Two-Stage Condensing Gas Furnaces With Variable Speed Blower 96.0% AFUE INSTALLATION INSTRUCTIONS J962V*D Downflow Furnace WARNING FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury, death or property damage. • Installation and service must be performed by a qualified installer, service agency or the gas supplier. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION...............................3 REQUIREMENTS & CODES...............................................4 Combustion Air Quality.....................................................5 Heating Load.....................................................................5 Installation in a Garage.....................................................5 Clearances to Combustible Materials...............................6 Operation of Furnace During Construction.................
IMPORTANT SAFETY INFORMATION INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING - indicates a potentially hazardous situation that if not avoided, could result in personal injury or death.
REQUIREMENTS & CODES WARNING: The safety information listed below must be followed during the installation, service, and operation of this furnace. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death. • This furnace must be installed in accordance with these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.
The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance.
WARNING: Do not place combustible material on or against the furnace cabinet or within 6 inches of the vent pipe. Do not place combustible materials, including gasoline or any other flammable vapors and liquids, in the vicinity of the furnace. Clearances to Combustible Materials This furnace is Design Certified in the U.S. and Canada by CSA International for the minimum clearances to combustible materials. NOTE: The furnace is listed for installation on combustible or non-combustible flooring.
COMBUSTION AIR & VENTING REQUIREMENTS WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation: 1.
has the additional advantage that it isolates the system from the effects of negative pressure in the house. CAUTION: Exhaust fans, clothes dryers, fireplaces and other appliances that force air from the house to the outdoors can create a negative pressure inside the house, resulting in improper furnace operation or unsafe conditions such as flame roll out. It is imperative that sufficient air exchange with the outdoors is provided to prevent depressurization.
Vent or Chimney Ventilation Louvers (each end of attic) Vent or Chimney --- Outlet Air Water Heater Furnace Inlet Air Air Duct Water Heater Furnace Air Ducts must be at least 1 sq. in. per 2,000 Btuh of total input rating. Air Duct --- --- --- Alternate Air Inlet NOTE: Air openings shall each have a free area of not less than one square inch per 4,000 Btuh of the total input rating of all equipment in the enclosure. Ventilation Louvers For Unheated Crawl Space Figure 3.
Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to provide outside air using one opening (See NFGC). Generally, confined spaces must have 2 openings in the space for combustion air. One opening must be within 12 inches of the ceiling, and the other must be within 12 inches of the floor. However, an alternative method recently adopted by the NFGC uses one opening within 12 inches of the top of the space.
FURNACE MODELS (BTU) SINGLE VENT PIPE LENGTH (FT.) WITH 1 LONG RADIUS ELBOW* DUAL VENT PIPE LENGTH (FT.) WITH 1 LONG RADIUS ELBOW ON EACH PIPE* OUTLET 2” DIAMETER OUTLET 3” DIAMETER INLET / OUTLET 2” DIAMETER INLET / OUTLET 3” DIAMETER 60,000 60 90 60 90 80,000 30 90 30 90 100,000 30 90 25 90 115,000 N/A 90 N/A 90 *NOTES: 1. Subtract 2.5 ft. for each additional 2 inch long radius elbow, 5 ft. for each additional 2 inch short radius elbow, 3.5 ft.
• in. 18” M ax. 36” M t st ven Exhauon C opti te faceplarews c ng kit Mountito wall with s ) d secure (both pipes • t st ven Exhauon A opti lbow 90° E t st ven Exhauon B opti • . 8” Minx. a 36” M ions) it s (all po ustion Combinlet air • um maxim vel in. to le 12” mcted snow expe oth pipes) (b Figure 7. Inlet & Exhaust Pipe Clearances to U.S. installations. In Canada, CSA B149.1, takes precedence over these instructions.
Vent Freezing Protection CAUTION: When the vent pipe is exposed to temperatures below freezing (i.e., when it passes through unheated spaces, chimneys, etc.) the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaflex-type insulation or equivalent. Insulating pipe is important to avoid condensate icing. • Table 2 (page 12) lists the maximum length of flue pipe that can travel through an unconditioned space or an exterior space.
• When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil, the coil must be installed downstream (on the outlet side) of the furnace or in parallel with the furnace. • If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger.
B, C, & D, WIDTH CABINETS Opening in concrete floor VENT “A” 1-Pipe Options “B” CABINET SIZE DIM. “A” DIM. “B” B 16 5/8 19 1/4 C 20 1/8 19 1/4 D 23 5/8 19 1/4 NOTE: Dimensions shown in Inches. Table 3. Cutout Dimensions Concrete Floor Furnace Sheet Metal Plenum Figure 11. Furnace on a Concrete Slab Installation on a concrete slab 1. Create an opening in the floor according to the dimensions in Table 3. 2. Position the plenum and the furnace as shown in Figure 11.
1 2 3 4 5 6 78 Rubber Grommets AIR FLOW The 2 1/4” rubber grommet is used to seal the opening between the furnace cabinet and the 2” PVC vent pipe. The rubber grommet should be installed in the 3” hole prior to running the vent pipe out of cabinet. No sealants are required. See Figure 13. The 7/8” rubber grommet is used to seal the opening between the furnace cabinet and the gas pipe. The rubber grommet should be installed in the 1 5/8” hole prior to running the gas pipe into the cabinet.
The 1/2” x 3/4” hose barb can be used to route the condensate drain to the outside of the cabinet. It must be installed from inside the cabinet with the threaded end inserted thru the 1 1/16” hole. See Figure 23 (page 26) for hole location The condensate drain should be connected to the barbed end. Attach 1” PVC drain line to the threaded end. Typical Orientation 1. Install the PVC Tee vertically on the 2” vent pipe that is extending out the side of the cabinet.
• Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. See Figure 15 (page 18). • Per ANSI 21.
High Altitude Application (Natural Gas Only) The installation of this furnace at altitudes above 2,000 feet must meet the requirements of the National Fuel Gas Code or local jurisdiction. In Canada, the requirements for high altitude are different and governed by CGA B149.1. Please consult your local code authority. WARNING: The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices. Do not attempt to drill out orifices in the field.
ELECTRICAL WIRING WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. • Before servicing, disconnect all electrical power to furnace. • When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. • Verify proper operation after servicing.
Grounding ROOM THERMOSTAT (SINGLE STAGE) To minimize personal injury, the furnace cabinet must have an uninterrupted or unbroken electrical ground. The controls used in this furnace require an earth ground to operate properly. Acceptable methods include electrical wire or conduit approved for ground service.
then stage up to HIGH fire, until the heating load is met. See Figure 17 and the Low Voltage Connection section on page 21. The autostaging option on the furnace control board is selected using the autostage jumper located near the thermostat terminal block. See Figure 25 (page 30).
MOTOR CONTROL BOARD HUMIDISTAT DHUM DHUM R R Figure 20. DEHUM Wiring Configuration with Humidistat ADDED RELAY (Normally Open) BLOWER CONTROL R DEHUM Figure 21. DEHUM Wiring Configuration without Humidistat 2-STAGE GAS VALVES HI Input Adjusting Screw Do not perform these steps until all of the checks in the previous steps have been completed: 1. Set the thermostat to the lowest setting. 2. Turn off all electrical power to the furnace. 3. Follow the Operating Instructions on the furnace label. 4.
NOTE: Turning the adjusting screw clockwise increases the pressure and counterclockwise reduces the pressure. d. Reinstall plastic cap after adjustment is complete. Verifying & Adjusting Temperature Rise Confirm the temperature rise through the furnace is within the limits specified on the furnace rating plate. Any temperature rise outside the specified limits could result in premature failure of the heat exchanger. 1.
Fan Mode • When the thermostat energizes the G terminal for continuous fan (without calling for heat or cooling), the indoor fan is energized on the selected FAN speed. • If a call for cooling occurs during continuous fan, the blower will switch over to the selected COOL speed. • If the W terminal receives a call for heat during continuous fan, the blower will de energize. • A call for fan is ignored while in lockout.
9. Carefully remove the burner assembly from the furnace. DO NOT DAMAGE THE IGNITER WHILE REMOVING THE BURNER ASSEMBLY. 10.Inspect the burners for accumulated dust or debris. If necessary carefully clean them with a soft wire brush and a vacuum cleaner. DO NOT DAMAGE THE IGNITER WHILE CLEANING THE BURNER. 11.Replace all the parts in reverse order from which they were removed. 12.Follow the lighting instructions found on the furnace door to return the furnace to operation.
Gas Information GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) GAS FLOW RATES (CUBIC FEET PER HOUR) CUBIC FEET PER REVOLUTION OF GAS METER CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 TIME FOR ONE REVOLUTION (SECONDS) 1 5 10 10 12 360 300 1,800 1,500 3,600 3,000 66 68 55 53 273 265 545 529 14 257 1,286 2,571 70 51 257 514 16 225 1,125 2,250 72 50 250 500 18 200 1,000 2,000 74 49 243 486 20 180 900 1,800 76 47 237 474 22 164 818 1
HIGH ALTITUDE DERATION – PROPANE GAS INPUT (BTU) & STAGE ALTITUDE ABOVE SEA LEVEL 60,000 1ST 80,000 2ND 1ST 55 0 to 1,999 FT 4.2 2,000 to 2,999 FT 3,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 7,999 FT 8,000 to 10,000 FT 1ST 55 10.0 4.2 55 9.0 10.0 4.2 55 4.2 8.5 9.0 4.2 56 10.0 4.2 9.0 4.2 8.5 4.2 56 9.0 4.2 8.5 4.2 56 4.2 9.0 8.5 56 10.0 4.2 4.2 8.5 4.2 56 MANIFOLD PRESSURE ORIFICE SIZE 10.0 56 9.0 MANIFOLD PRESSURE ORIFICE SIZE 4.
HIGH ALTITUDE DERATION – NATURAL GAS WITH HIGH HEATING VALUE INPUT (BTU) & STAGE ALTITUDE ABOVE SEA LEVEL 60,000 1ST 0 to 1,999 FT 2,000 to 2,999 FT 3,000 to 3,999 FT 4,000 to 4,999 FT 5,000 to 5,999 FT 6,000 to 6,999 FT 7,000 to 7,999 FT 8,000 to 8,999 FT 9,000 to 9,999 FT 80,000 2ND 1ST 45 100,000 2ND 1ST 45 1.7 3.5 1.7 3.3 1.7 45 45 3.5 1.7 3.3 1.7 3.1 3.1 45 1.7 45 1.7 2.9 2.9 2.8 2.8 3.5 3.5 3.3 3.3 48 1.7 3.0 3.0 1.7 48 1.7 2.8 3.3 3.0 1.7 2.8 1.7 3.0 1.
Electrical Information L2-OUT L1-IN DEHUMIDIFIER OUTPUT DHUM_IN Y1_IN COOL SENSOR GROUND EXPANSION PORT CONNECTION TO FURNACE CONTROL BOARD MOTOR WIRING HARNESS FOR USE WITH IQ OUTDOOR UNITS Y/Y2 Figure 24.
BLUE FLAME ROLL-OUT BLUE FLAME SENSOR BROWN BROWN YELLOW FIELD WIRING LOW VOLTAGE HIGH VOLTAGE LINE L H 1 2 3 4 5 1 2 3 1 2 3 BLWR OFF DELAY 1 1 2 2 XMFR-N C 3 2 1 9 5 4 6 8 7 XMFR INDUCER BLACK RESISTOR (SELECT MODELS) DOOR SWITCH VENT LIMIT (ON SELECT MODELS) RED W2 W1 C R BLACK 120 V WHITE IGNITOR LINE- N LEGEND: BLACK WHITE BLUE VIOLET 24 V BLACK WHITE 10 11 12 Y/Y2 Y1 G 1 2 3 4 1 2 3 4 EAC GREEN 3 3 2 2 1 1 GREEN VIOLET ORANGE LOW PRESSURE SWITCH ORAN
Venting Information AIR SUPPLY INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTED US INSTALLATIONS B CANADIAN INSTALLATIONS A DIRECT VENT (2-PIPE) & CONVENTIONAL VENT (1-PIPE) FURNACES DIRECT VENT (2-PIPE) FURNACES CONVENTIONAL VENT (1-PIPE) FURNACES 12 inches (30cm) 12 inches (30cm) 12 inches (30cm) 6 inches (15cm) for appliances < 10,000 Btuh (3kW) 6 inches (15cm) for appliances < 10,000 Btuh (3kW) 12 inches (30cm) for appliances 10,000 Btuh - 100,000 Btuh (30kW) 9 inches (23cm) for app
OPTION 2 Plug Plug PVC Tee PVC Trap PVC Tee Rubber Grommet X OPTION 3 Plug See NOTE 5 COMBUSTION AIR COMBUSTION AIR Plug X OPTION 1 FLUE PIPE Rubber Grommet FLUE PIPE COMBUSTION AIR FLUE PIPE DOWNFLOW - 1 PIPE OPTIONS (B, C, & D WIDTH CABINETS ONLY) See NOTE 5 PVC Trap Rubber Grommet See VIEW A for drain line positions See VIEW B for drain line positions Inline Drain (Factory Supplied) VIEW -A- See VIEW C for drain line positions VIEW -C- VIEW -BField Supplied Drain Line Attached
Seal/Caulk Around Pipes at Building See Note FLUE PIPE Couplings with 2 Hose Clamps (Optional) 90° Elbow COMBUSTION AIR FLUE PIPE 7” Upward Pitch - 1/4” per foot (Flue Pipe) Wall 1 2 3 4 5 6 78 1 2 34 5678 Couplings with 2 Hose Clamps (Optional) 90° Elbow COMBUSTION AIR Support System on Vertical Rise AIR FLOW Normal Snow Level NOTE: Straps or other suitable supports at minimum of 5 ft. Intervals. First support placed as close to furnace connection as possible.
TROUBLESHOOTING If the furnace fails to operate check the following: • Is the thermostat operating properly? • Are the blower compartment door(s) in place? • Is the furnace disconnect closed? • Has the circuit breaker tripped or the control board fuse burned open? • Is the gas turned on? • Are any manual reset switches open? • Is the filter dirty or plugged? • Is the flame sensor coated? (Remove and clean with steel wool.
INSTALLATION CHECKLIST ELECTRICAL SYSTEM INSTALLER NAME: CITY: STATE: INSTALLATION ADDRESS: CITY: Electrical connections tight? YES NO Line voltage polarity correct? YES NO Supply Voltage:................................................................
