Installation, Start-up, Operating and Service and Maintenance Instructions SAFETY CONSIDERATIONS INTRODUCTION CODES AND Safety ........................ .................................. STANDARDS .......................... ......................................... General Installation Combustion ............................... and Ventilation Duct Systems Lining and Gas Pipe Pressure Electrical and Fibrous Connections Venting Bottom Glass Duct Testing ...........................
SAFETY CONSIDERATIONS FIRE, EXPLOSION, CARBON MONOXIDE ELECTRICAL POISONING Failure to follow this warning iniury, death, or property damage. which could result in personal iniury or death. CAUTION is used to identify unsafe practices which may result in minor personal iniury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. SHOCK, HAZARD could result AND 1.
1/16 [4a_ f_7/8 Q 57/S-- ,,@/,° 51/2 _R_Ctt# _52/_ [14a_ --TOp • _B OF¢.A_NG [!;_;t 71_511/15 27 @/4 1 _ 21.6 tT,_,_1 BOTTOM _T [15sN [15.1_ I N_N A10290 NOTES: 1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate. 2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's (a,) For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle. (b.) For 1200 CFM-20-in.
MiNiMUM iNCHESCLEARANCETO COMBUSTIBLECONSTRUCTION This furnace is approved for UPFLOW, DOWNFLOW, and HORIZONTAL installations. Clearancearrows do notchangewith furnaceorientation. This forced air furnace is improper adjustment, alteration, service, maintenance, or installation can cause serious injury or death. Read and follow instructions and precautions in User's Information Manual provided with this furnace. Installation and service must be performed by a qualified service agency or the gas supplier.
ANY WIRE National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/ NFPA 90B Step 2 mGeneral Current of the NFGC and the NFPA person's charged. 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact and Ventilation the grounded Air will be satisfactorily dis- etc.).
AIRFLOW d> THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDiTiONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TOTHE RIGHT OFTHE BURNER SECTION, AND AIR CONDiTiONED AiR IS DISCHARGED TO THE LEFT. t \ HORIZONTAL LEFT HORIZONTAL B RIGH-'_AIR FL_OW THE BLOWER IS LOCATED ABOVE THE THE BLOWER IS LOCATED TO THE LEFT BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED DOWNWARD OF THE BURNER SECTION, AND CONDiTiONED AIR IS DISCHARGED TO THE RIGHT. _AIRFLOW A02097 Fig.
PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD Failureto follow this caution may result in furnace FIRE component Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. (See Fig. 60 damage.
f. Size openings g. TWO CARBON MONOXIDE Failure to follow injury or death. POISONING this warning result in personal h. TWO The operation of exhaust clothes dryers, attic exhaust NEGATIVE PRESSURE requirements fans, kitchen ventilation fans, fans or fireplaces could create a CONDITION at the furnace. for combustion and ventilation Spaces having Outdoor Combustion 1. Provide tion, ventilation, air for proper ventilation outdoors or spaces the outdoors.
Table OTHER 2--Minimum THAN (1,000'S Space Volumes FAN-ASSISTED BTUH GAS 30 INPUT for 100 % Combustion, Ventilation, TOTAL and Dilution FAN-ASSISTED RATE) (1,000'S 40 50 44 ACH 66 Space Volume BTUH GAS from Indoors TOTAL INPUT RATE) 88 110 132 154 Ft 3 (M 3) 0.60 1,050 (29.7) 1,400 (39.6) 1,750 (49.5) 1,1 O0 (31.1) 1,650 (46.7) 2,200 (62.2) 2,750 (77.8) 3,300 (93.4) 3,850 (109.0) 0.60 1,260 (35.6) 1,680 (47.5) 2,1 O0 (59.4) 1,320 (37.3) 1,980 (56.
The Standard Method: However, installed in the space and 2. The air infiltration air changes Unusually rate is not known to be less than 0.40 1. Less than 0.40 ACH 2. Equal to or greater Method shall be used, is defined to get the total minimum appliances, such of Indoor input of all fan-assisted shall be sized as follows: openings size of Outdoor UPFLOW Bottom rooms can be considered a.
NOTE: Side return-air most HORIZONTAL openings openings can be used in UPFLOW configurations. in DOWNFLOW and 4. If downflow Do not use side return-air configuration. shown In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field-supplied, 5/16 x 1-1/2 in. (8 x 38 ram) nuts. (max) corrosion-resistant NOTE: Bottom closure must used.
If the screws are attached FURNACE APPROVED COIL ASSEMBLY OR COIL BOX screws are not in tension Platform the furnace sides and not the Furnace (are loaded in shear) for reliable support.
Table FURNACE CASING WIDTH 3--Opening Dimensions - In.
Table 4--Air FURNACE SiZE RETURN-AIR INLET 045-08/ Bottom 024048 045-12/ 036045 070-08/ 024070 070-12/ 036070 070-16/ 048070 090-14/ 042090 090-16/ 048090 Bottom or Side(s) Bottom or Side(s) Bottom or Side(s) Bottom or Side(s) Bottom or Side(s) Bottom or Side(s) Bottom 090-20/ 060090 or Side(s) Only Both Sides or 1 Side & Bottom 1 Side Only 110-12/ 036110 110-16/ 048110 Bottom Bottom or Side(s) Bottom 110-22/ 066110 or Side(s) Bottom Only Sides Delivery - CFM SPEED (wi
Table FURNACE SIZE RETURN-AIR iNLET 135-16/ Bottom 048135 135-22/ 066135 Bottom, or Only 060155 - CFM (with Filter)* 0.1 0.2 0.3 EXTERNAL 0.4 (Continued) STATIC 0.5 PRESSURE 0.6 (In. W.C.) 0.7 0.8 0.9 1.
_/4"(6mm) THREADED 4 REQ. ROD ASSEMBLY L. SECURE ANGLE IRON TO BOTTOM OF FURNACE WiTH 3 #8 x3/4 '' (19mm) SCREWS TYPICAL FOR 2 SUPPORTS 8" (203mm) MtN FOR DOOR REMOVAL 1" (25ram) SQUARE, 1-1/4"x1-1/4"x1/8" (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS REQ. PER ROD & (2) LOCK WASHERS A10130 Fig.
LINECONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BYINTERSECTIONS OF THETOPANDTWOSIDES OFTHEFURNACE JACKET ANDBUILDING JOISTS, STUDS, ORFRAMING. 17 3/4" (451 mm)OVERALL 43/4 '' (121mm) UNDER DOOR 1" (25mm) UNDER FURNACE ENTRY VENT EXTEND OUT 12" (305mm) FROM FACE OF DOOR 30-IN. (762mm) MIN WORK AREA *WHEN USED WITH SINGLE WALL VENT CONNECTIONS EQUIPMENT MANUAL SHU_OFFGAS VALVE SEDIMENT TRAP UNION A10164 Fig.
(_ RETURN AIR ® RETURN AIR DOWNFLOW RETURN AIRCONFIGURATIONS ANDRESTRiCTiONS AIR FLOW MODELS I! RETURN AIR CONNECTION ONLY 1 RETURN AIR CONNECTION ONLY 2 RETURN AIR CONNECTION ONLY 3 RETURN AIR COMBINATIONS OF 1,2, AND 3 066.060, -22 AND -20 MODELS YES NO NO NO ALL OTHER MODELS YES NO NO NO A02163 Fig.
accessories. Allaccessories MUST beconnected to duct to furnace FIRE external Refer to Table 5 for recommended casing. used to connect with appropriate HAZARD return-air instructions could result in personal damage. ducts to below. the back of Table the INTERNAL DIA. IN. (MM) The 3/4 Furnaces return-air duct must be connected to return-air opening Up flow and Horizontal LENGTH OF PIPE - FT (M) 20 (6.0) 30 (9.1) 40 (12.1) 50 (15.2) (12.7) 0.
TOP VIEW OF BURNER AND MANIFOLD Facto_ Ins ASSEMBLY 90 ° Elbow Supply 2"(51 ram) Nipple Street Elbow L Gas Valve A08551 A10291 Fig. 21 - Burner and Manifold Fig. 23 - Relocating J-Box GAS SUPPLY MAN UAL SHUTOFF VALVE ( SEDIMENT TRAP UNION O A02035 A10141 Fig. 22 - Typical Gas Pipe Arrangement be pressure in accordance Piping should NFGC, furnace local, and national plumbing and gas codes has been connected. After all connections made, purge lines operating furnace.
while swinging the front edge of the J-Box outboard of the casing. 2. Cut wire tie on loop in furnace ELECTRICAL SHOCK ANDFIREHAZARD Failure to follow this warning could result in personal iniury, death, or property 3. Move J-Box 4. Fasten 1. damage. The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2011 or local codes to minimize personal iniury if an electrical fault should occur.
Table 6--Electrical FURNACE OPERATING VOLTAGE RANGE VOLTSHERTZPHASE SIZE Maximum* 104 127 127 104 104 127 104 127 127 104 104 127 127 104 104 127 104 127 127 104 104 115-60-1 127 127 104 104 115-60-1 127 104 115-60-1 115-60-1 070=08/024070 115-60-1 070=12/036070 070=16/048070 115-60-1 115-60-1 090=14/042090 090=16/048090 115-60-1 115-60-1 090 = 20/060090 115-60-1 110=12/036110 110=16/048110 115-60-1 115-60-1 110=22/066110 135=16/048135 115-60-1 115-60-1 135=22/066135 155
BLOWER TWINNING AND/OR COMPONENTTEST TERMINAL OFF-DELAY J2 JUMPER HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS 3-AMP FUSE LED OPERATION & DIAGNOSTIC LIGHT L2 PL1 -LOW VOLTAGE MAIN HARNESS CONNECTOR ____ 115-VAC(L2)N EL CONNECTIONS TERMINAL 1.0 AMP MAX.) DD c ;PARE SPARE-2 L SPARE-3 PL2 1 PL2-HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR 115 VAC (L1) LINE VOLTAGE CONNECTION Al1619 Fig. 25 - Furnace Control .... ....
-V WIRING Make field 24-v connections at the 24-v terminal strip. (See Fig. 25.) Connect terminal Y as shown in Fig. 26 for proper cooling operation. Use only AWG No. 18, color-coded, copper thermostat wire. CARBON is required, use ONLY a 3-amp. fuse of identical Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using l/4-in female quick connect terminals to the two male l/4-in quick-connect terminals on the control board marked EAC-I and EAC-2.
1.If a vent 1. Vent connector (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow. 2. Do not connect this Category dedicated or common vent. portion positive 5. Category vertically MASONRY CHIMNEY NOTE: These exterior clay accessory furnaces Chimney for correct ONLY furnaces are CSA design-certified chimneys Adapter kit usage. on the furnace Kit.
CHIMNEY For additional iNSPECTiON CHART requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances 211 Rebuild crown.
APPLIANCE APPLICATION REQUIREMENTS The vent connector can exit the cabinet of the furnace through one of 5 locations. Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.
Table 7--Exterior Masonry Chimney Fan+ Nat with Type-B Double Combined Rating Installations Wall Vent Connectors ©NFPA Appliance Input in Thousands Maximum of Btuh & AGA per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT FT. (M) Table SQ. IN. (SQ. MM) 6 (1.8) 12 (7741) 74 19 (12258) 119 28 (18064) 178 8 (2.4) 80 130 193 279 10 (3.0) 138 152 207 233 299 15 (4.5) 84 NR 20 (6.0) NR NR 25O 368 30 (9.
Caution!! for the following For FURNACE all other Table 9--Minimum applications, use the applications, follow VENT ORIENTATION elbow exclusively left, then iNPUT Heights vertical the vent national MiNiMUM FURNACE ORIENTATION Vent Vent minimum heights fuel VENT gas as specified MiNiMUM DIAMETER IN. (rnm)* (BTUH/HR) up Fig. 32 154,000 132,000 110,000(036/12 only) Vent elbow right, then up Fig. 35 below. code. VERTICAL 5 (127) 12 (3.6) 154,000 132,000 5 (127) 7 (.
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SEE NOTES: 1,2,4,5,7,8,9 following these figures SEE NOTES: 1,2,4,7,8,9 on the page following these figures on the page A03214 Fig. 35 - Horizontal Left Application-Vent then ° /A Elbow A03218 Right Fig. 38 - Horizontal Right Application-Vent Elbow Right Up i ,\/, SEE NOTES: 1,2,4,5,7,8,9 following these figures SEE NOTES: 1,2,4,5,7,8,9 following these figures on the page on the page A03219 A03215 Fig. 36 - Horizontal Left Application-Vent Elbow Fig.
START-UP, ADJUSTMENT, CHECK AND SAFETY Step 1 mGeneral ELECTRICALSHOCK FIRE HAZARD Failure Failure to follow this warning could iniury, death and/or property damage. result iniury, in personal HAZARD to follow this warning could result in personal or death. Blower access door switch opens l15-v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.
8001-9000 (2438-2743) 9001-10,000 (2743 -3048) * Derate multiplier range. 32-38 0.86 38-40 0.82 EXAMPLE 2:(0-2000 ft. (0-610 M) altitude) For 22,000 Btuh per burner application use Table 14. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 43" factors are based on midpoint altitude for altitude Manifold pressure: 3.7-In. W.C. *Furnace is shipped with No. 43 orifices.
b. When thermometer readings stabilize, subtract returnair temperature from supply-air temperature to determine air temperature rise. FURNACE NOTE: Blower access door must be installed for proper temperature rise measurement. NOTE: n Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the midpoint of rise range or slightly above. • Gas input for heating operation. • Derate for altitude if applicable.
............. oR PCB _v -B- _oI_ , _ (NATURAL _2_I) R_'__ 2 i NEUTRAL _ SPARE-1 _,_o I I I _ Y TBB=N I I ...... R_ HUM _I I w u _TE#6 FuIr_ SEC-2 RED - BLU _BLK MEDLO _ COOL NOTE #5 START _ PRS ...... il _ LGPS I_ OTE_11/ _--_-- BLK B-- -.... i >d PL3 I -- • II FRS1 | NO )-- I RED I E i MOTOR SPEED CHANGE BLOWER RELAY, SPDT BLWR BLWM BUSS SLOWER MOTOR RELAY, SPST - {NO.
A93059 A06666 Fig. 42 - Gas Control Fig. 43 - Valve Orifice Hole THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) HOOK-AR( AMMETER FROM UNIT 24-V CONTROL TERMINALS EXAMPLE: 5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS = 0.5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING A96316 Fig. 44 - Amp.
Step 4 reCheck Safety 3. Check Pressure Switch This control proves operation of the draft inducer blower. Controls The flame sensor, gas valve, and pressure switch were all checked in the Start-up procedure section as part of normal operation. a. Turn off l15-v power to furnace. b. Disconnect inducer motor lead wires from wire harness. 1. Check Main Limit Switch(es) This control shuts off combustion control system and energizes air-circulating blower motor, if furnace overheats.
Table 12--Gas Rate (cu ft.
Table data based RANGE HEAT AVG. ALTITUDE FT. (M) U.S.A, U.S.A, U.S.A, Size* and Manifold on 22,000 btuh per burner, GAS Pressure derated (In. W.C.) 4 percent SPECIFIC VALUE 0.58 for Gas Input for each 1000 GRAVITY OF NATURAL 0.60 Rate ft. (305 M) above sea level) GAS 0.62 0.64 AT ALTITUDE (BTU/CU FT.) Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. 900 42 3.5 42 3.6 42 3.7 41 3.5 925 42 3.3 42 3.4 42 3.5 42 3.
Table 14-Orifice (Tabulated data based RANGE HEAT AVG. ALTITUDE FT. (M) U.S.A. U.S.A. U.S.A. U.S.A. btuh Pressure per burner, GAS (In. W.C.) for Gas Input derated 4 percent SPECiFiC VALUE 0.58 Rate for each 1000 GRAVITY (Continued) ft. (305 M) above OF NATURAL 0.60 sea level) GAS 0.62 0.64 AT ALTITUDE (BTU/CU U.S.A. Size* and Manifold on 22,000 FT.) No. Pressure No. Pressure No. Pressure No. Pressure 725 43 3.4 43 3.5 43 3.6 43 3.7 750 43 3.2 43 3.
(Tabulated Table 15--Orifice data based on 21,000 Size* and Manifold btuh per burner, Pressure derated (In. W.C.) for Gas Input 4 percent SPECiFiC ALTITUDE RANGE FT. (M) U,S,A. U,S,A. U,S,A. OF NATURAL 0.60 sea level) GAS Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (BTU/CU No. Pressure No. Pressure No. Pressure No. 0.62 0.64 Pressure 900 42 3.2 42 3.3 42 3.4 42 3.5 925 43 3.7 43 3.8 42 3.2 42 3.3 950 43 3.5 43 3.6 43 3.
Table (Tabulated 15--Orifice data based FT. (M) ALTITUDE (BTU/CU 5001 to 6000 (1524 to 1829) U.S.A. 6001 to 7000 (1829 to 2134) 7001 to 8000 U.S.A. (2134 to 2438) U.S.A. 8001 to 9000 (2438 to 2743) 9001 to 10,000 U.S.A, btuh AVG. GAS HEAT VALUE AT ALTITUDE RANGE U.S.A. Size* and Manifold on 21,000 (2743 3048) to FT.) Pressure per burner, (In. W.C.) for Gas Input derated 4 percent SPECIFIC 0.58 Rate for each 1000 GRAVITY (Continued) ft. (305 M) above OF NATURAL 0.
If status status code recall is needed, briefly code recat[ is completed remove component then reconnect one main limit _re to display 11 12 13 14 21 22 23 24 STATUS CODES IS A ]WO code. DIGIT NUMBER WITH THE FI RST DIGIT DETERMI NED BY THE NUMBER OF SHORT 31 33 34 TEST I To initiate thermostat wiii flash the lead.
Thecontrol system alsorequires anearthground forproper operation ofthecontrol andflame-sensing electrode. The24-vcircuitcontains anautomotive-type, 3-amp.fuse located onthecontrol. (See Fig.25.)Anyshorts of the24-v wiringduring installation, service, ormaintenance willcause this fusetoblow. If fusereplacement isrequired, useONLY a3-amp. fuse.Thecontrol LEDwill display status code24whenfuse needs tobereplaced. Proper instrumentation is required toservice electrical controls.
6. Remove 2 screws holding deck and slide blower 7. Clean blower CUTHAZARD Failure to follow this brush caution may result in personal Sheet metal parts may have sharp edges and wear appropriate protective clothing, gloves when handling parts and servicing Media cabinet NOTE: accessories cabinet or burrs. Use care safety glasses and furnaces. 8. Vacuum motor. filter cabinet any loose priate degreaser. 3/4-in. supply (19 ram) filter rack are from the factory.
NOTE: access If thermostat door beginning switch ternfinals is closed, a heating or cooling c. Perform component of the SERVICE access door. d. Verify blower 16. If furnace ACCESS are jumpered blower Inducer assembly collector box. cycle. 7. Disconnect self-test as shown at the bottom 8. Remove label, located on the front of blower is rotating in the correct direction 17. Downflow or horizontal furnace only: thermostat furnaces a.
f i. Install NOx baffles (if removed). 14. Reinstall 1-7/8 15. (47.6 mm) internal vent pipe, if applicable. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field-supplied, corrosion-resistant, 16. Replace blower sheet metal screws located 180 ° apart. access door only, if it was removed. 17. Set thermostat above for proper operation. 18.
gized until the flame is sensed or until the 2-second flame proving period begins. d. Flame-ProvingWhen the burner flame is proved at the flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout.
START Is LED status light on? ,_ls there 115V at Lt and L2? ,-,_,_ Is door switch closed? -,_,_,_ Is door switch -"_ Is circuit breaker I closed? YES _ YES _ I ls there 24V at SEC-1 and SEC-2? _ I Isthere YES t15V going to switch? YES _ closed? p II YES YES NO Replace furnace control, l [ Replace door switch. J Replace transformer.
31 NO PREVIOUS CODE - Stored codes are erased after 72 hours. On RED LED boards stored status codes can also be erased whenever power (115V or 24V) is interrupted. Run system through a heating or cooling cycle to check system. --€, BLOWER ON AFTER POWER UP - (115V OR 24V) - Normal operation. Blower runs for 90 seconds, if unit is powered up during a call for heat (R-W closed) or when (R-W opens) during the blower on-delay period.
PARTS REPLACEMENT CASING INFORMATION GROUP GAS CONTROL GUIDE GROUP Outer door Manifold Blower door Burner Top filler plate Orifice Bottom filler plate Flame sensor Bottom enclosure Hot surface igniter assembly Gas valve ELECTRICAL GROUP Manual reset linfit switches Burner support Linfit switch(es) Circuit board HEAT EXCHANGER Door switch Cell panel Control bracket Junction box Heat exchanger Transformer harness l15v Wiring harness 24v BLOWER INDUCER GROUP Housing as
Copyright 2013 Carrier Corp. • 7310 W. Morris St. • Indianapolis, Manufacturer reserves the right to change, IN 46231 at any time, specifications and designs . without notice and without Edition Date: obligations.
