Lennox GAS FURNACE Fit’s All 80 (application guide) APPLICATION GUIDE GAS FURNACE Fit’s All 80 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Installation and service must be performed by a qualified installer, service agency or the gas supplier. Installation by an unqualified person may lead to equipment damage and/or a hazardous condition which may cause bodily injury and harm and, as such, at the sole discretion of the manufacturer, the entire warranty may be voided and be of no further force and effect. WHAT TO DO IF YOU SMELL GAS: Do not try to light any appliance. Extinguish any open flame. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department. 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. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. Install this furnace only in a location and position as specified in The Location/Placement Section on page 6 of these instructions. Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section on page 8 of these instructions. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in Venting on page 12 of these instructions. 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, as specified in The Gas Connection section on page 16 of these instructions. Always install furnace to operate within the furnace's intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in Furnace Specifications on page 3 of these instructions. See furnace rating plate. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See page 11 for Ducting. A gas-fired furnace for installation in a residential garage must be installed as specified in The Location / Placement section on page 7 of these instructions. The furnace is not to be used for temporary heating of buildings or structures under construction. As noted on page 6 under Introduction. FURNACE SPECIFICATIONS MODEL HEATING CAPACITY EFFICIENCY vs Lower Calorifique Value UNIT DIMENSIONS (inches) DUCT SUPPLY OPENING (inches) DUCT RETURN OPENING (inches) VENT PIPE DIA. (inches) VOLTAGE MAX. OVER CURRENT PROTECTION AMPS MAX. UNIT AMPS TEMPERATURE RISE RANGE NET WEIGHT BTU/H Kw A B C D E F G H °C °F KG LBS MPGA 050 B3 50 15 90% 291/2 131/2 381/4 11 1/2 203/9 12 215/8 4 230 - I - 50 Hz 15 9,9 25-42 45-75 47 105 MPGA 075 B3 75 22 90% 291/2 131/2 381/4 111/2 203/8 12 215/8 4 15 9.9 25-42 45-75 50 113 MPGA 075 B4 75 22 90% 291/2 17 381/4 16 203/3 15 1/2 215/8 4 15 11.7 17-33 30-60 59 134 MPGA 100 B4 100 29 90% 291/2 17 381/4 15 203/3 151/2 215/8 4 15 11,7 25-42 45-75 62 141 MPGA 100 B5 100 29 90% 291/2 201/2 381/4 181/2 203/3 19 21 5/8 4 15 11.7 17-33 30 -60 70 159 MPGA 125 B5 125 36 90% 291/2 201/2 381/4 181/2 203/3 19 21 5/8 4 20 11.7 25-42 46-75 74 167 * REDUCER SUPPLIED WITH FURNACE WHEN CONNECTION SIZE IS DIFFERENT THAN PIPE DIA. REQUIRED (H) FOR FLUE VENT PIPE. FURNACE BLOWER SPECIFICATIONS AND AIR FLOW DATA BLOWER SYSTEM BLOWER SPEED EXTERNAL STATIC (IN. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 MPGA050B3 (10X6 WHEEL) (1/3HP MOTOR) LOW 824 776 726 675 622 567 511 453 393 332 MED 1170 1120 1066 1009 949 885 818 747 673 595 HIGH 1480 1428 1372 1312 1249 1183 1113 1039 962 882 MPGA075B3 (10X6 WHEEL) (1/3HP MOTOR) LOW 824 776 726 675 622 567 511 453 393 332 MED 1170 1120 1066 1009 949 885 818 747 673 595 HIGH 1480 1428 1372 1312 1249 1183 1113 1039 962 882 MPGA075B4 (12X9 WHEEL) (1 HP MOTOR) LOW 1297 1278 1257 1233 1207 1178 1147 1114 1078 1040 MED 1635 1618 1599 1577 1553 1526 1497 1465 1431 1394 HIGH 2015 1972 1925 1873 1816 1755 1689 1618 1543 1463 MPGA100B4 (10X9 WHEEL) (1 HP MOTOR) LOW 1297 1278 1257 1233 1207 1178 1147 1114 1078 1040 MED 1635 1618 1599 1577 1553 1526 1497 1465 1431 1394 HIGH 2015 1972 1925 1873 1816 1755 1689 1618 1543 1463 MPGA100B5 (12X9 WHEEL) (1 HP MOTOR) LOW 1683 1613 1537 1456 1370 1279 1182 1080 973 861 MED 2081 2000 1925 1855 1792 1734 1683 1637 1597 1563 HIGH 2552 2496 2440 2385 2331 2277 2224 2172 2120 2069 MPGA125B5 (12X12 WHEEL) (1 HP MOTOR) LOW 1683 1613 1537 1456 1370 1279 1182 1080 973 861 MED 2081 2000 1925 1855 1792 1734 1683 1637 1597 1563 HIGH 2552 2496 2440 2385 2331 2277 2224 2172 2120 2069 NOTES: Air flow values in cubic feet per minute (CFM). Data taken without filters in place or A/C evaporator in place. When operating the furnace in the heating mode, the static pressure and the temperature rise (supply air temperature minus return air temperature) must be within those limits specified on the rating label. Failure to follow this warning could lead to severe furnace damage. Turn OFF all gas and electrical power to furnace before performing any maintenance or service on unit. (Unless specific test requires gas and electrical supplies.) Failure to take this precaution may result in personal injury due to electrical shock or uncontrolled gas leakage. FURNACE WIRING SPECIFICATIONS Zoom in 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. INTRODUCTION This furnace is design certified by CSA International as a Category I furnace using air from inside the structure for combustion. It is shipped as a packaged unit, complete with burners and controls, and requires a line voltage (115V) connection to the junction box, a thermostat hook-up as per the wiring diagram and a gas line connection. This furnace can be installed in either upflow, downflow or horizontal airflow positions. The design of this furnace is NOT CSA Certified for installation in recreation vehicles, in manufactured (mobil) homes, outdoors or for temporary construction heating. This furnace has been designed to interface with split system cooling equipment (approved by a nationally recognized testing laboratory) so as to provide "year round air conditioning". The blower has been sized for both heating and cooling and the furnace controls include a cooling fan relay. The furnace installation must conform with local building codes or in the absence of local codes, with the latest edition of the (U.S.) National Fuel Gas Code ANSI Z223.1 (NFPA-54) or Canadian Natural Gas and Propane Installation Codes CSA B149.1. For complete information on installation standards consult the (U.S.) National Fuel Gas Code, obtainable from the National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269 or the American Gas Association, 1515 Wilson Boulevard Arlington, VA 22209 or the Canadian installation codes obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Etobicoke, Ontario, Canada M9W 1R3. This furnace is designed for minimum continuous return-air temperature of 60°F dB or intermittent operation down to 55°F dB such as when used with a night setback thermostat. Return-air must not exceed a maximum continuous temperature of 85°F dB. These instructions are written for individual residential installation only. For multi-unit installation or commercial applications, please contact manufacturer for recommendations. LOCATION / PLACEMENT Site Selection: This furnace may be located in an attic, closet, basement, crawl space, alcove or suspended from the ceiling of a utility room or basement. Select a location that will meet all requirements for safety, clearances, ventilation and combustion air, ductwork design, gas piping, electrical wiring and venting. Clearances: The following minimum clearances, or greater, must be provided between the furnace and adjacent construction. MINIMUM INSTALLATION CLEARANCES TABLE 1 "UPFLOW" POSITION "DOWNFLOW" POSITION "HORIZONTAL" POSITION Suitable for alcove or closet installation** on combustible flooring at minimum clearance from adjacent construction not less than the following: Suitable for alcove or closet installation** on non-combustible flooring at minimum clearance from adjacent construction not less than the following: * Installation on combustible flooring only when installed on special base (see model & rating label for proper special base). Suitable for attic, alcove or closet installation** on combustible flooring at minimum clearance from adjacent construction not less than the following: * Line contact only permissible between lines formed by intersection of the top and two sides of the furnace jacket and building joist, studs, or framing. Top Sides Back Front Vent 2" 1" 1" 6" 6" with single wall vent 2" 1" 1" 3" 1" with B1 vent ** For closet installation see Air for Combustion and Ventilation. Failure to comply with all of the clearances will create a fire hazard. Do not place combustible material on the furnace jacket. Failure to comply with this warning will create a fire hazard. This furnace is not watertight and is not designed for outdoor installation. This furnace shall be installed in such a manner as to protect the electrical components from water. Outdoor installation would lead to a hazardous electrical condition and to premature furnace failure. The furnace should also be located as near to the center of the air distribution system as possible, and should be installed level. This furnace may be installed on non-combustible flooring or on wood flooring, however, it must not be installed directly on carpeting, tile or any other combustible material. In the downflow position, it must be installed on non-combustible flooring or on the special base listed on the rating label. In a horizontal position, line contact is only permissible between lines formed by the intersection of the furnace top, the front and back sides, and building joists, studs or framing (See Figure 1). Furnace must not lean back. It must be level or tilt up to 2° to the front. (See Figure 1.) A clearance of at least 30" should be provided at the front of the unit for servicing. For attic installations, the passageway and servicing area adjacent to the furnace should be floored. 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.) If the furnace is to be suspended from the ceiling, it will be necessary to use steel pipe straps around each end of the furnace. These straps should be attached to the furnace with sheet metal screws and to the rafters with bolts. The furnace may also be suspended by using an angle iron frame bolted to the rafters. (See Table on page 3 for size and weight of furnace.) Care must be taken to allow for service access. If a furnace is to be installed in a residential garage, it must be installed so the burners and the ignition source are located not less than 18" above the floor and the furnace must be located or protected to avoid physical damage by vehicles. AIR FOR COMBUSTION AND VENTILATION Contaminated Combustion Air: This furnace is not to be installed in a structure defined as having contaminated combustion air. Allowing exposure to substances containing chlorine or fluoride could harm the furnace and void the warranty. Substances to avoid include, but are not limited to: Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De-icing salts or chemical Carbon tetrachloride Halogen type refrigerants Cleaning solvents (such as perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials Unrefined gases Contaminated combustion air may cause premature failure of the heat exchanger that may lead to a hazardous condition and/or bodily harm, or loss of life. Adequate Ventilation and Combustion Air: This section is provided to give guidelines for the introduction of air for ventilation and combustion air. The total quantity of air provided to the installation area must equal the requirements of all gas appliances in the area. Adequate facilities for providing air for combustion and ventilation must be provided in accordance with the latest edition of the National Fuel Gas Code ANSI Z223.1/NFPA54 or CSA B149.1 Natural Gas and Propane Installation Codes, or applicable provisions of the local building codes. The furnace shall be installed in a location in which the facilities for ventilation permits satisfactory combustion of gas, proper venting and maintenance of ambient temperature at safe limits under normal conditions of use. The furnace shall be located so as not to interfere with proper circulation of air. In addition to air needed for combustion, ventilation in the form of process air must be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust and odor control. Air must be supplied for ventilation, including all air required for comfort and proper working conditions for personnel. For purposes of this instruction the following definitions apply: Confined Space: A space whose volume is less than 50 cubic feet per 1000 Btu/hr of the aggregate input rating of all appliances installed in that space. Unconfined Space: A space whose volume is not less than 50 cubic feet per 1000 Btu/hr of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space. If the installation area meets the definition of "Unconfined Space" and does not have additional air requirements as described, the furnace may be installed without making special provisions for combustion and ventilation air. Whenever this furnace is installed in an area along with one or more gas appliances, the total Btu/hr input of all appliances must be included when determining the free area requirements for combustion and ventilation air openings. Do not block the combustion or ventilation air openings in the furnace. Any blockage will result in improper combustion and may result in a fire hazard or unsafe condition. 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). These openings must be located 12 inches from the top and bottom of the furnace area respectively and must be at least 3 inches long on the smaller side of the opening (See Figure 2). Neither opening can be blocked at any time. Zoom in If ventilation and/or combustion air must be supplied to the "Confined Space" from outside the building structure, two permanent openings to the outdoors must be created. Each opening must have a free area of not less than one square inch per 4000 Btu per hour of total input of all appliances within the "Confined Space". These openings must be located 12 inches from the top and bottom of the furnace area respectively (See Figures 3, 4, and 5). Neither opening can be blocked at any time. Zoom in Zoom in Zoom in For an attic installation it is important to keep insulation 12" or more away from any furnace openings. Some types of insulating materials may be combustible. 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. from the top and bottom of the furnace area. Neither opening can be blocked at any time (See Figure 6). Zoom in Furnaces installed with combustion air drawn from a heated space which includes exhaust fans, fireplaces, or other devices that may produce a negative pressure should be considered confined space installations. 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. Ductwork Recommendation: The supply duct work should be attached to the flanged opening provided at the discharge end of the furnace. See page 3 "Furnace Specificatons" for the dimensions of this opening. A left, right, or bottom return air opening must be used as determined by the layout of the installation. An externally mounted air filter is required. This furnace has a two piece bottom panel. For bottom or end duct return, remove the back portion of the bottom panel by removing the four (4) screws - two (2) on each side toward the back of the furnace (See Figure 7). Tilt furnace toward the front, the back portion of the panel will drop down. Then the back portion can be removed by pulling toward the back of the furnace. Knockouts are provided on both sides of the furnace to facilitate the cutout required to the return air ductwork. Furnace cutouts must be the full size specified by the corner markers. Undersized cutouts will adversely affect the airflow capability of the furnace and could cause overheating of the heat exchanger. The following recommendations should be followed when installing the ductwork: Install locking-type dampers in all branches of the individual ducts to balance out the system. Dampers should be adjusted to impose the proper static at the outlet of the furnace. Noncombustible flexible duct connectors are recommended to connect both the supply and return ducts to the furnace. In cases where the return air grille is located close to the blower inlet, there should be at least one 90° air turn between blower and return grille. Further reduction in sound can be accomplished by installing acoustical air turning vanes and/or lining the inside of the duct with acoustical material. It is recommended that the supply duct be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be 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. If an air conditioning coil is installed, the access panel to the coil can be used for this purpose. When supply ducts carry air circulated by the furnace to areas outside the spaces containing the furnace, the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space containing the furnace. Incorrect ductwork termination and sealing will create a hazardous condition that could lead to bodily harm. Air openings, intake and outlet pipes, return air grilles and warm air registers must not be obstructed. To Convert to Downflow Position: Convert the combustion blower to side flue exit, as outlined on page 14. Install proper special base per Table 2 for installation on combustible flooring (follow instructions supplied with special base). It is recommended that the return air be connected to the bottom panel of the furnace when it is installed in the downflow position. NOTE: SPECIAL SUB-BASE NOT REQUIRED WHEN FURNACE IS MOUNTED ON A METAL CASED EVAPORATOR COIL. SPECIAL BASE INSTALLATION Table 2 MODEL SPECIAL BASE NUMBER CAT. NO. MPGA050B3 MPGA075B3 20066501 68L77 MPGA075B4 MPGA100B4 20066502 68L78 MPGA100B5 MPGA100B5 20066503 68L79 NOTE: Installation on combustible flooring only when installed on one of the above listed special bases or as identified on the furnace model and rating label. Filters: Air filters must be used in every installation. For side return installations, air filters must be installed external to the furnace casing. An external filter rack kit with filter (parts No. 20069901 or Cat. No. 68L75 12 / 15." x 25" sizes and 20069902 or Cat. No. 68L76 for 15." / 19" x 25" sizes) is available as an optional accessory. For bottom (end) return installations, the above optional external rack may be used, if the unit was not provided with a internal filter. Minimum filter size and suggested filter materials are shown in Table 3. (If different type filter is used, it must be an equivalent high airflow capacity.) EXTERNAL FILTER RACK SIZE Table 3 MODEL SIDE RETURN BOTTOM/END RETURN 050-3 075-3 15 Ѕ X 25 12 X 25 075-4 100-3 15 Ѕ X 25 15 Ѕ X 25 100-5 125-5 15 Ѕ X 25 19 X 25 When installing the furnace with cooling equipment for year round operation, the following recommendations must be followed for series or parallel air flow: 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. 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. IMPORTANT: The dampers should be adequate to prevent cooled air from entering the furnace, and if manually operated, must be equipped with means to prevent operation of either the cooling unit or furnace unless the damper is in the full cool or full heat position. The coil MUST be installed on the air discharge side of the furnace. Under no circumstances should the air flow be such that cooled, conditioned air can pass over the furnace heat exchanger. This will cause condensation in the heat exchanger and possible failure of the heat exchanger that could lead to a fire hazard and/or hazardous conditions that may lead to bodily harm. Heat exchanger failure due to improper installation will not be covered by warranty. VENTING Venting for the furnace must be to the outside and in accordance with local codes or requirements of the local utility. In the absence of local codes, venting must conform to the applicable sections of the latest edition of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes, and the vent manufacturers instructions. This furnace is CSA International certified as a Category I forced air appliance and can not be vented into a vent system with any Category II, III or IV appliance. It must be vented vertically, or nearly vertically, unless installed with a listed mechanical venter in accordance with horizontal venting instructions. It must not be connected to any portion of a mechanical draft system operating under positive pressure. The 3" (in.) to 4" (in.) vent adaptor coupling (supplied with unit) MUST BE USED. It must be connected directly to the outlet of the combustion blower using a field supplied corrosion resistant sheet metal screw (See Figure 8). Pre-Installation Vent System Inspection: Before this furnace is installed, it is highly recommended that any existing vent system be completely inspected. For a chimney or "B" vent, this should include the following: Inspection for any deterioration in the chimney or "B" vent. If deterioration is discovered, the chimney must be repaired or the "B" vent must be replaced. Inspection to ascertain that the vent system is clear and free of obstructions. Any blockage must be cleared before installing this furnace. Cleaning the chimney or "B" vent if previously used for venting a solid fuel burning appliance or fireplace. Confirming that all unused chimney or "B" vent connections are properly sealed. Verification that the chimney is properly lined and sized per the applicable codes. This furnace must NOT vented ALONE into an existing masonry chimney (either tile lined or unlined) unless the chimney is also lined with either a type B vent system or a listed single wall, metal lining system. Both of these systems must be sized in accordance with the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes. Before venting this furnace into a chimney, check the chimney for deterioration and repair if necessary. This furnace must not be vented into a chimney serving a separate appliance designed to burn solid fuel. Type"B" vent connectors must be used on all installations and it must be sized per the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes. Type "B" Vent: The furnace is also approved for use with a "B" vent that terminates through the roof. Refer to the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes for proper sizing and set-up of this furnace with "B" vent for a dedicated vent system or a common vented system. AUXILIARY DRAFT INDUCERS Table 4 Vent Kit MFR Model * Furnace Input Field Controls Co. SWG-4G 50000, 75000, 100000 or 125000 Tjernlund Products Inc. SS1 OR SS1C 50000, 75000, 100000 or 125000 GPAK-J 50000, 75000 or 100000 GPAK-1 100000 or 125000 * See rating label on this furnace for input Vent Length: Max. 60 ft. - Min. 12 ft. Vent Diameter: 4 in. Follow instructions included with venting kit for proper installation and setup. Location Requirements for Horizontal Venting: Locate the vent terminal adhering to the following minimum clearances: Vent terminal must be located at least one (1') foot above the grade or at least one (1') foot above the normal expected snowfall. Avoid installing vent terminal above public walkways. If this is not possible, install the terminal at least seven (7') feet above the walkway. Vent terminal should be at least four (4') feet to the side of and at least one (1') foot above doors and windows. Vent terminal should be at least three (3') feet above any forced air inlet located within ten (10') feet. Vent terminal should be located at least six (6') feet from the combustion air intake of another appliance. Vent terminal should be located at least four (4') feet above any electric or gas meters, regulators, and relief equipment. General Venting Requirements: This furnace may be common vented only with other Category I appliances. Common venting is allowed as permitted by National and/or local codes. Refer to the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes for proper sizing and set up. The vent must be terminated with a listed vent cap or roof assembly. This venting must be installed in accordance with the vent manufacturer's instructions and be in accordance with all local codes and/or National Codes. Follow Figure 9 for vent exit options. The following requirements are provided for a proper venting system: Be sure that the chimney flue is clear of any dirt or debris. Be sure that the chimney is not servicing an open fireplace. Never reduce the pipe size below the outlet size of the furnace without checking the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes. All pipe should be supported using the proper clamps and/or straps. These supports should be at least every four (4') feet. All horizontal runs of pipe should have at least a 1/4" (in.) per foot of upward slope from the furnace to the vent terminal. All runs of pipe should be as short as possible with as few turns as possible. Seams should be tightly joined and checked for leaks. The flue pipe must not extend into the chimney but be flush with the inside wall. The chimney or vent pipe must extend at least three (3') feet above the highest point where it passes through a roof of a building and at least two (2') feet higher than any portion of a building within a horizontal distance of ten (10') feet. It shall also extend at least five (5') feet above highest connected equipment flue collar. 10. The 3" to 4" vent adaptor coupling must be used to connect to the combustion blower outlet. It must be installed directly to the combustion blower outlet (See Figure 8). To Convert to Side Flue Exit: Remove the louver door from the furnace. (Be sure the side vent exit knock-out is removed from the right side panel of the cabinet. See Figure 9.) Disconnect the pressure switch tubing from the combustion blower. Remove the four (4) screws that secure the combustion blower adaptor plate to the flue collector box, taking care to support the blower assembly so that it does not fall. Rotate the blower 90° (degrees) clockwise, so that the outlet of the blower is pointing toward the right side panel of the furnace. Insure that the gasket is in place between the blower adaptor plate and the flue collector box. Reattach the blower assembly to the flue collector box, using the four (4) screws removed in step 3. Be sure that the screws are properly tightened and that the gasket seals the plate to the box. Reconnect the pressure switch tubing to the combustion blower. (Optional) Install vent pipe guard. Kit Number 20284801. For Horizontal Positions: It is not necessary to reposition any of the components of the furnace in order to install it in either horizontal position. As outlined above, it is permissible to use the side vent exit for the horizontal-left position, if desired. Checking For Vent Oversizing: If this furnace is replacing a furnace that is attached to a venting system serving other appliances, the venting system is likely to be too large to properly vent all of the attached appliances. An improperly sized venting system can lead to condensation, leakage, or spillage. 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 for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: Seal any unused openings in the venting system. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Close fireplace dampers. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use. 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 28. In all instances, other than wiring for the thermostat, the wiring to be done and any replacement of wire shall conform with the temperature limitation for Type T wire [63°F rise (35°C)]. The electrical connections and the thermostat connections are made at the openings on either side panel of the unit in the control box area. Either side may be used as convenient, but the provided hole plugs must be inserted in the unused holes. The control system depends on the correct polarity of the power supply. Connect "Hot" (H) wire and "Ground" (G) wire as shown in furnace wiring specification on wiring diagram. Use reference Table on page 3 (Furnace Specifications), for over current protection, max unit amp rating and wire size. Use copper wire only for 115Vsupply service to unit. When replacing any original internal wiring, use only 105°C, 16 AWG copper wire. Instructions for wiring the thermostat are packed in the thermostat (field supplied) box. Make the thermostat connections as shown in furnace wiring specifications at the 24-volt terminal board located in the control box. When installing optional accessories to this appliance, follow the manufacturer's installation instructions included with the accessory. The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or approved conduit when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning can result in an electrical shock, fire, bodily harm, or loss of life. GAS CONNECTIONS Gas piping shall be of such size and so installed as to provide a supply of gas sufficient to meet maximum demands without undue loss of pressure between the gas meter and the furnace. It is recommended that the gas line to the furnace shall be a separate line direct from the meter, unless the existing gas line is of ample capacity. Refer to gas pipe capacity table in the National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do no use a connector which has previously serviced another gas appliance. Use a joint compound (pipe dope) that is resistant to the action of liquefied petroleum gases or any other chemical constituents of the gases to be conducted through the piping. For proper furnace operation the maximum gas supply pressure is 14" w.c. and the minimum gas supply pressure is 4.5" w.c. - Natural (11" w.c. - LP) as shown on rating label. Before any system of gas piping is finally put into service, it should be carefully tested to determine if it is gas tight. Check all piping for leaks using soapy water and a brush. The piping must stand a pressure of six (6) inches of mercury (3 PSIG) for a period of ten (10) minutes or as required by local authority. 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, personal injury or loss of life. The furnace and its individual shutoff valve must be disconnected from the supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.5kPa or 14"w.c.). The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 PSIG (3.5kPa or 14"w.c.). Failure to follow the above procedures could lead to a hazardous condition and bodily harm. This furnace is manufactured for use with Natural gas and must be converted using the proper LP conversion kit for use with LP (Propane) gas. For LP (Propane) gas, a tank regulator is required to reduce supply pressure to 12"-13"w.c. For manifold pressure see Table 6. A main manual shut off valve must be used in the gas piping. The shut off type and location must follow local codes and should always be in an accessible but protected location. In the absence of local codes the recommended methods for installing the gas piping to the furnace are shown in Figures 11 and 12. The gas valve contains two threaded ports for a 1/8" NPT tap in order to test incoming gas pressure and outgoing manifold pressure (See Figure 13). Many soaps used for leak testing are corrosive to certain metals. Piping must be rinsed thoroughly with clean water after leak check has been completed. Never use an open flame when testing for gas leaks! Use of an open flame could lead to a fire or explosion. THEORY OF OPERATION Here's How Your System Works: Call For Heat The thermostat calls for heat by energizing the "W" terminal. The control checks to see the limit switch is closed and pressure switch is open. If the limit switch is open, the control responds per the Open Limit section following. If the pressure switch is closed, the control will flash "3" on the LED and wail indefinitely for the pressure switch to open. If the pressure switch is open, the control proceeds to pre-purge. Pre-Purge The control energizes the induced draft motor and waits for the pressure switch to close. The control flashes "3" on the LED while the pressure switch is open. If the pressure switch does not close within 60 seconds of the inducer energizing, the control will de-energize the inducer for 300 seconds, and then re-energize the inducer. This cycle shall continue as long as a call for heat exists until the pressure switch is proven. When the pressure switch is proven closed, the control begins the pre-purge time. If flame is present any time while in pre-purge, the control will flash "5" on the LED and go into soft lockout. The control runs the inducer for a 15 second pre-purge time, then proceeds to the ignition trial period. Ignition Trial Period The control energizes the spark and main gas valve. The inducer remains energized. If flame has not been sensed within the 7 second ignition trial, the control de-energizes the gas and spark outputs and proceeds with ignition retires. If flame is not established after three (3) trials for ignition, the control will flash "2" on the LED and goes into lockout. Blower On Delay The control waits for 30 seconds from the time the gas valve opened and then energizes the indoor blower heat speed. The gas valve and inducer remain energized. The control proceeds to steady heat mode. Steady Heat Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heal remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and blower off delay time. Open Limit Any time the limit switch is open, the control de-energizes the gas valve and runs the indoor blower motor on heat speed, and runs the induced draft motor. While the limit switch is open, the control flashes "4" on the LED. Check for a restriction in the duct system (i.e. dirty filters, blocked ductwork, closed registers......} . When the switch re-closes, the control runs the induced draft motor through post-purge and runs the indoor blower through the selected fan off delay. If the call for heat is still present when the limit switch closes, the control will begin an ignition sequence while the blower off delay continues. Note: An open limit switch breaks the power ("R") to the thermostat. Cycling on the limit is an abnormal condition and a corrective action must be taken. Failure to correct this condition could damage the heat exchangers and void the warranty. Post Purge The inducer output remains on for a 15 second post-purge period after the thermostat is satisfied. Blower Off Delay. The indoor blower motor is de-energized after a 90 second blower off delay. Blower timing begins when the thermostat is satisfied. If the thermostat calls for heat while in the blower off delay, the control immediately restarts the ignition sequence while the blower off delay continues, Should overheating occur, or the gas supply fail to shut OFF. turn OFF the manual gas valve to the appliance BEFORE turning OFF the electrical supply. A failure to adhere to this warning can result in a fire or explosion and bodily harm. For cooling operation, when the inside temperature exceeds the thermostat setting, the thermostat will turn ON the cooling system. When the thermostat calls for cooling, power from the transformer energizes the fan control board (for blower operation) and the outdoor condensing unit (for air conditioning). The fan control board will automatically turn on the blower and condensing unit. The air moving over the indoor coil by the blower is cooled (and dehumidified) and passes through the ducts to the room registers. When the thermostat is satisfied, the fan control board is de-energized and the condensing unit is shut-off. The blower will continue to operate for an additional 30 seconds for added cooling efficiency. STARTUP AND OPERATIONAL CHECKOUT 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. The automatic gas valve controls the flow of gas to the main burners. The ignition system control switch built into the automatic valve body has 2 positions: "OFF" and "ON" (Figure 13). To shut off gas manually:Rotate switch from "ON" to "OFF" position. When in "OFF" position, the main burners are extinguished. This furnace is equipped with an automatic hotsurface ignition control and does not require the manual lighting for furnace operation. Do not attempt to manually light the burners. Failure to follow this warning can lead to electrical shock that could result in bodily harm. After the ductwork connections have been made, gas piping and electrical wiring completed and the furnace has been properly vented, the unit should be started and adjusted for proper operation. Check off the following steps as they are completed. Be sure all electrical power is OFF. Check all wiring using proper wiring diagram on inside of the control box cover. Turn ON the electrical power. Set the gas control knob in the "ON" position. Set the thermostat above room temperature. The ignitor will spark and the main burner will ignite. Recheck for leaks in the manual shut off valve, gas control valve and gas connections using a soap solution. Never use an open flame when testing for gas leaks! Use of an open flame could lead to a fire or explosion. Many soaps used for leak testing are corrosive to certain metals. Piping must be rinsed thoroughly with clean water after leak check has been completed. Manifold Pressure Adjustment: Turn OFF the gas and electrical before preceeding! Remove the manifold pressure tap pipe plug from the gas valve (Figure 13 outlet pressure tap) and install a pressure tap and connect it to a manometer. Turn on the gas and electrical supplies, then measure the manifold pressure with the furnace in operation. Remove the cap to access the screw for input adjustment (Figure 13 Pressure Regulator). Turn regulator-adjusting screw IN to increase pressure, OUT to decrease pressure. Replace the cap. Measure the manifold pressure. For Natural gas, best results are obtained with a manifold pressure of 3.2" to 3.5"w.c. For units that have been converted to LP (Propane) gases, a manifold pressure of 10"w.c. is necessary. After proper adjustment, turn OFF gas, replace manifold pressure tap pipe plug and turn ON gas. At higher altitudes and varying heating valves, manifold pressure or orifice changes maybe required. Consult Tables 7 and 8 for appropriate values. Failure to follow this warning could lead to a hazardous furnace operating condition and result in serious bodily injury or loss of life. Determining Furnace Input - Natural Gas ONLY: NOTE: Louvered access door of furnace must be in place when checking gas input. Turn OFF all other gas appliances (except for pilot burners) served by the same gas meter. With furnace operating in full heat cycle, note how many seconds it takes for one full revolution of the smallest dial on the meter. Typically, this will be a 1/2 - or - 1 - cubic foot test dial. Using the number of seconds for one revolution and the size of the meter dial, determine the cubic foot per hour of gas flow by using the formula provided below or Table 5. Gas Rate (Cubic Feet per Hour) TABLE 5 Seconds for One Revolution TEST DIAL 1/2 Cubic Feet 1 Cubic Feet 2 Cubic Feet 10 160 360 720 12 150 300 600 14 129 257 514 16 113 225 450 18 100 200 400 20 90 180 360 22 82 164 325 24 75 150 300 26 69 138 276 28 64 129 258 30 60 120 240 32 56 113 226 34 53 106 212 36 50 100 200 38 47 95 190 40 45 90 180 42 43 86 172 44 41 82 164 46 39 78 156 48 37 75 150 50 36 72 144 52 35 69 138 54 34 67 134 56 32 64 128 58 31 62 124 60 30 60 120 4. Calculate the furnace input using the following formula: 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 main orifices size if required. 5. Calculate the unit's actual input rate. Example: If the heating value of the natural gas is 1015 Btu/cu. and it takes 60 seconds to burn 2 cu. ft. of gas then: Burner Orifice Sizing: The furnace is supplied with standard orifices for the gas shown on the rating plate. Table 6 shows combinations of heating values and specific gravities for various gases, from which proper input can be obtained. If changing orifices is required, remove the manifold from the furnace (following the instructions found on page 23) and replace orifices as required by Table 6, the altitude derating section of this instruction or as local code dictates. Burner Orifice Selection TABLE 6 Type of Gas@Manifold Press. (Heating Value-Specific Gravity) Btu per Cu. Ft. Orifice Size (Drill #) Natural Manifold Press.= 3.5"w.c.   800-0.6 40 900-0.6 41 1000-0.6 42 1100-0.6 43 Propane Manifold Press.= 10"w.c.   2500-1.53 54 After securing the manifold assembly, replace all other components and/or wiring, being sure that all connections and screws are tightened properly. Altitude Derating: The following information is provided as guidelines for altitude derating and is not meant to supersede any state or local codes. Local codes have priority over any others and in some case might limit your options in dealing with an altitude derate situation. NOTE: In Canada for altitudes up to 4500 ft. (1372 m) see the rating label on this furnace for proper manifold pressure and orifice size. Certification for installations at altitudes over 4500 ft. (1372 m) is the jurisdiction of local authorities. Check with your local gas company to find out if the gas supply in your area is derated. Gas deration negates the necessity of performing any adjustment on the furnace. If your gas supply is not derated, and regardless of the type of gas used, installation of this furnace at elevations above 2,000 ft. requires an input reduction at the rate of four percent (4%) for each 1,000 ft. above sea level. Unless an orifice change is specified by an applicable code, or the furnace is to be installed above 6,999 feet, the recommended method of altitude derating this furnace is to appropriately lower your manifold pressure. The appropriate manifold pressures based on the elevation and the heating value can be found in Table 7. High Altitude Manifold Pressure Derate (with standard 42 orifice Natural / 54 orifice LP sizes) TABLE 7 Altitude (Feet) *Heating Value of Natural Gas (BTU/FT3) LP Propane 900 950 1000 1050 1100 2500 0-999 4.32 3.88 3.50 3.16 2.84 10 1000-1999 4.32 3.88 3.50 3.16 2.84 10 2000-2999 3.67 3.29