Residential Gas Furnaces

Installation Instructions
*RA Full Size Series 80+ High Efficiency Upflow/Horizontal *RK Full Size Series 80+ High Efficiency Downflow

*RA 80+ Upflow/Horizontal

*RK 80+ Downflow

! WARNING:
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier. • •

WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department. Extinguish any open flame.

! FOR YOUR SAFETY:
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all instructions carefully before starting the installation.

Table of Contents
Furnace Specifications ................................................................................................................. 4-5 Upflow/Horizontal Models ....................................................................................................... 4 Downflow Models .................................................................................................................... 5 Capacities-Furnace Airflow Data ........................................................................................ 6-7 Safety Information ............................................................................................................................. 8 Installation Requirements ............................................................................................................ 8-9 Supply Air Plenum Installation ..................................................................................................... 10 Installation on a Concrete Slab ........................................................................................... 10 Installation on a Combustible Floor .................................................................................... 10 Venting and Combustion Air Requirements ................................................................................ 11 General ................................................................................................................................. 11 Installation in an Unconfined Space ................................................................................... 11 Installation in a Confined Space ......................................................................................... 12 Horizontal Furnace Installation ................................................................................... 12 Air From Inside ............................................................................................................. 13 Outdoor Air Using Vertical Ducts ................................................................................ 13 Air Directly Through an Exterior Wall .......................................................................... 13 Outdoor Air Using A Crawl Space and Ventilated Attic ............................................ 14 Outdoor Air Through Horizontal Ducts ....................................................................... 14 Venting Requirements .................................................................................................................... 14 General ................................................................................................................................. 14 Category I - Common Venting ............................................................................................. 15 Category III - Horizontal Venting ......................................................................................... 16 Horizontal Venting for Upflow Models ........................................................................ 16 Horizontal Venting for Downflow Models ................................................................... 17 Horizontal Power Venting .................................................................................................... 18 Vent Termination Clearance ................................................................................................ 19 Location of Outdoor Terminations ....................................................................................... 20 Horizontal Installation .................................................................................................. 20 Flexible Vent Systems .......................................................................................................... 21 Circulating Air Supply .................................................................................................................... 21 General ................................................................................................................................. 21 Return Air .............................................................................................................................. 21 Gas Supply and Piping .................................................................................................................. 22 General ................................................................................................................................. 22 Leak Check ........................................................................................................................... 22 Conversion ............................................................................................................................ 23 High-Altitude Application ...................................................................................................... 23 Natural Gas High Altitude Conversion ................................................................................ 23 LP/Propane Gas Sea Level and High Altitude Conversion ......................................... 23-24 Electrical Wiring ............................................................................................................................. 25 General ................................................................................................................................. 25 Line Voltage Wiring .............................................................................................................. 25 Low Voltage Wiring ............................................................................................................... 26 Start-up & Adjustments .................................................................................................................. 27 General ................................................................................................................................. 27 Start-Up Procedures ............................................................................................................. 27 Verifying and Adjusting Firing Rate .................................................................................... 27 Verifying and Adjusting Temperature Rise .................................................................... 27-28 Verifying Burner Operation .................................................................................................. 29 Verifying Operation of Supply Air Limit Switch ................................................................... 29 Description of Components ........................................................................................................... 29 Wiring Diagram ................................................................................................................................ 30 Maintenance ..................................................................................................................................... 31 Vent System .......................................................................................................................... 31 Air Filter(s) .............................................................................................................................. 31 Lubrication ............................................................................................................................ 32 Blower Compartment ............................................................................................................ 32 Heat Exchanger and Burner Maintenance ......................................................................... 32 Cleaning of Flue Passages ................................................................................................. 32 Cleaning of Burners ............................................................................................................. 33 System Operation Information ...................................................................................................... 33 General ................................................................................................................................. 33 Sequence of Operation ....................................................................................................... 33 Heating Mode ............................................................................................................... 33 Cooling Mode ............................................................................................................... 34 Fan Mode ..................................................................................................................... 34 Furnace Fails to Operate ..................................................................................................... 34 Twinning ................................................................................................................................ 35 Installation/Performance Checklist ............................................................................................. 36

) 11 3/4 11 3/4 11 3/4 17 1/4 11 3/4 17 1/4 17 1/4 20 17 1/4 20 20 Note: (*) Can be C or N Table 1A.000 96.000 144. Upflow Unit Dimensions FURNACE DIMENSIONS AND SHIPPING WEIGHTS Model *RA 045(*)-08 060(*)-12 072(*)-12 072(*)-16 072(*)-17 096(*)-12 096(*)-16 096(*)-20 120(*)-16 120(*)-20 144(*)-20 Furnace Input (Btuh) 45.000 60.000 120.000 A (in.FURNACE SPECIFICATIONS .000 72.000 96.000 72.000 120. Upflow Furnace Dimensions and Shipping Weights 4 .) (lbs) 3 4 4 4 4 4 4 4 4 4 5 123 134 135 152 135 163 163 174 174 182 194 D (IN.) 14 1/4 14 1/4 14 1/4 19 3/4 14 1/4 19 3/4 19 3/4 22 1/2 19 3/4 22 1/2 22 1/2 Dimensions B C (in.) 12 3/4 12 3/4 12 3/4 18 1/4 12 3/4 18 1/4 18 1/4 21 18 1/4 21 21 3 1/4 3 3/4 3 3/4 3 3/4 3 3/4 3 3/4 3 3/4 3 3/4 3 3/4 3 3/4 4 1/4 Shipping Flue Outlet Weight (in.) (in.000 72.000 96.Upflow/Horizontal Models A 23 3/4 3/4 19 3/4 3/4 FLUE OUTLET 3/4 B C 3/4 Unit Shown in Upflow Position Rotate 90˚ Clockwise or Counter Clockwise for Horizontal Application 25 1/8 11/2 X 31/2 Cut-out for Gas Connection 11/2 X 31/2 Cut-out for Gas Connection 43 7/8 Cut-out for Electric Connection 7/8 Cut-out for Electric Connection 33 25 1/4 301/4 251/4 25 5/8 15 Return Air Opening (Side) 20 1/2 7/8 11/4 1 1/4 23 27 5/8 D Return Air Opening (Bottom) 1 1/4 23 Figure 1A.

000 72.000 96.000 135.Downflow Models C 3/4" 3/4" 23 5/8" 19 3/4" 3/4" 4" Dia.out for Gas Connection 3/4" 19 3/4" (Bottom Opening) 27 7/8" B (Bottom Opening) Figure 1B. Downflow Unit Dimensions DOWNFLOW FURNACE MODELS FURNACE DIMENSIONS AND SHIPPING WEIGHTS Model Number *RK 060(*)-12 072(*)-12 072(*)-16 096(*)-12 096(*)-16 120(*)-20 135(*)-20 Furnace Input (Btuh) 60.FURNACE SPECIFICATIONS .000 120. Vent A B 3/4" C L C L 24 1/2" Cut-out for Electric Connection Both sides 43" 25" Cut-out for Gas Connection 1-1/2 x 3-1/2 (both sides) 25" 27 1/8" 15 1/2" 10 1/4" Cut .000 96.000 D ime nsions A B C inches inches inches 14 1/4 12 3/4 5 1/2 14 1/4 12 3/4 5 1/2 19 3/4 18 1/4 11 19 3/4 18 1/4 11 19 3/4 18 1/4 11 19 3/4 18 1/4 11 19 3/4 18 1/4 11 Shipping Weights (lbs) 134 135 147 154 156 182 182 Note: (*) Can be C or N Table 1B. Downflow Furnace Dimensions and Shipping Weights 5 .000 72.

80+ UPFLOW/HORIZONTAL FURNACE MODELS Motor HP 0.7 CFM 0.4 0. Furnace Airflow Data 3/4 1/2 3/4 3/4 47 60 52 78 57 48 53 53 62 72 47 59 69 49 57 71 - 096(†)-20C 96.2 CAPACITIES —Furnace Airflow Data 6 0.000 1/3 072(†)-16B 72. .6 Rise CFM Rise CFM Rise CFM Rise Rise 045(†)-08A 45.000 120(†)-16B 120.1 0.000 3/4 58 60 096(†)-12B 96.000 1/3 072(†)-12A 72.000 1/2 Table 2. .000 High * Medium Low ** High * Medium Low ** High * Medium Low ** High * Med-High Med-Low Low ** High *** Med-High Med-Low Low **** High * Medium ** Low High * Med-High Med-Low ** Low High * Med-High Med-Low Low ** High * Med-High** Med-Low Low High * Med-High Med-Low ** Low High * Med-High** Med-Low Low 1000 760 630 1380 1220 820 1380 1220 820 1980 1710 1490 1270 1950 1500 1160 910 1530 1380 930 1980 1720 1470 1270 2340 1910 1520 1370 1900 1720 1450 1260 2300 1910 1540 1320 2240 1900 1520 1330 970 740 620 1350 1190 800 1350 1190 800 1910 1660 1470 1250 1900 1450 1130 870 1450 1320 900 1910 1670 1440 1240 2290 1880 1510 1350 1830 1670 1420 1230 2250 1880 1530 1310 2190 1860 1510 1310 48 62 50 55 80 50 58 48 54 54 64 74 48 59 69 50 58 72 - 950 730 610 1310 1160 780 1310 1160 780 1830 1610 1420 1230 1810 1420 1090 840 1390 1250 870 1840 1610 1410 1220 2280 1860 1490 1340 1750 1610 1380 1200 2190 1860 1520 1300 2130 1820 1490 1290 50 64 52 58 51 59 49 54 52 56 66 75 49 60 70 51 60 73 51 67 56 61 53 61 40 49 55 56 58 68 77 49 60 71 52 61 73 53 70 59 66 55 64 40 50 56 57 61 71 50 61 72 54 62 75 55 73 64 71 51 57 66 40 50 57 61 64 74 51 62 74 55 64 70 79 55 60 70 41 51 57 65 69 79 45 52 64 75 57 65 - 920 720 600 1260 1120 760 1260 1120 760 1760 1540 1380 1190 1810 1380 1060 810 1300 1190 820 1760 1560 1370 1190 2180 1830 1480 1320 1630 1560 1340 1170 2130 1830 1500 1280 2070 1780 1480 1280 870 690 570 1210 1070 730 1210 1070 730 1660 1470 1320 1140 1770 1340 1030 770 1220 1100 750 1680 1480 1320 1140 2150 1810 1460 1300 1580 1480 1280 1120 2090 1800 1480 1260 2020 1740 1450 1250 820 670 540 1150 1020 700 1150 1020 700 1570 1390 1250 1080 1730 1310 980 740 1130 1020 670 1590 1410 1270 1090 2080 1790 1440 1280 1490 1410 1220 1070 2040 1770 1450 1230 1960 1700 1420 1230 770 640 510 1080 950 670 1080 950 670 1460 1300 1170 1010 1700 1280 940 710 1040 920 580 1500 1320 1200 1040 2000 1770 1420 1260 1400 1320 1150 1020 2000 1740 1420 1200 1910 1660 1390 1210 700 620 470 1000 880 640 1000 880 640 1350 1200 1090 920 1670 1250 900 680 940 820 470 1410 1230 1130 970 1920 1750 1400 1230 1320 1230 1070 960 1950 1700 1390 1170 1850 1620 1360 1180 77 51 59 64 75 41 52 59 69 74 46 53 65 59 67 - † Can be C or N.000 144(†)-20C 144.8 CFM Rise CFM Model Number *RA- Heating Input (Btuh) Motor Speed 1/5 External Static Pressure (Inches Water Column) 0.000 060(†)-12A 60.000 1/2 45 54 55 45 66 43 46 55 57 46 68 43 47 56 58 47 70 44 47 57 60 49 71 46 49 60 62 45 51 74 41 48 51 63 65 47 53 43 50 53 67 48 68 50 57 42 46 54 49 55 72 45 51 71 54 62 40 45 50 59 072(†)-17A 72.5 0.000 120(†)-20C 120.3 Rise CFM CFM Rise 0.000 1/3 096(†)-16B 96.

2.80+ DOWNFLOW FURNACE MODELS 0.6 Rise CFM Rise CFM Rise CFM Rise 1260 36 1230 37 1190 38 40 1110 41 1080 42 1060 43 56 795 57 780 58 770 59 CFM 1120 1010 750 Rise 40 45 60 072(†)-12A 72. Data is for operation with filter(s). Actual temperature rises may vary.000 MOTOR MOTOR SPEED HP HIGH* MEDIUM 1/3 LOW** EXTERNAL STATIC PRESSURE (INCHES OF WATER COLUMN) 0.5 0.2 0.1 0.000 HIGH* MEDIUM LOW** 1/3 1380 1180 830 46 65 1345 1145 810 47 67 1330 1130 805 48 67 1260 1110 795 49 68 1230 1080 780 50 70 1190 1060 770 46 51 71 1160 1040 760 47 52 71 1120 1010 750 49 54 72 072(†)-16B 1/2 72. 7 .000 HIGH* MED-HIGH** MED-LOW LOW 2440 1920 1630 1430 41 51 61 69 2395 1910 1620 1425 42 52 62 70 2385 1900 1610 1415 42 52 62 70 2375 1890 1600 1405 42 53 63 - 2360 1875 1585 1390 42 53 63 - 2340 1870 1580 1380 43 53 63 - 2320 1860 1570 1370 43 54 64 - 2300 1840 1550 1360 44 55 65 - † Can be C or N. Furnace Airflow Data 2440 1920 1630 1430 47 56 63 2395 1910 1620 1425 47 56 64 2385 1900 1610 1415 48 56 64 2375 1890 1600 1405 48 57 64 2360 1875 1585 1390 48 57 65 2340 1870 1580 1380 120.8 MODEL NUMBER *RK CFM 1380 1180 830 Rise 38 55 CFM 1345 1145 810 Rise 40 56 CFM 1330 1130 805 CFM 1160 1040 760 Rise 39 44 60 HEATING INPUT 060(†)-12A 60.4 0. These conditions are not recommended.000 HIGH* MEDIUM** LOW 1/3 1475 1200 795 49 60 - 1460 1195 785 50 61 - 1445 1180 770 50 61 - 1430 1165 755 51 62 - 1410 1145 735 51 63 - 1400 1140 720 52 64 - 1380 1120 710 52 65 - 1360 1110 690 53 65 - 1/2 096(†)-16B 96.Not Recommended NOTES: 1.000 HIGH* MED-HIGH MED-LOW** LOW 48 57 66 2320 1860 1570 1370 49 58 66 2300 1840 1550 1360 49 58 67 135(†)-20B 3/4 135. Temperature rises in the table are approximate. 3. Temperature rises and airflows for external static pressures greater than 0.000 HIGH* MED-HIGH MED-LOW LOW** 1850 1460 1210 1020 45 53 1790 1435 1195 1010 38 45 54 1775 1420 1180 995 38 46 55 1755 1400 1160 975 39 47 56 1735 1380 1140 955 39 48 57 1700 1360 1120 940 40 49 58 1680 1340 1110 930 41 49 58 1650 1320 1090 910 41 50 60 096(†)-12B 96.7 0.000 HIGH* MED-HIGH MED-LOW** LOW 1950 1600 1375 1180 45 53 61 1890 1580 1360 1165 46 53 62 1865 1555 1335 1140 47 54 64 1835 1525 1305 1110 48 56 65 1805 1495 1275 1080 40 48 57 67 1770 1470 1250 1060 41 49 58 68 1730 1450 1230 1030 42 50 59 70 1700 1420 1200 1010 43 51 60 - 120(†)-20B 3/4 Table 2A.3 0. Airflow rates of 1800 CFM or more require two return air connections. ** Factory Set Cooling Speed ** Factory Set Heating Speed .5 are for reference only.

Use a commercially available soap solution made specifically for the detection of leaks to check all connections. 2. 4. located as close to the vent (or chimney) and as close to the center of the air distribution system as possible. 6. Clearances to Combustibles This furnace is Design Certified by CSA International for the minimum clearances to combustible material listed in Table 3. 36 inches is the recommended clearance from the front of the unit. These publications are available from: National Fire Protection Association. Access for positioning and servicing the unit must be considered when locating unit. Please note that a panel or door can be located such that the minimum clearance on the rating plate is satisfied. Never test for gas leaks with an open flame. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace. The *RK gas furnace is for downflow operation only. Refer to the furnace rating plate. The furnace must be installed upstream from a refrigeration system. current revision of the National Fuel Gas Code (ANSI-Z223. Inc. Inc.1). This furnace is certified for use on wood flooring. to allow the furnace to be moved to the installation point. 30 inches is the minimum required clearance from the front of the unit for positioning it. 1430 Broadway New York. and/or personal injury. for the specific model number and clearance information. The furnace is not to be used for temporary heating of buildings or structures under construction. Combustion products must be discharged outdoors. or any combustible material other than wood flooring. A gas-fired furnace for installation in a residential garage must be installed as specified on Page 9 of these instructions. 7. tile. This furnace is not to be used for temporary heating of buildings or structures under construction. as specified on Page 21 of these instructions. See Table 1 for overall dimensions to determine the required clearances in hallways. Provide adequate combustion and ventilation air to the furnace space as specified on Pages 11 through 18. located inside of the furnace cabinet. etc. Refer to the furnace rating plate. This furnace must not be installed directly on carpeting. Install this furnace only in a location and position as specified on Table 3 of these instructions. but that panel or door must be removable and allow the appropriate clearance for your installation. as specified on Table 2 of these instructions. The furnace must be installed on a level surface. 8. See furnace rating plate. Connect this furnace to an approved vent system only. 5. Use only with type of gas approved for this furnace.SAFETY INFORMATION 1. 9. the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. 3. stairs. The furnace must be installed so that all electrical components are protected from water. Installation in a mobile home could cause fire.Warm Air Heating and Air Conditioning Systems 8 . Location Upflow gas furnaces are shipped ready for installation in the upflow or horizontal right or left positions. Batterymarch Park Quincy. doorways. New York 10018 Additional helpful publications are: NFPA-90A . Massachusetts 02269 ! WARNING: This furnace is not approved for installation in mobile homes. INSTALLATION REQUIREMENTS Requirements and Codes This furnace must be installed in accordance with these instructions. as specified on Pages 14 through 18. 24 inches is the minimum required clearance from the front of the unit for servicing it.B149 installation code. and in Canada with the CAN/CGA . Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range.Installation of Air Conditioning and Ventilating Systems NFPA-90B . all applicable local building codes. The current revision of the National Fuel Gas Code is available from: American National Standards Institute. property damage.

the sub-base is not necessary. furnace must be installed on non-combustible flooring. part number 904165. Failure to install the subbase may result in fire. or any combustible material other than wood flooring. tile. BOTTOM Table 3. A special combustible floor sub-base is required when installing on a combustible floor. property damage and personal injury. Allow 24" minimum clearance for servicing. the plenum attached to the coil casing must be installed such that its surfaces are at least 1" from combustible construction. ! CAUTION: The downflow sub-base must not be installed directly on carpeting. When the furnace is installed on a factory or site-built cased air conditioning coil.Downflow Warning (*RK Models): The design of the downflow furnace is certified for natural or propane gas and for installation on non-combustible flooring. Upflow Furnace Models UPFLOW APPLICATION TOP SIDE LEFT SIDE RIGHT SIDE TOP BOTTOM HORIZONTAL APPLICATION SIDE BOTTOM Downflow Furnace Models INSTALLATION CLEARANCES Vent Connector Type LEFT SIDE RIGHT SIDE VENT BACK BOTTOM TOP FRONT TOP Standard Single Wall Metal Vent 0" 0" 6" 0" 0"** 1" 4"*** Type B-1 Double Wall Metal Vent 0" 0" 1" 0" 0"** 1" 4"*** LEFT SIDE RIGHT SIDE ** *** For Downflow furnace installations only. Minimum Clearances to Combustible Material 9 . The recommended clearance is 36". However. The special downflow subbases are factory supplied accessories.

Downflow Sub-Base Dimensions Sheet Metal Plenum Figure 3. . *RK 060-12. Furnace with Coil Assembly on a Wood Floor Figure 4. 072-12 Figure 2. 135-20 Hole in Floor *RK 060-12. Installation on a concrete slab.*RK 1.75" 13.63" 13. Place the plenum and the furnace as shown in Figure 3. 072-12 Figure 6. 096-12. including gasoline and any other flammable vapors and liquids.75" 20. 18. . 120-20. 096-12.25" Hole in Floor Hole in Floor 19. Do not place combustible materials. and the furnace must be located or protected to avoid physical damage by vehicles. Opening in Wood Floor 10 . Install the sub-base according to the installation instructions. Construct a hole in the floor per the dimension in Figure 2. 2. 2. B.25" Downflow Sub-base Furnace Wood Floor *RK 072-16. 1. Installation on a combustible floor. Opening for Concrete Slab Sheet Metal Plenum Concrete Floor Furnace Figure 5. 096-16. 120-20 135-20. this furnace is approved for use on combustible flooring when NORDYNE combustible floor sub-base kit #904165 is used. Supply Air Plenum Installation A.63" Sheet Metal Plenum 1" Minimum Hole in Floor *RK 072-16.*RK For downflow furnace installation. Cut hole and frame the hole per the dimensions in Figure 4.25" 19. Furnace on a Concrete Slab Furnace Coil Assembly Wood Floor 18. (See Figure 5) ! WARNING: Do not place combustible material on or against the furnace cabinet or within 6 inches of the vent pipe.25" 20. in the vicinity of the furnace. 096-16.A gas-fired furnace installed in a residential garage must be installed so the burners and the igniter are located not less than 18 inches (457 mm) above the floor.

• Hydrochloric acid • Cements and glues • Antistatic fabric softeners for clothes dryers • Masonry acid washing materials ! CAUTION: Combustion air must not be drawn from a corrosive atmosphere. If the furnace is installed in a confined space it is recommended that the necessary combustion air come from the outdoors by way of attic. If the space has an 8 foot ceiling. the plenum attached to the coil casing must be installed such that its surface is at least 1” from combustible material in Figure 6. 2.000] to be considered unconfined. These safety devices are manually reset switches. a space including a water heater rated at 45. the combustion air must be free of chemicals which form corrosive acidic compounds in the combustion gases. varnishes. Air openings in the furnace door. For example.000 cubic feet [50 x (45 + 75) = 6. 3. However. The recommended source of combustion air is to use the outdoor air supply. the floor area of the space must be 750 square 11 . Consult local codes for special requirements. The following types of installation may require Outdoor Air for combustion. or direct opening. etc.1 or .2). the use of indoor air in most applications is acceptable except as follows: 1.3.000 Btuh input and a furnace rated at 75. However. turning off the gas supply to the burners. For Canadian installations consult Canadian Installations Codes and (CAN/CGA B149. use only the correct part specified in the Replacement Parts List. If a switch must be replaced. Detailed instructions for determining the adequacy of an installation can be found in the current revision of the National Fuel Gas Code (ANSI Z223. the sub-base is not necessary. crawl space.1 / NFPA54) or in applicable local building codes. there must be no exposure to the installations or substances listed in Item 3 below.000 Btuh of the combined input rates of all appliances which draw combustion air from that space. DO NOT install jumper wires across these switches to defeat their function. and return air grilles must not be restricted. paint removers. If outdoor combustion air is used. air duct.000 Btuh requires a volume of 6. VENTING AND COMBUSTION AIR REQUIREMENTS General Provisions must be made in the installation of this furnace to provide an adequate supply of air for combustion. Installation In An Unconfined Space An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1. warm air registers. DO NOT reset a switch without identifying and correcting the fault condition. If the furnace is operated with inadequate air for combustion one of the flame roll-out switches located in the burner compartment or the vent switch will open. When the furnace is installed on a factory or site-built cased air conditioning coil. Combustion Air Quality To maximize heat exchanger life. ! WARNING: Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the furnace. due to chemical exposures: • Commercial buildings • Buildings with indoor pools • Furnaces installed in laundry rooms • Furnaces installed in hobby or craft rooms • Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply may also require Outdoor Air for combustion: • Permanent wave solutions • Chlorinated waxes and cleaners • Chlorine based swimming pool chemicals • Water softening chemicals • De-icing salts or chemicals • Carbon tetrachloride • Halogen type refrigerants • Cleaning solvents (such as perchloroethylene) • Printing inks.

Keep all insulating materials away from the louvered door. The required sizing of these openings is determined by whether inside or outside air is used to support combustion. Refer to Table 3. The furnace could also be suspended by an angle iron frame bolted to the rafters. in “tight” buildings (with weather stripping and caulk to reduce infiltration). fireplaces. (See Figures 7 and 8. even though the furnace is located in an unconfined space. In general. or other devices that may produce a negative pressure should be considered confined space installations. for clearance specifications. Installation In A Confined Space A confined space is an area with volume less than 50 cubic feet per 1.) If the furnace is to be suspended from the ceiling. basement. if type "B-1" vent pipe is used (See Figure 8).000 / 8 = 750). *RA Horizontal Installation Suspended in Attic or Crawl Space Note: Line Contact is Permissible Gas Inlet Type “B” Vent Coil Plenum Electrical Supply Connection Combustible Platform Louver Door Figure 8. and the other must be within 12 inches of the floor. One opening must be within 12 inches of the ceiling. *RA Horizontal installation on a Platform 12 . the method by which the air is brought to the space. However. It can be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow.000 Btuh of the combined input rates of all appliances drawing combustion air from that space. The *RA series furnace may be installed directly on combustible wood flooring or supports. ! WARNING: Furnaces installed with combustion air drawn from a heated space which includes exhaust fans. it may be necessary to provide outside air to ensure adequate combustion and venting. it will be necessary to use steel straps around each end of the furnace. Figure 7. Furnaces installed in a confined space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace. crawl space or alcove. and by the total input rate of all appliances in the space.) Access for positioning and servicing must be considered when locating the unit. Horizontal Furnace Installation The *RA series furnaces can be installed horizontally in an attic. a furnace installed in an unconfined space will not require outside air for combustion. Minimum Clearances to Combustible Material. Insulating materials may be combustible. These straps should be attached to the furnace with sheet metal screws and to the rafters with bolts. small equipment rooms and garages are confined spaces.feet (6. Furnace closets. A confined space must have two openings into the space for combustion air. It is recommended for further reduction of fire hazard that cement board or sheet metal be placed between the furnace and the combustible floor and extend 12 inches beyond the front of the louvered door. (See Figure 7.

both air ducts must extend above the attic insulation. in. For example. in. in. 12" Max Water Heater a. Total Input Rating (Btu/hr) 40. ! CAUTION: Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure. 30 sq. in.000 140. Outdoor Air Using Vertical Ducts (See Figure 10) If combustion air is taken from outdoors through vertical ducts. in. in. Round Duct Diameter 12" 12" 12" 12" 13" 14" 15" Vent or Chimney Figure 9. each opening must have a free area of at least 120 square inches. in. Each opening must be at least 100 sq.000 60.000 140.000 100. 25 sq.000 120. 15 sq. Equipment in a Confined Space with all Combustion Air Drawn from the Inside Vent or Chimney Ventilation Louvers at each end of attic Outlet Air Duct must be at least 1 sq. in. in. each opening must have a free area of at least 100 square inches. Air From Inside (See Figure 9) If combustion air is taken from the heated space. If the combined input rate of all appliances is 120. Attic Insulation Inlet and Outlet Ducts must extend above attic insulation. the two openings must each have a free area of at least one square inch per 1. Round Duct Diameter 4" 5" 5" 6" 6" 7" 8" Round Duct Diameter 4" 5" 5" 6" 6" 7" 8" Figure 10. 160 sq. All Combustion Air from Ventilated Attic.000 Btuh of total input rating. Water Heater Total Input Rating (Btu/hr) 40. 40 sq. in.000 Water Heater Minimum Free Area (Each Opening) 10 sq. in. 25 sq.000 Btuh of total input rating. in. 120 sq. 20 sq.000 60. - 12" Max Furnace Inlet Air Duct must be at least 1 sq. in. 20 sq. Vent or Chimney Openings to adjacent space.000 160.000 100. per 4. in.000 120. in.000 120. in. in. provide sufficient ventilation to prevent negative pressures from occurring in the room. whichever is greater. in.000 Btuh.000 80. 100 sq. in. 30 sq.000 Minimum Free Area (Each Opening) 10 sq. Air Directly Through An Exterior Wall (See Figure 11) 12" Max. Each opening to outside must be at least 1 sq. per 1000 Btuh of total input rating.000 Minimum Free Area (Each Opening) 100 sq. 15 sq. Furnace 12" Max Total Input Rating (Btuh) 40.000 60. but not less than 100 square inches of free area. in. in. per 4. if the combined input rate of all appliances is less than or equal to 100. per 4000 Btuh of total input rating. The combustion air openings must not be restricted in any manner. in.000 80.See the venting section for venting guidelines and specifications. 140 sq.000 Btuh of total input of all appliances in the confined space.000 Btuh of total appliance input. 40 sq. or 1 sq. in. 100 sq.000 100.000 Btuh. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Exterior Wall 13 .000 80. Furnace 12" Max. in. 35 sq. in. 35 sq. the openings and ducts must have a minimum free area of one square inch per 4. In installations drawing combustion air from a ventilated attic.000 160.000 160. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Vertical Ducts Figure 11. See minimum area per table. 100 sq. in.000 140. If the unit is installed in an area with an exhaust fan.

per 4000 Btuh of total input rating.2) installation codes.000 60. or by ducts. the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input. Each opening to outside must be at least 1 sq. Vent or Chimney Ventilation Louvers at each end of attic Outlet Air Duct must be at least 1 sq.000 160.000 80. with the outdoor spaces (crawl or attic) that freely communicate with the outdoors. in. 60 sq. each opening shall have a minimum free area of 1 square inch per 4. Water Heater Ventilation Louvers for unheated crawl space Bleed Tube Crawl Space Figure 12.If combustion air is provided directly through an exterior wall. Equipment in a Confined Space with All Combustion Air Drawn from a Crawl Space and Ventilated Attic Sensor Tubes Bleed Tube Orifice . Attic Insulation Figure 13. 80 sq. in. Outdoor Air Using a Crawl Space and Ventilated Attic (See Figure 12) When directly communicating with the outdoors.000 Btuh of total appliance input.Press switch operat at high altitud can be made responsive by covering blee orifice Collector Pan Figure 14. with the instructions provided below.000 140. in. If the unit is installed in an area with an exhaust fan. 40 sq. 12" Max Total Input Rating (Btu/hr) 40. the current revision of the National Fuel Gas Code (ANSI-Z223. in. If the furnace vent is to be connected to a chimney serving a fireplace. This furnace must never be vented to a chimney flue servicing a fireplace or other appliance designed to burn solid fuel. in. *RA Bleed Tube Installation 14 - VENTING REQUIREMENTS - - - 12" Max Air Duct - Air Duct - Round Duct Diameter 5" 6" 7" 8" 9" 10" 10" .000 Btuh of total appliance input.000 100. the openings and ducts must have a minimum free area of one square inch per 2. per 4. in. 50 sq. 70 sq. the furnace shall be connected to a factory built chimney or vent complying with a recognized standard. in. the fireplace must be sealed off from Vent or Chimney Outdoor Air Using Horizontal Ducts (See Figure 13) If combustion air is taken from outdoors through horizontal ducts. In Canada. For Category I furnace installations. The openings shall communicate directly. per 2000 Btuh of total input rating. Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Horizontal Ducts Pressure Switch Furnace Inlet Air Duct must be at least 1 sq. provide sufficient ventilation to prevent negative pressures from occurring in the room.000 Water Heater Minimum Free Area (Each Opening) 20 sq. The combustion air openings must not be restricted in any manner. or a masonry or concrete chimney lined with a lining material acceptance to the authority having jurisdiction. in. Consult local codes for special requirements. venting shall conform to the requirements of the current (CAN/CGA B149. in.1 or . 30 sq. Venting into an unlined masonry chimney or concrete chimney is prohibited. Must extend above attic insulation. in. Furnace General This furnace must be vented in compliance with.000 120.000 Btuh of total input rating.1/NFPA54).

As far as practical. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Natural Gas and Propane Installation Codes. 3. These fasteners should be evenly spaced around the flue diameter. Turn on clothes dryers and any appliance not connected to the venting system. may be insulated if local codes allow. such as range hoods and bathroom exhausts. 9. the venting system is likely to be too large to properly vent the remaining appliances. Inspect the venting system for proper size and horizontal pitch. 5. windows. 6. leakage. 8. ANSI Z223.the chimney. corrosion and other deficiencies which could cause an unsafe condition. Close fireplace dampers. Natural Gas and Propane Installation Codes and these instructions. leakage. while all other appliances connected to the venting system are not in operation: 1. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above. Determine that there is no blockage or restriction. Category I . Adjust the thermostat so appliance is operating continuously. Use the flame of a match or candle. but which are exposed to ambient temperatures below 35° F must be insulated to prevent condensation. as required in the National Fuel Gas Code. The following steps shall be followed for each appliance connected to the venting system being placed into operation. etc. 15 . Single wall metal vents shall not be used for Category I venting. The furnace vent. not exposed to weather.1/NFPA 54 and/or CSA B149. An improperly sized venting system can result in the formation of condensate. Category I furnaces must be vented vertically or near vertically. 4. metal vent only. while all other appliances connected to the vent system are not in operation: ! WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. if possible. so they are operating at maximum speed. All vent insulation shall be foil backed fiberglass of one inch minimum thickness. exhaust fans. Do not operate a summer exhaust fan. the venting system must be corrected in accordance with the National Fuel Gas Code. Any part of the vent system. Turn on any exhaust fans. If improper venting is observed during any of the above tests. Place the appliance being inspected into operation.1.Common Venting When an existing furnace is removed from a venting system serving other appliances. The steps outlined in the warning below shall be followed with each individual appliance connected to the vent system placed in operation. spillage. Seal any unused openings in the venting system. 2. close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. 1/NFPA 54 or the CSA B149. if metal. 7. ANSI Z223. Three sheet metal fasteners (field supplied) should be used to secure the vent pipe to the furnace flue. Follow the lighting instructions.1. fireplace dampers and any other gas-fired burning appliance to their previous conditions of use. return doors.

use only the part specified in the Replacement Parts List. Select the appropriate dilution cover plate as noted with vent kit #903196. The blocked vent switch is a manually reset device. Vent Collar Detail Blue Switch Limit Switch Flame Roll-Out Switch Vent Limit Wire Nut Blue Figure 16. This pipe is available from the following manufacturers: Z-FLEX Inc. DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip.The venting system should be designed to have the minimum number of elbows or turns. When venting horizontal. ! WARNING: Upon completion of the furnace installation.) Cover Plate Covered Vent Collar Hole Nut Figure 15. Category III: Horizontal Venting NOTE: The reduced NOx models (eighth character N) are not approved as a Category III (Category III) furnace for use with horizontal venting. The furnaces are approved for use with 3" single wall AL29-4C stainless steel vent pipe in horizontal vent applications. Fit the clearance hole in the cover plate over the weld stud. If this switch must be replaced. Bypass the vent switch by removing both wires from the vent switch and attaching them to the wire nut.vent brand name (Star34 Vent) This vent pipe must be used for the entire length of the vent run. All model furnaces will require Vent Kit #903196 for horizontal venting. Tighten the nut securely while holding the cover plate in position. Limit Circuit Wiring . (See Figure 14. . vent manufacturer for use on Category III appliances.vent brand name (Saf-T Vent) Flex-L International . All horizontal runs shall be sloped upwards from the furnace at 1/4 inch per running foot of vent. NOTE: No bleed tube is required for the *RA 045(C. Leaks in the flue system can result in serious personal injury or death due to exposure of flue products. or plenum. and the venting system must be sealed in both horizontal and vertical runs. Do not cover the hole in the bleed tube. Discard the 1/2 inch long piece of tubing. Place the assembly back on the pressure switch sensor tube and the collector pan sensor tube. Remove the nut and restrictor plate from the vent collar assembly and discard the restrictor plate. Cut 1/2 inch from one end of the rubber sensor tube. Remove the rubber tubing from the pressure switch sensor tube and the collector pan sensor tube.) 3. including carbon monoxide. (See Figure 15. . the blocked vent switch located in the vent plate will open. The cover plate must cover the hole(s) on the vent collar assembly. supply air duct. DO NOT install a jumper wire across this switch to defeat its function. If the furnace is operated with blocked or restricted venting. Select the correct bleed tube using the table supplied with vent kit #903196 and place the other two pieces of tubing on both ends of the bleed tube. the vent pressure is positive.vent brand name (Z-VENT) Heat-fab Inc.N)-08 model. fold in half and cut along the bend line. (See Figure 16. Supports for the vent pipe must be installed a minimum of every five feet along the vent run to ensure no displacement after installation. For horizontal venting installations in both the United States and Canada the transition assembly must be modified by adding a bleed tube to the pressure switch tube and bypassing the vent switch. The installation must be in accordance with all instructions supplied by the 16 Horizontal Venting For Upflow Models: 1. Under no circumstances shall any portion of the vent system extend into or pass through any return air duct. this is defined as a Category III furnace. turning off the gas supply to the burners. carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed.) 2.

either when joining pipes and fittings or using support straps. All joints must be sealed with high temperature silicone before locking bands are installed. When installing the condensate tube be sure to form a trap by means of a 3" loop filled with water. strip wires and tie together in a wire nut. Remove wire terminals. The components of the horizontal vent system must not be penetrated with screws. by removing both wires from the switch. Do not cover the hole in the bleed tube.) 5. or rivets. Combustion Tube Remove and Discard Screw ! CAUTION: Do not drill holes through the vent pipe or fittings on a horizontal vented furnace.) 2. (See Figure 18. NOTE: The direction of the male-female joints from the drain tee to the termination tee is opposite to standard gas appliance venting. located on blower compartment door. remove and discard the combustion tube from the transition assembly.) 3. (See Figure 20.) Keep the number of pipe fittings to a minimum. (See Figure 17. *RK Bleed Tube Installation Figure 19. Insert the bleed tube into the tubing. *RK Reducer Installation 17 . By-pass the vent switch. this includes inside and outside the building. Install and seal a 4" to 3" reducer to the transition. Maintain a minimum of 6 inches of air space between the vent and combustibles at all times.) Attach the new high temperature vent pipe to the reducer. Restrictor Plate Transition Inducer Figure 18. the joint must still be sealed with silicone and the locking band used. Place the tubing assembly back on the pressure switch sensor tube and collector pan sensor tube. screws.) 4. (See Figure 18. (See Figure 16. Do not use sheet metal screws. or other devices. rivets. Remove and discard the restrictor plate and screw from the transition assembly. Insure the seal between inducer and transition assembly is not broken. *RK Horizontal Vent Modification Collector Pan Bleed Tube Bleed Tube Orifice Pressure Switch Special 3" AL29-4C Stainless Steel Vent Pipe 4" to 3" Reducer Transition Figure 17.Horizontal Venting: *RK Models: 1. or rivets will cause leaks. (See Figure 19. Remove the rubber tubing from the pressure switch sensor tube and the collector pan sensor tube. The male end of the pipes point towards the furnace. Drilling. If the lengths of pipe must be cut. To gain access to the restrictor plate. Select the appropriate dilution cover plate as noted with vent kit #903196. Cut the tubing approximately 3" from one end.

Loop Furnace Model Number Pipe Reducer Maximum Max. Horizontal runs must be supported with 3/4" pipe strap at a maximum of 5 foot intervals and at each point where an elbow is used. High TEMP RED. 2. Recommended sealants: Dow Corning Sealant 736 RTV. uninterrupted ring of adhesive material around the pipe at the fitting socket. GE 106 RTV. a sidewall vent hood and a barometric draft control. The kit includes a power venter. Push the pipe and fitting together while twisting the pipe or fitting. All horizontal sections must have a slope toward the drain tee of not less than 1/4" per foot to prevent the collection of condensate at any location other than at the tee.1. When the pipe is at the socket bottom. ! WARNING: The entire vent system must be sealed with a high temperature sealant which will withstand temperatures of 450°F.. The complete adhesive material ring provides the seal required for the positive pressure vent. Horizontal Venting Requirements Furnace Model Number Pipe Reducer Maximum Max. Feet *RA Size Needed # Elbows Vent Pipe 045C-08 3" None 4 35 060C-12 3" 4" to 3" 4 35 072C-12 3" 4" to 3" 4 35 072C-16 3" 4" to 3" 4 35 072C-17 3" 4" to 3" 4 35 096C-12 3" 4" to 3" 4 35 096C-16 3" 4" to 3" 4 35 096C-20 3" 4" to 3" 4 35 120C-16 3" 4" to 3" 4 35 120C-20 3" 4" to 3" 4 35 144C-20 3" 4" to 3" 3 30 Note: Special 5" to 4" Reducer Kit. Installation Instructions are provided with the kit. Installation must conform to those instructions and applicable requirements of local codes. All vent systems must include a tee and drain plug for collection and disposal of condensate. Additional adhesive or rotation of the pipe or fitting may be required for a complete seal. Horizontal Venting Requirements . 7. 3. Support Locking Band 90˚ Elbow Tee Drain Plug Wall Thimble (For combustible wall material) Locking Band 0-6' 1/4" Per Foot Rise Termination Tee Outside Wall 3" Dia. 6. The power venter establishes negative pressure in the vent piping and the furnace operates as if connected to Category I vertical venting. The kit is for use only when exhaust is through an exterior wall. except when a wall thimble is used. Typical Horizontal Vent Installation 18 Table 4. Horizontal Power Venting — The Tjerlund GPAK1TN horizontal kit is certified for use with this furnace. Apply an adhesive bead around the outside of the pipe approximately 1/4" from the end of the pipe. inspect the joint. The drain tee must be installed within the first 5 feet of vent run to protect the furnace. It has an electrical interlock to assure that the furnace will not operate when the power venter is off. Twisting the pipe or fitting spreads the adhesive completely within the fitting socket. p/n 902249 required for model number *RA144C-20. Maintain a 6 inch minimum air space to combustibles from all sections of the stainless steel vent system. 5. Look for a complete. Feet Size Needed # Elbows Vent Pipe *RK 060C-12 3" 4" to 3" 4 35 072C-12 3" 4" to 3" 4 35 072C-16 3" 4" to 3" 4 35 096C-12 3" 4" to 3" 4 35 096C-16 3" 4" to 3" 4 35 120C-20 3" 4" to 3" 4 35 135C-20 3" 4" to 3" 4 30 Figure 20. High Tech Ind. normally with horizontal vent piping. This includes the first fitting or pipe attached to the furnace. 4.

deck.1 Natural Gas and Propane Installation Code In accordance with the current ANSI Z223.VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED A = Clearance above grade. 36 inches (91 cm) for appliances >100.000 Btuh (3 kW) and ≤ 100.13 m) † 12 inches (30 cm) ‡ 3 feet (91 cm) above if within 10 feet (3 m) horizontally 7 feet (2.1 / NFPA 54 National Fuel Gas Code † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Btuh (3 kW). deck. Btuh (3 kW).1. veranda.00 Btuh (30 kW).00 Btuh (30 kW) 6 feet (1.00 Btuh (30 kW) * * * * C = Clearance to permanently closed window D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal E = Clearance to unventilated soffit F = Clearance to outside corner G = Clearance to inside corner H = Clearance to each side of center line extended above meter/regulator assembly I = Clearance to service regulator vent outlet J = Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance * * * * * * 3 feet (91 cm) within a height 15 feet * above the meter/regulator assembly 3 feet (1.1 / NFPA 54 or CSA B149. porch deck. and the requirements of the gas supplier and the manufacturer’s installation instructions.2 m) below or to side of opening. or balcony 1 2 * In accordance with the current CSA B149. 12 inches (30 cm) for 1 foot (300 mm) above opening appliances > 10.83 m) * 6 inches (15 cm) for appliances ≤ 10.000 4 feet (1.13 m) K = Clearance to a mechanical air supply inlet L = Clearance above paved sidewalk or paved driveway located on public property M = Clearance under veranda. one of the following statement shall be included: “Clearance in accordance with local installation codes. porch. porch.83 m) 7 feet (2. ‡ Permitted only if veranda. 12 inches (30 cm) for 1 foot (300 mm) above opening appliances > 10.” Figure 21.000 4 feet (1. or balcony is fully open on a minimum of two sides beneath the floor. * For clearances not specified in ANSI Z223.000 Btuh (3 kW) and ≤ 100. 36 inches (91 cm) for appliances >100.00 Btuh (30 kW). or balcony B = Clearance to window or door that may be opened Canadian Installations 12 inches (30 cm) 1 US Installations 12 inches (30 cm) 2 6 inches (15 cm) for appliances ≤ 10.2 m) below or to side of opening. Vent Termination Clearances for Direct Vent Furnaces 19 .

Location of Outdoor Terminations Horizontal Installation The vent termination tee must be installed with the following minimum clearances. Avoid areas where condensate drainage may cause problems such as above planters. (See Figure 23. Be sure to check this carefully before cutting the vent pipe. Penetrating a combustible wall requires the use of a wall thimble.1/NFPA 54 and/or the CSA B149. 6. 3.) A 6-1/2 inch square framed opening is required to insert the thimble halves. (See Figure 21. ANSI 2223. Attach a 3 inch coupling to the end of the pipe that extends through the wall or thimble. Natural Gas and Propane Installation Code. The inside of the tee must be a minimum of 12 inches from the outside of the wall. Do not terminate above any public walkway. patios. The termination tee must be 12 inches above snow level or grade level which ever is higher. The thimble is adjustable to varying wall thickness and is held in place by applying sealant to the male sleeve before assembly. 5. When penetrating a noncombustible wall. 2. the hole through the wall must be large enough to maintain the pitch. pipe clearance for passage. or adjacent to windows where the steam from the flue gases may cause fogging. Also run a bead of sealant around the outer wall thimble.) Vent termination clearances shall be consistent with the National Fuel Gas Code. All minimum clearances specified must be maintained to protect building materials from degradation by flue gases. Cut an 8 inch minimum piece of vent pipe and connect the coupling to the termination tee. 7. See Figure 22 for alternate method to achieve 12" above snow level.) Use Wall Thimble at Vent Points Termination Tee Support Ground Level Figure 22. (See Figure 22. This prevents the vent pipe from being pushed inward. 1. and provide for proper sealing. Select the point of wall penetration where the minimum 1/4 inch per foot of upward slope can be maintained.1. 4. Alternate Horizontal Vent Installation 20 . The vent pipe must extend 1-1/4 inches through the outer thimble half for a combustible wall.

Wall Thimble Outer Half Locking Band Protective Screen Inner Shield 41/2" Dia. NOTE: Do not use the back of the furnace for return air. Typical Termination . right side return. This opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. If outside air is used as return air to the furnace for ventilation or to improve indoor air quality. the vent manufacturer's instructions and the instructions listed below. two openings must be used for return air. indoor return air applications. If a cooling system is installed in parallel with the furnace. the coil must be installed downstream (on the outlet side) of the furnace or in parallel with the furnace. If a manually operated damper is installed.Flexible Vent Systems Flexible gas vent is approved for use in vertical single vent or common vent installations only. If a combination of indoor and outdoor air is used. The vent must not sag. The flexible vent must be installed in accordance with the venting tables for vertical or common venting only. All horizontal sections must have a slope toward the furnace of not less than 1/4" per foot. It is recommended that the outlet duct be provided with a removable access panel. 90B). the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal. a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger. or bottom return. is not less than 50° F (10° C) during operation. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. The minimum distance to combustibles is 1" for type B insulated and 6" for single wall. The cover for the opening shall be attached in such a manner as to prevent leaks. including carbon monoxide poisoning that could result in personal injury or death. The venting system must be installed in accordance with the local authorities. the system must be designed so that the return air Inside Combustible Wall Wall Thimble (Inner Half) 3" Vent Pipe Outer Overlapping Shield 61/2" Dia. or have any bends greater than 90 degrees. When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil. The vent system must be supported in horizontal runs with 3/4" pipe strap at a maximum of 5 foot intervals. Return Air In applications where the supply ducts carry heated air to areas outside the space in which the furnace is installed. contains the airflow data for each furnace model. Table 2 and 2a. it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position. ! WARNING: The solid base of the furnace must be in place when the furnace is installed with side return air ducts. Inside Combustible Wall Inner Overlapping Shield 63/8" Dia. the return air must be delivered to the furnace by duct(s) sealed to the furnace casing. 21 Figure 23. Removal of all or part of the base could cause products of combustion to be circulated into the living space and create potentially hazardous conditions. running full size and without interruption. Where maximum airflow is 1800 CFM or more. in the front pages of these instructions. 3" Termination Tee 12" Min Outside Combustible Wall For upflow/horizontal installations: The return air ductwork may be connected to any or all of the following: left side return. CIRCULATING AIR SUPPLY General Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No.

Typical Gas Service Connection 22 . All return ductwork must be secured to the furnace with sheet metal screws. A typical gas service hookup is shown in Figure 24. All gas piping must be installed in compliance with local codes and utility regulations. or sagging between the furnace and the floor or platform. For installations in confined spaces.Left Side Entry Manifold General This furnace may be installed for either left or right side gas entry. IMPORTANT NOTES: 1. 2. or property damage. elevator shafts. A drip leg should be installed in the vertical pipe run to the unit.GAS SUPPLY AND PIPING ! WARNING: Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Upflow Models. Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert. explosion. all connections must be tested for gas leaks. stove. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shutoff. Compounds used on threaded joints of gas piping must be resistant to the actions of liquefied petroleum gases. Doing so may result in fire. gas vents. In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code (ANSI Z223. carbon monoxide poisoning. chimneys. The shut-off valve should be readily accessible for service and/or emergency use. Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace.1 or .Right Side Entry Shut-Off Valve Some utilities require Shut-Off Valve to be 4 to 5 feet above floor Automatic Gas Valve (with manual shut-off) Ground Joint Union Burner Assembly Dripleg Manifold Figure 24. To check for leaks in gas piping systems. the joint between the furnace and the return air plenum must be air tight. The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps. use only a soap and water solution or other approved method. Gas piping must not be run in or through air ducts. 3.2) Installation Codes.1) or (CAN/CGA B149. The tap should be readily accessible for service use. cracks. When return air is provided through the bottom of the furnace. Leak Check After the gas piping to the furnace is complete. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. etc. Shut-Off Valve Some utilities require Shut-Off Valve to be 4 to 5 feet above floor Automatic Gas Valve (with manual shut-off) Burner Assembly Ground Joint Union Dripleg Downflow Models. all return ductwork must be adequately sealed and joints must be taped. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace. An 1/8 inch NPT tap must be installed in the gas line to the unit for use when measuring the gas supply pressure. The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required. etc. personal injury. Table 5 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

using only approved parts. Conversion of this furnace to utilize LP/propane gas must be made by qualified service personnel. For higher altitudes (between 5000 and 10. CAPACITY OF BLACK IRON GAS PIPE (CU. lighters. The heating values used in Tables 6 & 7 are based on sea level values. a. Never test for gas leaks with an open flame. LP/Propane Gas Sea Level and High Altitude Conversion IMPORTANT NOTE: When converting a low NOx furnace from Natural gas to LP/propane gas. using factory authorized or approved parts. High Altitude Application High altitude application with this furnace can be field performed by a simple adjustment of manifold pressure. above sea level). To determine the cubic feet per hour of gas flow required by the furnace. death or property damage. candles. property damage.).60) . or death. personal injury or loss of life.0. divide the input rate of the furnace by the heating value of the gas: Cubic Feet Per Hour Required Input To Furnace (Btu/hr) Heating Value of Gas (Btu/Cu. personal injury. Ft.60) NOMINAL BLACK IRON PIPE DIAMETER (in. The heating value of gas at high altitude is always lower than the sea level heating value. ft. the furnace must be disconnected from the gas supply piping system to prevent damage to the gas control valve.! CAUTION: Do not use matches. it is necessary to remove the NOx Baffles from the furnace. #54 or #55 drill size orifice should be used depending upon the rated firing rate of the unit (see 23 ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury. carbon monoxide poisoning. If the test pressure is less than or equal to 1/2 psig (14 inch W. above sea level. Capacity of Black Iron Gas Pipe (cu. and if necessary changing the orifices.C. FT. The changes required depend on the installation altitude and the heating value of the gas. ! WARNING: This furnace was equipped at the factory for use with natural gas only. Conversion Conversion of this furnace to use LP/propane gas must be made by qualified service personnel. #53. explosion.C. Conversion to LP/propane gas can be accomplished by first replacing the natural gas orifices with the appropriate LP/propane orifices shown in Table 8 or 9. above sea level. Natural Gas High Altitude Conversion All factory shipped furnaces are ready to operate between zero and 4999 ft. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY .) 1/2 3/4 1 1 1/4 1 1/2 LENGTH OF PIPE RUN (feet) 10 130 280 520 1050 1600 20 90 190 350 730 1100 30 75 150 285 590 890 40 65 130 245 500 760 50 55 115 215 440 670 60 50 105 195 400 610 70 45 95 180 370 560 80 40 90 170 350 530 The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace. or other sources of open flame to check for gas leaks. Note: for installations between zero and 5000 ft. A special kit. conversion can be achieved simply by adjusting the furnace manifold pressure as shown in Table 6. the furnace must be isolated from the gas supply line by closing the manual shut-off valve. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. IMPORTANT NOTE: When pressure testing the gas supply lines at pressures greater than 1/2 psig (14 inch W.) Table 5. per hour) for Natural Gas (specific gravity = . The gas heating value based on sea level can be obtained from your local gas utility. is required to convert the furnace to operate on LP/propane gas. supplied by the manufacturer.000 ft.). Failure to use the proper conversion kit can cause fire. A fire or explosion may result causing property damage.

5 3.5 10.999 5.000 to 8. After changing the orifices. sea level.2 2.0 For a Natural Gas Sea Level Heating Value of 900 to 999 Btu/cu.5 3.5 Manifold Pressure Setting (in WC) 3.For a Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.5 Table 6. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3.8 2. .0 Table 7. above sea level. 24 United States LP/Propane Gas Sea Level and High Altitude Conversion Kit .5 3.5 Manifold Pressure Setting (in WC) 3.5 10.999 Manifold Pressure in (WC) for an LP Gas Heating Value of 2.5 3. use Table 7 to determine the appropriate manifold pressure for your installation.0 8. and high altitude is detailed in the installation instructions provided with the conversion kit.000 ft.ft. above sea level.5 3.ft.0 9.000 to 1.999 10. Elevation (feet above sea level) 2.000 to 6.000 to 5.5 3.0 2.8 For a Natural Gas Sea Level Heating Value of 1. Above Sea Level Table 8 or 9).P/N 904090A This kit is for LP/propane conversion in the United States at altitudes between zero and 10. Natural and LP gas Orifice Sizes for Elevations between 5000 and 10. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3. Manifold Pressure (in WC) for Natural Gas at Various Altitudes 0 to 1.500 Btu/hr. Approved conversion kits are listed below.100 Btu/cu. Follow the installation instructions supplied with the kit for proper installation.ft. a # 55 or #56 drill size orifice should be used.999 7. Conversion to LP/propane. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3. Natural and LP Gas Orifice Sizes for Elevations between zero and 4999 ft.000 ft.5 Manifold Pressure Setting (in WC) 3. Above Sea Level Furnace Rating Plate Input (Btu/h) 45000 60000 72000 96000 120000 135000 144000 Orifice Drill Size Nat 44 45 43 43 43 41 43 LP 55 56 55 55 55 55 55 Table 9.000 to 4. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes Furnace Rating Plate Input (Btu/h) 45000 60000 72000 96000 120000 135000 144000 Orifice Drill Size Nat 44 45 43 43 43 41 43 LP 54 55 54 54 54 54 54 Table 8.000 8. However for installations above 5000 ft.

000 60. 25 ft. above sea level.0 21. Thermostat Wire Gauge Recommended Thermostat Wire Length 2-wire 4 or 5-wire (heating) (cooling) 55 ft. Verify proper operation after servicing.000 120.000 72.1 7.2 12. and with the current revision of the National Electric Code (ANSI/NFPA 70). or death. Follow the installation instructions supplied with the kit for proper installation.75 14.000 135.50 22.75 22.0 7.) ! WARNING: To avoid electric shock. 45 ft. For Canadian installations the electrical connections and grounding shall be done in accordance with the current Canadian Electrical Furnace Model Number *RA. personal injury. Maximum Operating Voltage Minimum Maximum Minimum Maximum Operating Furnace Wire Fuse or Circuit Voltage Amperes Gauge Breaker Amps** 045(†)-08 060(†)-12 072(†)-12 072(†)-16 072(†)-17 096(†)-12 096(†)-16 096(†)-20 120(†)-16 120(†)-20 135(†)-20 144(†)-20 45. Part 1 and/or local codes). Refer to the furnace nameplate and Table 10 for electrical requirements.000 144. 110 ft.000 72.25 14.1 9.2 12.2 9. Code (CSA C22. ELECTRICAL WIRING General Electrical connections must be made in accordance with all applicable local codes and ordinances.50 22.P/N 904091A This kit is for LP/propane conversions in Canada at altitudes between zero and 4500 ft. 140 ft.0 12.000 14. If any of the original wire as supplied with the furnace must be replaced.*RK Furnace Input (Btu/hr) Cabinet Width (in.0 12. 70 ft. **Time-delay fuses or HACR-type circuit breakers are required.000 96. Line Voltage Wiring The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace.50 19.000 96.1.) Nominal Electrical Supply ! CAUTION: Label all wires prior to disconnection when servicing controls.000 72.75 22. (See Table 10. 90 ft.50 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 127 127 127 127 127 127 127 127 127 127 127 127 103 103 103 103 103 103 103 103 103 103 103 103 5. 24 22 20 18 Table 10.000 120.2 14 14 14 14 10 14 14 12 14 12 12 12 15 15 15 15 35 15 15 20 15 20 20 20 Note: (†) can be C or N.) An electrical disconnect must be installed to be readily accessible from and located within sight of the furnace. (See the Wiring Diagram label in the furnace and Figure 25. it must be replaced with wire having a temperature rating of at least 105°C. Electrical Data 25 .25 19.1 9.25 19.Canadian LP/Propane Gas Sea Level and High Altitude Conversion Kit .000 96. Wiring errors can cause improper and dangerous operation.75 19.6 7.25 14. 225 ft. turn off the electric power at the disconnect or the main service panel before making any electrical connections.

FIELD WIRING Low Voltage Connections Neutrals Unused Motor Leads L1 XFMR HEAT COOL HUM 6 3 5 2 4 1 Figure 26. Do not use gas piping as an electrical ground. The low voltage (24 volt) connections from the thermostat are made at the terminal strip on the integrated control in the furnace. Low Voltage Wiring Install the thermostat per the manufacturer’s instructions. Line Voltage Field Wiring A/C Condensing Unit Condensing Unit Control Box COM 24 V 3 Amp Fuse Blower Off Timing Connect R&W For Heating Only Flame Signal Light (Yellow) Status Light (Red) Room Thermostat 9 6 8 5 7 4 3 2 1 NOTE: The "Y" terminal on the UTEC control board must be connected to the thermostat for proper cooling mode operation. sunlight. The controls used in this furnace require an earth ground to operate properly. Adverse affects include radiant loading from fireplaces. Add the current draw of the system components. The recommended minimum wire gauge for thermostat wiring is shown in Table 10. Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. IMPORTANT NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. unbroken ground to minimize injury should an electrical fault condition occur. and convective loading from warm air registers or electrical appliances. Verify that the incoming neutral line is connected to the white wire and the incoming “hot” line is connected to the black wire. Field Supplied Fused Service Panel Black (Hot) White (Neutral) Green or Bare (Ground) Field Supplied Panel Connector Black White Ground Black White Ground Black White Ground Field Line Voltage Wiring Factory Line Voltage Wiring Field Supplied Disconnect Within Sight of Furnace Junction Box (may be internal or external to the furnace). Four-wire Heating/Cooling Applications 60 90 120 180 R R Y G W C Y G W EAC HUM TWIN EAC M3 M2 M1 . These connections can be made in the field supplied disconnect at the furnace. Set the heat anticipator according to the thermostat manufacturer’s instructions for heat anticipator settings.The furnace cabinet must have an uninterrupted. or 2. These furnaces will not operate unless the polarity and ground are properly connected. See Figure 26 for the proper connections for heating only (two-wire) and heating/ cooling (four-wire) applications. Figure 25. See Figure 25. To determine the heat anticipator setting either: 1. 26 Low Voltage Field. The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected. or lighting fixtures. Measure the current flow on the thermostat RW circuit after the circulating blower motor has started.

verify that: 1. water column (0. • Heating value of the gas (obtained from gas supplier) = 1040 Btu per cubic foot. Shut off all other gas fired appliances. w. Follow the procedure below to determine the firing rate. Follow the procedures given on the operating instruction label attached to the furnace. The blower door is in place. After the furnace has run for approximately five minutes. 5. • Firing rate = 1040 x 90 = 93. water column (0. The line voltage power leads are securely connected. If necessary. Verifying and Adjusting Temperature Rise Verify the temperature rise through the furnace is within the range specified on the furnace rating plate. Place thermometers in the return and supply air stream as close to the furnace as possible.c. To adjust the manifold pressure. and is not less than 4. Y. Set the thermostat above room temperature and verify the operating sequence. (0.600 Btuh. Start-up Procedures After all of the above checks have been made: 1. Start the furnace and allow it to run for at least three minutes.0 in. water column (0. Example: • Time for 1 revolution of a gas meter with a 1 cubic foot dial = 40 seconds. 4.40 psig). ! CAUTION: Do not re-drill the burner orifices. The roll-out and vent safety manual reset switches are closed.36 psig). 3. remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counterclockwise to reduce pressure. Close the disconnect(s) to provide line voltage to the furnace. Convert the time per revolution to cubic feet of gas per hour using Table 11. set the thermostat below room temperature and verify steps (9) through (11) of the Sequence of Operation. W. 6. 2. DO NOT install a jumper wire across a switch to defeat its function.16 psig) for natural gas. Verifying and Adjusting Firing Rate The firing rate must be verified for each installation to prevent over-firing the furnace. that the polarity of the connections is correct. Set the thermostat to the lowest setting. If the orifice size must be changed. 2.51 psig). Refer to either Table 6 for natural gas or Table 7 for LP/ propane gas to verify the manifold pressure setting required for your particular installation. • From Table 11 read 90 cubic feet per hour of gas. For LP gas the line service pressure must not exceed 14 in. The gas line has been purged and all connections are leak tight. 6. Measure the time (in seconds) required for the gas meter to complete one revolution. IMPORTANT NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure.0 in. The 27 . Replace the regulator cap after adjustments are complete. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour. and that the furnace is properly grounded. (See the Sequence of Operation). If a switch reopens on start-up.START-UP AND ADJUSTMENTS General Prior to start-up. 1. The gas line service pressure does not exceed 10. 4. DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip. 2. 4. use only new orifices. See the High Altitude Application section for additional information of firing rate at elevations above 2000 ft. 3. Adjustments to the firing rate can be made by adjusting the gas manifold pressure. 3. 5. 5.5 in. and G) are securely connected to the correct leads on the terminal strip of the circuit board. press the red button to reset a switch. The manifold pressure must be set to the appropriate value for your installation. and must not be less than 11. At altitudes above 2000 feet it must not exceed that on the rating plate less 4% for each 1000 feet. The thermostat wires (R. closing the door switch in the line voltage circuit.

See Figure 27 for blower on and off time adjustments. For typical duct systems. The wiring diagram on the furnace and Figure 28 show the speed taps for adjusting motor speed. Remove the desired blower tap. If it is desired that the blower operate at the same speed for heating and cooling. Adjust all registers and duct dampers to the desired position and run the furnace for ten to fifteen minutes before taking any temperature readings. it may be necessary to change the blower speed. or death.thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings. The integrated control is factory wired to turn the blower motor off 120 seconds after the gas valve is closed. the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting. If necessary for comfort. the “off” time may be changed by adjusting the Blower Off jumper on the integrated control. Heating and cooling speed selection is made by moving the leads on the integrated control located in the furnace. GAS FLOW RATE (CUBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) CUBIC FEET PER REVOLUTION OF METER 1 5 10 TIME FOR ONE REVOLUTION (SECONDS) CUBIC FEET PER REVOLUTION OF METER 1 5 10 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 360 300 257 225 200 180 164 150 138 129 120 113 106 100 95 90 86 82 78 75 72 69 67 64 62 60 58 56 1800 1500 1286 1125 1000 900 818 750 692 643 600 563 529 500 474 450 429 409 391 375 360 346 333 321 310 300 290 281 3600 3000 2571 2250 2000 1800 1636 1500 1385 1286 1200 1125 1059 1000 947 900 857 818 783 750 720 692 667 643 621 600 581 563 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 55 53 51 50 49 47 46 45 44 43 42 41 40 39 38 38 37 36 35 35 34 33 33 32 32 31 31 30 273 265 257 250 243 237 231 225 220 214 209 205 200 196 191 188 184 180 176 173 170 167 164 161 158 155 153 150 545 529 514 500 486 474 462 450 439 429 419 409 400 391 383 375 367 360 353 346 340 333 327 321 316 310 305 300 Table 11. Lower blower speeds will increase the temperature rise and higher blower speeds will decrease the temperature rise. tape off the unused blower lead and install the jumper wire found in the plastic instruction bag. ! WARNING: To avoid electric shock. personal injury. and straight quick connect to the cooling speed tap. The furnace is equipped with a multi-speed motor. The temperature rise is the difference between the supply and return air temperatures. disconnect the electric power before performing any maintenance. and install the jumper wire piggyback to the heating speed tap. Reconnect the desired blower tap to piggyback quick connect. The integrated control is factory set to start the circulating air blower 30 seconds after the gas valve is opened. If the temperature rise measured is outside the range specified. Gas Flow Rate 28 .

Flame Sensor The flame sensor acts to prove that flame has carried over from the igniter to the opposite end burner. If any component of the furnace must be replaced. Set the thermostat to a temperature above room temperature and verify that the Sequence of Operation is as described in these instructions. Set the thermostat to a temperature above room temperature and observe the ignition sequence. make sure that the blower door is in place and that there is power to the furnace. set the thermostat to a temperature below room temperature and verify that the burner flame extinguishes completely. If the burner flames are not properly drawn into the heat exchanger. make sure that the furnace door is in place and that there is power to the furnace. 6 5 4 3 2 1 Humidifier Tap (. Verify Operation of the Supply Air Limit Switch To verify operation of the supply air limit switch. the furnace will shut down within 7 seconds of ignition. and replace the limit switch. DESCRIPTION OF COMPONENTS Figure 29 shows the location of each of the functional components described below. if connected) will continue to operate if the flame roll-out switch opens. Block the return airflow to the furnace by installing a closeoff plate in place of or upstream of the filter(s). use only factory authorized replacement parts. refer to the Sequence of Operation Section of this manual . Integrated Control 29 60 90 120 180 R C Y G W TWIN COOL XFMR HEAT M1 M2 M3 HUM EAC L1 . Flames should extend from each burner without lifting off. curling. Remove the close-off immedi- ately after the limit switch opens. COM 24 V 3 Amp Fuse Blower Off Timing Flame Signal Light (Yellow) Status Light (Red) 9 8 7 6 5 4 3 2 1 Common Leads EAC HUM Neutrals Unused Motor Leads Connect Neutral Lead of Electronic Air Cleaner and/or Humidifier Here. set the thermostat to a temperature below room temperature. If no flame is sensed. shut off the power to the furnace.Verifying Burner Operation To verify operation of the burners.5A@ 120 VAC) These motor speed taps are not used for two-stage models Figure 27. Flame Roll-Out Switch The flame roll-out switch verifies that the burner flames are drawn into the heat exchanger tubes. or floating. The limit switch should function to turn off the gas valve within approximately four minutes (the exact time depending on the efficiency of the close-off in blocking the return air to the furnace). the flame rollout switch will open. The circulating air blower (and combustion blower.5A@ 120 VAC) Electronic Air Tap (. The burner flame should carry over immediately between all burners. If the furnace operates for more than four minutes with no return air. See the Replacement Parts List for the factory authorized replacement for each component. Also. The flames should be blue. without yellow tips. The circulating air and combustion blowers should continue to run when the limit switch opens. After verifying satisfactory flame characteristics.

Supply Air Limit Switch The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature. it must be replaced with wiring material having a temperature rating of at least 105° C. WD#710355-0 Figure 28. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold. For Upflow and Downflow Series Residential Furnaces BLUE BLUE BLUE BLUE FLAME ROLL-OUT SWITCH (SELECT MODELS ONLY) BLOWER DECK SWITCH (SELECT MODELS ONLY) SUPPLY AIR LIMIT SWITCH (ALL MODELS) FLAME ROLL-OUT SWITCH (ALL MODELS) VENT SAFETY SWITCH (SELECT MODELS ONLY) PRESSURE SWITCH VENT PRESSURE SWITCH (93+ MODELS ONLY) ORANGE BLUE BLUE ORANGE WHITE BLACK WHITE (NEUTRAL) BLACK 120V GROUND GREEN BLOWER DOOR SWITCH ROOM THERMOSTAT R Y G W TRANSFORMER WHITE W/ BLK STRIPES WHITE VENT SAFETY SWITCH (SELECT MODELS ONLY) 24 V BLK W/ WHITE STRIPES 180 120 90 60 120 V BLACK AIR CONDITIONER CONDENSING UNIT C Y Refer to the Installation Instructions provided with the furnace for the proper heating and cooling speeds for your application. Use copper conductors only. Pressure Switch The pressure switch verifies that the inducer is drawing the combustion gases through the heat exchanger. Wiring Diagram for Upflow and Downflow Models 30 BLACK RED BLUE . FLAME SENSOR RED YELLOW BROWN BLACK 3 OR 4 SPEED MOTOR C H GAS VALVE L MH ML ORANGE WHITE IGNITOR Legend Field Wiring Factory Wiring: Low Voltage High Voltage R C BLACK BLACK BLACK RED ORANGE BLUE INDUCER BLACK BLACK 1 2 3 4 5 WHITE 6 MOTOR PLUG FAULT CONDITION Power On Limit Circuit Open or External Load On "W" Pressure Switch is Open with Inducer On Ignition Failure (Check Ground) False Flame or Gas Valve Relay Shorted Power Off STATUS RED LIGHT ON 1 FLASH 2 FLASHES 4 FLASHES Continuous OFF FLAME YELLOW LIGHT Continuous Flash ON These wires are not present on all models Pressure Switch is Closed with Inducer Off 3 FLASHES 115 VAC & Neutral Reversed or no Ground 5 FLASHES FAULT CONDITION Low Flame Sensor Signal Flame Present If any of the original wire as supplied with the furnace must be replaced. Vent Safety Switch The vent safety switch shuts the furnace down if the vent becomes blocked or restricted.Gas Valve The gas valve controls the flow of gas to the burners.

Air Filter(s) ! WARNING: To avoid electrical shock. Any corroded section of vent pipe must be replaced. this check should include the following items. turn off the electric power at the disconnect or the main service panel before making any electrical connections. At a minimum. or in a return air grill to the furnace.MAINTENANCE It is recommended that the furnace be checked yearly. Filters should be changed or cleaned monthly during the heating season. New or ! WARNING: Products of combustion must not be allowed to enter the living space. ! WARNING: Never operate the furnace without a filter in place. Vent System Check the vent pipe to ensure that it is not corroded or blocked by debris. and possible fire. personal injury. or death. resulting in loss of efficiency. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. Air filter(s) are not supplied with the furnace as shipped from the factory. The installer must provide a high velocity filter and rack for a filter in the return air duct adjacent to the furnace. Dust and lint in the return air can build up on internal components. and any obstruction or blockage must be removed prior to operating the furnace. Location of Major Components 31 . equipment damage. Upflow Models 11 1 4 3 10 6 7 8 9 2 12 5 14 Downflow Models 15 13 9 16 7 14 6 10 5 2 13 11 12 3 4 1 1 2 3 4 Igniter Flame Sensor Gas Valve Roll-Out Switch(s) 5 Pressure Switch 6 Control Board 7 Blower Door Switch 8 Vent Assembly (Upflow Models) 9 Vent Switch 10 11 12 13 14 Low Voltage Transformer Burner Assembly Supply Air Limit Switch Blower Assembly Inducer 15 16 Combustion Tube w/insulation (Downflow Models) Vent Transition Assembly (Downflow Models) Figure 29.

and the burners should be inspected and cleaned (if required) by a qualified serviceman annually to ensure continued safe operation. 32 . Blower Compartment The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. 10. follow the steps below. igniter. Shut off the gas supply to the furnace either at the meter or at the manual valve in the gas supply piping. Filters for side return and bottom return applications are available from your local distributors. With a light. Cleaning Of Flue Passages If the flue passages must be cleaned. flame sensor. Remove the screws that hold the burner assembly in place and remove the burner assembly. Lubrication The bearings in the circulating air blower motor and inducer blower used in these furnaces are pre-lubricated and sealed at the factory. and remove the collector pan from the furnace. blocked vent switch. BE CAREFUL NOT TO BREAK THE SEALS AT EACH END OF THE COMBUSTION AIR TUBE. Repeat this sequence for each heat exchanger tube. 4. separate the ground-joint union in the gas supply piping at the furnace. overtemperature limit switch. Disconnect the wires from the gas valve. however. No further oiling of the bearings is required for the life of the motor. Turn the gas control lever to the OFF position. combustion air motor. 3. the vent system. 5. check the condition of the upper and lower sections of the heat exchanger tube. 11. Remove the nuts that hold the combustion air motor to the collector pan. 15. Replace the vent pipe or heat exchanger if leaks are found. Remove the louvered door from the furnace. Turn off all power to the furnace and set the thermostat to the lowest temperature setting. 12. For *RA upflow models: Remove the screws that hold the vent control assembly to the top panel. ! WARNING: Holes in the vent pipe or heat exchanger can cause products of combustion to enter the home. the flue passageways. When all heat exchanger tubes have been cleaned. 6. 1. pressure switch. 7. Slowly rotate the cable with the drill and insert it into the top portion of the heat exchanger. Remove the silicone rubber tube from the collector pan. While reversing the drill. 13. Heat Exchanger and Burner Maintenance The furnace should operate for many years without soot buildup in the flue passageways. flame roll-out switch. See Figure 29 for component location and identification. such as drain cleanout cable. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY. 9. Wiring errors can cause improper and dangerous operation. ! CAUTION: Label all wires prior to disconnection when servicing controls. Attach variable speed reversible drill to the other end of the spring cable. Remove the piping between the gas valve and the ground-joint union.newly renovated homes may require more frequent changing until the construction dust has been removed. Using wrenches. 2. Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life. The furnace heat exchanger tubes can now be cleaned by the use of a round wire brush attached to a length of high grade stainless steel cable. 14. work the cable in and out several times to obtain sufficient cleaning. Remove the screws that hold the collector pan in place. if necessary. Particular attention must be given to identify deterioration from corrosion or other sources. and remove the complete combustion air blower and combustion tube assembly. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death. 8. any debris inside the tubes can be removed with the nozzle of a vacuum cleaner.

18. See Figure 30 for component location and identification. applying 24 VAC to the W terminal on the control board. Replace all the parts in reverse order from which they were removed. Follow the lighting instructions found on the furnace door to return the furnace to operation. Do not operate the furnace without all doors and covers in place. Refer to the field and furnace wiring diagrams. Sequence of Operation The operating sequences for the heating. 1. 26. Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace. 3. Remove the upper louvered door from the furnace. Turn off all power to the furnace and set the thermostat to the lowest temperature setting. If the pressure switch is closed the heat mode sequence will not continue. if necessary. If the pressure switch does not close after 10 seconds the fault LED will blink 2 times repetitively and the inducer will continue to run until the switch is closed. the red LED will pulse at a rate of 1 blink per unit time. Verify proper operation after servicing. Remove the screws that hold the burner assembly in place and remove the burner assembly. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle of a vacuum cleaner. 10. Always replace the doors on the furnace after servicing or cleaning/changing the filters. 4. 6. The inducer is energized. 4. 2. cooling. 27 and 28. Verify proper operation after servicing. Using wrenches. Do not place combustible materials on or against the furnace cabinet or within 6 inches of the vent pipe. Remove the piping between the gas valve and the ground-joint union. Inspect the burners and clean them (if necessary) with a soft wire brush and/or the nozzle of a vacuum cleaner. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY. 9. 2. The pressure switch will close. 5. 7. 17. 6. 2. Change or replace the air filters monthly during any period when the circulating blower is operating regularly. Disconnect the wires from the gas valve. 5. flame rollout switches and blocked vent switch in series). SYSTEM OPERATION INFORMATION General Proper maintenance is most important to achieve the best performance from a furnace. 1. If an open limit is detected the control board will energize the inducer and the conditioned air blower. and fan modes are described below. Figures 25. While the limit is open. Follow these instructions for years of safe. 6. 8. separate the ground-joint union in the gas supply piping at the furnace. Heating Mode: 1. Be sure that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances. The control board checks for continuity on the 24 VAC limit control circuit (over-temperature limit switch. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER. igniter. 5.16.Follow the lighting instructions found on the furnace door to return the furnace to operation. follow the steps below. 11. 33 . 4. 3. On a call for heat the thermostat closes. Replace all the parts in reverse order from which they were removed. The inducer will pre-purge for 30 seconds and then the igniter will start its warm-up as follows: Initial Power up: After 30 seconds of igniter warm-up the gas valve (24 VAC) will then open. trouble free operation. BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITER WHILE CLEANING THE BURNER. Turn the gas control lever to the OFF position. Avoid operating the furnace when windows and doors are open. The furnace control checks for continuity across the pressure switch (24 VAC). Shut off the gas supply to the furnace either at the meter or at a manual valve in the supply piping. Cleaning of Burners If the burners must be cleaned. The igniter circuit will stay energized for 3 seconds after the gas valve opens. All other system functions will be inoperable until the limit circuit closes. 3. and flame sensor. If it remains closed for 10 seconds the red LED will blink 3 times repetitively until the fault condition clears.

If the inducer and circulating air blowers are operating. 8. The furnace control keeps the circulating air blower energized for 120 seconds (factory set) or 60. (See Figure 29. the timing remains fixed at this level. 2. and items 1 through 8 have been checked. If the furnace continues to not operate. The blowers continue to operate until the limit closes. Otherwise. Abnormal conditions: If a limit opens during operation. it will try again every hour if a call for heat remains. Cooling Mode: 1. When the limit closes the inducer blower is de-energized immediately. If the furnace is operated in the continuous ON position at the thermostat and is then switched to AUTO. Upon ignition failure. In general. the thermostat applies 24 VAC to the G terminal on the furnace control board. 10. And if successful. The furnace control must prove flame via the flame sensor 5 seconds after the gas valve opens. The circulating air blower is energized immediately on the heating speed. it remains there. 2. Has the circuit breaker tripped or the control board fuse burned open? 5. or 180 seconds (field adjustable). 3. The thermostat must be opened for at least ten seconds to reset the furnace control after a lock out. whenever ignition failure occurs the warm-up interval is increased by 3-seconds on the next try. 4. 90. the furnace control is locked and the red LED will blink 4 times repetitively. This closes the compressor contactor.) 12. The circulating air blower is de-energized after a 90-second delay. The inducer is de-energized after a 30-second postpurge. Is the gas turned on? 6. Are any manual reset switches open? 7. Is the thermostat operating properly? 2. contact a qualified servicemen to identify and repair the problem. If no flame is sensed. 3. 7. the circulating blower will operate for a specified delay (factory set at 120 seconds). If the furnace operates after depressing the reset button.After Initial Power up: The control has a programmed adaptive ignition feature which varies the warm-up period as follows: If ignition is successful the warm-up is reduced by 3seconds on each subsequent call for heat until ignition failure occurs. the inducer and circulating air blower continue to operate. the gas valve closes immediately and the inducer continues to run. 11. contact a qualified serviceman to identify and repair the problem. If successful. Are the blower compartment door(s) in place? 3. gas valve is de-energized. The furnace control energizes the circulating blower (115 VAC) on the cooling speed. the warm-up is increased by 3-seconds on the next try. all burners are on and the igniter cools off. Is the furnace disconnect closed? 4. Minimum and maximum warmup time limits are set at 6 and 54-seconds. The circulating air blower continues to operate for the specified delay (factory set at 120 seconds). depress the red reset buttons on the flame roll-out switches.) If the furnace operates after depressing the reset buttons. On a call for fan operation. Is the flame sensor coated? (Remove and clean with emery cloth. Is the filter dirty or plugged? 8. the G and Y terminals on the control board are de-energized opening the compressor contactor. Furnace Fails to Operate If the furnace does not operate check the following: 1. A second trial for ignition (step 6) begins if no flame is sensed on the fifth try for ignition. 9.) If the furnace locks out after 5 attempts for ignition. press the red reset button on the vent safety switch (See Figure 29). When the thermostat has been satisfied. furnace control. applying 24 VAC to the G and Y terminals on the 34 . The gas valve is deenergized immediately. On a call for cooling the thermostat closes. (See Figure 27. When the thermostat is satisfied. If flame is sensed. the furnace will attempt another ignition sequence in 1 hour. respectively. The furnace control energizes the circulating air blower on the heating speed 30 seconds after the gas valve circuit is energized . Fan Mode: 1.

Twinning 35 .) Thermostat W G Y R R C Y G W Twin Terminal R C Y G W Twin Terminal A/C Unit Figure 30. leave the fuses installed on each board. (See Figure 30. If using UTEC Control Boards.Twinning The control board on these furnaces is capable of being twinned to another furnace of the same series. The thermostat wires and the 1/4 inch quick-connect terminals marked “TWIN” on the furnace controls must be wired for twinning.

with furnace operating) Is there adequate fresh air supply for combustion and ventilation? ___________ Furnace Input: _________________ (Btuh) Supply Air Temperature: _________ (° F) Return Air Temperature: _________ (° F) Temperature Rise: ______________ (° F) Has the Owner's Information been reviewed with the homeowner? __________________ Is the Filter(s) secured in place? _________ Is the Filter(s) clean? __________________ Are Flue Connections tight? _____________ Is there Proper Draft? _________________ Is Vent free from restrictions? ___________ Has the Thermostat been calibrated? _____ Is the Thermostat level? ________________ Is the Heat Anticipator Setting correct? ____ Has the Literature Package been left near the furnace? _________________________ ¢708291/¤ 708291B 708291B (Replaces 708291A) Specifications and illustrations subject to change without notice and without incurring obligations. (03/04) O'Fallon. Printed in U.INSTALLATION/PERFORMANCE CHECK LIST LOCATION _________________ INSTALLER ________________ CITY ___________________ CITY ___________________ STATE ______________ STATE ______________ UNIT MODEL NUMBER ________________________________ UNIT SERIAL NUMBER _________________________________ Minimum Clearances per Table 3? _____ Electrical Connections tight? __________ Line Voltage Polarity correct? _________ Supply Voltage: _________ Volts Blower Motor HP: ___________________ FUEL TYPE: Natural Gas _______________________ LP/Propane ________________________ Gas Piping Connections leak-tested? ______________________ Gas Line Pressure: _________________ (in.S. water column. MO . with furnace operating) Manifold Pressure: __________________ (in.A. water column.

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