Installation Manual

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UPFLOW

*MEC96 / HORIZONTAL TWO-STAGE GAS FURNACE

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces.

Installer: Affix all manuals adjacent to the unit.

As a professional installer you have an obligation to know

the product better than the customer. This includes all safety precautions and related items. Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation. Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use. Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them. The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

TABLE OF CONTENTS SAFETY CONSIDERATIONS .................................... 3 SHIPPING INSPECTION ............................................ 4 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .................... 4 TO THE INSTALLER ............................................. 5 PRODUCT DESCRIPTION ....................................... 5 FEATURES ...................................................... 5 PRODUCT APPLICATION ....................................... 5 LOCATION REQUIREMENTS & CONSIDERATIONS ........... 6 CLEARANCES AND ACCESSIBILITY ................................... 7 EXISTING FURNACE REMOVAL ..................................... 8 THERMOSTAT LOCATION .......................................... 8 COMBUSTION & VENTILATION AIR REQUIREMENTS ................... 9 INSTALLATION POSITIONS .................................... 9 HORIZONTAL APPLICATIONS & CONSIDERATIONS ......... 9 FURNACE SUSPENSION .......................................... 10 FRONT COVER PRESSURE SWITCH TUBE LOCATION ................ 10 DRAIN TRAP AND LINES ........................................ 10 HORIZONTAL FURNACE LEVELING ................................ 10 ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS .............. 10 DRAIN PAN ................................................... 10 FREEZE PROTECTION ........................................... 10 PROPANE GAS/HIGH ALTITUDE INSTALLATIONS .......... 10 VENT/FLUE PIPE & COMBUSTION AIR PIPE ................ 11 DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT ................. 11 MATERIALS AND JOINING METHODS .............................. 11 PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ...... 12 TERMINATION LOCATIONS ........................................ 12 CANADIAN VENTING REQUIREMENTS .............................. 13 STANDARD FURNACE CONNECTIONS .............................. 13 VENT/FLUE PIPE .............................................. 13 NON-DIRECT VENT (SINGLE PIPE) PIPING ........................ 14 VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES ......................... 18 CONCENTRIC VENT TERMINATION ................................. 18 SIDE WALL VENT KIT .......................................... 18 CONDENSATE DRAIN LINES & DRAIN TRAP ................ 18 UPFLOW MODEL INSTALLED VERTICALLY .......................... 19 DRAIN EXITING RIGHT SIDE ..................................... 19 GENERAL DRAIN INFORMATION ................................... 19 FIELD SUPPLIED DRAIN ......................................... 19 DRAIN EXITING LEFT SIDE ...................................... 20 UPFLOW MODEL INSTALLED HORIZONTALLY WITH RIGHT SIDE DOWN 20 UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN . 20

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION. *NOTE:

Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.

IOG-2011 08/14

5151 San Felipe Suite 500 Houston, TX 77056 www.goodmanmfg.com • www.amana-hac.com © 2014 Goodman Manufacturing Company, L.P. is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.

OPERATIONAL CHECKS ....................................... 38 SAFETY CIRCUIT DESCRIPTION .............................. 38 INTEGRATED CONTROL MODULE ................................. 38 PRIMARY LIMIT ................................................. 38 AUXILIARY LIMIT ............................................... 38 ROLLOUT LIMIT ............................................... 39 PRESSURE SWITCHES ........................................... 39 FLAME SENSOR ................................................ 39 TROUBLESHOOTING ............................................. 39 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................... 39 CHECKING FLAME SENSOR ...................................... 39 LIMIT FAULT CODES ........................................... 39 DIAGNOSTIC CHART ............................................ 40 FAULT RECALL ................................................ 40 RESETTING FROM LOCKOUT ..................................... 41 MAINTENANCE ................................................. 41 ANNUAL INSPECTION ........................................... 41 FILTERS ....................................................... 41 BURNERS ..................................................... 42 INDUCED DRAFT AND CIRCULATOR BLOWERS ...................... 42 CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) 42 FLAME SENSOR (QUALIFIED SERVICER ONLY) ..................... 42 FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................... 43 BEFORE LEAVING AN INSTALLATION ........................ 43 REPAIR AND REPLACEMENT PARTS .......................... 43 TROUBLESHOOTING CHART ................................. 44 WIRING DIAGRAM ............................................. 46 SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS ... 47

ELECTRICAL CONNECTIONS ................................. 21 WIRING HARNESS .............................................. 21 115 VOLT LINE CONNECTIONS .................................. 21 JUNCTION BOX RELOCATION ..................................... 21 24 VOLT THERMOSTAT WIRING .................................. 22 SINGLE-STAGE HEATING THERMOSTAT APPLICATION ................ 23 FOSSIL FUEL APPLICATIONS ...................................... 23 TWINNING .................................................... 23 115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) .................. 23 GAS SUPPLY AND PIPING ...................................... 24 HIGH ALTITUDE DERATE ........................................ 24 PROPANE GAS CONVERSION ..................................... 24 GAS PIPING CONNECTIONS ...................................... 25 PROPANE GAS TANKS AND PIPING ............................... 26 CIRCULATING AIR & FILTERS ................................ 27 DUCT WORK - AIR FLOW ....................................... 27 CHECKING DUCT STATIC ........................................ 27 BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ............... 28 FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK ............................... 28 UPRIGHT INSTALLATIONS ......................................... 29 HORIZONTAL INSTALLATIONS ..................................... 29 STARTUP PROCEDURE & ADJUSTMENT ..................... 29 DRAIN TRAP PRIMING .......................................... 29 FURNACE OPERATION ........................................... 29 GAS SUPPLY PRESSURE MEASUREMENT ........................... 30 GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ........ 31 GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ........... 32 TEMPERATURE RISE ............................................ 32 CIRCULATOR BLOWER SPEEDS ................................... 33 BLOWER HEAT OFF DELAY TIMINGS ............................. 37 NORMAL SEQUENCE OF OPERATION ........................ 37 POWER UP ................................................... 37 HEATING MODE ............................................... 37 COOLING MODE ............................................... 38 FAN ONLY MODE ............................................. 38

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WARNING

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION , ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION , CONSULT A QUALIFIED INSTALLER , SERVICER AGENCY OR THE GAS SUPPLIER .

GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

WARNING

SAFETY CONSIDERATIONS

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE , PERSONAL INJURY OR LOSS OF LIFE. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE . WHAT TO DO IF YOU SMELL GAS:  D O NOT TRY TO LIGHT ANY APPLIANCE.  D O 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. INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P. gas by using the appropriate L.P. conversion kit listed in the PROPANE GAS/ HIGH ALTITUDE INSTALLATIONS section of this manual Install this furnace only in a location and position as specified in LOCATION REQUIREMENTS & CONSIDERATIONS section and INSTALLATION POSITIONS section of this manual. Provide adequate combustion and ventilation air to the furnace as specified in COMBUSTION & VENTILATION AIR REQUIREMENTS section of this manual.

WARNING THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF C ALIFORNIA TO CAUSE CANCER , BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM .

Combustion products must be discharged to the outdoors. Connect this furnace to an approved vent system only, as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section of this manual.

WARNING

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in GAS SUPPLY AND PIPING section of this manual.

HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION , MAINTENANCE AND SUPERVISION . IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED . IN THE EVENT THAT THE BUILDING

Always install a furnace to operate within the furnace’s intended temperature-rise range with a duct system which has external static pressure within the allowable range, as specified on the furnace rating plate and OPERATIONAL CHECKS section of these instructions.

MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT , ALL WATER -BEARING PIPES SHOULD BE DRAINED , THE BUILDING SHOULD BE PROPERLY WINTERIZED , AND THE WATER SOURCE CLOSED . IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT , ANY HYDRONIC COIL UNITS

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

SHOULD BE DRAINED AS WELL AND , IN SUCH CASE , ALTERNATIVE HEAT

A gas-fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIREMENTS AND CONSIDERATIONS section of this manual.

TO PREVENT POSSIBLE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK , THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER .

This furnace may be used as a construction site heater only if certain conditions are met. These conditions are listed in the PRODUCT APPLICATION section of this manual.

Drain trap must be primed at time of installation. Trap is internally partitioned; add water to both inlet ports until water appears at both sides of the outlet opening. Failure to prime trap at time of installation may have a negative effect on combustion quality and pressure switch action.

SOURCES SHOULD BE UTILIZED.

WARNING

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DANGER

CARBON MONOXIDE POISONING HAZARD Special warning for installation of furnaces or air handling units in enclosed area such as garages, utility rooms or parking areas. Carbon monoxide producing devices (such as automobile, space heater, gas water heater, etc.) Should not be operated in enclosed areas such as unventilated garages or utility rooms because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area and a carbon monoxide producing device is operated therein, there must be adequate direct outside ventilation. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode. CO can cause serious illness including permanent brain damage or death.

DANGER RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Avertissement special au sujet de l'installation d'appareils de chauffage ou de traitement d'air dans des endroits clos, tets les garages, les locaux d'entretien et les stationnements. Evitez de mettre en marche les appareils produisant du monoxyde de carbone (tels que les automobile, les appareils de chauffage autonome,etc.) dans des endroits non ventilés tels que les d'empoisonnement au monoxyde de carbone. Si vous devez faire fonctionner ces appareils dans un endroit clos, assures-vous qu'il y ait une ventilation directe provenant de l'exterie . Les émissions de monoxyde de carbone peuvent etre recircules dans les endroits clos, si l'appareil de chauffage ou de traitement d'air sont en marche. Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort.

PELIGRO ' POR MONÓXIDO DE CARBONO RIESGO DE INTOXICACIÓN Advertencia especial para la instalación de calentadores ó maneja oras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Los equipos ó aparatos que producen monóxido de carbono (tal como automóvil, calentador de gas, calentador de agua por medio de gas, etc) no deben ser operados en áreas cerradas debido al riesgo de envenenamiento por monóxido de carbono (CO) que resulta de las emisiones de gases de combustión. Si el equipo ó aparato se opera en dichas áreas, debe existir una adecuada ventilac ón directa al exterior. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. El monóxido de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte. 0140M00020-D

SHIPPING INSPECTION

WARNING

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

WARNING

The furnace must be carefully inspected on arrival for damage and POSSIBLE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH DUE TO bolts or screws which may have come loose in transit. In the event FIRE, EXPLOSION , SMOKE, SOOT, CONDENSATION , ELECTRICAL SHOCK of damage the consignee should: OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, 1. Make a notation on delivery receipt of any visible damage to REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT. shipment or container. 2. Notify carrier promptly and request an inspection. 3. With concealed damage, carrier must be notified as soon as possible - preferably within five days. 4. File the claim with the following support documents within a nine month statute of limitations. • Original or certified copy of the Bill of Lading, or indemnity bond. • Original paid freight bill or indemnity in lieu thereof. • Original or certified copy of the invoice, showing trade and other discounts or reductions. • Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS NOTE: Discharge your body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces. 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

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2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

TO THE INSTALLER Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.

WARNING TO PREVENT PROPERTY DAMAGE , PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER , OR RECREATIONAL VEHICLE.

PRODUCT DESCRIPTION FEATURES The *MEC96 furnace may be installed upflow or horizontally with left or right side down. The *MEC96 two-stage gas furnace features a multi-speed ECM indoor fan motor, two heating inputs (W1 & W2), two cooling inputs (YLO & Y) and a two stage gas valve. A single stage heating thermostat may also be used in conjunction with timed transition to high fire by the furnace integrated control board.

PRODUCT APPLICATION This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches, Retail stores, Nursing homes, Hotels/motels, Common or office areas In such applications, the furnace must be installed with the following stipulations: • It must be installed per the installation instructions provided and per local and national codes. • It must be installed indoors in a building constructed on site. • It must be part of a ducted system and not used in a free air delivery application. • It must not be used as a “make-up” air unit. • It must be installed as a two-pipe system for combustion air. • All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required). Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a: Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or, Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions. This furnace may be used as a construction site heater ONLY if all of the following conditions are met: • The vent system is permanently installed per these installation instructions. • A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used and can cause long term equipment damage. • Return air ducts are provided and sealed to the furnace. • A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained. • Air filters are installed in the system and maintained during construction replaced as appropriate during construction, and upon completion of construction. • The input rate and temperature rise are set per the furnace rating plate. 5



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100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used. NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized for adequate combustion and ventilation in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1 Installation Codes. The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up. All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met: • Gas furnaces must be installed by a licensed plumber or gas fitter. • A T-handle gas cock must be used. • If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring. To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following: American National Standards Institute National Fire Protection Association CSA International 25 West 43rd Street, 4th Floor 1 Batterymarch Park 8501 East Pleasant Valley New York, NY 10036 Quincy, MA 012169-7471 Independence, OH 44131 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America. A copy of the CAN/CSA B149 Installation Codes can also be obtained from: CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1R3

LOCATION REQUIREMENTS & CONSIDERATIONS Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements section when selecting a furnace location.

WARNING

WARNING

POSSIBLE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION , SMOKE, SOOT, CONDENSATION , ELECTRICAL SHOCK

TO PREVENT POSSIBLE EQUIPMENT DAMAGE , PROPERTY DAMAGE, PERSONAL INJURY OR DEATH , THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT. • • •







OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.

Centrally locate the furnace with respect to the proposed or existing air distribution system. Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating. Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Vent/Flue Pipe and Combustion Air Pipe -Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace. Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to Condensate Drain Lines and Trap for further details. Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Combustion and Ventilation Air Requirements. Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applications and Considerations for leveling of horizontal furnaces. 6

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Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood. Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances: permanent wave solutions chlorinated waxes or cleaners chlorine-based carbon tetrachloride water softening chemicals swimming pool chemicals deicing salts or chemicals halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements for details. If the furnace is used in connection with a cooling coil unit, install the furnace upstream or in parallel with the cooling coil unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace. For vertical applications, the minimum cooling coil width shall not be less than furnace width minus 1”. For upflow applications, the front of the coil and furnace must face the same direction. If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles. If the furnace is installed horizontally, ensure the access doors are not on the “up/top” or “down/bottom” side of the furnace. Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.

CLEARANCES

AND

ACCESSIBILITY

NOTES: • For servicing or cleaning, a 24” front clearance is required. • Unit connections (electrical, flue and drain) may necessitate greater clearances than the minimum clearances listed above. • In all cases, accessibility clearance must take precedence over clearances from the enclosure where *MEC96 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS accessibility clearances are greater. (INCHES)

Installations must adhere to the clearances to combustible matePOSITION* SIDES REAR FRONT BOTTOM FLUE TOP rials to which this furnace has been design certified. The miniUpflow 0" 0" 3" C 0" 1" mum clearance information for this furnace is provided on the Horizontal 6" 0" 3" C 0" 6" unit’s clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation’s gas, C = If placed on combustible floor, floor MUST be wood only. electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Vent/Flue Pipe and Combustion Air Pipe for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit. TOP TOP

BOTTOM BOTTOM

Figure 1

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Specification Sheet applicable to your model for minimum clearances to combustible surfaces. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement. 7

EXISTING FURNACE REMOVAL NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances. The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for GasFired Central Furnaces ANSI Z21.47, CSA-2.3 latest edition Section 1.23.1. The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-05 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. 4. Close fireplace dampers. 5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. 6. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 7. Test for spillage from draft hood appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or National Gas and Propane Installation Code CSA B149.1-05. 9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Installation Codes.

THERMOSTAT LOCATION The thermostat should be placed approximately five feet from the floor on a vibration-free, inside wall in an area having good air circulation. Do not install the thermostat where it may be influenced by any of the following: • Drafts, or dead spots behind doors, in corners, or under cabinets. • Hot or cold air from registers. • Radiant heat from the sun. • Light fixtures or other appliances. • Radiant heat from a fireplace. • Concealed hot or cold water pipes, or chimneys. • Unconditioned areas behind the thermostat, such as an outside wall. Consult the instructions packaged with the thermostat for mounting instructions and further precautions.

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COMBUSTION & VENTILATION AIR REQUIREMENTS

WARNING

TO AVOID PROPERTY DAMAGE , PERSONAL INJURY OR DEATH, Improved construction and additional insulation in buildings have SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF reduced heat loss by reducing air infiltration and escape around FLUE GASES MUST BE SUPPLIED . MOST HOMES REQUIRE OUTSIDE AIR BE doors and windows. These changes have helped in reducing heatSUPPLIED INTO THE FURNACE AREA. ing/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air. House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide. If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-05 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

INSTALLATION POSITIONS

Figure 2A

Figure 2B

Figure 2C

Recommended Installation Positions

*MEC96 models may be installed upflow or horizontally with left or right side down. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.

HORIZONTAL APPLICATIONS & CONSIDERATIONS When installing a furnace horizontally, additional consideration must be given to the following:

9

FURNACE SUSPENSION If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following diagram. The length of rod will depend on the application and the clearances necessary. If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water.

FRONT COVER PRESSURE SWITCH TUBE LOCATION When an upflow model is installed horizontally with left side 2" 2" 3/8" ANGLE IRON (3 PLACES) down, the front cover pressure switch tube must be relocated to the lower port of the collector box cover. 1. Remove tube from front cover pressure switch and collector box cover. 2. Remove rubber plug from bottom collector box port and install on top collector box port. 3. Locate 24” x 1/4” tube in parts bag. 4. Install one end on front cover pressure switch. 5. Route tube to lower port on collector box cover and cut off excess tubing. X

X

Figure 2

DRAIN TRAP AND LINES In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5” below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.

HORIZONTAL FURNACE LEVELING Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should have a slight tilt from back to front with the access doors downhill from the back panel approximately 1/2 to 3/4 inches. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.

DRAIN PAN A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).

FREEZE PROTECTION Refer to Horizontal Applications and Conditions - Drain Trap and Lines.

WARNING

PROPANE GAS/HIGH ALTITUDE INSTALLATIONS This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice and orifice change to compensate for the energy content difference between natural and propane gas.

POSSIBLE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED . THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION .

ALL CONVERSIONS MUST BE PERFORMED BY A

QUALIFIED INSTALLER OR SERVICE AGENCY.

High altitude installations may require both a pressure switch and an orifice/spring change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. 10

For installations above 7000 feet, please refer to the furnace Specification Sheets for required kit(s). Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

M anifo ld P ressure Gas

A ltitude

Natural 0-7000 P ro pane 1 LP M -08* suppo rts

Kit

Orifice

High Stage

Lo w Stage

P ressure Switch Change

No ne

# 45

3.5" w.c.

1.9" w.c.

No ne

1.25mm

10.0" w.c.

6.0" w.c.

No ne

LP M -08* 1

bo th Ho neywell and White-Ro dgers 2-stage valves

N O T E : In Canada, gas furnaces are o nly certified to 4500 feet.

VENT/FLUE PIPE & COMBUSTION AIR PIPE

WARNING

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH . CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION .

WARNING In addition to PVC and ABS pipe and fittings, Innoflue® by UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY Centrotherm Eco Systems and PolyPro® by M&G Duravent are INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE also approved vent and combustion air materials for installaFURNACE TO ASSURE IT IS PROPERLY SEALED . LEAKS IN THE FLUE tions in the U.S.A. and Canada. Manufacturers Installation SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO instructions for these products must be followed. These prodEXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE. ucts have specific instructions for installing, joining and terminating. Do not mix materials or components of one manufacturer with materials or components of another manufacturer. All furnaces are built with 2" vent / intake pipe and connectors. For furnaces requiring installation of 3" pipe, the transition from 2" to 3" should be done as close to the furnace as practically possible. This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connectors” other than those shipped with this product. It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

MATERIALS AND JOINING METHODS Two-three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.

WARNING TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E ., SPARKS , OPEN FLAMES , AND EXCESSIVE HEAT ) AS THEY ARE COMBUSTIBLE LIQUIDS . AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.

The use of Schedule 40 PVC or ABS cellular core (Foam Core) plastic pipe is also acceptable as a flue/vent and intake pipe material. PVC primer meeting ASTM F656 and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufactures instructions for cutting, cleaning and solvent cementing of PVC. For Canadian installations; all PVC pipe, fittings and joining materials must be UL S636 listed. 11

As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/16” minimum from the plane of one opening to the center line of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/ flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions. Some models require the use of 3” pipe. Do not transition from a 2” to 3” pipe in a horizontal section of pipe as this may create a water trap. PREFERRED ACCEPTABLE

NO TRANSITION ON HORIZONTAL PLANE, THIS CREATES A WATER TRAP AND RESTRICTS FLUE GASES

TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE TO AVOID CREATING A WATER TRAP IN VENT PIPING.

Figure 4

Figure 5

Figure 6

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches. Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated arNon-Direct Vent eas) must be insulated with 1/2” thick closed cell foam. Inspect & Direct Vent piping for leaks prior to installing insulation. Vent/Flue Terminations

TERMINATION LOCATIONS

Non-Direct Vent Vent/Flue Termination

NOTE: Refer to Location Requirements and Considerations for combustion air contaminant restrictions. The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on termination construction. • All terminations (flue and/or intake) must be located at least 12 inches above ground level or the anticipated snow level. • Vent terminations (non-direct and direct vent) must terminate at least 3 feet above any forced air inlet located within 10 feet. NOTE: This provision does not apply to the combustion air intake termination of a direct vent application. 12

No Terminations Above Walkway

<10' 3' min.

4' min.

12" 4' min. 12" min.

Grade or Highest Anticipated Snow Level

12" min. 12" min.

Forced Air Inlet Direct Vent Vent/Flue Termination

Vent Termination Clearances Figure 7

Non-Direct Vent Vent/Flue Termination

• • • • •

The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building. The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet). The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up). A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

NOTE: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.

CANADIAN VENTING REQUIREMENTS In Canada, venting must conform to the requirements of the current CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, ULCS636 compliant two- or three-inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. The certified piping should be clearly marked with the ULC Std “S636” on the pipe and fittings. Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

STANDARD FURNACE CONNECTIONS It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported.

VENT/FLUE PIPE The vent pipe outlet is sized to accept 2” pipe. Secure vent/flue pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by creating an offset using two 45 degree elbows. This joint can be rotated on the fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg. elbow when considering elbow count.

V E N T 45 DEGREE LONG-SWEEP ELBOWS

NOTE: For non-direct vent installations, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. Increased Clearance Configuration Figure 8

DIRECT VENT INSTALLATIONS

On upflow units secure the combustion air intake pipe directly to the air intake coupling or glue a short section of pipe into the furnace vent fitting and install the rubber coupling supplied with the furnace.

NON-DIRECT VENT INSTALLATIONS A minimum of one 90° elbow should be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS .

ALTERNATE VENT/FLUE LOCATION

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps and the “Alternate Vent/Flue Location” figure.

13

NOTE: In the horizontal left installation position, a means of condensate collection must be provided to keep vent pipe condensate from entering the draft inducer housing. If the vent drain elbow is eliminated from the installation, an RF000142 kit must be used.

Insert flange. Cut 2 ½” long. RF000142

1. Remove the four screws from the vent pipe flange on top the furnace. 2. Remove the internal elbow and vent pipe 3. Cut 2 1/2" from the flange . 4. Remove plastic plug in line with the inducer outlet 5. Install cut end of the flanged section and connect to inducer with rubber coupling supplied with furnace. 6. Install screws removed in step 1 securing flange to cabinet.

Figure 9

CUT HERE

WARNING THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET , EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELDSUPPLIED VENT /FLUE PIPING , AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE

Vent/Flue Pipe Cuts Figure 10

ALTERNATE COMBUSTION AIR PROVISION

(Upflow / Horizontal models only) When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down – venting, an alternate combustion air opening can be used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1 7/8" measured from the front edge of the cabinet in line with the knock out. To use the alternate combustion air location: 1. Remove screws and combustion air flange from cabinet. 2. Insert cabinet plug in unused combustion air hole. CAUTION 3. Drill a pilot hole at the cabinet dimple (size dictated by knockout tool used). BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS 4. Use a knockout tool to create a 3" diameter hole WHEN REINSTALLING COUPLING AND SCREWS. 5. Install combustion air flange and secure with screws removed in step one.

NON-DIRECT VENT (SINGLE PIPE) PIPING Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. Although non-direct vent installations do not require a combustion air intake pipe, a minimum of one 90° elbow should be attached to the furnace’s combustion air intake if: an upright installation uses the standard intake location, or a horizontal installation uses the alternate air intake location. This elbow will guard against inadvertent blockage of the air intake.

14

VENT/FLUE PIPE LENGTHS

AND

DIAMETERS

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/ flue pipe system of a non-direct vent installation. In addition to the vent/flue pipe, a single 90° elbow should be secured to the combustion air intake to prevent inadvertent blockage. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

*M EC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe)

(6)

M aximum Allowable Length of Vent/Flue Pipe & Combustion Air Pipe (ft) Unit Input

40,000

VENT/FLUE PIPE TERMINATIONS 60,000

Number of Elbows

Pipe Size (4)

(Btu)

(in.) 2

or 2 1/2 2 or 2 1/2

(1) (2) (3) (5)

1

2

3

4

5

6

7

8

120

115

110

105

100

95

90

85

95

90

85

80

75

70

65

60

NOTE: If either a 90 degree or 45 degree elbow is used for termination, it must be pointed downward.

80,000 "B"

2 or 2 1/2

75

70

65

60

55

50

45

40

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

80,000 "B"

3

200

193

186

179

172

165

158

151

80,000 "C"

2 or 2 1/2

25

20

15

10

5

N/A

N/A

N/A

80,000 "C"

3

200

193

186

179

172

165

158

151

100,000

2 or 2 1/2

25

20

15

10

5

N/A

N/A

N/A

100,000

3

200

193

186

179

172

165

158

151

120,000

2 or 2 1/2

45

40

35

30

25

20

15

10

120,000

3

95

90

85

80

75

70

65

60

Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

1) 2) 3)

Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination. Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee. Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system. 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe. Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow. One 90° elbow should be secured to the combustion air intake connection.

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe 4) 5) and Combustion Air Pipe. To secure the pipe passing through the wall and prohibit damage to piping con6) nections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

15

DOWN VENTING UPFLOW MODEL FURNACES ONLY Figure 11

Use alternate vent & combination air locations Vent Pipe

r Floo Combustion Air Pipe To Field Supplied Condensate Disposal

ce lspa w a r /C ent m e s Ba

t min. Slope 1/4” per foo

Field Supplied Drain Tee on Vent Pipe

Condensate trapped to previent flue gas from escaping

All piping and fittings must be joined per material manufacturer’s specifications to prevent separation and flue gas leaks.

NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacles between pipes, etc.).

12" MIN.

TEE (OPTIONAL)

COMBUSTION AIR INTAKE (OPTIONAL)

12” MIN HEIGHT DIFFERENCE BETWEEN INTAKE AND VENT

*Not required for single pipe installation

O RO

FL

VENT/FLUE TEE (OPTIONAL) or 45° ELBOW TURNED DOWN or 90° ELBOW TURNED DOWN

INE

12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL

INTAKE SCREEN OPTIONAL

3 .AX M ” 96

”M

IN.

Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level Figure 14

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

Figure 12

ELBOWS Figure 13

STRAIGHT

16

DIRECT VENT (DUAL PIPE) PIPING The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe. Installation of screens, while strongly recommended, is not required and will not affect performance of the unit. Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Vent/Flue and Combustion Air Pipe - Termination Locations or Concentric Vent Termination for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Vent/Flue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems. If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required.

VENT/FLUE

AND

10”- 24”

6” MAX

COMBUSTION AIR PIPE TERMINATIONS 4” MIN

The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent. Vent & Combustion Air Intake Measurements for Standard Horizontal Terminations (Dual Pipe) Center to center = 10” min / 24” max. Vertical separation: 0” - 24” Vent termination from wall = 8” min / 12” max. Combustion air intake from wall = 6” max. Vent and intake clearance to ground or anticipated snow level = 12” min.

90º OR 45° ELBOW SCREEN (OPTIONAL)

12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe) Figure 15

90° ELBOWS 90° ELBOWS

3” - 24”

3”-24” BETWEEN PIPES AIR INTAKE SCREEN

AIR INTAKE

(OPTIONAL)

SCREEN (OPTIONAL)

12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL

12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL

Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.

Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) Figure 17

Alternate Horizontal Vent Termination (Dual Pipe) Figure 16 17

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit. If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the following figure. Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation.

CONCENTRIC VENT TERMINATION Refer to the directions provided with the Concentric Vent Kit (CVENT) for installation specifications.

3”MIN 24”MAX 12” MIN SEPARATION 3” MIN

OPTIONAL INTAKE SCREENS

12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces Figure 18

SIDE WALL VENT KIT This kit is to be used with 2” or 3” direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other. These kits are NOT intended for use with single pipe (non-direct vent) installations. Refer to the directions furnished with the Side Wall Vent Kit (p/n 0170K00000S or 0170K000001S) for installation specifications.

CONDENSATE DRAIN LINES & DRAIN TRAP

H orizontal Installation

Ve rtica l Installation

Side Wall Vent Kit Figure 19

A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes. Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups. • The drain trap supplied with the furnace must be used. • The drain trap must be primed at time of installation. • The drain line between furnace and drain location must meet local and nation codes. • The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain. • Do not trap the drain line in any other location than at the drain trap supplied with the furnace. • If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. • If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.

18

GENERAL DRAIN INFORMATION All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in the factory position. All furnace models installed horizontally require the trap to be relocated. Many drain hoses have a built–in grommet which will provide a cabinet seal when installed. See instructions below for your model and installation position. NOTE: Both sides of the drain trap must be primed prior to initial furnace start up

#2

#1

#3

FIELD SUPPLIED DRAIN

#5 #4

Drain the furnace and air conditioning coil if applicable, in compliance with code requirements. In horizontal installations, a field installed rubber coupling will allow the drain trap to be removed for cleaning. The drain trap must be primed before initial furnace start up. When an air conditioning coil drain is connected to the field supplied furnace drain, it must be vented.

#8

#7

#9 Coupling

#10

#6

#11

100 Degree Elbow

Figure 20 NOTE: Hoses are model specific and not all hoses will be shipped with all models.

UPFLOW MODEL INSTALLED VERTICALLY The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet.

DRAIN EXITING RIGHT SIDE 1. Locate and Install the 45º pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through hole in the right side of the cabinet and secure with two field supplied #8 self-tapping screws (see Figure 21). 2. Locate the long drain hose #3 and cut at line “A” . 3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp. 4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp. 5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

Hose #1 Hose #2

45 degree barb-pipe adapter

45 degree barb-pipe adapter

Installer selects right or left side drain and installs this hose accordingly.

Figure 21 19

DRAIN EXITING LEFT SIDE 1. Install the 45 degree pipe / hose drain coupling from the outside of the cabinet (barbed end goes in the cabinet) through the hole in the left side of the cabinet and secure with two field supplied #8 self-tapping screws (see Figure 21). 2. Locate the long drain hose #3 and cut at “B” line for a 17.5" cabinet; cut at line “C” for a 21" cabinet; do not cut for a “D” width cabinet. 3. Install large end of hose #3 to trap outlet and secure with 1.25" clamp. 4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp. 5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

UPFLOW MODEL INSTALLED HORIZONTALLY DOWN

WITH

RIGHT SIDE

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace. 1. Remove the clamps from both ends of the drain hoses. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and two hoses from the blower deck 4. Remove the two plugs from the right side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow ) Locate hose #5 and cut it at line “C”. Install the cut end of hose #5 from outside the cabinet through the cabinet drain hole nearest the top. Secure it Hose #5-Cut at “C” Hose #11 to the barbed fitting in the elbow with a red clamp. 6. (Draining the Collector Box) Install the non-grommet end Figure 22 of hose #11 from outside the cabinet in the bottom drain hole. Install on collector box and secure with a silver clamp. 7. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet. 8. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

UPFLOW

MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE

DOWN

Minimum 5 3/8" clearance is required for the drain trap beneath the furnace. 1. Remove the clamps from the two drain tubes on the trap. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and hoses from the blower deck . 4. Remove the two plugs from the left side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow) Locate hose #6. Measuring from the non-grommet end; cut off and discard 1 ½” for a “D” Hose #6 width cabinet, 5” for a “C” width cabinet, 8 ½” for a “B” Hose #11 Hose #5 width cabinet. 6. Remove the rubber plug from vent – drain elbow side port. Figure 23 Place hose #6 on the vent – drain elbow side port and secure with a silver clamp . 7. Place cap on vent – drain elbow barb fitting and secure with red clamp 8. Locate hose #5 and cut 3” from the non-grommet end. Discard the section without the grommet. 9. Insert the cut end of tube #5 through the lower cabinet drain hole. 10. Connect hose #6 & hose #5 using 100º elbow and secure with two red clamps. 20

11. (Draining the Collector Box) Install the non-grommet end of hose #11 from outside the cabinet in the bottom drain hole. Install on collector box and secure with a silver clamp. 12. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet. 13. Place cap on vent – drain elbow barb fitting and secure with red clamp. 14. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.

ELECTRICAL CONNECTIONS WARNING

WIRING HARNESS

HIGH VOLTAGE !

The wiring harness is an integral part of this furnace. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor.

TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED .

WARNING

HIGH VOLTAGE !

115 VOLT LINE CONNECTIONS

TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS . WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION . VERIFY PROPER OPERATION AFTER SERVICING .

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location. Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. For direct vent applications, the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non-reactive UL approved sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below. NOTE: Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance.

JUNCTION BOX RELOCATION WARNING Line voltage connections can be made through either the right EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A or left side panel. The furnace is shipped configured for a right PRECAUTION WHEN REMOVING HOLE PLUGS . side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps. 1. Remove the burner compartment door. 2. Remove and save the two screws securing the junction box to the side panel. 3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2.

21

To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check.

WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT.

1. Measure resistance between the neutral (white) connection and one of the burners. 2. Resistance should measure 10 ohms or less.

WARNING

HIGH VOLTAGE ! TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH , THE FURNACE MUST BE ELECTRICALLY

This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch.

GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE , WITH THE LATEST EDITION OF THE

NATIONAL ELECTRIC C ODE.

WARNING TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE.

24 VOLT THERMOSTAT WIRING IMPORTANT NOTE

Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. The following figure shows connections for a “heat/cool system”.

WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER OPERATION, FILTER REMOVAL OR ROUTINE MAINTENANCE.

This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring. As shipped, the furnace S1-1 switch is OFF; S1-2 switch is ON. This is the correct position to use a single stage heating thermostat with auto timing transition to high fire.

R

R

Y

R

Furnace Integrated Control Module

C

Remote Condensing Unit (Single-Stage Cooling)

Thermostat - Single -Stage Heating with Single-Stage Cooling NOTE: To apply a single-stage Heating Thermostat, the thermostat selector switch on the Integrated Control Module must be set on single-stage. Figure 24

R

Y

Furnace Integrated Control Module

C

Y2

W1

W2

Y

W1

W2

Furnace Integrated Control Module

Y2

Remote Condensing Unit (Single-Stage Cooling)

Thermostat - Two-Stage Heating with Single-Stage Cooling Figure 25

Remote Condensing Unit (Two-Stage Cooling)

Thermostat - Two-Stage Heating with Two-Stage Cooling Thermostat Wiring Diagrams Figure 26

22

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

Staging DIP Switches

A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a single-stage thermostat offers a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 10 or 20 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTO mode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.

DIP Switch

(factory setting)

S1-1

S1-2

Heat Staging

OFF

OFF

2 Stage Stat*

ON

OFF

10 min delay

OFF

ON

AUTO

ON

ON

20 min delay

* no high fire without W2 call

FOSSIL FUEL APPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace). A heat pump thermostat with three stages of heat is required to properly use a two-stage furnace in conjunction with a heat pump. Refer to the fossil fuel kit installation instructions for additional thermostat requirements. Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the furnace two-stage integrated control module and the “FURNACE” terminal strip on the fossil fuel control board.

TWINNING Using the “TWIN” terminals and proper wiring enables two *MEC96 furnaces of the same model and size to be twinned. Twinning allows simultaneous operation of two furnaces and forces the indoor blower motors of each furnace to operate synchronously into a common duct system. Using the twinning function will require only field installed wiring with no external kits or parts. · The staging DIP switches and speed tap DIP switches must be set the same on both furnaces.

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)

Room Thermostat

Furnace 1

Furnace 2

Y2

Ylo

Ylo

Y

Y

Y

W

W

W

W2

W2

W2

R

R

R

G

G

G

C

C

C

The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional fieldsupplied humidifier and/or electronic air cleaner. The accessory load specifications are noted in the chart at right: Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The humidifier and electronic air cleaner hot terminals are identified as HUM and EAC. The humidifier and electronic air cleaner neutral terminals are identified as NEUTRAL. All field wiring must conform to applicable codes. Connections should be made as shown.

Humidifier Electronic Air Cleaner

1.0 Amp maximum at 120 VAC 1.0 Amp maximum at 120 VAC

WARNING

HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

23

If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box. The integrated control module humidifier terminal (HUM) is energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminal (EAC) is energized with 115 volts whenever the circulator blower is energized. This terminal can also be used to provide 115 volt power to a humidifier transformer. The remaining primary transformer wire would be connected to the Line N on the control board.

GAS SUPPLY AND PIPING The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude. Inlet gas supply pressures must be maintained within the ranges specified in the adjacent table. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

Accessories - Accessories Wiring Figure 27

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE , THE

HIGH ALTITUDE DERATE

INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT

When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range. High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Consult the furnace Specification Sheet for appropriate kits. Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

INLET GAS SUPPLY PRESSURE Natural Gas

Minimum: 4.5" w.c.

Maximum: 10.0" w.c.

Propane Gas

Minimum: 11.0" w.c.

Maximum: 13.0" w.c.

WARNING POSSIBLE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED . THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION .

ALL CONVERSIONS MUST BE PERFORMED BY A

QUALIFIED INSTALLER OR SERVICE AGENCY.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Consult the furnace Specification Sheet for pressure switch.

PROPANE GAS CONVERSION This unit is configured for natural gas. To operate this furnace on L.P. Gas, an LPM-08 LP Conversion Kit must be used. Consult the furnace Specification Sheet for a listing of appropriate kits. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency. WARNING

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convert24

TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE OF NATURAL /PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER /TANK TO THE FURNACE.

ible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the lighting instructions label or Startup Procedure & Adjustment for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1. To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the inNatural Gas Capacity of Pipe staller may also need to supply a transition piece from 1/2" pipe to In Cubic Feet of Gas Per Hour (CFH) a larger pipe size. The following stipulations apply when connecting gas piping. Refer to Gas Piping Connections figure for typical gas line connections to the furnace. •

Gas piping must be supported external to the furnace cabinet so that the weight of the gas line does not distort the burner rack, manifold or gas valve.

• Use black iron or steel pipe and fittings for building piping.



Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound. Use pipe joint compound on male threads ONLY. Always use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads.

Length of Nominal Black Pipe Size Pipe in Feet 1/2" 3/4" 1" 1 1/4" 10 132 278 520 1050 20 92 190 350 730 30 73 152 285 590 40 63 130 245 500 50 56 115 215 440 60 50 105 195 400 70 46 96 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific Gravity Gas)

1 1/2" 1600 1100 980 760 670 610 560 530 490 460

CFH = BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)

• Use ground joint unions. • Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches •

long. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.

• Always use a back-up wrench when making the connection to the gas valve to keep it from turning. The orientation of the gas •

valve on the manifold must be maintained as shipped from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve. Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

• Tighten all joints securely. • Connect the furnace to the building piping by one of the following methods:

– –

Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.

• Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace.

• Protect connectors and semirigid tubing against physical and thermal damage when installed. Ensure aluminum-alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage. The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the 25

cabinet per local codes. 1/2” NPT pipe and fittings are required. For models with an “L” shaped manifold, a 4 1/2” long nipple is required. For models with a hook shaped manifold, a 2” long nipple is required.

Alternate Gas Line Location

A semi-rigid connector to the gas piping can be used outside the cabinet per local codes. From the elbow, the length of pipe and the fittings required will vary by the side chosen, location of union and cabinet width. The union may be placed inside or outside of the cabinet.

Gas Valve

Manifold

Burners

Manual Shut Off Valve (upstream from ground joint pipe union)

*Ground Joint Pipe Union

*Ground Joint Pipe Union

Drip Leg Grommet in Standard Gas Line Hole

GAS PIPING CHECKS Before placing unit in operation, leak test the unit and gas connections. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

*NOTE: Union may be inside furnace cabinet where allowed by local codes.

UPFLOW Figure 28 Gas Connections

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPA).

WARNING TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.

PROPANE GAS TANKS AND PIPING A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions listed in the Safety Precautions section of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

WARNING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT , AN EXCAVATED AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO

For satisfactory operation, propane gas pressure must be 10” WC CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING at the furnace manifold with all gas appliances in operation. MainDEVICE IN CASE OF A GAS LEAK. taining proper gas pressure depends on three main factors: • SINCE PROPANE GAS IS HEAVIER THAN AIR , ANY LEAKING GAS CAN 1. Vaporization rate, depending on temperature of the liquid, SETTLE IN ANY LOW AREAS OR CONFINED SPACES. and “wetted surface” area of the container or containers. • ROPANE GAS ODORANT MAY FADE , MAKING THE GAS UNDETECTABLE P 2. Proper pressure regulation. (Two-stage regulation is EXCEPT WITH A WARNING DEVICE . recommended for both cost and efficiency). 3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend 5 to 15 PSIG First Stage on length of pipe run and total load of all appliances. (20 PSIG Max.) Regulator Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

Continuous 11" W.C.

200 PSIG Maximum

Second Stage Regulator

Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Always use a pipe thread sealant approved for all gases. Refer to the this illustration for typical propane gas installations and piping. 26

Propane Gas Installation (Typ.) Figure 29

Sizing Between First and Second Stage Regulator*

Sizing Between Second or Second Stage Regulator & Appliance*

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.

Maximum Propane Capacities listed are based on 1/2” W.C. pressure drop at 11” W.C. setting.

Pipe or Tubing Length Feet 10 20 30 40 50 60 80 100 125 150 175 200

Nominal Pipe Size Schedule 40

Tubing Size, O.D. Type L 3/8" 730 500 400 370 330 300 260 220 200 190 170 160

1/2" 1,700 1,100 920 850 770 700 610 540 490 430 400 380

5/8" 3,200 220 2,000 1,700 1,500 1,300 1,200 1,000 900 830 780 730

3/4" 5,300 3,700 2,900 2,700 2,400 2,200 1,900 1,700 1,400 1,300 1,200 1,100

Capacities in 1,000 BTU/hour.

7/8" 8,300 5,800 4,700 4,100 3,700 3,300 2,900 2,600 2,300 2,100 1,900 1,800

1/2" 3,200 2,200 1,800 1,600 1,500 1,300 1,200 1,000 900 830 770 720

3/4" 7,500 4,200 4,000 3,700 3,400 3,100 2,600 2,300 2,100 1,900 1,700 1,500

To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879

Pipe or Tu bin g Lengt h F eet

3/8"

1/2"

5/8"

3/4"

7 /8"

1/2"

3/4"

10 20

39 26

92 62

199 131

3 29 2 16

501 346

275 189

567 393

30 40 50

21 19 18

50 41 37

107 90 79

1 81 1 45 1 31

277 233 198

152 129 114

315 267 237

590 504 448

1,212 1,039 913

1,858 1,559 1,417

60 80

16 13

35 29

72 62

1 21 1 04

187 155

103 89

217 185

409 346

834 724

1,275 1,066

100 125 150

11 10 9

26 24 21

55 48 43

90 81 72

138 122 109

78 69 63

162 146 132

307 275 252

630 567 511

976 866 787

200 8 19 39 66 100 250 8 17 36 60 93 *Data in accor dance wit h NFPA pamphlet No. 54

54 48

112 100

209 185

439 390

665 590

Propane Gas Piping Chart I

Nom inal Pipe Size Schedu le 40

T ub ing Size, O.D. T yp e L

1"

1- 1/4" 1-1/2"

1,07 1 2,205 732 1,496

3,307 2,299

Propane Gas Piping Chart II

CIRCULATING AIR & FILTERS DUCT WORK - AIR FLOW Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D. Install the duct system in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. For upflow installations requiring 1800 CFM or more, use either two side returns or bottom return or a combination of side /bottom. Flexible joints may be used for supply and return connections to reduce noise transmission. To prevent the blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber.

CHECKING DUCT STATIC Refer to your furnace rating plate for the maximum ESP (external duct static) rating.

WARNING NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY.

Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between the furnace and the cooling coil. This reading is usually taken by removing the “A” shaped block off plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. Take a duct static reading at the test hole. Tape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower. Too much external static pressure will result in insufficient air that can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure. To determine total external duct static pressure, proceed as follows; 1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure) 2. Measure the static pressure of the supply duct. (Positive Pressure) 3. The difference between the two numbers is .4” w.c. Example: static reading from return duct = -.1" w.c. static reading from supply duct = .3" w.c. total external static pressure on this system = .4" w.c. 27

NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing. 4. Consult proper tables for the quantity of air. If the total external static pressure exceeds the maximum listed on the furnace rating plate, check for closed dampers, registers, undersized and/ or oversized poorly laid out duct work. The temperature rise of the furnace must be within the temperature rise range listed on the furnace rating plate.

BOTTOM RETURN AIR OPENING [UPFLOW MODELS] The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the Checking Static Pressure corners of the opening, cut the sheet metal along the scribe lines to free the (80% Furnace Shown, 90% Similar) duct flanges. Using the scribe line along the duct flange as a guide, unfold the Figure 30 duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be reduced by approximately 18% if duct flanges are not unfolded. This could cause performance issues and noise issues. When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.

WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR OPENINGS.

When the furnace is installed without a cooling coil, it is recommended that a removable access panel be provided in the outlet air duct. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream. The access panel must be made to prevent air leaks when the furnace is in operation. When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without filters, the warranty will be voided.

CUT USING TIN SNIPS PRESS OUT BY HAND

CUT FOUR CORNERS AFTER REMOVING SHEET METAL SCRIBE LINES OUTLINING DUCT FLANGES

Duct Flange Cut Outs Figure 31

On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. NOTE: An undersized opening will cause reduced airflow. Refer to the following table to determine filter area requirements. Change filters before occupants take ownership of a new home!

28

UPRIGHT INSTALLATIONS

Filter Sizing Chart

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. The figure at right shows possible filter locations.

HORIZONTAL INSTALLATIONS

Model

Minimum Filter Size

*MEC960302BN**

16 X 24

*MEC960402BN**

20 X 24

*MEC960603BN**

24 X 30

*MEC960803BN**

24 X 30

*MEC961004CN**

(2) 18 x 24

*MEC961205DN**

2 (20 X 25)

[Based on 300 ft/min filter face velocity]

Filters must be installed in either the central return register or in the return air duct work.

STARTUP PROCEDURE & ADJUSTMENT AIR FLOW

Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjustment items, refer to further information in Operational Checks section.

SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE)

FILTER

The drain trap MUST be primed prior to furnace startup. To prime, fill both sides of the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system.

FILTER

DRAIN TRAP PRIMING

CENTRAL RETURN GRILLE

FURNACE OPERATION Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed.

Figure 32

FURNACE STARTUP 1. 2. 3. 4.

Close the manual gas shutoff valve external to the furnace. Turn off the electrical power to the furnace. Set the room thermostat to the lowest possible setting. Remove the burner compartment door.

NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 5. Move the furnace gas valve manual control to the OFF position. 6. Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air. 7. If you smell gas after five minutes, immediately follow the Safety Instructions on page 3 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position. 8. Replace the burner compartment door. 9. Open the manual gas shutoff valve external to the furnace. 10. Turn on the electrical power to the furnace. 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to desired temperature.

FURNACE SHUTDOWN 1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. The circulator blower will shut off after the time delay expires (selectable 90, 120, 150, 180 seconds). 2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position. 3. Close the manual gas shutoff valve external to the furnace. 4. Replace the burner compartment door. 29

GAS SUPPLY PRESSURE MEASUREMENT

CAUTION

GAS PRESSURE TEST

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE , THE

The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use

INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

the following procedure. Open to Atmosphere

INLET

Manometer Hose

OUTLET

Outlet Pressure Boss

High Fire Regulator Adjust Regulator Vent

Gas Valve On/Off Selector Switch White-Rodgers Model 36J54 (Two-Stage) Figure 33A

Low Fire Regulator Adjust

Inlet Pressure Boss Manometer

High Fire Coil Coaxial Coil Terminal (HI) Terminal (M) Common On/Off Switch Terminal(C)

White-Rodgers Model 36J54 Connected to Manometer Figure 33B

1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg. See White-Rodgers 36J54 gas valve figure for location of inlet pressure tap.

INLET GAS SUPPLY PRESSURE Natural Gas

Minimum: 4.5" w.c.

Maximum: 10.0" w.c.

Propane Gas

Minimum: 11.0" w.c.

Maximum: 13.0" w.c.

NOTE: If measuring gas pressure at the drip leg, a field-supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure tap on the White-Rodgers 36J54 gas valve, then use the 36G/J Valve Pressure Check Kit, Part No. 0151K00000S. 3. Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line. 4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table. If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace. 6. Turn OFF any unnecessary gas appliances stated in step 3.

30

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT Gas Line

Only small variations in gas pressure should be made by adjusting the gas valve Gas Shutoff pressure regulator. The manifold pressure must be measured with the burners Valve operating. To measure and adjust the manifold pressure, use the following procedure. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the Gas Line furnace. To Furnace 2. Turn off all electrical power to the system. 3. Outlet pressure tap connections: Open To Atmosphere White-Rodgers 36J54 valve: Back outlet pressure test screw (inlet/outlet Drip Leg Cap pressure tap) out one turn (counterclockwise, not more than one turn). With Fitting 4. Attach a hose and manometer to the outlet pressure tap (White-Rodgers valve). Manometer Hose 5. Turn ON the gas supply. 6. Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat. 7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure Manometer using the Manifold Gas Pressure table shown below. Measuring Inlet Gas Pressure 8. Remove regulator cover screw from the low (LO) outlet pressure regulator (Alt. Method) Figure 34 adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. 9. Close thermostat “R”, “W1” and “W2” contacts to provide a call for high stage heat. CAUTION 10. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw clockwise to increase TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE , THE pressure or counterclockwise to decrease pressure. Replace GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING regulator cover screw. PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING 11. Turn off all electrical power and gas supply to the system. THE GAS VALVE PRESSURE REGULATOR . 12. Remove the manometer hose from the hose barb fitting or outlet pressure tap. 13. Replace outlet pressure tap: White-Rodgers 36J54 valve: Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum). 14. Turn on electrical power and gas supply to the system. 15. Close thermostat contacts “R” and “W1/W2” to energize the valve. M anifold Gas Pressure Using a leak detection solution or soap suds, check for leaks at outlet pressure tap plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY! NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

31

Gas Natural Propane

Low Stage High Stage Low Stage High Stage

Range 1.6 - 2.2" w .c. 3.2 - 3.8" w .c. 5.7 - 6.3" w .c. 9.7 - 10.3" w .c.

Nom inal 1.9" w .c. 3.5" w .c. 6.0" w .c. 10.0" w .c.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) The actual gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure. 1. Turn OFF the gas supply to all other gas-burning appliances except the furnace. 2. While the furnace is operating at high fire rate, time and record one complete revolution of the gas meter dial measuring the smallest quantity, usually the dial that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds). 3. If the 1/2 cu. ft. dial was used, multiply your number x 2. EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78. This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH. NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. for Natural and + 0.5” for LP from the specified setting. Consult your local gas supplier if additional input rate adjustment is required. 4. Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances are functioning properly and that all pilot burners are operating.

TEMPERATURE RISE Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the Specification Sheet applicable to your model. Determine and adjust temperature rise as follows: 1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position. 2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger. 3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize. 4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.

32

SUPPLY AIR

RETURN AIR

Temperature Rise Measurement Figure 35

CIRCULATOR BLOWER SPEEDS

WARNING

This furnace is equipped with a multi-speed ECM motor. Two TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, wiring harnesses connect the motor to the integrated control TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS . board and furnace power supply. The line voltage (115 VAC) power supply to the motor is constant and not switched by the control board. Motor operation is also dependent on a 24 VDC signal on one of the four speed taps on the motor. The airflow tables for heating and cooling speeds show the relationship between airflow (CFM) and external static pressure for each size furnace. Circulator Blower Speed Facts 1. Motor speed Tap wiring must remain in factory position on the control board and motor. 2. There are 4 speed Tap wires to the motor T1, T2, T3, T4. 3. There are 5 speeds available, depending on DIP switch settings and found in air flow table for each size furnace. 4. T1 terminal is always energized for Low Heat / Constant Fan speed. 5. T2 terminal is always energized for High Heat speed. 6. T3 terminal is always energized in Low Cooling. 7. T4 terminal is always energized in High Cooling. 8. Heating input (W1/ W2) always has priority over all other thermostat input. 9. Cooling input (YLo/ Y) has priority over continuous fan input. 10. Continuous fan input (G) has lowest priority. *The blower speed wiring connections must remain in factory position. 1. Refer to the air flow table for your specific model furnace 2. If a cooling or heat pump condensing unit is being used in conjunction with this furnace, the three DIP switches in S2 are used to select the proper cooling speeds to match the outdoor unit size. Typical CFM requirements are 400 CFM / Ton. 1. Turn OFF power to the furnace. 2. Select the heating and cooling blower speeds that match the installation requirements from the airflow table in this manual or the Service Manual, If factory cooling speeds do not match the installation requirements, the dip switch settings must be changed from factory position 3. Turn ON power to furnace. 4. Verify proper temperature rise in heat modes and CFM in cooling modes In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner’s needs.

33

DIP SWITCH SETTING 0.1

0.2

0.3

0.4

0.5

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

870 870 885 874 1146

658 658 821 697 1097

548 548 755 612 1049

469 469 684 533 1002

413 413 621 470 941

349 349 557 414 895

293 293 508 361 846

N/A N/A 461 303 787

ON OFF OFF

Ylo Y

874 928

697 868

612 810

533 743

470 670

414 614

361 560

303 505

ON ON OFF

Ylo Y

928 1146

868 1097

810 1049

743 1002

670 941

614 895

560 846

505 787

OFF ON OFF

Ylo Y

928 870

868 658

810 548

743 469

670 413

614 349

560 293

505 N/A

OFF OFF ON

Ylo Y

928 885

868 821

810 755

743 684

670 621

614 557

560 508

505 461

OFF ON ON

Ylo Y

874 1146

697 1097

612 1049

533 1002

470 941

414 895

361 846

303 787

ON OFF ON

Ylo Y

885 1146

821 1097

755 1049

684 1002

621 941

557 895

508 846

461 787

ON ON ON

Ylo Y

885 874

821 697

755 612

684 533

621 470

557 414

508 361

461 303

0.6

0.7

0.8

*MEC960302BN All DIP Switch Positions All DIP Switch Positions FACTORY SETTING

All DIP Switch Positions OFF OFF OFF

21 30

28 32

34 35

40 39

0.6

45 43

0.7

0.8

DIP SWITCH SETTING 0.1

0.2

0.3

0.4

0.5

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

847 847 989 856 1143

694 694 932 667 1095

611 611 882 546 1046

535 535 819 466 996

471 471 773 413 946

415 415 695 357 890

357 357 650 302 834

Ylo Y

856 960

667 898

546 840

466 780

413 711

357 659

302 596

N/A

ON ON OFF

Ylo Y

960 1143

898 1095

840 1046

780 996

711 946

659 890

596 834

547 778

OFF ON OFF

Ylo Y

960 847

898 694

840 611

780 535

711 471

659 415

596 357

547 313

OFF OFF ON

Ylo Y

960 989

898 932

840 882

780 819

711 773

659 695

596 650

547 586

OFF ON ON

Ylo Y

856 1143

667 1095

546 1046

466 996

413 946

357 890

302 834

N/A

ON OFF ON

Ylo Y

989 1143

932 1095

882 1046

819 996

773 946

695 890

650 834

586 778

ON ON ON

Ylo Y

989 856

932 667

882 546

819 466

773 413

695 357

650 302

N/A

*MEC960402BN All DIP Switch Positions FACTORY SETTING

All DIP Switch Positions All DIP Switch Positions OFF OFF OFF

ON OFF OFF

29 36

34

36 38

41 40

47 43

53 46

313 313 586 N/A

778

547

778

586

DIP SWITCH SETTING 0.1

0.2

0.3

0.4

0.5

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

894 894 1328 782 1236

846 846 1287 629 1189

780 780 1249 547 1149

720 720 1215 469 1101

660 660 1170 396 1066

603 603 1131 333 1017

554 505 554 505 1085 1046

Ylo Y

782 1149

629 1104

547 1057

469 1017

396 963

333 918

ON ON OFF

Ylo Y

1149 1236

1104 1189

1057 1149

1017 1101

OFF ON OFF

Ylo Y

1149 894

1104 846

1057 780

OFF OFF ON

Ylo Y

1149 1328

1104 1287

OFF ON ON

Ylo Y

782 1236

ON OFF ON

Ylo Y

ON ON ON

Ylo Y

*MEC960603BN All DIP Switch Positions All DIP Switch Positions FACTORY SETTING

All DIP Switch Positions OFF OFF OFF

ON OFF OFF

42 40

44 41

48 43

52 44

0.6

57 46

0.7

0.8

N/A

N/A

969

928

N/A

N/A

865

822

963 1066

918 865 1017 969

822 928

1017 720

963 660

918 603

822 505

1057 1249

1017 1215

963 1170

918 865 822 1131 1085 1046

629 1189

547 1149

469 1101

396 1066

333 N/A 1017 969

1328 1236

1287 1189

1249 1149

1215 1101

1170 1066

1131 1085 1046 1017 969 928

1328 782

1287 629

1249 547

1215 469

1170 396

1131 1085 1046 333 N/A N/A

865 554

N/A

928

DIP SWITCH SETTING *MEC960803BN

0.2

0.3

0.4

0.5

0.6

0.7

0.8

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

1221 1221 1311 750 1111

1172 1172 1293 644 1068

1128 1128 1249 569 1025

1087 1087 1203 507 984

1049 1049 1172 442 941

1005 1005 1122 388 885

959 959 1088 328 N/A

922 922 1041

Ylo Y

750 894

644 842

569 784

507 726

442 682

388 618

328 562

N/A

ON ON OFF

Ylo Y

894 1111

842 1068

784 1025

726 984

682 941

618 885

562 N/A

519 801

OFF ON OFF

Ylo Y

894 1221

842 1172

784 1128

726 1087

682 1049

618 562 1005 959

519 922

OFF OFF ON

Ylo Y

894 1311

842 1293

784 1249

726 1203

682 1172

618 562 519 1122 1088 1041

OFF ON ON

Ylo Y

750 1111

644 1068

569 1025

507 984

442 941

388 885

ON OFF ON

Ylo Y

1311 1111

1293 1068

1249 1025

1203 984

1172 941

1122 1088 1041 885 N/A 801

ON ON ON

Ylo Y

1311 750

1293 644

1249 569

1203 507

1172 442

1122 1088 1041 388 328 N/A

All DIP Switch Positions FACTORY SETTING

0.1

All DIP Switch Positions All DIP Switch Positions OFF OFF OFF

ON OFF OFF

41 54

35

42 55

44 57

46 59

47 61

328 N/A

N/A

801

519

N/A

801

DIP SWITCH SETTING 0.1

0.2

0.3

0.4

0.5

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

1522 1522 1861 1004 1772

1464 1464 1803 890 1713

1402 1402 1749 805 1662

1338 1338 1698 710 1609

1280 1280 1653 620 1540

1230 1230 1594 553 1498

1167 1167 1549 474 1452

1101 1101 1504 406 1399

ON OFF OFF

Ylo Y

1004 1312

890 1235

805 1170

710 1101

620 1037

553 962

474 880

406 820

ON ON OFF

Ylo Y

1312 1772

1235 1713

1170 1662

1101 1609

1037 1540

962 880 820 1498 1452 1399

OFF ON OFF

Ylo Y

1312 1522

1235 1464

1170 1402

1101 1338

1037 1280

962 880 820 1230 1167 1101

OFF OFF ON

Ylo Y

1312 1861

1235 1803

1170 1749

1101 1698

1037 1653

962 880 820 1594 1549 1504

OFF ON ON

Ylo Y

1004 1772

890 1713

805 1662

710 1609

620 1540

553 474 406 1498 1452 1399

ON OFF ON

Ylo Y

1861 1772

1803 1713

1749 1662

1698 1609

1653 1540

1594 1549 1504 1498 1452 1399

ON ON ON

Ylo Y

1861 1004

1803 890

1749 805

1698 710

1653 620

1594 1549 1504 553 474 406

*MEC961004CN All DIP Switch Positions All DIP Switch Positions FACTORY SETTING

All DIP Switch Positions OFF OFF OFF

41 48

43 49

44 51

47 52

0.6

49 54

0.7

0.8

DIP SWITCH SETTING 0.1

0.2

0.3

0.4

0.5

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM Rise

CFM CFM CFM

G W1 W2 Ylo Y

1796 1796 2211 1106 1683

1753 1753 2162 1017 1628

1697 1697 2122 946 1565

1645 1645 2076 855 1511

1589 1589 2029 764 1445

1536 1536 1986 681 1387

ON OFF OFF

Ylo Y

1106 1399

1017 1327

946 1259

855 1185

ON ON OFF

Ylo Y

1399 1683

1327 1628

1259 1565

OFF ON OFF

Ylo Y

1399 1796

1327 1753

OFF OFF ON

Ylo Y

1399 2211

OFF ON ON

Ylo Y

ON OFF ON

ON ON ON

*MEC961205DN All DIP Switch Positions All DIP Switch Positions FACTORY SETTING

All DIP Switch Positions OFF OFF OFF

0.6

0.7

0.8

1478 1478 1984 605 1340

1425 1425 1942 N/A 1276

764 1118

681 605 1051 980

N/A 913

1185 1511

1118 1445

1051 980 913 1387 1340 1276

1259 1697

1185 1645

1118 1589

1051 980 913 1536 1478 1425

1327 2162

1259 2122

1185 2076

1118 2029

1051 980 913 1986 1984 1942

1106 1683

1017 1628

946 1565

855 1511

764 1445

681 605 N/A 1387 1340 1276

Ylo Y

2211 1683

2162 1628

2122 1565

2076 1511

2029 1445

1986 1984 1942 1387 1340 1276

Ylo Y

2211 1106

2162 1017

2122 946

2076 855

2029 764

1986 1984 1942 681 605 N/A

42 48

36

43 49

44 50

45 51

47 53

BLOWER HEAT OFF DELAY TIMINGS The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 90, 120, 150, 180 seconds using the DIP switches provided on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference. Refer to the following figures for switch positions and corresponding delay times.

NORMAL SEQUENCE OF OPERATION POWER UP • • • •

When power is supplied, the control will energize the Red LED, microcomputer runs its self-check routine. The control will check the status of the gas valve circuitry. Line polarity is checked. The control then enters standby waiting for a call for heat or cool.



The Furnace status LED will display a slow green flash signaling standby mode.

HEATING MODE Call for 1st Stage Heat Only: • On a call for first stage heat, the thermostat contacts close signaling the control module. • The microcomputer runs its self-check routine. • The Amber LED will display a slow flash signaling normal heat operation. • The control module checks the high limit (and/or auxiliary limit) switch(es) for normally closed contacts. • The control checks the low pressure switch for a shorted condition • The gas valve relay status is checked for proper operation. Once the low pressure switch is detected open, the inducer blower is energized at high speed and the humidifier is enabled. • The low pressure switch is checked for closure. • Once the low pressure switch is closed, the pre-purge period begins. The inducer will be energized at high speed for the pre-purge period. • Following the completion of pre-purge, the inducer switches to low speed and the igniter warm up period begins. • After completion of the igniter warm up period: a. Trial for ignition begins. b. The first stage of the gas valve is energized. • The igniter is de-energized when flame is sensed or at the conclusion of the ignition activation period (IAP), whichever comes first. • When flame is sensed, the delay to heat on period begins timing. • After the delay to heat on period, the circulator fan is energized at the low heat speed. • The EAC contact is energized with the circulator. Call for 2nd Stage After First Stage: • The inducer motor goes to high speed. • The pressure switches are checked for closure. Closure of the second stage pressure switch will energize the high fire stage of the gas valve. • The high speed circulator output is energized. NOTE: A call for 2 stage without a call for 1st stage will be ignored, and a three amber flash code will be displayed on the LED. This error code will only be stored in memory once during a single power cycle. nd

2nd Stage Satisfied, First Stage Still Calling: • When the second stage of the thermostat is satisfied, the inducer blower is reduced to low speed which deenergizes the second stage of the gas valve. • After the high heat off delay expires, the circulator is reduced to low heat speed. • Note: A call for second stage without a call for first stage will be ignored.

37

COOLING MODE Low stage cooling Mode sequence: • On a call for lo cool, the YLO and G thermostat contacts close signaling the control module. • The LED will display a “GREEN”1 flash • The compressor and condenser fan are energized. The compressor is connected to the YLO terminal of the control module. • The circulator fan is energized at lo cool speed after a cool on delay. The electronic air cleaner will also be energized. • After the thermostat is satisfied, the compressor is de-energized and the 45 second fan off delay period begins. • Following the 45 second cool mode fan off delay period, the cool circulator and air cleaner relay are de-energized. Single cooling stage thermostat or 2nd stage cooling Mode sequence: • On a call for cool, the Y and G thermostat contacts close signaling the control module. • The LED will display a “GREEN”2 flash • The compressor and condenser fan are energized. The circulator fan is energized at cool speed after a cool on delay. The electronic air cleaner will also be energized. • After the thermostat is satisfied, the compressor is de-energized and the fan off delay period begins. • Following the 45 second fan off delay period, the cool circulator and air cleaner relay are de-energized. Note: If a call for both YLO and Y are present, Y will have priority.

FAN ONLY MODE MANUAL FAN ON: • Call for continuous fan (24 volts on the furnace “G” terminal. • The LED will display solid “GREEN”. • The circulator blower is energized at low heat speed and the electronic air cleaner is also energized after the fan on delay period has expired.

OPERATIONAL CHECKS The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.

SAFETY CIRCUIT DESCRIPTION A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module.

INTEGRATED CONTROL MODULE The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an LED.

PRIMARY LIMIT The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor. The limit guards against overheating as a result of insufficient conditioned air passing over the heat exchanger.

AUXILIARY LIMIT The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures. They are a normally-closed (electrically), manual-reset sensors. These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.

38

ROLLOUT LIMIT The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed (electrically), manual-reset sensors. These limits guard against burner flames not being properly drawn into the heat exchanger.

PRESSURE SWITCHES The pressure switches are normally-open (closed during operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions.

FLAME SENSOR The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame.

TROUBLESHOOTING ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces. 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground. 2. Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

CHECKING FLAME SENSOR Flame current can be measured in two ways: 1. Putting a D.C. microamp meter in series with the flame rod 2. Putting a D.C. volt meter across the two solder pads in the flame current section of the control board. 1 D.C. volt = 1 microamp. See Figure 36.

Flame Current Solder Pads

LIMIT FAULT CODES If the control detects the high limit circuit open, the RED LED will flash FOUR times and energize the inducer and indoor blower. If the limit circuit opens five times within a single call for heat, the furnace will go into lockout for one hour. The RED LED will display a FOUR flash code during this time. The control board can be reset by cycling 115 volt power to the furnace. If the limit circuit opens and does not close within five minutes, the control assumes the blower has failed the RED LED will flash ELEVEN times.

If the limit circuit opens and does not close within fifteen minutes, the control assumes the manual rollout or fuse has opened and the RED LED will flash FIVE times. The control will enter a one hour lockout and the inducer will run continuously.

Figure 36

In an open limit condition the red LED will flash as described above but the error code will not be stored in memory until the limit resets or until 15 minutes has elapsed. So if the limit resets in less than 5 minutes a four flash code will be stored. If the limit resets in more than 5 but less than 15 minutes, an eleven flash code will be stored. If the limit is still open after 15 minutes, a five flash code will be stored. 39

DIAGNOSTIC CHART Refer to the Troubleshooting Chart in the back of this manual for assistance in determining the source of unit operational problems. External Lockout A control lockout resulting from an external fault sensed by the control, such as an unsuccessful recycle or retry period, or a limit trip. Once in External Lockout, the control will shut down for a period of one hour before attempting another trial for ignition. Internal Lockout A failure internal to the control board.

FAULT RECALL Retrieving Fault Codes To retrieve fault codes, push and release the “LAST ERROR” button for more than 1/5 second and less than 5 seconds (the LED will indicate this period by solid GREEN for 1/5 second to 5 seconds). The LED will flash up to five stored fault codes, beginning with the most recent. If there are no fault codes in memory, the LED will flash two green flashes. The control will flash the most recent error first and the oldest error last. If multiple faults exist there will be 2 seconds between codes. Solid LED error codes will not be displayed. Fault Code Reset To clear the fault code memory, push and hold the “LAST ERROR” button for more than 5 seconds and less than 10 seconds (the LED will indicate this period by RAPID GREEN FLASH for 5 seconds to 10 seconds). The LED will flash three green flashes when the memory has been cleared. The ignition control is equipped with a momentary push button switch that can be used to display on the diagnostic LED the last five faults detected by the control. The control must be in Standby Mode (no thermostat inputs) to use the feature.

40

Depress the push button switch for approximately 2 seconds. Release the switch when the LED is turned off. The diagnostic LED will then display the flash codes associated with the last five detected faults. The order of display is the most recent fault to the least recent fault.

RESETTING FROM LOCKOUT Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is characterized by a non-functioning furnace and a one flash diagnostic LED code. If the furnace is in “lockout”, it can be reset in any of the following ways. 1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period. 2. Manual power interruption. Interrupt 115 volt power to the furnace for 1 - 20 seconds. 3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 1 - 20 seconds. NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Troubleshooting Chart for aid in determining the cause.

MAINTENANCE ANNUAL INSPECTION

WARNING

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary. • • • • • •

HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.

Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace. Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways. Burners. Check for proper ignition, burner flame, and flame sense. Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace. Wiring. Check electrical connections for tightness and/or corrosion. Check wires for damage. Filters.

FILTERS FILTER MAINTENANCE Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size.

FILTER REMOVAL

WARNING TO AVOID ELECTRICAL SHOCK , INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE IGNITER , HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE

Depending on the installation, differing filter arrangements can be FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER applied. Filters can be installed in either the central return regisHANDLE THE IGNITER . ter or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance.

To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit.

41

HORIZONTAL UNIT FILTER REMOVAL

CAUTION

Filters in horizontal installations are located in the central return register or the ductwork near the furnace. To remove: 1. Turn OFF electrical power to furnace. 2. Remove filter(s) from the central return register or ductwork. 3. Replace filter(s) by reversing the procedure for removal. 4. Turn ON electrical power to furnace.

TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED M INIMUM FILTER SIZE TABLE OR SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.

MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL Follow the manufacturer’s directions for service.

BURNERS Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). They should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.

WARNING

HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.

INDUCED DRAFT AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary.

FLAME SENSOR (QUALIFIED SERVICER ONLY) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following cleaning, the flame sense signal should be as indicated in the Specifications Sheet. Burner Flame Figure 37

42

FLUE PASSAGES (QUALIFIED SERVICER ONLY) The heat exchanger flue passageways should be inspected at the beginning of each heating season.

BEFORE LEAVING AN INSTALLATION • Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance. • Leave literature packet near furnace.

REPAIR AND REPLACEMENT PARTS • When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers with the order.

• Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description. • Parts are available from your distributor. Functional Parts ListGas Valve Gas Manifold Natural Gas Orifice Propane Gas Orifice Igniter Flame Sensor Rollout Limit Switch Primary Limit Switch Auxiliary Limit Switch Pressure Switch Induced Draft Blower Door Switch

Blower Motor Blower Wheel Blower Mounting Bracket Blower Cutoff Blower Housing Transformer Heat Exchanger with Recuperator Coil Coil Front Cover Integrated Control Module Transformer

43

TROUBLESHOOTING CHART Symptoms

Green LED Code

Amber LED Code

Red LED Code

Fault Description

Check

Cautions

•Furnace fails to operate •None •Control board LED is off

•None

•None

•Defective disconnect switch •Determine cause and restore •Confirm electrically safe •defective door switch • No proper high and low volt power condition before 115 volt power •No 24 volt supply proceeding with repairs power

•Furnace is waiting for a •Solid ON call

•None

•None

•Furnace is not receiving a call

•None Required

•Confirm electrically safe condition before proceeding with work

•Rapid Flash •None

•None

•Furnace is receiving a call for •None Required fan (24 volts on G terminal

•Confirm electrically safe condition before proceeding with work

•Furnace fan only is running

•Normal operation with •One low stage call for cooling repeating (Ylo & G) flash

•None

•None

•Normal operation with low •None Required stage call for cooling (Ylo & G)

•Confirm electrically safe condition before proceeding with work

•Normal operation with •Two high or single stage call repeating for cooling (Y & G) flashes

•None

•None

•Normal operation with high or single stage call for cooling •None Required (Y & G)

•Confirm electrically safe condition before proceeding with work

•Normal operation with low stage call for heat •None (W1)

•One repeating flash

•None

•Normal operation with low stage call for heat (W1)

•None Required

•Confirm electrically safe condition before proceeding with work

•Normal operation with high or single stage call •None for heat

•Two repeating flashes

•None

•Normal operation with high •None Required or single stage call for heat

•Confirm electrically safe condition before proceeding with work

•Furnace does not operate, three Amber •None flashes on control board

•Three repeating flashes

•None

•Furnace does not operate, four Amber •None flashes on control board

•Four repeating flashes

•None

•Furnace does not operate, rapid Amber •None flashes on control board

•Furnace does not operate, one Red flash on control board

•None

•Furnace does not operate, two Red flashes on control board, •None possible inducer operation

•Furnace does not operate, three Red •None flashes on control board

•Faulty thermostat or thermostat wiring or •W2 call present without W1 improperly connected thermostat wires •Faulty thermostat or •Ylo or Y call present without thermostat wiring or improperly connected G thermostat wires

•Confirm electrically safe condition before proceeding with repairs •Confirm electrically safe condition before proceeding with repairs

•Rapid

•None

•Low flame sense current

•Clean flame rod with •Dirty / coated flame rod, poor steel wool. Confirm flame, improper gas pressure, electrically safe condition poor flame sense wire or before proceeding with connections repairs

•None

•One repeating flash

•Flame sensed when no flame should be present

•Gas valve stuck open, improper wiring to gas valve, shorted flame rod or wire

•None

•Two repeating flashes

•Faulty pressure switch, •Confirm electrically safe pressure switch wires shorted, condition before •Pressure switch stuck closed control board inducer relay proceeding with repairs stuck closed

•Three repeating flashes

•Faulty pressure switch, pressure switch or tubing or •Confirm electrically safe wiring / connection, control condition before board inducer relay failed, vent proceeding with repairs pipe restriction / excessive elbows or length

•None

•Low fire pressure switch stuck open

44

•Confirm electrical and gas safe conditions before proceeding with repairs

TROUBLESHOOTING CHART Symptoms

Associated Green Amber LED Code2 LED Code LED Code

•Furnace does not operate, four Red •None flashes on control board

•Furnace does not operate, five Red •None flashes on control board

•Furnace does not operate, six Red flashes •None on control board •Furnace does not operate, seven Red •None flashes on control board

•Furnace does not operate, eight Red •None flashes on control board

Red LED Code

Fault Description

Check

Cautions

•Temperature rise, duct static, •Confirm electrically safe gas pressure, burner alignment, condition before orifice plate position, wiring to proceeding with repairs all limits

•None

•Four repeating flashes

•Open limit circuit, main limit, aux limit, or roll out switch

•None

•Five repeating flashes

•Control board fuse, •Limit & rollout circuit open Temperature rise, duct static, •Confirm electrically safe for 15 minutes. Open control gas pressure, burner alignment, condition before board fuse or rollout switch orifice plate position, wiring to proceeding with repairs all limits

•None

•Six repeating flashes

•Pressure switch cycling lockout, pressure switch has opened 5 times in the same heating cycle

•None

•Seven repeating flashes

•Confirm electrical and •Lockout - excessive retries •Gas pressure, gas valve, front gas safe conditions from flame not being proven cover pressure switch, flame before proceeding with during trial for ignition rod repairs

•None

•Eight repeating flashes

•Confirm electrical and • Lockout - excessive recycles •Gas pressure, gas valve, front gas safe conditions from flame proving being lost cover pressure switch, flame before proceeding with after being proven rod repairs

•Confirm electrically safe •Excessive venting restriction, condition before leaking pressure switch tubing proceeding with repairs

•None

•Nine repeating flashes

•Improper grounding or reverse polarity

•115 volt hot & neutral supply to furnace reversed, hot wire (door switch & L1 on control •Confirm electrically safe board) must read 115 volts to condition before ground & neutral. Neutral wire proceeding with repairs should measure 0 volts to ground

•Furnace does not operate, ten Red flashes •None on control board

•None

•Ten repeating flashes

•Gas valve current detected with no call for heat

•Verify gas valve is not receiving voltage from an electrical short. If valve wiring is correct replace control board

•Furnace does not operate, eleven Red •None flashes on control board, inducer running

•None

•Eleven repeating flashes

•Confirm electrically safe •Open limit switch circuit for •Re-set main power and check condition before more than 5 minutes indoor blower operation proceeding with repairs

•Furnace does not operate, twelve Red •None flashes on control board

•None

•Twelve repeating flashes

•Control board igniter relay not energizing igniter

•Replace control board

•Confirm electrically safe condition before proceeding with repairs

•Furnace does not operate, control board Red LED on solid

•None

•None

•Solid ON

•Control board internal fault •Replace control board

•Confirm electrically safe condition before proceeding with repairs

•Furnace does not operate, control board Red LED rapid flash

•None

•None

•Rapid Flash •Twinning error

•Correct twinning wiring

•Confirm electrically safe condition before proceeding with repairs

•None

•Three double flashes

•Verify pressure switch function & tubing, verify inducer operating and pulling enough vacuum to engage switch

•Confirm electrically safe condition before proceeding with repairs

•Furnace does not operate, nine Red •None flashes on control board

•Furnace does not operate, control board Red LED with three double flashes

•None

•Second stage pressure switch stuck open

45

•Confirm electrical and gas safe conditions before proceeding with repairs

WIRING DIAGRAM

HIGH FIRE PRESSURE SWITCH

C NO

NO

L

N

WH DISCONNECT

PU

RD WH

HI

3

C

2

PU

TO 115VAC/ 1 /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE

OR

BR

FLAME SENSOR C

GY

WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.

GY

NO

BR

TWO STAGE GAS VALVE PM 1 (WHITE RODGERS)

FRONT COVER PRESSURE SWITCH

MANUAL RESET ROLLOUT LIMIT CONTROLS (SINGLE CONTROL ON 30 kBTU AND 40 kBTU)

BL

OR

PK AUTO RESET PRIMARY LIMIT CONTROL

PU

2 1

GN

INDUCED DRAFT BLOWER

WH RD BK

3

N

DISCONNECT

JUNCTION BOX

GND INDOOR AIR CIRCULATOR BLWR GND

GND

BURNER COMPARTMENT

NEUTRAL

LINE

YL

PK

HUM-OUT

RD BK RD WH WH

PK

BR

24V THERMOSTAT CONNECTIONS

OR

CIRC-H

5 CIRCUIT CONNECTOR

L1

T3

S1

S2

Y1

PU YL

LED’S

7

10

2

5

8

11

3

6

9

12

AUTO RESET PRIMARY LIMIT CONTROL

HLO (11)

PS1 (12)

C NO

W2 Y2

PS2 (2) TO MICRO

G

PK BR

LOW FIRE PRESS. SWITCH

NO C

HIGH FIRE PRESS. SWTICH

MANUAL RESET ROLLOUT LIMIT CONTROLS

HLI (6)

O DEHUM

4

TH (5)

AUTO RESET AUXILIARY LIMIT CONTROLS W1

BR 1

NEUTRAL 40 VA TRANSFORMER

24 VAC TO +VDC

GN

BL

GY DIAGNOSTIC

FLAME SENSOR 115 VAC

FUSE 3 A

R

NEUTRAL

HOT SURFACE IGNITER

FS

NEUTRAL

NEUTRAL

ID BLWR IND LO

IGN

LINE

HUM X-FMR

T4

EAC-H

T1 COM

T2

LINE

NEUTRAL

ELECTRONIC AIR CLEANER IND HI

WH WH WH

BK BK

BK

NEUTRAL

HUMIDIFIER

HUM EAC

RD BK

MVL (7) MVC (8)

C

NO FRONT COVER PRESSURE SWITCH

C

MVH (1)

OR 24 V 3 A

HI

5 4 3

WH RD

GN

BK

WH

GND

BK

BLOWER COMPARTMENT DOOR SWITCH (OPEN WHEN DOOR OPEN)

CIRCULATOR BLOWER

RED LED FLASH CODE STEADY ON = INTERNAL GV ERROR, MICRO AND FREQUENCY CHECK

0 RAPID

= TWINNING ERROR

1 1 FLASH = FLAME SENSED WHEN NO FLAME SHOULD BE PRESENT 2 2 FLASHES = PRESSURE SWITCH STUCK CLOSED/INDUCER ERROR 3

3 FLASHES = 1ST STAGE PRESSURE SWITCH STUCK CLOSED/INDUCER ERROR

4

4 FLASHES = OPEN LIMIT SWITCH

5 5 FLASHES = OPEN ROLLOUT/OPEN FUSE DETECTED 6

6 FLASHES = PRESSURE SWITCH CYCLE LOCKOUT

7 7 FLASHES = EXTERNAL LOCKOUT (RETRIES) 8 8 FLASHES = EXTERNAL LOCKOUT (RECYCLES) 9 9 FLASHES + GROUNDING OR REVERSED POLARITY 10 10 FLASHES = GAS FLOW WITH NO CALL FOR HEAT 11 11 FLASHES = LIMIT SWITCH OPEN-BLOWER FAILURE 12 12 FLASHES = IGNITOR RELAY FAILURE

AMBER LED FLASH CODE

0 RAPID

INTEGRATED CONTROL MODULE

= LOW FLAME SENSE CURRENT 1ST STAGE HEAT (W1)

2 2 FLASHES = NORMAL OPERATION WITH CALL FOR 2ND STAGE HEAT

3 3 FLASHES = W2 PRESENT WITH NO W1 4 FLASHES = Y PRESENT WITH NO G CALL, YLO PRESENT WITH NO G CALL

GREEN LED FLASH CODE STEADY ON = STANDBY

0 RAPID = NORMAL OPERATION WITH CALL FOR FAN (G) 1 1 FLASH = NORMAL OPERATION WITH CALL FOR

EQUIPMENT GND COLOR CODES: PK PINK FIELD GND BR BROWN FIELD SPLICE WH WHITE BL BLUE SWITCH (TEMP.) GY GRAY IGNITER RD RED YL YELLOW SWITCH (PRESS.) OR ORANGE OVERCURRENT PU PURPLE PROT. DEVICE GN GREEN JUNCTION BK BLACK TERMINAL INTERNAL TO INTEGRATED CONTROL

LOW STAGE COOL (YLO + G)

2 2 FLASHES = NORMAL OPERATION WITH CALL FOR HIGH STAGE COOL/ OR SINGLE STAGE COOLING (Y + G)

3 DOUBLE FLASHES = 2ND STAGE PRESSURE SWITCH STUCK OPEN/INDUCER ERROR

GND

NOTES: 1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS. 2. MANUFACTURER’S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING. 3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 $ C. USE COPPER CONDUCTORS ONLY. 4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES. 5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY (NO THERMOSTAT INPUTS)

1 1 FLASH = NORMAL OPERATION WITH CALL FOR

4

INDOOR AIR CIRCULATOR BLWR

TO MICRO

BK WH

40 VA

4 3 2 1

TRANSFORMER

2

WH

OR

1

BK

GY

ECM MTR HARNESS

BK OR

BL

TO R

115 VAC

24 VAC

RD

GND

TR (9)

FUSE

PM C

GAS VALVE

GND (4)

G C TWIN

YLO Y W1 W2 R

INTEGRATED CONTROL MODULE

INTEGRATED CONTROL MODULE

PU

AUTO RESET AUXILIARY LIMIT CONTROL

BK RD

WH

BLOWER COMPARTMENT

BL RD OR

GND

L

DOOR SWITCH

CHASSIS GROUND

BL

HIGH VOLTAGE! Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

WARNING:DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.

BK

OR

1

YL

YL

BR

C

2 CIRCUIT CONNECTOR

JUNCTION BOX

OR

PU

GY

OR LOW FIRE PRESSURE SWITCH

2

GN

GRD

ID BLOWER TWO-STAGE PRESSURE SWITCH ASSEMBLY

HOT SURFACE IGNITER

TO 115 VAC/ 1 /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE

GND

0140F02011-A

PLUG CONNECTION LOW VOLTAGE (24V) LOW VOLTAGE FIELD HI VOLTAGE (115V) HI VOLTAGE FIELD

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

46

SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

VENT/FLUE TEE

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the DISTANCE BETWEEN COMBUSTION time of installation of the side wall horizontal vented gas VENT AND GRADE AIR INTAKE. fueled equipment, the installing plumber or gasfitter shall DISTANCE BETWEEN observe that a hard wired carbon monoxide detector with COMBUSTION AIR an alarm and battery back-up is installed on the floor level INTAKE AND GRADE where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

EXEMPTIONS The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer: 1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and 2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

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NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.

Visit our web sites at www.goodmanmfg.com or www.amana-hac.com for information on:

• Products • Warranties • Customer Services

• Parts • Contractor Programs and Training • Financing Options

5151 San Felipe Suite 500 Houston, TX 77056 www.goodmanmfg.com • www.amana-hac.com © 2014 Goodman Manufacturing Company, L.P. is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company, L.P., Houston, TX. All rights reserved.

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Installation Manual

UPFLOW *MEC96 / HORIZONTAL TWO-STAGE GAS FURNACE (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirement...

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