INSTALLATION AND SERVICING INSTRUCTIONS AND USER'S INFORMATION MANUAL **INSTALLER — AFFIX THIS INSTRUCTION PACKET ADJACENT TO THE FURNACE. **HOMEOWNER — RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE. INSTRUCTIONS D'ENTRETIEN ET INSTALLATION ET MANUEL DE L'USAGER **INSTALLATEUR -- PLACEZ LA POCHETTE D'INSTRUCTIONS À COTÉ DU GÉNÉRATEUR D'AIR CHAUD. **PROPRIÉTAIRE -- CONSERVEZ CES INSTRUCTIONS POUR Y RÉFÉRER PLUS TARD. LITERATURE BOOKLET NO.
Owner Record Furnace Model # Serial # Installation Date INSTALLED BY: Dealer Address Telephone # License # Contact Person Other Equipment Installed: Equipment Type Model # Serial # Installation Date Serial # Installation Date Serial # Installation Date Equipment Type Model # Equipment Type Model # WHEN FRENCH IS REQUIRED! ATTENTION: MR.
USER'S INFORMATION MANUAL Gas-Fired Furnace READ ALL INSTRUCTIONS IN THIS MANUAL AND RETAIN THIS AND ALL ADDITIONAL INSTRUCTIONS FOR FUTURE REFERENCE. Congratulations... ...you have one of the most modern gas furnaces made. Your unit has been carefully selected to keep you warm and comfortable during the winter months. It will deliver superb performance with only minimal help from you. To keep your operating costs low and to eliminate unnecessary service calls, we have provided a few guidelines.
For your safety Read before operating Here are a few "Do's and Don'ts" • Do become familiar with the User's Instruction Manual and Installation Instructions. Do not use this furnace if any part has been under water. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion.
11. Set the thermostat to the desired setting. 12. If the furnace will not operate, follow the instructions in "To Turn Off Gas to Furnace" and call your service technician or gas supplier. Fan Operation You may wish to increase your comfort by setting your system for continuous air circulation of the indoor air. The fan switch on the thermostat permits you to do this. With the switch in the "ON" position the fan will operate continuously.
authorized dealer at once to obtain a qualified service inspection: • Rust, flakes, or other deposits • Coatings • Corrosion Maintenance Of Your Furnace Always shut off all power to the unit before attempting any of the following maintenance procedures. Failure to do so may result in personal injury. There are routine maintenance steps you should take to keep your furnace operating efficiently. This maintenance will assure longer life, lower operating costs, and fewer service calls.
Your furnace may use either a disposable filter, permanent filter, electronic or high efficiency media air cleaner. Consult filter/cleaner manufacturer for maintenance service and static pressure drop for air moving requirements. In all direct vent (two pipe) instances, the vent outlet shall be installed so as to be in the same atmospheric pressure zone as the combustion air intake. 2. This furnace is not designed for use with a vent damper.
Make sure the condensate drain line does not become blocked or plugged. Visual inspection of condensate flow can easily be made while the furnace is operating. Use a flashlight to illuminate discharge end of the condensate drain that is placed in the sewer opening. The furnace will not operate properly if condensate drain line becomes blocked or plugged. If this event occurs, have the furnace inspected by a qualified service technician.
AFFIX LABEL HERE INSTALLATION INSTRUCTIONS UPFLOW OR LEFT HORIZONTAL TWO STAGE HEAT VARIABLE SPEED GAS-FIRED CONDENSING WARM AIR FURNACE Issue 0442 TABLE OF CONTENTS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Furnace Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Control Board & Variable Speed Motor Features . . . . . . . . . . .
SAFETY The following is a list of safety precautions and their locations in this manual. These safety rules and precautions must be followed when installing this furnace. 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. 2. Install this furnace only in a location and position as specified in The Location/Placement Section on page 6 of these instructions. 3.
FURNACE SPECIFICATIONS UNIT DIMENSIONS * DUCT SUPPLY OPENING AIR INLET & VENT DUCT RETURN OPENING CONNECTION DIA.* MAX. OVER CURRENT PROTECTION MAX. ELECTRICAL TEMPERATURE NET UNIT SUPPLY MIN. RISE WEIGHT AMPS WIRE SIZE(AWG) RANGE LBS MODEL LENGTH A B C F G H EV050U3 29 1/2 13 1/2 47 3/8 11 1/2 18 15/16 12 21 5/8 2 15 9.9 14 45-55 131 EV075U3 29 1/2 13 1/2 47 3/8 11 1/2 18 15/16 12 21 5/8 2 15 9.
BLOWER MOTOR SPECIFICATIONS AND AIRFLOW ADJUSTING DATA Adjusting Airflow HEAT SETTING MODEL MOTOR HP BLOWER WHEEL ADJUST HEAT HEATING CFM EV050U3 EV075U3 EV100U4 EV125U5 1/2 1/2 3/4 1 10 X 6 10 X 6 12 X 9 12 X 12 COOL SETTINGS COOL CFM @ .
FURNACE WIRING SPECIFICATIONS 20558801 Issue 0442 Page 5 of 32
The furnace cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. The unit must also be electrically grounded in accordance with local codes, or in the absence of local codes, with the latest edition of the (U.S.) National Electrical Code ANSI/NFPA No. 70 or CSA Standard C22.1; Part 1 Canadian Electrical Code, if an external electrical source is utilized. DO NOT use gas piping as an electrical ground.
If furnace is tilted back condensate will collect in the secondary heat exchanger which will result in improper combustion, fire hazard, or other unsafe conditions which could result in property damage, personal injury or death. Failure to comply with all of the clearances will create a fire hazard. INSTALLATION POSITIONS If the furnace is to be installed in a crawl space, consult local codes. (Use of a concrete pad 1" to 2" thick is recommended.
AIR FOR COMBUSTION AND VENTILATION Contaminated Combustion Air: If the furnace is to be installed in a structure defined as having contaminated combustion air, the furnace must use the direct vent (two pipe) configuration using noncontaminated outside air for combustion. Allowing exposure to substances containing chlorine or fluoride could harm the furnace and void the warranty.
If ventilation and/or combustion air must be supplied to the "Confined Space" from inside the building structure, two permanent openings to an additional room of sufficient volume as to combine the volumes of the spaces to meet the criteria for an "Unconfined Space" must be created. Each opening must have a free area of not less than one square inch per 1000 Btu per hour of total input of all appliances within the "Confined Space" (but not less than 100 square inches).
Figure 4 CONFINED SPACE / OUTDOOR AIR FROM ATTIC When horizontal ducts are used to supply air from the outdoors, they must be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts must not be less than 3 inches. Each opening must have a free area of not less than one square inch per 2,000 Btu per hour of total input of all appliances within the "Confined Space". These openings must be located 12 in.
DUCTING The proper sizing of warm air ducts is necessary to insure satisfactory heating operation. Ductwork should be in accordance with the latest editions of (U.S.) NFPA-90A (Air Conditioning Systems) and NFPA-90B (Warm Air Heating and Air Conditioning Systems) or Canadian equivalent. viewed for possible openings using light assistance or a probe can be inserted by sampling the air stream. The access panel shall be designed so as to prevent leaks when locked in position.
When installing the furnace with cooling equipment for year round operation, the following recommendations must be followed for series or parallel air flow: 1. In series flow applications, the coil is mounted after the furnace in an enclosure in the supply air stream. The furnace blower is used for both heating and cooling airflow. 2. In parallel flow installation, dampers must be provided to direct air over the furnace heat exchanger when heat is desired and over the cooling when cooling is desired.
Figure 8 VENT TERMINATION CLEARANCES 20558801 Issue 0442 Page 13 of 32
Horizontal (Side Wall) Vent Termination: To prevent blockage of the combustion air and exhaust vent by snow, vent termination must be made 12" (in.) above the anticipated maximum snow accumulation level (See Figure 10). A minimum of 4' (ft.) clearance must be provided from electric meters, gas meters, regulators and relief equipment. In Canada refer to the current Canadian Fuel Gas Code. Terminations must terminate not less than onefoot above, below or horizontal from any inlet to building.
The vertical vent system can be installed through an existing chimney provided that: Figure 16 CONCENTRIC VENT VERTICAL MOUNTING a. No other appliance is vented into the chimney. b. The vent system does not terminate within the chimney and the termination clearances shown in Figure 14 are maintained. c. Both the air intake and exhaust vent run the length of the chimney. d. The top of the chimney is sealed and weather proofed.
TABLE 4 Allowable Max Vent Lengths for 3" Diameter Venting APPLICATION * Allowable Max Vent Lengths of 3" dia.
Installation of Air Inlet Connector: The air inlet connector must be installed on the top panel of the furnace (See Figure 19). The connector and mounting screws are shipped in the vestibule of the furnace. The air inlet connector is placed over the hole pattern in the top panel and the lip on the bottom of the connector must fit into the hole on the top panel. The connector is then secured to the top panel using the four (4) No. 10 x 5/8 sheet metal screws.
Figure 21 UPFLOW TRAP Figure 22 HORIZONTAL TRAP Condensate Disposal Drain: This furnace must use the condensate trap supplied with the unit (See Figures 17 and 18) for proper drain installation. The drain must terminate at a floor drain, sewer system, or drain vent for proper condensate removal. Drain installation must conform to local building codes. In addition, the trap must be filled with water on the initial start-up of the unit.
ELECTRICAL CONNECTIONS When installed, the furnace must be electrically grounded in accordance with local codes or, in the absence of local codes, with the (U.S.) National Electrical Codes, ANSI/NFPA 70 or CSA Standard C22.1; Part 1 Canadian Electrical Code. For proper installation refer to furnace rating label for electrical ratings and for the field wiring of this unit refer to furnace wiring specifications on page 5 or alternately from the wiring diagram on page 31.
FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. 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. A fire or explosion may result causing property damage, persoal injury or loss of life.
CONTROL BOARD & VARIABLE SPEED MOTOR FEATURES Humidifier Connections: Terminals are provided on the blower control board for connections to a 120-volt optional humidifier. The "HUM" terminal is energized whenever the thermostat calls for heat. Refer to furnace wiring diagram for specific connection information. Electronic Air Cleaner Connections: Terminals are provided on the blower control board for connection of a 120-volt optional electronic air cleaner.
UNIT SEQUENCE OF OPERATION Here's How Your Heating System Works: Standby Mode When the control is in standby mode, it continually monitors thermostat input, rollout switch, and flame sense. Call For Heat On a call for 1st stage heat (W1) from the room thermostat, the ignition control performs a 1-second selfcheck. The control verifies the limit switch is closed and both low and high pressure switches are open.
STARTUP AND OPERATIONAL CHECKOUT 6. The hot-surface ignitor will heat-up to an "orange" glow, the main burners will ignite. Do not use this furnace as a construction heater. Use of this furnace as a construction heater exposes the furnace to abnormal conditions, contaminated combustion air and the lack of air filters. Failure to follow this warning can lead to premature furnace failure and/or vent failure which could result in a fire hazard and/or bodily harm.
10.0" w.c. (2nd stage). After proper adjustments, reconnect violet wire and furnace should go up to 2nd stage high fire. Turn OFF gas, replace manifold pressure tap pipe plug, regulator adjustment vent cap, and turn ON gas. Example: 3.50"w.c. Gas valve outlet pressure tap reading -.15"w.c. Burner box inlet pressure (hose not connected) 3.65"w.c. Actual manifold pressure instead of the desired 3.5"w.c.
4. Calculate the furnace input using the following formula: BTUH = Cubic Ft/Hr x BTU/Cubic Foot The local gas supplier should be able to provide the heating value of the gas, in BTU/cubic foot. If a specific value is not available, use 1000 BTU/cubic foot for Natural gas or 2500 BTU/cubic foot for Propane (LP). Furnace input should be maintained within ± 2% of the value on the rating plate or appropriate altitude derate. Adjust manifold pressure or change orifices size if required.
The switch is located behind the burner access door. Removing the burner access panel from the furnace, and reset by pushing in the button in the middle of the switch (between the two wire connections - See Figure 31). Very little force is required to push the reset button, and a "click" should be heard when the switch resets. Hand drilling of orifices is never acceptable since it could lead to delayed ignition, overfiring, improper combustion, flashback and flame rollout.
the homeowner how to operate the furnace system before leaving the job site. Figure 32 PRESSURE SWITCH LOCATION AND CONNECTION If the pressure switch activates to shut the furnace down, the vent and drain systems must be checked and cleared. Failure to do so may result in serious bodily harm or nuisance furnace shutdown and/or a hazardous condition that may lead to property damage, personal injury or death.
SEQUENCE OF OPERATION DIRECT IGNITION SYSTEM CONTROL 20558801 Issue 0442 Page 28 of 32
SERVICING THE FURNACE 7. Turn on utilities and check for leaks using soapy water and a brush. 8. A visual check of the main burner should be made at the beginning of each heating season. 9. Check the input rate and adjust if necessary. 10. Perform a safety check of the limit control and pressure switch. 11. Check the air filter, clean and/or replace as necessary. 12. Periodic cleaning of condensing coil and drain lines maybe necessary for proper operation. 13. Replace the appropriate access panels or door.
4. Remove the burner access panel by removing the seven (7) No. 10 sheet metal screws that secure the panel to the cabinet. Be careful not to damage the rubber seal strips that are attached to the cabinet (behind the access panel). 5. Remove the No. 10 sheet metal screws that secure the manifold seal plate and gasket to the bottom of the burner box.
CONTROL SYSTEM DIAGNOSTICS Troubleshooting Make the following visual checks before toubleshooting: Table 9 Failure Codes - Red LED 1. Check to see that the power to the furnace and the integrated ignition/blower control board is ON. LED Status 2. The manual shutoff valves in the gas line to the furnace must be open Fault Description LED Off No power to control or control hardware fault detected LED On Normal operation 1 Flash Flame present with gas valve off 3.
WIRING DIAGRAM 20558801 Issue 0442 Page 32 of 32
