

Orange Alt Cooling or alt Heating 1175 1130 1085 1035 990 945 900 855 805 760

Red AltCooling.Donotuseforheating. 1080 1015 955 920 875 820 780 725 670 620

0702116

Gray Cooling. Do not use for heating. 1735 1685 1640 1595 1545 1495 1450 1405 1360 1310

Yellow Alt Cooling or alt Heating 1480 1435 1395 1340 1290 1240 1190 1135 1085 1030

Blue Heating or alt Cooling 1315 1275 1225 1180 1135 1085 1030 975 915 860

Orange Alt Cooling or alt Heating 1135 1080 1030 985 935 885 835 770 705 645

Red AltCooling.Donotuseforheating. 980 930 875 820 775 715 665 595 530 455

0901714

Gray Cooling. Do not use for heating. 1355 1320 1285 1245 1210 1165 1125 1080 1025 815

Yellow Alt Cooling or alt Heating 1295 1255 1220 1185 1140 1100 1055 1005 955 815

Blue Heating or alt Cooling 1220 1185 1150 1105 1065 1025 975 915 840 740

Orange Alt Cooling or alt Heating 1030 985 940 900 845 790 715 655 590 535

Red AltCooling.Donotuseforheating. 945 905 855 800 750 670 600 540 490 435

0902116

Gray Cooling. Do not use for heating. 1625 1580 1535 1490 1445 1395 1340 1260 1135 995

Yellow Alt Cooling or alt Heating 1425 1380 1335 1290 1235 1185 1125 1075 1020 640

Blue Heating or alt Cooling 1440 1395 1350 1305 1255 1200 1145 1090 1040 950

Orange Alt Cooling or alt Heating 1260 1210 1160 1105 1050 990 935 880 820 755

Red AltCooling.Donotuseforheating. 1095 1040 980 905 845 780 720 650 585 520

0902120

Gray Cooling. Do not use for heating. 2180 2130 2080 2030 1980 1925 1870 1805 1745 1680

Yellow Alt Cooling or alt Heating 1900 1845 1795 1740 1685 1635 1570 1500 1435 1375

Blue Heating or alt Cooling 1685 1620 1565 1505 1455 1385 1320 1260 1200 1140

Orange Alt Cooling or alt Heating 1390 1315 1240 1175 1095 1030 970 900 825 760

Red AltCooling.Donotuseforheating. 1240 1155 1075 990 915 835 765 690 615 555

0902420

Gray Cooling. Do not use for heating. 2190 2135 2075 2015 1960 1900 1835 1775 1705 1630

Yellow Alt Cooling or alt Heating 1870 1810 1745 1685 1625 1565 1495 1420 1345 1280

Blue Heating or alt Cooling 1580 1510 1445 1385 1320 1240 1175 1115 1050 970

Orange Alt Cooling or alt Heating 1305 1220 1160 1075 1000 930 865 770 690 610

Red AltCooling.Donotuseforheating. 1210 1075 1000 915 845 765 675 595 515 425

1102120

Gray Cooling. Do not use for heating. 2255 2205 2150 2100 2040 1985 1920 1835 1735 1615

Blue Heating or alt Cooling 1945 1890 1830 1770 1715 1655 1600 1545 1480 1430

Yellow Alt Cooling or alt Heating 1600 1525 1465 1400 1335 1275 1210 1150 1080 1015

Orange AltCooling.Donotuseforheating. 1420 1340 1280 1200 1140 1065 1005 925 865 790

Red AltCooling.Donotuseforheating. 1280 1205 1140 1055 990 910 840 760 695 630

1102420

Gray Cooling. Do not use for heating. 2250 2190 2130 2070 2005 1950 1885 1820 1755 1685

Blue Heating or alt Cooling 1995 1930 1865 1800 1740 1670 1605 1535 1465 1400

Yellow Alt Cooling or alt Heating 1540 1460 1385 1305 1235 1165 1095 1035 955 890

Orange AltCooling.Donotuseforheating. 1345 1195 1135 1055 980 920 845 770 695 620

Red AltCooling.Donotuseforheating. 1335 1075 965 890 820 735 660 580 505 440

1352420

Gray Cooling. Do not use for heating. 2065 2005 1940 1875 1810 1740 1670 1600 1530 1470

Blue Heating or alt Cooling 1825 1760 1695 1630 1560 1490 1420 1350 1275 1205

Yellow Alt Cooling or alt Heating 1760 1690 1625 1555 1485 1415 1345 1275 1200 1130

Orange AltCooling.Donotuseforheating. 1620 1550 1480 1405 1335 1260 1195 1130 1065 995

Red AltCooling.Donotuseforheating. 1325 1260 1185 1100 1025 955 885 805 735 670

1. A filter is required for each return---air inlet. Airflow performance included 3/4---in. (19 mm) washable filter media such as contained in factory --- a u t h o r iz e d

accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 In. W.C. available external static pressure.

2. Adjust the blower speed tabs as necessary for the proper air temperature rise for each installation.

3. --- --- Indicates unstable operating conditions.

4. If the same motor speed tap is needed for heating and cooling, a Jumper Wire accessory kit is available (see Specification sheet for the current Jumper

Wire accessory part number), see Function column for applicable limitations.

Specifications are subject to change without notice.

18 441 01 6200 00

Table 6 – Maximum Capacity of Pipe*

NOMINAL IRON

PIPE

INTERNAL

DIAMETER LENGTH OF PIPE --- FT. (M)

SIZE IN. (mm) In. (mm) 10 20 30 40 50

1/2 (13) 0.622 (16) 175 (53) 120 (37) 97 (30) 82 (25) 73 (22)

3/4 (19) 0.824 (21) 360 (110) 250 (76) 200 (61) 170 (52) 151 (46)

1 (25) 1.049 (27) 680 (207) 465 (142) 375 (114) 320 (98) 285 (87)

1---1/4 (32) 1.380 (35) 1400 (427) 950 (290) 770 (235) 660 (201) 580 (177)

1---1/2 (38) 1.610 (41) 2100 (640) 1460 (445) 1180 (360) 990 (301) 900 (274)

* Cubic ft. of natural gas per hr for gas pressures of 0.5 psig (14 ---In. W.C.) or less and a pressure drop of 0.5 ---In. W.C. (based on a 0.60 specific gravity

gas). Ref: Chapter 6 current edition of ANSI Z223/NFPA 54.

Piping should be pressure and leak tested in accordance with

NFGC in the United States, local, and national plumbing and gas

codes before the furnace has been connected. After all

connections have been made, purge lines and check for leakage at

furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe must

be disconnected from furnace and capped before and during

supply pipe pressure test. If test pressure is equal to or less than

0.5 psig (14--In. W.C.), turn off electric shutoff switch located on

furnace gas control valve and accessible manual equipment

shutoff valve before and during supply pipe pressure test. After

all connections have been made, purge lines and check for

leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and

minimum inlet supply pressures marked on the rating plate with

the furnace burners ON and OFF.

UNION

SEDIMENT

TRAP

MANUAL

SHUTOFF

VALVE

(REQUIRED)

GAS

SUPPLY

A02035

Fig. 18 -- Typical Gas Pipe Arrangement

A02075

Fig. 19 -- Upflow Return Air Configurations and Restrictions

Specifications are subject to change without notice. 19441 01 6200 00

A02163

Fig. 20 -- Downflow Return Air Configurations and Restrictions

A02162

Fig. 21 -- Horizontal Return Air Configurations and Restrictions

2” (51mm)

Street Elbow

A08551

Fig. 22 -- Burner and Manifold

Specifications are subject to change without notice.

20 441 01 6200 00

Table 7 – Electrical Data

Unit Size

Volts-

Hertz-

Phase

Operating Voltage*

Range Unit

Ampacity#

Minimum Wire

Size AWG

Maximum Wire

Length

Maximum

Fuse

or CKT

BKR Amps

Maximum Minimum feet m

0451412 1 1 5 --- 6 0 --- 1 127 104 7.8 14 47 14.3 15

0451712 1 1 5 --- 6 0 --- 1 127 104 10.3 14 36 11 15

0701412 1 1 5 --- 6 0 --- 1 127 104 7.8 14 47 14.3 15

0701712 1 1 5 --- 6 0 --- 1 127 104 7.8 14 47 14.3 15

0702116 1 1 5 --- 6 0 --- 1 127 104 13.3 14 27 8.2 15

0901714 1 1 5 --- 6 0 --- 1 127 104 11 14 33 10.1 15

0902116 1 1 5 --- 6 0 --- 1 127 104 11 14 33 10.1 15

0902120 1 1 5 --- 6 0 --- 1 127 104 16.9 12 34 10.4 20

0902420 1 1 5 --- 6 0 --- 1 127 104 13.5 14 27 8.2 15

1102120 1 1 5 --- 6 0 --- 1 127 104 17.4 12 33 10.1 20

1102420 1 1 5 --- 6 0 --- 1 127 104 14 14 26 7.9 15

1352420 1 1 5 --- 6 0 --- 1 127 104 14 14 26 7.9 15

* 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.

{Time---delay type is recommended.

}Length shown is as measured one way along wire path between unit and service panel for maximum 2 percent voltage drop.

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow safety warnings could result in dangerous

operation, serious injury, death or property damage.

Improper servicing could result in dangerous operation,

serious injury, death or property damage.

-- Before servicing, disconnect all electrical power to

furnace.

-- When servicing controls, label all wires prior to

disconnection. Reconnect wires correctly.

-- Verify proper operation after servicing.

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Blower access panel door switch opens 115--v power to

control. No component operation can occur. Do not bypass

or close switch with panel removed.

!WARNING

See Fig. 25 for field wiring diagram showing typical field 115--v

wiring. Check all factory and field electrical connections for

tightness.

Field--supplied wiring shall conform with the limitations of 63_F

(35_C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal

injury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken

ground according to current edition of NEC NFPA 70 or

local codes to minimize personal injury if an electrical fault

should occur. This may consist of electrical wire, conduit

approved for electrical ground or a listed, grounded power

cord (where permitted by local code) when installed in

accordance with existing electrical codes. Refer to the

power cord manufacturer’s ratings for proper wire gauge.

Do not use gas piping as an electrical ground.

!WARNING

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in intermittent

furnace operation.

Furnace control must be grounded for proper operation or

else control will lock out. Control must remain grounded

through green/yellow wire routed to gas valve and manifold

bracket screw.

CAUTION

115--V WIRING

Verify that the voltage, frequency, and phase correspond to that

specified on unit rating plate. Also, check to be sure that service

provided by utility is sufficient to handle load imposed by this

equipment. Refer to rating plate or Table 7 for equipment

electrical specifications.

Make all electrical connections in accordance with current edition

of National Electrical Code (NEC) NFPA 70 and any local codes

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