Page 1: Table Of Contents
PG96VAT TWO-STAGE 4-WAY MULTIPOISE CONDENSING GAS FURNACE SERIES B ALL SERIES C SIZES 60080, 60100, 66120 Installation, Start−up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES 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 Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions WARNING included in literature and attached to the unit. CAUTION FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous CUT HAZARD...
Page 4: Codes And Standards
12. Maintain a 1−in. (25 mm) clearance from combustible ma- installation must comply with the national codes listed below and terials to supply air ductwork for a distance of 36 in. (914 all authorities having jurisdiction. mm) horizontally from the furnace. See NFPA 90B or local In the United States and Canada, follow all codes and standards for code for further requirements.
Page 5: Electrostatic Discharge (Esd) Precautions
ELECTROSTATIC DISCHARGE (ESD) LOCATION PRECAUTIONS PROCEDURE CAUTION CAUTION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD FURNACE RELIABILITY HAZARD Improper use or installation of this furnace may result in Failure to follow this caution may result in unit component premature furnace component failure. Unless otherwise damage.
Page 6 General WARNING These furnaces are shipped with materials to assist in proper furnace installation. These materials are shipped in the main FIRE, INJURY OR DEATH HAZARD blower compartment. See Table 1 for loose parts bag contents. Failure to follow this warning could result in personal This furnace must: injury, death and/or property damage.
Page 7: Minimum Clearances To Combustible Materials
Table 1 – Loose Parts Bag DESCRIPTION QUANTITY Outlet Restrictor Plate (provided with 40K BTUH furnaces only; see Note) Air Intake Pipe Flange Vent Pipe Flange Pipe Flange Gaskets Sharp Tip Screws (Vent and Inlet Flanges) Vent Pipe Coupling Vent Pipe Coupling Clamps Pressure Switch Tube Rubber Drain Elbow Drain Tube Clamps...
Page 8 A12267 PG96VAT SHIP WT. FURNACE SIZE LB (KG) 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 (54.4) 42060 141.5 (63.7) 17-1/2 (445) 15-7/8 (403) 16 (406) 8-3/4 (222) 48080 151.5 (68.2)
Page 9 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 10: Air For Combustion And Ventilation
AIR FOR COMBUSTION AND WARNING VENTILATION Introduction CARBON MONOXIDE POISONING HAZARD Direct Vent (2−pipe) Applications Failure to follow this warning could result in personal injury or death. When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, The operation of exhaust fans, kitchen ventilation fans, other gas appliances installed in the space with the furnace may clothes dryers, attic exhaust fans or fireplaces could create a...
Page 11 Indoor Combustion AirE NFPA & AGA of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). See Fig. 7. Standard and Known−Air−Infiltration Rate Methods c. Combining space on different floor levels. The volumes of Indoor air is permitted for combustion, ventilation, and dilution, if spaces on different floor levels shall be considered as com- the Standard or Known−Air−Infiltration Method is used.
Page 12: 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) FURNACE (1 SQ. IN./4,000 BTUH) (1,100 SQ.
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 and remove trap. If alternate vent position 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 The return−air duct must be connected to bottom, sides (left or supply−air duct must be connected to ONLY the furnace supply right), or a combination of bottom and side(s) of main furnace outlet or air conditioning coil casing (when used). When installed casing.
Page 23 Suspended Furnace Support supplied accessory air cleaner may also be used in place of the filter rack. The furnace must be supported under the entire length of the For upflow applications, the filter can be installed on either side of furnace with threaded rod and angle iron.
Page 24 Table 5 – Filter Media Pressure Drop (Clean) Versus Airflow − In. W.C. (Pa) Representative AfterMarket Filter Media* 14 x 25 Filter FactoryAccessory FactoryAccessory (356 x 635 mm) Washable Media* Fiberglass* Pleated* (1in. / 2.5 cm) (4in. / 10 cm) (1in.
Page 25 Table 7 – Air Filter Selection and Duct Sizing − In. (mm) FILTER SIZE FURNACE CASING WIDTH FILTER TYPE SIDE BOTTOM RETURN RETURN 16 x 25 x 3/4 14 x 25 x 3/4 14-3/16{ (360) Washable* (406 x 635 x 19) (356 x 635 x 19) 16 x 25 x 3/4 16 x 25 x 3/4...
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 A11037 Fig. 25 − Leveling Legs Fig. 28 − Downflow Return Air Configurations and Restrictions LEVEL 0-IN.
Page 29 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 30: 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 31 Table 9 – Cooling and Heating Air Delivery − CFM (Bottom Return with Filter) (SW15 and SW2-2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size Cooling Switch Settings External Static Pressure (ESP) In. W.C. SW28 SW27 SW26 30040...
Page 32 Table 9 − Cooling and Heating Air Delivery − CFM (Bottom Return with Filter) (Continued) (SW15 and SW2-2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size Cooling Switch Settings External Static Pressure (ESP) In. W.C. SW28 SW27 SW26...
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 10 – 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. 35 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 7. Install the green ground screw to the J−Box bracket and maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3−amp. fuse of identical size. See Fig. 39. attach both ground wires to the green ground screw. Thermostats 8.
Page 37: Electrical Data
Table 11 – Electrical Data TWO-STAGE PWM FURNACES UNIT VOLTS- OPERATING VOLTAGE MAXIMUM UNIT MINIMUM MAXIMUM MAXIMUM SIZE HERTZ- RANGE* UNIT AMPACITY# WIRE WIRE LENGTH FUSE OR CKT PHASE AMPS SIZE FT (M)} Maximum* Minimum* AMPS{ 30040 115-60-1 10.3 (10.9) 42060 115-60-1 10.9...
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. 37 − Field−supplied Isolation Relay for Humidifiers with Internal Power Supply W/W1 Y/Y2 A11401 Fig. 38 − Typical Two−Stage Field Wiring Diagram...
Page 39 MODEL PLUG AIR CONDITIONING (A/C) & SW1 SETUP OUTDOOR HUMIDIFIER CONNECTOR CONTINUOUS FAN (CF) SWITCHES AND AIR TEMP TERMINAL (24-VAC AIRFLOW SETUP SWITCHES BLOWER OFF- CONNECTOR 0.5 AMP MAX). ACRDJ – AIR DELAY CONDITIONING RELAY DISABLE JUMPER TWINNING CONNECTOR 24-V THERMOSTAT TERMINALS FLASH UPGRADE...
Page 40 THERMOSTAT THERMOSTAT 11, and 16 15, and 16 2-Stage Furnace with Single-Speed Heat Pump 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT 15, and 16 12 and 16 2-Stage Furnace with Two-Speed Heat Pump 2-Stage Furnace with Two-Speed Air Conditioner A12096 Fig.
Page 41 NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Heat pump MUST have a high pressure switch for HYBRID HEATr dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two speed heat pump control. Heat pumps with date code 1601E and later do not have or require a “ZONE”...
Page 42 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 43: Vent Termination Kit For Direct Vent (2−Pipe) Systems
Table 12 – 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 44 prevailing winds. The roof location is preferred since the vent and required by National code authorities. Allowable vent terminations combustion air system is less susceptible to damage or are shown in Fig. 55. The combustion air pipe terminates in a contamination.
Page 45 accessory concentric vent terminations or pipe lengths and elbows NOTICE used for “standard” vent terminations (see vent termination figures associated with Table 16) do not require a deduction from the Maximum Equivalent Vent Length. Include a deduction for a Tee OPTIONAL CONFIGURATION FOR COMBUSTION when used for Alberta and Saskatchewan terminations.
Page 46 Installing the Vent Pipe Adapter and Combustion Air The vent pipe may pass through unconditioned areas. The amount of exposed pipe allowed is shown in Table 15. Pipe Adapter 1. Using winter design temperature (used in load calculations), WARNING find appropriate temperature for your application and fur- nace model.
Page 47 1. Working from furnace to outside, cut pipe to required WARNING length(s). 2. De−burr inside and outside of pipe. CARBON MONOXIDE POISONING HAZARD 3. Chamfer outside edge of pipe for better distribution of primer and cement. Failure to follow this warning could result in personal injury or death.
Page 48 Table 13 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 ½-in. 3-ft. 2 ½-ft. 3-ft. 3-ft. 3.25-ft. 38-mm 914-mm 762-mm 914-mm 914-mm 1000 mm 2-in. 3-ft. 3-ft. 3-ft. 3-ft. 3.25-ft. 51-mm 914-mm 914-mm 914-mm 914-mm 1000 mm...
Page 49 2-Pipe and 1-Pipe Vent Termination (Direct Vent / 2-Pipe System ONLY) NOTE: Follow the instructions of the vent terminal manufacturer. When two or more furnaces are vented near each other, two vent terminations may be installed as shown in Fig. 54, but next vent These instructions are provided as a reference, only.
Page 50: Maximum Allowable Exposed Vent Lengths Insulation
Table 15 – Maximum Allowable Exposed Vent Lengths Insulation Table − Ft. / In. Unit Size 40,000* BTUH 60,000 BTUH Uninsulated 3/8in. Insulation 1/2in. Insulation Uninsulated 3/8in. Insulation 1/2in. Insulation Pipe Dia. 1 ½ 2 ½ 1 ½ 2 ½ 1 ½...
Page 51: Maximum Equivalent Vent Length
NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 17 − Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 16 – Maximum Equivalent Vent Length − Ft./In. Unit Size 40,000 60,000...
Page 52 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 17. 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 53 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 54 Slope vent pipe back to the furnace at least ¼” per foot Use 45 deg. Elbows where Avoid short horizontal offsets with 90 possible, to ensure conden- deg. Elbows. Short offsets can be sate drainage. difficult to slope and may trap con- densate.
Page 55 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. (1 meter ) away from the inside corner, refer to the For all other items, refer to the Inside Inside Corner Clearance Corner Clearance Table.
Page 56 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 57 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 58 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 59 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 60 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 61 ¾ in. (222mm) for 3 in. (76mm) ¾ in. (172mm) for 2 in. (51mm) 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13305 Fig. 54 − Combustion Air and Vent Pipe Termination for Direct Vent (2−Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
Page 62 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 63 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 64 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 65: Start−Up, Adjustment, And Safety Check
START−UP, ADJUSTMENT, AND SAFETY 1. Remove blower door. 2. Locate setup switches on furnace control. CHECK 3. Configure the setup switches as necessary for the NOTICE application. 4. Replace blower door. NOTE: If a bypass humidifier is used, setup switch SW1-3 (Low Important Installation and Start−up Procedures Heat Rise Adjust) should be in ON position.
Page 66 1. Remove upper and middle collector box drain plugs oppo- NOTICE site of the condensate trap. See Fig. 69. 2. Connect field-supplied 5/8-in. (16 mm) ID tube with at- tached funnel to upper collector box drain connection. The NATURAL GAS manifold pressure adjustments in Table 21 compensate for BOTH altitude AND gas heating value.
Page 67 Therefore: Orifice No. 44 e. Move setup SW1—2 on furnace control to ON position to lock furnace in low−heat operation. See Fig. 66 and Fig. * Furnace is shipped with No. 44 orifices. In this example, all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.
Page 68 f. Refer to Table 20 for cubic ft. of gas per hr. 2. When thermometer readings stabilize, subtract return−air temperature from supply−air temperature to determine air g. Multiply gas rate cu ft./hr by heating value (Btuh/cu ft.) to temperature rise. obtain input rate.
Page 69 b. Turn Dip switch SW−7 or SW−8 ON or OFF for desired e. Set heat anticipator on thermostat per thermostat blower off delay. See Table 19 and Fig. 39, 66 and 75.) instructions and install on subbase or wall. Adjust Cooling Airflow – High-Speed and f.
Page 70 TWO-STAGE ON/OFF Switch Regulator Seal Cap Regulator Adjustment Regulator Seal Cap under Cap 1/2” NPT Inlet 1/8” NPT Inlet Pressure Tap BURNER 1/2” NPT Outlet ORIFICE 1/8” NPT Manifold Pressure Tap A11152 A93059 Fig. 60 − Gas Valve without Tower Pressure Ports Fig.
Page 71 A14317 Fig. 65 − Service Label Information...
Page 72 Furnace Setup Switch Description SET UP NORMAL SW IT CH NAME DESCRIPT ION OF USE SW IT CH POSIT ION Turn ON to retrieve up to 7 stored status codes for SW1 -1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected.
Page 73: Altitude Derate Multiplier For U.s.a
Table 18 – Altitude Derate Multiplier for U.S.A. Table 19 – Blower Off Delay Setup Switch PERCENT DERATE SETUP SWITCH ALTITUDE MULTIPLIER (SW1-7 AND -8) DESIRED HEATING MODE DERATE FACTOR* POSITION BLOWER OFF DELAY (SEC.) 0–2000 0-610 1.00 SW1-7 SW1-8 2001–3000 610-914 0.95...
Page 74: Orifice Size And Manifold Pressure
Table 21 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...
Page 75 Table 21 − Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...
Page 76: Service And Maintenance Procedures
SERVICE AND MAINTENANCE Electrical Controls and Wiring PROCEDURES Each pressure switch is labeled with the reference location (noted as “COLLECTOR BOX−LPS” or “HOUSING−HPS” on the Untrained personnel can perform basic maintenance functions such switch). The nominal break point of each switch is shown on the as cleaning and replacing air filters.
Page 77 NOTE: The Status Codes cannot be retrieved by disconnecting Care and Maintenance the limit switch. To retrieve Status Codes, follow the procedure WARNING below. 2. Turn Setup Switch, SW1−1 “ON.” 3. Manually close blower door switch. FIRE OR EXPLOSION HAZARD 4.
Page 78 4. Inspect burner compartment before each heating season for The inducer and blower motors are pre−lubricated and require no rust, corrosion, soot or excessive dust. If necessary, have additional lubrication. These motors can be identified by the furnace and burner serviced by a qualified service agency. absence of oil ports on each end of the motor.
Page 79 Refer to Fig. 72. 13. Reinstall blower assembly in furnace. 14. Reinstall 2 screws securing blower assembly to blower 1. Disconnect power at external disconnect, fuse or circuit deck. breaker. 15. Reconnect blower leads to furnace control. Refer to furnace 2.
Page 80 Flushing Collector Box and Drainage System 13. Install the gas pipe to the gas valve. WARNING WARNING FIRE OR EXPLOSION HAZARD ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury, injury, death, and/or property damage.
Page 81 11. Flush condensate drain lines with warm water. Remember WARNING to check and clean the relief port on the collector box. 12. Shake trap dry. ELECTRICAL SHOCK, FIRE OR EXPLOSION 13. Clean port on collector box with a small wire. HAZARD To re-install Condensate Drain and Trap: Failure to follow this warning could result in personal...
Page 82 Secondary Heat Exchangers 13. When furnace is re−started, flush condensate pump with clear water to check for proper operation before re−starting The condensing side (inside) of the secondary heat exchanger furnace. CANNOT be serviced or inspected without complete removal of 14.
Page 83 Burner Flame Burner Manifold A11273 A89020 Fig. 70 − Cleaning Heat Exchanger Cell Fig. 71 − Burner Flame IGNITER BURNER SUPT. ASSY BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig. 72 − Burner Assembly...
Page 84 GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE (WHEN USED) MOTOR, BLOWER SCREW (GND) A11584 Fig.
Page 85: Sequence Of Operation
SEQUENCE OF OPERATION after the low−heat pressure switch LPS closes. If the high−heat pressure switch HPS fails to close NOTE: Furnace control must be grounded for proper operation or and the low−heat pressure switch LPS closes, the else control will lock out. Control is grounded through furnace will operate at low−heat gas flow rate until green/yellow wire routed to gas valve and burner box screw.
Page 86 heat airflow for 90, 120, 150, or 180 seconds (depending the length of previous cooling period of the single−stage on selection at blower−OFF delay switches). The furnace thermostat. control CPU is factory−set for a 120−second blower−OFF NOTE: The air conditioning relay disable jumper ACRDJ must delay.
Page 87 4. Dehumidification Mode the thermostat is satisfied, the blower motor BLWM will op- See Fig. 39 and 40 for thermostat connections. erate an additional 90 seconds at high−cooling airflow be- The dehumidification output, D or DHUM on the humidity fore transitioning back to continuous−blower airflow. When sensing thermostat should be connected to the furnace con- the R−to−G circuit is opened, the blower motor BLWM will trol thermostat terminal DHUM.
Page 88 A113325A Fig. 74 − Troubleshooting Guide...
Page 89 A113325B Troubleshooting Guide (Continued)
Page 90 A150087 Fig. 75 − Wiring Diagram...
Page 91 The qualified installer or service agency must use only factory−authorized replacement parts, kits, or accessories when modifying this product. Catalog No: IM-PG96VAT-11 Copyright 2017 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 08/17 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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