Page 1: Table Of Contents
PG92SCS ALL Single-Stage 4-Way Multipoise PG92SBS 048080 ONLY Condensing Gas Furnace Installation, Start-up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES Loose Parts Bag ........SAFETY CONSIDERATIONS .
Page 2 Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA−54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a. 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:...
Page 3: Safety Considerations
SAFETY CONSIDERATIONS CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal injury. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and Failure to follow this warning could result in dangerous gloves when handling parts, and servicing furnaces.
Page 4: Codes And Standards
13. These furnaces SHALL NOT be installed directly on carpet- regulations of the serving gas supplier, local building, heating, ing, combustible tile, or any other combustible material oth- plumbing, and other codes. In absence of local codes, the er than wood flooring. In downflow installations, factory installation must comply with the national codes listed below and accessory floor base MUST be used when installed on com- all authorities having jurisdiction.
Page 5: Electrostatic Discharge (Esd) Precautions
S CANADA: Current edition of Canadian Electrical Code CSA 1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL C22.1 OR ANY WIRE CONNECTED TO THE CONTROL Condensate Drain Connection PRIOR DISCHARGING YOUR BODY’S S US: Current edition of National Standard Plumbing Code, ELECTROSTATIC CHARGE TO GROUND.
Page 6 A12267 PG92SCS SHIP WT. LB (KG) FURNACE SIZE CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 30040 14-3/16 (361) 12-1/2 (319) 12-9/16 (322) 7-1/8 (181) 121.0 (55.0) 48060 142.0 (64.5) 17-1/2 (445) 15-7/8 (403) 16 (406) 8-3/4 (222) 48080 151.0 (68.6) 60080 158.5 (72.0)
Page 7 THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION, BURNER SECTION, AND...
Page 8 LOCATION WARNING CAUTION CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD PERSONAL INJURY AND/OR PROPERTY Failure to follow this warning could result in personal injury DAMAGE HAZARD or death and unit component damage. Improper use or installation of this furnace may result in Corrosive or contaminated air may cause failure of parts premature furnace component failure.
Page 9: Air For Combustion And Ventilation
CAUTION WARNING FIRE HAZARD FURNACE CORROSION HAZARD Failure to follow this warning could result in personal Failure to follow this caution may result in furnace damage. injury, death and/or property damage. Air for combustion must not be contaminated by halogen Do not install the furnace on its back or hang furnace with compounds, which include fluoride, chloride, bromide, and control compartment facing downward.
Page 10 The following requirements apply to the Standard Method and to The opening shall commence within 12 in. (300 mm) of the the Known Air Infiltration Rate Method. ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the 1.
Page 11: Minimum Free Area Required
Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. IN./4,000 BTUH) (1,100 SQ.
Page 12 * Minimum opening size is 100 sq in. (64516 sq. mm) with *Minimum dimensions of 3‐in. (76mm) minimum dimensions of 3‐in. (76mm) NOTE: Use any of the following combinations of openings: { Minimum of 3‐in. (76mm) when type‐B1 vent is used. A &...
Page 13: Condensate Trap
CONDENSATE TRAP NOTICE Condensate Trap − Upflow Orientation When the furnace is installed in the upflow position, it is not The field−supplied, accessory horizontal drain trap grommet is necessary to relocate the condensate trap or associated tubing. ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. Refer to Fig.
Page 14 Remove pressure switch tube from front pressure switch and discard. A new tube is shipped in the loose parts bag. Remove relief tube from relief Remove tube from relief port. port on condensate trap. Remove the screw that secures the trap to the collector box and remove trap.
Page 15 Remove plug from If alternate vent position collector box. is required, loosen clamp DO NOT DISCARD. on inlet of vent elbow. Remove the screw that secures the trap to the collector box and remove trap. Unconverted Factory Configuration As Viewed in the Horizontal Right Orientation NOTE: Remove knockout in casing before re installing the condensate trap.
Page 16 Remove the screw that secures the condensate trap to the collector box If alternate vent position and remove trap. is required, loosen clamp on vent elbow inlet. Remove relief tube from relief port on condensate trap. Remove front pressure switch tube and discard. A new tube is shipped in the Loose Parts bag.
Page 17: Condensate Drain
CONDENSATE DRAIN CONNECTION c. All condensate piping is at least 3/4-in. PVC and there is a relief tee at the top of condensate drain piping as shown CAUTION in Fig. 14. NOTE: On narrower casings, it may be easier to remove the condensate trap, connect the drain line components and re-install FROZEN AND BURST WATER PIPE HAZARD the condensate trap.
Page 18 6. From the outside of the casing, insert the angled end of the 2. To allow for servicing the trap, the condensate drain elbow Z-pipe through drain hole in the left side of the casing and in the loose parts bag can be used to make a coupler to behind the inducer or gas valve.
Page 19 Evaporator Coil + + + + = Positive pressure < + = Pressure lower than areas with + − = Negative pressure Condensing Furnace Blower creates positive pressure. Positive pressure extends into coil condensate drain (no trap). < + < + <...
Page 20 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Evaporator Coil + + + Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä 3/4” PVC Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä...
Page 21 INSTALL CLAMPS ON DRAIN TUBE ATTACH ELBOW TO ATTACH DRAIN TUBE TO CONDENSATE FORMED END CONDENSATE TRAP DRAIN TRAP OF GROMMET CUT FORMED END OFF PULL DRAIN STUB CONDENSATE DRAIN THROUGH CASING ELBOW CONNECT SHORT END OF ’Z’ PIPE TO MODIFIED DRAIN ELBOW FACTORY SUPPLIED 1/2 IN.
Page 22 Return Air Connections 4. Install special base coil assembly or coil box as shown in Fig. 21. WARNING NOTE: It is recommended that the perforated supply−air duct flanges be completely removed from furnace when installing the furnace on a factory−supplied cased coil or coil box. To remove the FIRE HAZARD supply−air duct flange, use wide duct pliers or hand seamers to A failure to follow this warning could cause personal injury,...
Page 23 bottom return air is used. To remove bottom closure panel, see Fig. CAUTION 23 and 24. Side Return Air Inlet MINOR PROPERTY HAZARD These furnaces are shipped with bottom closure panel installed in bottom return−air opening. This panel MUST be in place when Failure to follow this caution may result in minor property side return air inlet(s) are used without a bottom return air inlet.
Page 24 TIPS FROM CONTRACTORS: Install a media cabinet capable Provide duct transitions, as required, to smoothly transition airflow of incorporating a 4−in. (102 mm) thick media filter. This allows from the return duct system to the filter (or IAQ device) to the room for future upgrades to other IAQ devices.
Page 25 Table 6 – Filter Media Pressure Drop (Clean) Versus Face Velocity− In. W.C. (Pa) Representative AfterMarket Filter Media* FactoryAccessory Face Velocity Washable Fiberglass* Pleated* (m/s) (1in. / 2.5 cm) (1in. / 2.5 cm) (2in. / 5 cm) (1in. / 2.5 cm) (2in.
Page 26: Opening Dimensions
FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING OPENING A10491 Fig. 21 − Installation on Combustible Flooring Table 8 –...
Page 27 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 22 − Duct Flanges BOTTOM CLOSURE SCREWS (2) Representative drawing only, SCREWS (4) some models may vary in appearance. Lay furnace on the back or side BOTTOM PLATE Remove the two (2) screws that secure the bottom...
Page 28 5/ 16  (8mm) (8mm) 5/ 16   (44mm)  (44mm) (8mm)  (8mm) 5/ 16  (44mm) 3/ 4  3/ 4  (44mm) A89014 Fig. 25 − Leveling Legs A11037 Fig. 28 − Downflow Return Air Configurations and Restrictions LEVEL 0-IN.
Page 29 HORIZONTAL LEFT TOP RETURN NOT PERMITTED FOR ANY MODEL. SEE TABLE BELOW. SUPPLY RETURN *RETURN *HORIZONTAL LEFT BOTTOM RETURN NOT PERMITTED FOR ALL MODELS. SEE TABLE BELOW. A14006 Fig. 30 − Horizontal Left Return Air Configurations and Restrictions Table 9 – Horizontal Left and Right Return Air Connections HORIZONTAL LEFT RETURN AIR CONNECTIONS CASING INPUT*...
Page 30 COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305x559 mm) sheet metal in front of burner compartment area. The sheet metal MUST extend underneath the furnace casing by 1-in. (25 mm) with the door removed.
Page 31: Air Ducts
AIR DUCTS NOTICE Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFICIALS ductwork design performance requirements in your area. General Requirements The duct system should be designed and sized according to accepted national standards such as those published by: Air...
Page 32 Table 10 – Air Delivery − CFM (With Filter) Test Airflow Delivery @ Various External Static Pressures Return Air Wire Lead Cooling CFM / Furnace Connection Color Tons Black 388 1145 1100 1060 1015 Blue 030040 SIDE/BOTTOM Yellow Black 376 1600 1545 1505 1475 1505 1445 1400 1330 1235 1140 Yellow 377 1380 1340 1335 1330 1320 1285 1225 1155 1085 1000 048060...
Page 33: Gas Piping
GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal FIRE OR EXPLOSION HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal If local codes allow the use of a flexible gas appliance injury, death, and/or property damage.
Page 34: Electrical Connections
Table 11 – Maximum Capacity of Pipe ELECTRICAL CONNECTIONS NOMINAL LENGTH OF PIPE - FT (M) WARNING IRON PIPE SIZE (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) ELECTRICAL SHOCK, FIRE OR EXPLOSION 3/4 (19) HAZARD 1 ( 25) Failure to follow safety warnings could result in 1‐1/4 (32) 1400...
Page 35 The J−Box cover, mounting bracket and screws are shipped in the CAUTION loose parts bag included with the furnace. See Fig. 36 for J−Box mounting locations. The J−Box mounting bracket and green ground screw is used as a FURNACE MAY NOT OPERATE HAZARD grounding point for all line voltage wiring options.
Page 36 24−V Wiring 7. Install the green ground screw to the J−Box bracket and attach both ground wires to the green ground screw. Make field 24−v connections at the 24−v terminal strip. See Fig. 8. Connect any code required external disconnect(s) to field 40.
Page 37: Electrical Data
Table 12 – Electrical Data MINIMUM MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS- MAXIMUM UNIT WIRE WIRE FUSE OR CKT RANGE* HERTZ- UNIT UNIT SIZE AMPACITY# SIZE LENGTH PHASE AMPS Maximum* Minimum* FT (M)} AMPS{ 30040 115-60-1 49 (14.9) 48060 115-60-1 11.7 31 (9.4) 48080 115-60-1...
Page 38 To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Fig. 38 − Field−supplied Isolation Relay for Humidifiers with Internal Power Supply FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2...
Page 39 TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL J2 JUMPER BLOWER OFF-DELAY HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS TEST/TWIN 0.5 AMP@24VAC 3-AMP FUSE FUSE 3-AMP SEC-2 SEC-1 LED OPERATION & EAC-2 DIAGNOSTIC LIGHT PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 115-VAC(L2)NEUTRAL CONNECTIONS...
Page 40 VENTING NOTE: Planning for the venting system should be done in conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation. Venting for this furnace shall follow all Local codes for Category IV venting systems.
Page 41 Other gas appliances with their own venting system may also use WARNING the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code, and the vent or liner manufacturer’s installation instructions. Care must CARBON MONOXIDE POISONING HAZARD be taken to prevent the exhaust gases from one appliance from Failure to follow the steps outlined below for each appliance...
Page 42: Vent Termination Kit For Direct Vent (2−Pipe) System
Table 13 – Vent Termination Kit for Direct Vent (2−pipe) Systems Approved Two−Pipe Termination Fittings Vent and Allowable 1 1/2−in. 2−in. 2 1/2−in. 3−in. 4−in. Combustion Air Concentric Vent (38 mm) (51 mm) (64 mm) (76−mm) (102 mm) Pipe Diameters 1 1/2−in.
Page 43 Ventilated Combustion Air prevailing winds. The roof location is preferred since the vent and combustion air system is less susceptible to damage or The vent pipe for a Ventilated Combustion Air System must contamination. The termination is usually located away from terminate outdoors.
Page 44 The Maximum Vent Length for the vent and combustion air pipe The measured length of pipe used in a single or 2−pipe termination (when used) is determined from the Maximum Equivalent Vent is included in the total vent length. Include deductions from the Length in Table 17 minus the number of fittings multiplied by the Maximum Equivalent Vent Length (MEVL) contained in the deduction for each type of fitting used from Table 18.
Page 45 Combustion Air and Vent Piping Insulation 3. Tighten the clamp around the vent elbow. Torque the clamp to 15 lb−in. See Fig. 46−49. Guidelines Installing the Vent Pipe Adapter and Combustion Air NOTE: Use closed cell, neoprene insulation or equivalent. Pipe Adapter The vent pipe may pass through unconditioned areas.
Page 46 1. Working from furnace to outside, cut pipe to required 16. Horizontal portions of the venting system shall be length(s). supported to prevent sagging. Space combustion air piping and vent piping hangers as shown in Table 14. Support 2. De−burr inside and outside of pipe. pipes using perforated metal hanging strap or commercially 3.
Page 47 Optional Installation of the Vent Pipe NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference, only. NOTE: DO NOT USE THIS TECHNIQUE FOR Cut one 4−in. (102 mm) diameter hole for 2−in. (50 mm ND) kit, POLYPROPYLENE VENTING SYSTEMS.
Page 48 2-Pipe and 1-Pipe Vent Termination 4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CE- NOTE: Follow the instructions of the vent terminal manufacturer. MENT POLYPROPYLENE FITTINGS. These instructions are provided as a reference, only. (Direct Vent / 2-Pipe System ONLY) NOTICE When two or more furnaces are vented near each other, two vent...
Page 49: Maximum Allowable Exposed Vent Lengths Insulation
Table 16 – Maximum Allowable Exposed Vent Lengths Insulation Table − Ft. / M Maximum Allowable Exposed Vent Length in Unconditioned Space 40,000* BTUH 60,000 BTUH Unit Size Uninsulated Uninsulated 3/8in. Insulation 1/2in. Insulation 3/8in. Insulation 1/2in. Insulation Pipe Dia. Winter 1 ½...
Page 50: Maximum Equivalent Vent Length
Table 17 – Maximum Equivalent Vent Length NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 18 − Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Single Stage 92% - Ft.
Page 51 Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system from Table 18. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems.
Page 52 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 Fig. 41 − Vent Coupling and Adapter with Gaskets TABS ON THE INDUCER OUTLET RESTRICTOR SNAP INTO THE SLOTS AT THE OUTLET OF THE INDUCER FOR USAGE: SEE MAXIMUM EQUIVALENT VENT LENGTH TABLE (10FT.
Page 53 FURNACE NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig. 44 − Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration No operable windows, doors or Clearance distances for intakes of any type within the items greater than 3 feet shaded areas of Wall A and B.
Page 54 Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove. S The clearance distances apply when the vent is at least 3 feet (1 meter) from, but not more than 6 feet (2 meters) away from an inside corner.
Page 55 Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. & UPFLOW LEFT CONFIGURATION DOWNFLOW LEFT CONFIGURATION A11309A A11311A Rotate vent elbow to required position. Any other unused Any other unused knockout may be used knockout may be used...
Page 56 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL LEFT-VERTICAL VENT CONFIGURATION HORIZONTAL RIGHT-VERTICAL VENT CONFIGURATION A11327A A11337 Alternate combustion air connection. Rotate vent elbow to required position. Vent Pipe Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT-LEFT VENT CONFIGURATION HORIZONAL LEFT-LEFT VENT CONFIGURATION A11328A A11336...
Page 57 NOTES FOR VENTING OPTIONS 1. Attach vent pipe adapter with gasket to furnace casing. 2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3. Slide vent pipe through adapter and coupling into vent elbow. 4.
Page 58 A12326 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony...
Page 59 A12325 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony or...
Page 60 ¾ ¾ 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13077 Fig. 54 − Combustion Air and Vent Pipe Termination for Direct Vent (2−Pipe) System Roof Termination (Preferred) Vent Maintain 12 in (305mm) minimum clearance above highest anticipated snow level maximum of...
Page 61 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL 12 IN. (305 MM) MIN. BRACKET SEPARATION BETWEEN COUPLING BOTTOM OFCOMBUSTION 12 IN. (305 MM) MIN. SEPARATION AIR AND BOTTOM OF VENT. BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN.
Page 62 Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 57 − Vent Terminations for Ventilated Combustion Air...
Page 63 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 58 − Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE−APPROVED DRAIN OR CONDENSATE PUMP Recommend “T” fitting with 4−inch minimum height standpipe (A) of same diameter or larger extending upward. Dry Well Dry Well (water tight...
Page 64: Start−Up, Adjustment, And Safety Check
START−UP, ADJUSTMENT, AND SAFETY Prime Condensate Trap with Water CHECK WARNING NOTICE CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal injury Important Installation and Start−up Procedures or death. Failure to follow this procedure may result in a nuisance Failure to use a properly configured trap or NOT smoke or odor complaint.
Page 65 Adjustments provided in the furnace installation instructions to match the required orifice to the manifold pressure to the heat content and WARNING specific gravity of the gas. To do this: 1. Obtain average yearly gas heat value (at installed altitude) from local gas supplier.
Page 66 13. Remove manometer from the inlet pressure tap of the gas input or decrease manifold pressure to decrease input. Re- valve. peat steps b through e of Step 1 until correct heat input is achieved. Re−install regulator seal cap on gas valve. WARNING 3.
Page 67 1. Remove thermostat from subbase or from wall. WARNING 2. Connect an amp meter across the R and W subbase termi- nals or R and W wires at wall. 3. Record amp draw across terminals when furnace is in low ELECTRICAL OPERATION HAZARD heat and after blower starts.
Page 68: Altitude Derate Multiplier For U.s.a
Table 20 – Altitude Derate Multiplier for U.S.A. PERCENT DERATE ALTITUDE MULTIPLIER DERATE FACTOR* 0–2000 0-610 1.00 2001–3000 610-914 0.95 3001–4000 914-1219 0.93 4001–5000 1219-1524 8-10 0.91 5001–6000 1524-1829 10-12 0.89 BURNER 6001–7000 1829-2134 12-14 0.87 ORIFICE 7001–8000 2134-2438 14-16 0.85 8001–9000 2438-2743...
Page 69 338309-201 Rev. E A11602 Fig. 64 − Service Label Information...
Page 70: Gas Rate
Table 21 – Gas Rate (CU ft./hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1800 1636 1500...
Page 71: Orifice Size And Manifold Pressure
Table 22 – Orifice Size and Manifold Pressure (in. W.C.) for Gas Input Rate SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Manifold Orifice...
Page 72 Table 22 − Orifice Size and Manifold Pressure (in. W.C.) for Gas Input Rate (Cont.) SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Manifold...
Page 73: Service And Maintenance Procedures
SERVICE AND MAINTENANCE the switch. The maximum make point of the switch is 0.10 inches of water above the maximum break point of the switch. PROCEDURES Example: Nominal break point on pressure switch is 0.68−in. Untrained personnel can perform basic maintenance functions such W.C.
Page 74 5. The LED will flash the last stored fault code. Refer to the 5. Verify that the Status LED glows. If not, check that the Service Label (Fig. 64) to interpret the LED. power supply is energized and that the blower door is secure.
Page 75 The minimum maintenance on this furnace is as follows: 8. Turn on electrical supply to furnace. Blower Motor and Wheel Maintenance 1. Check and clean air filter each month or more frequently if required. Replace if torn. To ensure long life, economy, and high efficiency, clean 2.
Page 76 10. Torque blower wheel set screw to 160 +/− 20 lb−in. when WARNING reassembling. 11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen ELECTRICAL SHOCK AND FIRE HAZARD set screw on blower wheel and reposition if necessary.
Page 77 Flushing Collector Box and Drainage System 7. Install the remaining manifold mounting screws. 8. Check the igniter alignment. See Fig. 65, 66 and 71. WARNING 9. Attach the wires to the roll-out switches. 10. Align the burner assembly with the openings in the primary cell inlet panel and attach the burner assembly to the cell ELECTRICAL SHOCK AND FIRE HAZARD panel.
Page 78 To re-install Condensate Drain and Trap: WARNING 1. Remove adhesive backing from condensate trap gasket 2. Install gasket on collector box ELECTRICAL SHOCK, FIRE OR EXPLOSION 3. Align the condensate trap with the drain opening on the col- HAZARD lector box and secure the trap with the screw Failure to follow this warning could result in personal 4.
Page 79 9. Remove the middle unused rubber plug from the port on the WARNING collector box opposite the condensate trap. See Fig. 67. 10. Repeat Steps 5 through 8. FIRE OR EXPLOSION HAZARD 11. If a condensate pump is used, check with pump manufacturer to verify pump is safe for use with antifreeze used.
Page 80 BURNER SUPT. ASSY IGNITER BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 A11273 Fig. 71 − Burner Assembly Fig. 68 − Cleaning Heat Exchanger Cell Burner Flame Burner Manifold A11461 Fig. 69 − Burner Flame GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW...
Page 81: Sequence Of Operation
SEQUENCE OF OPERATION Simultaneously, the electronic air cleaner terminal EAC−1 is energized and remains energized as long as the blower NOTE: Furnace control must be grounded for proper operation or motor BLWM is energized. control will lock out. Control is grounded through green/yellow f.
Page 82 A11622 Fig. 72 − Troubleshooting Guide...
Page 83 A12421 Troubleshooting Guide (Cont)
Page 84 A12420 Fig. 73 − Wiring Diagram...
Page 85 PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Burner Bottom plate Flame sensor Control door Gas valve Door knob assembly Hot surface igniter Top filler plate Manifold Orifice Electrical Group Heat Exchanger Group 3−Amp fuse Circuit board Containment plate Control box Coupling box...

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