92-24161-22 Rev. 21 High Efficiency Modulating Gas Furnace ...The (-)GFD,(-)GGD and (-)GJD series furnaces are design-certified by CSA for use with natural and L.P. gases as follows:

92-24161-22-21SUPERSEDES 92-24161-22-20

INSTALLATION INSTRUCTIONSFOR (-)GFD UPFLOW, (-)GGD DOWNFLOW, & (-)GJDDEDICATED HORIZONTAL HIGH EFFICIENCYMODULATING CONDENSING GAS FURNACES

ISO 9001:2000

(-)GFD

(-)GGD

(-)GJD

MODULATINGTHERMOSTATINSTALLATION

SEE PAGE 46

2

IMPORTANT: To insure proper installation and operation of this product, com-pletely read all instructions prior to attempting to assemble, install, operate, main-tain or repair this product. Upon unpacking of THE furnace, inspect all parts fordamage prior to installation and start-up.

CONTENTSSafety Information..................................................................................................3

Installation Check List ............................................................................................5

General Information ...............................................................................................6

Location Requirements and Considerations..........................................................9

Venting and Combustion Air Piping .....................................................................18

Non-Direct Vent Pipe Installation .........................................................................20

Direct Vent Pipe Installation.................................................................................24

Condensate Drain/Optional Neutralizer ...............................................................34

Gas Supply and Piping ........................................................................................38

Electrical Wiring ...................................................................................................43

Thermostats .........................................................................................................45

Applications..........................................................................................................48

Accessories..........................................................................................................59

High Altitude Installations.....................................................................................63

Integrated Furnace Control ..................................................................................67

Start-Up Procedures ............................................................................................70

Maintenance ........................................................................................................73

Troubleshooting ...................................................................................................76

Wiring Diagram ....................................................................................................84

Installation Instructions are updated on a regular basis. This is done as productchanges occur or if new information becomes available. In this publication, anarrow ➤ denotes changes from the previous edition or additional new material.

IMPORTANT: All Rheem productsmeet current Federal OSHA Guidelinesfor safety. California Proposition 65warnings are required for certain prod-ucts, which are not covered by theOSHA standards.California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to theState of California to cause cancer orbirth defects such as fiberglass insula-tion, lead in brass, and combustionproducts from natural gas.All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes, hav-ing the same label on all our productsfacilitates manufacturing and shipping.We cannot always know “when, or if”products will be sold in the Californiamarket.You may receive inquiries from cus-tomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are those chem-icals and substances commonly asso-ciated with similar equipment in ourindustry and other manufacturers.• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• BenzeneMore details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled and main-tained.

INSTALL THIS FURNACE ONLYIN A LOCATION AND POSITIONAS SPECIFIED IN THE LOCA-TION REQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS.PROVIDE ADEQUATE COMBUS-TION AND VENTILATION AIR TOTHE FURNACE SPACE ASSPECIFIED IN THE VENTINGSECTION OF THESE INSTRUC-TIONS.

PROVIDE ADEQUATE COMBUS-TION AND VENTILATION AIR TOTHE FURNACE SPACE ASSPECIFIED IN THE COMBUS-TION AND VENTILATION AIRSECTION OF THESE INSTRUC-TIONS.

COMBUSTION PRODUCTSMUST BE DISCHARGED OUT-DOORS. CONNECT THIS FUR-NACE TO AN APPROVED VENTSYSTEM ONLY, AS SPECIFIEDIN VENT PIPE INSTALLATIONSECTION OF THESE INSTRUC-TIONS.

ALWAYS INSTALL FURNACE TOOPERATEWITHIN THE FUR-NACE'S INTENDED TEMPERA-TURE-RISE RANGEWITH ADUCT SYSTEMWHICH HAS ANEXTERNAL STATIC PRESSUREWITHIN THE ALLOWABLERANGE, AS SPECIFIED INDUCTING SECTION OF THESEINSTRUCTIONS. SEE ALSOFURNACE RATING PLATE.

WHEN A FURNACE ISINSTALLED SO THAT SUPPLYDUCTS CARRY AIR CIRCULAT-ED BY THE FURNACE TOAREAS OUTSIDE THE SPACECONTAINING THE FURNACE,THE RETURN AIR SHALL ALSOBE HANDLED BY DUCT(S)SEALED TO THE FURNACE CAS-ING AND TERMINATING OUT-SIDE THE SPACE CONTAININGTHE FURNACE.

WHENTHIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BEINSTALLED SOTHE BURNERSAND IGNITION SOURCE ARELOCATED NO LESS THAN 18INCHES ABOVE THE FLOOR.THIS IS TO REDUCE THE RISKOF IGNITING FLAMMABLEVAPORSWHICH MAYBE PRESENT IN A GARAGE.ALSO,THE FURNACE MUST BELOCATED OR PROTECTEDTOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOL-LOWTHESEWARNINGS CANCAUSE A FIRE OR EXPLOSION,RESULTING IN PROPERTY DAM-AGE, PERSONAL INJURY ORDEATH.

USE OF THIS FURNACE ISALLOWED DURING CON-STRUCTION IF THE FOLLOWINGTEMPORARY INSTALLATIONREQUIREMENTS ARE MET.INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:• PROPER VENT INSTALLA-TION;

• FURNACE OPERATINGUNDER THERMOSTATIC CON-TROL;

• RETURN AIR DUCT SEALEDTO THE FURNACE;

• AIR FILTERS IN PLACE;• SET FURNACE INPUT RATEAND TEMPERATURE RISEPER RATING PLATE MARK-ING;

• MEANS FOR PROVIDINGOUTDOOR AIR REQUIREDFOR COMBUSTION;

• RETURN AIR TEMPERATUREMAINTAINED BETWEEN 55°F(13°C) AND 80°F (27°C); AND;

• CLEAN FURNACE, DUCTWORK AND COMPONENTSUPON SUBSTANTIAL COM-PLETION OF THE CONSTRUC-TION PROCESS, AND VERIFYFURNACE OPERATING CON-DITIONS INCLUDING IGNI-TION, INPUT RATE, TEMPER-ATURE RISE AND VENTING,ACCORDING TO THEINSTRUCTIONS.

! WARNINGUSE ONLYWITH TYPE OF GASAPPROVED FOR THIS FUR-NACE. REFER TO THE FURNACERATING PLATE.

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADE SPECIF-ICALLY FOR THE DETECTIONOF LEAKS TO CHECK ALL CON-NECTIONS, AS SPECIFIED INGAS SUPPLY AND PIPING SEC-TION OF THESE TION INSTRUC-TIONS.

! WARNING

THIS FURNACE IS NOTAPPROVED OR RECOMMENDEDFOR INSTALLATION ON ITSBACK,WITH ACCESS DOORSFACING UPWARDS, ORWITHSUPPLY AIR DISCHARGING TOTHE RIGHT-HAND SIDEWHENFACING THE FRONT OF THEFURNACE. SEE FIGURES 5 AND6 FOR PROPER INSTALLATIONOF HORIZONTAL MODELS.

! WARNING

! WARNING

3

SAFETY INFORMATION

DO NOT INSTALL THIS FUR-NACE IN A MOBILE HOME!! THISFURNACE IS NOT APPROVEDFOR INSTALLATION IN AMOBILE HOME. DOING SOCOULD CAUSE FIRE, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

! WARNINGDO NOT JUMPER OR OTHER-WISE BYPASS OVERTEMPERA-TURE OR ANY OTHER LIMITSOR SWITCHES ONTHE FUR-NACE. IF ONE OF THESE LIMITSOR SWITCHES SHOULDTRIP OROPEN,THE USER IS TO BEINSTRUCTED TO CALL A QUALI-FIED INSTALLER, SERVICEAGENCY ORTHE GAS SUPPLI-ER. FOR MANUALLYRESETABLE SWITCHES,THEUSER IS FURTHER INSTRUCTEDTO NEVER RESET THE SWITCH,BUT TO CALL A QUALIFIEDTECHNICIAN. MANUAL RESETSWITCHES MAY REQUIRE FUR-THER CORRECTIVE ACTIONS.FAILURE TO FOLLOWTHISWARNING COULD RESULT INCARBON MONOXIDE POISON-ING, SERIOUS INJURY ORDEATH. IF THE UNIT ISINSTALLED IN A CLOSET,THEDOOR MUST BE CLOSEDWHENMAKINGTHIS CHECK.INSTALLERS ANDTECHNICIANSARE INSTRUCTEDTO REPLACEANY LIMIT OR SAFETYSWITCH/DEVICE ONLYWITHIDENTICAL REPLACEMENTPARTS.

4

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSING PROP-ERTY DAMAGE. FUMES ANDODORS FROMTOXIC, VOLATILEOR FLAMMABLE CHEMICALS, ASWELL AS AUTOMOBILE EXHAUSTAND CARBON MONOXIDE (CO),CAN BE DRAWN INTO THE LIVINGSPACE THROUGH LEAKINGDUCTS AND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE4).• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CAR-BON MONOXIDE FROM MIGRAT-ING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHASWATER HEATERS OR BOIL-ERS - ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENT DEPRES-SURIZATION OF THE SPACEAND POSSIBLE MIGRATION OFCOMBUSTION BYPRODUCTSINCLUDING CARBON MONOX-IDE INTO THE LIVING SPACE.

IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCEWITH THE CSAINTERNATIONAL (CSA) CERTIFI-CATION OR THESE INSTRUC-TIONS, CAN RESULT IN UNSATIS-FACTORY OPERATION AND/ORDANGEROUS CONDI-TIONS ANDARE NOT COVERED BY THE UNITWARRANTY.

IN COMPLIANCEWITH RECOG-NIZED CODES, IT IS RECOM-MENDED THAT AN AUXILIARYDRAIN PAN BE INSTALLEDUNDER ALL EVAPORATOR COILSOR UNITS CONTAINING EVAPO-RATOR COILS THAT ARE LOCAT-ED IN ANY AREA OF A STRUC-TUREWHERE DAMAGE TO THEBUILDING OR BUILDING CON-TENTS MAY OCCUR AS A RESULTOF AN OVERFLOW OF THE COILDRAIN PAN OR A STOPPAGE INTHE PRIMARY CONDENSATEDRAIN PIPING. SEE ACCES-SORIES SECTION OF THESEINSTRUCTIONS FOR AUXILIARYHORIZONTAL OVERFLOW PANINFORMATION (MODEL RXBM).

! WARNING NOTICE

NOTICE

5

INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

ELECTRICAL

115 V.A.C. supply (Single Circuit)

Polarity observed

Furnace properly grounded (Earth ground)

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling speed

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connectedand clamped

Freeze protection (if necessary)

______ Neutralizer (if needed)

VENTING – DIRECTVENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

VERTICAL – CONCENTRIC (RXGY-E03A)

Intake – 12" min. above roof/snow level

HORIZONTAL – STANDARD (RXGY-D02, -D02A, -D03,-D03A)


12" min. above grade/snow level

HORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03,-D03A, -D04 OR -D04A)


Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-E03A)


Intake “Y” rotated above center

Exhaust sloped toward furnace

VENTING – NON-DIRECT VENT (VERTICAL ONLY)

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)

12" min. above roof/snow level

Model #

Serial #

Date of installation

HORIZONTAL – STANDARD


HORIZONTAL – ALTERNATE

Above anticipated snow level

6

➤ FIGURE 2DOWNFLOW FURNACE (-)GGD

GENERAL INFORMATIONThe (-)GFD,(-)GGD and (-)GJDseries furnaces are design-certifiedby CSA for use with natural and L.P.gases as follows:• As direct vent, central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special air intakesystem outlined in these instruc-tions.

• As non-direct, central forced air fur-nace taking combustion air fromthe installation area or using airducted from the outside.

• IMPORTANT: Proper application,installation and maintenance of this

FIGURE 1UPFLOW FURNACE (-)GFD

furnace are required if consumersare to receive the full benefits forwhich they have paid.

Install this furnace in accordance withthe American National StandardZ223.1 – latest edition entitled“National Fuel Gas Code” (NFPA54,90A and 90B) and requirements orcodes of the local utilities or otherauthorities having jurisdiction. This isavailable from the following:National Fire Protection

Association, Inc.Batterymarch ParkQuincy, MA 02269

CSA International - U.S.8501 East Pleasant Valley RoadCleveland, Ohio, 44131Canadian installations must beinstalled in accordance with CSA,local installation codes andauthorities having jurisdiction.CSA is available from:CSA International - Canada178 Rexdale Blvd.Etobicoke (Toronto), Ontario,Canada M9W-1R3

I678

ITEMNO. PART NAME

1 CONDENSATE TRAP2 DOOR SWITCH3 JUNCTION BOX4 TRANSFORMER5 LOW PRESSURE SWITCH6 HIGH PRESSURE SWITCH7 EXHAUST TRANSITION8 CONNECTOR9 MAIN LIMIT10 EXHAUSTAIR PIPE11 VENT CAP PLUG12 FLAME SENSOR13 OVERTEMPERATURE SWITCH

ITEMNO. PART NAME

14 TOP PLATE15 BURNER16 IGNITER17 COMBUSTION AIR INLET18 GAS VALVE19 CAPACITOR20 INDUCED DRAFT BLOWER21 POWER FACTOR CHOKE22 IGNITION CONTROL23 INTEGRATEDFURNACECONTROL24 BLOWER MOTOR25 R/A SENSOR26 BLOWER HOUSING

ITEMNO. PART NAME

1 GAS VALVE2 CAPACITOR3 LOW PRESSURE SWITCH4 HIGH PRESSURE SWITCH5 BLOWER HOUSING6 POWER FACTOR CHOKE7 BLOWER MOTOR8 DOOR SWITCH9 JUNCTION BOX10 COMBUSTION AIR INLET11 HALC12 TOP PLATE13 RETURN AIR SENSOR

ITEMNO. PART NAME

14 VENT CAP PLUG15 EXHAUSTAIR PIPE16 INTEGRATEDFURNACECONTROL17 TRANSFORMER18 IGNITION CONTROL19 INDUCED DRAFT BLOWER20 CONNECTOR21 EXHAUST TRANSITION22 MAIN LIMIT23 CONDENSATE TRAP24 IGNITER25 OVERTEMPERATURE SWITCH26 BURNER27 FLAME SENSOR

7

➤ FIGURE 3HORIZONTAL FURNACE (-)GJD

27 FACTORY-INSTALLED STREET ELBOW

8

tions are available from: “NationalFire Protection Association, Inc.,Batterymarch Park, Quincy, MA02269.” These publications are:

• ANSI/NFPA No. 70-(Latest Edition)National Electrical Code.

• NFPA90A Installation of AirConditioning and VentilatingSystems.

• NFPA90B Installation of warm airheating and air conditioning sys-tems.

• The equipment has been evaluat-ed in accordance with the Code ofFederal Regulations, Chapter XX,Part 3280.

IMPORTANT INFORMA-TION ABOUT EFFICIENCYAND INDOOR AIRQUALITYCentral cooling and heating equip-ment is only as efficient as the ductsystem that carries the cooled orheated air. To maintain efficiency,comfort and good indoor air quality, itis important to have the proper bal-ance between the air being suppliedto each room and the air returning tothe cooling and heating equipment.Proper balance and sealing of theduct system improves the efficiencyof the heating and air conditioningsystem and improves the indoor airquality of the home by reducing theamount of airborne pollutants thatenter homes from spaces where theductwork and / or equipment is locat-ed. The manufacturer and the U.S.Environmental Protection Agency’sEnergy Star Program recommendthat central duct systems be checkedby a qualified contractor for properbalance and sealing.

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSING PROP-ERTY DAMAGE. FUMES ANDODORS FROMTOXIC, VOLATILEOR FLAMMABLE CHEMICALS, ASWELL AS AUTOMOBILE EXHAUSTAND CARBON MONOXIDE (CO),CAN BE DRAWN INTO THE LIVINGSPACE THROUGH LEAKINGDUCTS AND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE4).• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CAR-BON MONOXIDE FROM MIGRAT-ING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHASWATER HEATERS OR BOIL-ERS - ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENT DEPRES-SURIZATION OF THE SPACEAND POSSIBLE MIGRATION OFCOMBUSTION BYPRODUCTSINCLUDING CARBON MONOX-IDE INTO THE LIVING SPACE.

IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCEWITH THE CSAINTERNATIONAL (CSA) CERTIFICA-TION OR THESE INSTRUCTIONS,CAN RESULT IN UNSATISFACTORYOPERATION AND/OR DANGEROUSCONDI-TIONS AND ARE NOT COV-ERED BY THE UNIT WARRANTY.

IN COMPLIANCEWITH RECOG-NIZED CODES, IT IS RECOMMEND-ED THAT AN AUXILIARY DRAIN PANBE INSTALLED UNDER ALL EVAPO-RATOR COILS OR UNITS CONTAIN-ING EVAPORATOR COILS THAT ARELOCATED IN ANY AREA OF ASTRUCTUREWHERE DAMAGE TOTHE BUILDING OR BUILDING CON-TENTS MAY OCCUR AS A RESULTOF AN OVERFLOW OF THE COILDRAIN PAN OR A STOPPAGE IN THEPRIMARY CONDENSATE DRAIN PIP-ING. SEE ACCESSORIES SECTIONOF THESE INSTRUCTIONS FORAUXILIARY HORIZONTAL OVER-FLOW PAN INFORMATION (MODELRXBM).

matches what is required for thejob specification.

• Read the entire instructions beforestarting the installation.

• Some building codes require extracabinet insulation and gasketingwhen unit is installed in attic appli-cations.

• If installed in an unconditionedspace, apply caulking around thepower wires, control wires, refriger-ant tubing and condensate linewhere they enter the cabinet. Sealthe power wires on the insidewhere they exit conduit opening.Caulking is required to prevent airleakage into and condensate fromforming inside the unit, control box,and on electrical controls.

• Install the unit in such a way as toallow necessary access to thecoil/filter rack and blower/controlcompartment.

• Install the unit in a level position toensure proper condensatedrainage. Make sure unit is level inboth directions within 1/8”.

• Install the unit in accordance withany local code which may applyand the national codes. Latest edi-

RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be opened immedi-ately. If damage is found, it shouldbe noted on the delivery papers, anda damage claim filed with the lastcarrier.• After unit has been delivered tojob site, remove carton taking carenot to damage unit.

• Check the unit rating plate for unitsize, electric heat, coil, voltage,phase, etc. to be sure equipment

NOTICE

NOTICE

! WARNING

FIGURE 4MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

9

5. IMPORTANT: If installing in autility room, be sure the door iswide enough to:a. allow the largest part of the

furnace to pass; orb. allow any other appliance

(such as a water heater)to pass.

6. Install the furnace level andplumb. If it is not level, conden-sate cannot drain properly, possi-bly causing furnace to shutdown.

IMPORTANT: Do not attempt to twinthe modulating furnace. The charac-teristics of the ECM blower motorpreclude twinning applications.

LOCATION REQUIREMENTS AND CONSIDERATIONSGENERAL INFORMATION

DO NOT USE THIS FURNACEDURING CONSTRUCTION IFAIR LADEN CORROSIVE COM-POUNDS ARE PRESENT SUCHAS CHLORINE AND FLUORINE.OTHERWISE, PROVISIONSMUST BE TAKEN TO PROVIDECLEAN, UNCONTAMINATEDCOMBUSTION AND VENTILA-TION AIR TO THE FURNACE.FURNACE COMBUSTION ANDVENTILATION AIR CONTAMI-NATEDWITH THESE COM-POUNDS FORMS ACIDS DUR-ING COMBUSTIONWHICH COR-RODES THE HEAT EXCHANGERAND COMPONENT PARTS.SOME OF THESE CONTAMI-NANTS ARE FOUND IN, BUTNOT LIMITED TO, PANELING,DRYWALL, ADHESIVES,PAINTS, STAINS, VARNISHES,SEALERS, AND MASONRYCLEANING MATERIALS.

DO NOT INSTALL THIS FUR-NACE IN A MOBILE HOME!!THIS FURNACE IS NOTAPPROVED FOR INSTALLATIONIN A MOBILE HOME. DOING SOCOULD CAUSE FIRE, PROPER-TY DAMAGE, PERSONALINJURY OR DEATH.

WHENTHIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BEINSTALLED SOTHE BURNERSAND IGNITION SOURCE ARELOCATED NO LESS THAN 18INCHES ABOVE THE FLOOR.THIS IS TO REDUCE THE RISKOF IGNITING FLAMMABLEVAPORSWHICH MAYBE PRESENT IN A GARAGE.ALSO,THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOL-LOWTHESEWARNINGS CANCAUSE A FIRE OR EXPLOSION,RESULTING IN PROPERTY DAM-AGE, PERSONAL INJURY ORDEATH.1. IMPORTANT: If installing the unit

over a finished ceiling or livingarea, be certain to install an auxil-iary condensate drain pan underthe entire unit. Extend this auxil-iary drain pan under any evapora-tor coil installed with the furnaceand the open portion of the con-

densate drain assembly. See“Condensate Drain/Neutralizer”section for more details.

2. IMPORTANT: If using a coolingevaporator coil with this furnace.Be sure the air passes over theheat exchanger before passingover the cooling coil. The cooledair passing over the warm ambientair inside the heat exchangertubes can cause condensationinside the tubes resulting in corro-sion and eventual failure.

3. IMPORTANT: Install the furnacelevel. If it is not level, condensatecannot drain properly, possiblycausing furnace shut down.

NOTE: These furnaces are approvedfor installation in attics, as well asalcoves, utility rooms, closets andcrawlspaces. Make provisions to pre-vent freezing of condensate.4. IMPORTANT: If this furnace is

installed in a garage, attic or anyother unconditioned space, a self-regulating heat tape must beinstalled around the condensatetrap and along the entire length ofthe condensate drain in the uncon-ditioned space.The heat tape should meet the fol-lowing requirements:a. The heat tape must be UL listed.b. Install the heat tape per the

manufacturer’s instructions forthe entire length of drain pipe inthe unconditioned space.

c. The heat tape should be ratedat 3 or 5 watts per foot at 120V.

! WARNING

! WARNING

CAUTION!

FIGURE 4HORIZONTAL FURNACEWITH HEAT TAPE ON CONDENSATE TRAP

SUPPLYAIR

RETURNAIR

DRAINPIPE

HEATTAPE

TRAP

10

THIS FURNACE IS NOTAPPROVED OR RECOMMENDEDFOR INSTALLATION ON ITS BACK,WITH ACCESS DOORS FACINGUPWARDS, ORWITH SUPPLY AIRDISCHARGINGTOTHE RIGHTHAND SIDEWHEN FACINGTHEFRONT OF THE FURNACE.SEE FIGURES 5 AND 6 FOR PROP-ER INSTALLATION OF HORIZON-TAL MODELS.

SOME MODELS HAVE A SHIPPINGBRACKET INSTALLED TO PRO-TECT THE BLOWER ASSEMBLYDURING SHIPPING.LOCATE AND REMOVETHE SHIP-PING BRACKET FROMTHE SIDEOF THE BLOWER HOUSINGBEFORE OPERATING UNIT. SEE

FIGURE 7.THE FOLLOWING MODELSINCLUDE THE ADDITIONAL BRACK-ET (WHICH MUST BE REMOVED)ON THE BLOWER ASSEMBLY:(-)GFD/GGD/or GJD-09EZCMS(-)GFD/GGD/or GJD-10EZCMS(-)GFD/GGD/or GJD-12ERCMS

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withmodels as listed in the tables underFigures 9, 10 and 11 are certified byCSA Laboratories for the clearances tocombustible materials shown in inches.See name/rating plate and clearancelabel for specific model number andclearance information.Service clearance of at least 24 inchesis recommended in front ofall furnaces.FOR PURPOSES OF SERVICINGTHIS APPLIANCE, ACCESSIBILITYCLEARANCES,WHERE GREATER,SHOULDTAKE PRECEDENCE OVERFIRE PROTECTION CLEARANCES.

! WARNINGFURNACES MUST NOT BEINSTALLED DIRECTLY ON CARPET,TILE OR OTHER COMBUSTIBLEMATERIAL. INSTALLATION ON ACOMBUSTIBLE MATERIAL OTHERTHANWOOD FLOORING MAYRESULT IN FIRE CAUSING DAM-AGE, PERSONAL INJURY ORDEATH.(-)GGD FURNACES MAY NOT BEINSTALLED DIRECTLY TO A COM-BUSTIBLE FLOOR. A SPECIALFLOOR BASE IS REQUIRED.(-)GFD upflow furnaces and (-)GGDdownflow furnaces are designedand certified for installation oncombustible (wood only) floors.(-)GGD downflow furnaces may beinstalled on a cased evaporator coilmounted on a combustible (woodonly) floor or (for installations with-out an evaporator coil) installed ona special base for combustiblefloors mounted to a combustible(wood only) floor. The necessaryfloor base for installing a (-)GGDfurnace in the downflow configura-tion to a combustible (wood only)floor is an accessory sold throughfinished goods. Following is a listof floor base models by furnaceinput size.

(-)GGD Furnace Special Base ForBTU’s Combustible Floors60, 75 RXGC-B1790, 105 RXGC-B21120 RXGC-B24

Upflow furnaces are shipped witha bottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle. See filter sec-tion for details.

FIGURE 7REMOVING SHIPPING BRACKET

92-24379-01

CAUTION!

CAUTION!

FIGURE 6HORIZONTAL FURNACE INSTALLEDW/SUPPORT BRACKETS

GASPIPE

INTAKEVENT

ELECTRICALCONDUIT

RETURNAIR

SUPPLYAIR

EXHAUSTVENT

TRAP

11

SITE SELECTION1. Select a site in the building near

the center of the proposed, or exist-ing, duct system.

2. Give consideration to the vent sys-tem piping when selecting the fur-nace location. Vent from the fur-nace to the termination with mini-mal length and elbows.

3. Locate the furnace near the exist-ing gas piping. If running a new gasline, locate the furnace to minimizethe length and elbows in the gaspiping.

4. Locate the furnace to maintainproper clearance to combustiblesas shown in Figures 9, 10 & 11.

COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET.THE AREAAROUNDTHE FURNACE MUST BEKEPT CLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS AND LIQ-UIDS. PLACEMENT OF COM-BUSTIBLE MATERIALS ON,AGAINST OR AROUNDTHE FUR-NACE JACKET CAN CAUSE ANEXPLOSION OR FIRE RESULTING INPROPERTY DAMAGE, PERSONALINJURY OR DEATH.THE HOMEOWN-ER SHOULD BE CAUTIONEDTHATTHE FURNACE AREA MUST NOT BEUSED AS A BROOM CLOSET ORFOR ANY OTHER STORAGE PUR-POSES.

! WARNING

FIGURE 8BASE FOR COMBUSTIBLE FLOORS

12

AO39201

FIGURE 9PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS

(-)GFD

UPFLOWMODELS

NOTE:For1800

ormoreCFM

,bothside

returnsmustbeused

whennotusing

abottomreturnconfiguration.

AIRFLOW

13

!FIGURE 10DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS

IMPO

RTANT:THISFURNACEMAY

ONLY

BEINSTALLED

SOASWHEN

FACINGTHEFRONTOFTHEFUR-

NACE,SUPPLY

AIRISDIS-

CHARGED

ONTHELEFT

HAND

SIDE.

(-)GJD

NOTE:For1800

ormoreCFM

,bothside

returnsmustbeused

whennotusing

abottomreturnconfiguration.

AIRFLOW

(RET

URN)

(SUPP

LY)

14

!FIGURE 11DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS

A084901.S01JWR 7-21-99

DOWNFLOWMODELS

(Dow

nflowConfiguration)

(-)GGD

AIRFLOW

15

DUCTINGProper airflow is required for the correctoperation of this furnace.Too little airflow can cause erratic oper-ation and can damage the heatexchanger. The supply and return ductmust carry the correct amount of air forheating and cooling if summer air con-ditioning is used.Size the ducts according to acceptableindustry standards and methods. Thetotal static pressure drop of the supplyand return duct should not exceed 0.2"w.c.

NEVER ALLOWTHE PRODUCTSOF COMBUSTION FROMTHEFLUETO ENTERTHE RETURNAIR DUCTWORK ORTHE CIRCU-LATED AIR SUPPLY. ALL RETURNDUCTWORK MUST BE ADE-QUATELY SEALED ANDSECUREDTOTHE FURNACEWITH SHEET METAL SCREWS;AND JOINTS,TAPED. SECUREALL OTHER DUCT JOINTSWITHAPPROVED CONNECTIONS ANDSEAL AIRTIGHT.WHEN A FUR-NACE IS MOUNTED ON A PLAT-FORMWITH RETURNTHROUGHTHE BOTTOM, IT MUST BESEALED AIRTIGHT BETWEENTHE FURNACE ANDTHE RETURNAIR PLENUM.THE FLOOR ORPLATFORM MUST PROVIDEPHYSICAL SUPPORT OFTHEFURNACEWITHOUT SAGGING,CRACKS, OR GAPS AROUNDTHEBASE, PROVIDING A SEALBETWEENTHE SUPPORT ANDTHE BASE.

FAILURETO PREVENT PROD-UCTS OF COMBUSTION FROMBEING CIRCULATED INTOTHELIVING SPACE CAN CREATEPOTENTIALLY HAZARDOUS CON-DITIONS, INCLUDING CARBONMONOXIDE POISONINGTHATCOULD RESULT IN PERSONALINJURY OR DEATH.DO NOT, UNDER ANY CIRCUM-STANCES, CONNECT RETURN ORSUPPLY DUCTWORKTO ORFROM ANY OTHER HEAT PRO-DUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.IMPORTANT: Some high efficiency filtershave a greater than normal resistance toairflow. This can adversely affect furnaceoperation. Be sure to check airflow ifusing any filter other than the factory-pro-vided filter.

UPFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

UPFLOW FURNACE: A SOLID METALBASE PLATE MUST BE INSTALLED INTHE FURNACE BOTTOMWHEN USINGSIDE AIR RETURN. FAILURETOINSTALL A BASE PLATE COULDCAUSETHE PRODUCTS OF COMBUS-TIONTO CIRCULATE INTOTHE LIVINGSPACE AND CREATE POTENTIALLYHAZARDOUS CONDITIONS, INCLUD-ING CARBON MONOXIDE POISONINGOR DEATH.

2. Open the return air compartment.a. If using side return air, do notremove the bottom base.

b. Cut an opening in the side .The opening should be cut thefull width of the knockouts onthe unit.NOTE:When using sidereturn, return air plenums,RXGR-C17B, C21B and C24Bare available from the factory.

c. Remove the bottom base, ifusing bottom return air.Remove the panel by remov-ing the two screws attachingthe base to the front baseangle. See Figure 12.NOTE:Where the maximumairflow is 1800 CFM or more,both sides or the bottom mustbe used for return air.

3. Connect the return duct or returnair cabinet to the unit. Make theconnection air tight to prevententraining combustion gases froman adjacent fuel-burning appli-ance.

4. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas. DO NOTuse a rear air return.

5. If summer air conditioning isdesired, position the indoor coil onthe supply air side of the unit.Insure that no air can bypass thiscoil.

6. Connect the supply air plenum tothe furnace plenum opening.IMPORTANT: If a flexible ductconnector must be used, it MUSTbe rated for a minimum tempera-ture of 250°F. continuous.

! WARNING

FIGURE 12BOTTOM PANEL REMOVAL

NOTE: FILTER AND FILTER-ROD ARE SHIPPED ON TOP OF SOLID BOTTOM. REMOVE FILTERAND FILTER ROD TO ACCES SOLID BOTTOM 542201-B1

! WARNING

16

DOWNFLOW UNITS1. Position the unit to minimize longruns of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning is desired,position the indoor coil on the supplyair side of the unit. Insure that no aircan bypass this coil.

3. If installing on a combustible floorand not using an air conditioningplenum, install the special base forcombustible floors. See Figure 8.

THE DOWNFLOW FURNACE DESIGNIS CERTIFIED FOR INSTALLATIONON A NON-COMBUSTIBLE FLOOR.USE THE SPECIAL BASE SPECIFIEDON THE FURNACE CLEARANCELABEL. FAILURE TO INSTALL THESPECIAL BASE MAY RESULT INFIRE, PROPERTY DAMAGE, PER-SONAL INJURY OR DEATH. THISSPECIAL BASE IS SHIPPED FROMTHE FACTORY AS AN ACCESSORY.4. Connect the furnace to the supplyair plenum.

5. Connect the return air ducting tothe return air opening at the top ofthe unit. Make the connection airtight to prevent entraining combus-tion gases from an adjacent fuel-burning appliance.

6. Be sure to have adequate spacefor the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

HORIZONTAL UNITS((-)GJD MODELS)IMPORTANT: This furnace may only beinstalled so as when facing the front ofthe furnace, supply air is discharged onthe left hand side.1. Position the unit to minimize longruns or runs with many turns andelbows.

2. If summer air conditioning isdesired, position the indoor coil onthe supply air side of the unit. Insurethat no air can bypass this coil.

3. Connect the furnace to the supplyair plenum.

! WARNING

4. Connect the return air ducting to thereturn air opening at the right end ofthe unit. Make the connection airtight to prevent entraining combus-tion gases from an adjacent fuel-burning appliance.

5. Be sure to have adequate spacefor the unit filter.NOTE: DO NOT take return air frombathrooms, kitchens, furnace rooms,garages, utility or laundry rooms, orcold areas.

! Return air can come from : (1) out-side the building, (2) from return air

ducting from several inside rooms, or(3) a combination of the two. Whenusing outside air, design and adjustthe system to maintain a return airtemperature above 55°F during theheating season. If return air comesfrom both inside and outside thebuilding, design the ducting systemwith a diverting damper so that thevolume of return air entering the fur-nace equals that which would nor-mally enter through the return airintake of the furnace. Any duct open-ing pulling return air from the outsidemust not be any higher nor closerthan 10 feet to the furnace exhaustvent.

17

SUPPLY AIR SENSOREach furnace comes shipped from thefactory with a supply air sensor. Installthe sensor, in the supply air plenumtrunk, with two, field supplied, #8 sheetmetal screws, using the following guide-lines:1. 12” downstream of the evaporator

coil, if installed.2. If no evaporator coil is used, locate

the sensor out of direct line-of-siteof the heat exchanger and not clos-er than 18” downstream of the fur-nace outlet.

3. Attach the supply air sensor wiresonto the terminals marked “SASensor” on the integrated furnacecontrol board (See Figure 13).

4. Do not extend the supply-air sensorwire.NOTE: Improper placement of thesupply air sensor can adverselyaffect furnace temperature rise.

NOTE: In downflow circumstanceswhere building construction does notallow for the placement of the sensor tofall within these parameters, the supplyair sensor should not be connected.This means that the furnace will rununder default parameters. When run-ning under default parameters, the “82”code will appear for 90 seconds. Afterthat, the fault code will be stored in thecontrol board’s memory and will showonly upon power cycling. Default airflowparameters can be manually adjusted.See section discussing IntegratedFurnace Control (IFC) board in thismanual.

FIGURE 13SUPPLY AIR SENSOR TERMINALS

18

GENERAL INFORMATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SEC-TION. FAILURE TO PROPERLYVENT THIS FURNACE OR PRO-TECT IT FROM INADEQUATECOMBUSTION AIR CAN CAUSECARBON MONOXIDE POISON-ING, AN EXPLOSION OR FIRE,RESULTING IN PROPERTY DAM-AGE, PERSONAL INJURY ORDEATH.

OVER TEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the burner compartment toprotect against over temperature condi-tions. If a switch is tripped, it must bemanually reset.

DO NOT JUMPER OVERTEM-PERATURE OR ANY OTHERSAFETY SWITCHES! IF ONE OFTHESE OVER TEMPERATURESWITCHES SHOULD TRIP, CALLA QUALIFIED INSTALLER, SER-VICE AGENCY OR THE GASSUPPLIER. DO NOT RESET THESWITCHESWITHOUT TAKINGCORRECTIVE ACTION. FAILURETO DO SO CAN RESULT IN CAR-BON MONOXIDE POISONING ORDEATH. IF THIS UNIT ISINSTALLED IN A CLOSET, THEDOOR MUST BE CLOSEDWHENMAKING THIS CHECK.REPLACE THE OVER TEMPERA-TURE SAFETY SWITCHES ONLYWITH THE IDENTICAL REPLACE-MENT PART.

IN CANADA, PRODUCTS CERTI-FIED FOR INSTALLATION ANDINTENDED TO BE VENTEDWITHPLASTIC VENT SYSTEMS (PVC,CPVC) MUST USE VENT SYS-TEMS THAT ARE CERTIFIED TOTHE STANDARD FOR TYPE BHGAS VENTING SYSTEMS, ULCS636.

THE COMPONENTS OF THECERTIFIED MATERIAL MUSTNOT BE INTERCHANGEDWITHOTHER VENT SYSTEMS ORUNLISTED PIPE/FITTINGS.PLASTIC COMPONENTS ANDSPECIFIED PRIMERS ANDGLUES OF THE CERTIFIED SYS-TEM MUST BE FROM A SINGLESYSTEM MANUFACTURER ANDNOT INTERMIXEDWITH OTHERSYSTEM MANUFACTURER’SPARTS.NOTE: INLET AIR PIPING IS NOTCONSIDEREDTO BE A PART OFTHE “VENTING SYSTEM”.THEREQUIREMENTTHATVENT MATE-RIAL BE CERTIFIEDTO ULC S636DOES NOT APPLYTO INLET AIRPIPING.

INSTALLATIONWITHPRE-EXISTING VENTSYSTEMSWhen the installation of this furnacereplaces an existing furnace that isremoved from a vent system servingother appliances (such as a waterheater), the existing vent system is likelyto be too large to properly vent theremaining attached appliances.Follow the steps below with each appli-ance remaining connected to the origi-nal common vent system. Place theappliance to be tested in operation,while the other appliances remainingconnected to the common vent systemare not in operation. Test the operationof each appliance individually by the fol-lowing method.1. Permanently seal any unused

openings in the common ventingsystem.

2. Visually inspect the venting systemfor proper size and horizontal pitchand determine that there is noblockage, restriction, leakage, cor-rosion or other deficiencies whichcould cause an unsafe condition.

3. If practical, close all building doors,windows and all doors between thespace where the appliancesremaining connected to the com-mon venting system are located.Turn on clothes dryers and anyappliance not connected to the

common venting system. Turnon any exhaust fans, such asrange hoods and bathroomexhausts, so they will operate atmaximum speed. Do not operatea summer exhaust fan. Closefireplace dampers.

4. Follow the lighting instructions.Place the appliance beinginspected into operation. Adjustthe thermostat so the appliancewill operate continuously.

5. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigaror pipe.

6. After it has been determined thateach appliance that remains con-nected to the common ventingsystem properly vents (whentested as outlined above), returndoors, windows, exhaust fans,fireplace dampers and any othergas-burning appliance to theirprevious conditions of use.

7. If improper venting is observedduring any of the above tests,resize the common venting sys-tem. Refer to latest edition of theNational Fuel Gas Code ANSIZ223.1, or the CSA-GAMA vent-ing tables for Category I fur-naces.NOTE: Schedule 40 ABS-DWVpipe and fittings may be used asan alternate to PVC pipe for thecombustion air inlet and ventpipes.NOTE: Cellular core PVC is alsoapproved for use. It must beschedule 40 PVC-DWV cellularpipe manufactured under ASTMF-891.

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING

! WARNING

19

3. Apply a thin coat of cementevenly in the socket. Quicklyapply a heavy coat of cement tothe pipe end and insert pipe intofitting with a slight twisting move-ment until it bottoms out.NOTE: Cement must be fluid; ifnot, recoat.

4. Hold the pipe in the fitting for 30seconds to prevent the taperedsocket from pushing the pipe outof the fitting.

5. Wipe all excess cement from thejoint with a rag. Allow 15 minutesbefore handling. Cure time variesaccording to fit, temperature andhumidity.NOTE: Stir the solvent cementfrequently while using. Use anatural bristle, one inch widebrush or the applicator suppliedwith the can.

IMPORTANT: For Proper InstallationDO NOT use solvent cement that hasbecome curdled, lumpy or thickened.DO NOT thin. Observe shelf precau-tions printed on containers. For appli-cation below 32°F, use only low-tem-perature-type solvent cement.For correct installation of the ventpipe, follow the instructions providedby the manufacturers of the pipe,primer and solvent.

JOINING PIPE ANDFITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLY FLAM-MABLE. PROVIDE ADEQUATEVENTILATION AND DO NOTASSEMBLE COMPONENTSNEAR HEAT SOURCE OR ANOPEN FLAME. DO NOTSMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALL CAU-TIONS ANDWARNINGS PRINT-ED ON MATERIAL CONTAIN-ERS. FAILURE TO FOLLOWTHESE GUIDELINES MAYRESULT IN FIRE, EXPLOSIONOR ASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures must conformto American National StandardInstitute and American Society forTesting and Materials (ANSI/ASTM)standards as shown below:

IMPORTANT: The plastic combustionair and venting components are MADEof PVC. If using ABS piping, ensure thatthe solvent cement is compatible forjoining PVC to ABS components or usea mechanical connection that can with-stand the vent temperatures and is cor-rosion resistant.

CEMENTING JOINTSProperly seal all joints in the PVC ventusing the following materials and proce-dures:PVC CLEANER-PRIMER ANDPVC MEDIUM-BODY SOLVENTCEMENTIMPORTANT: After cutting pipe, removeall ragged edges and burrs. This isimportant to prevent increase in pres-sure drop throughout the system.1. Cut pipe end square. Chamfer edge

of pipe. Clean fitting socket andpipe joint area of all dirt, grease andmoisture.

2. After checking pipe and socket forproper fit, wipe socket and pipe withcleaner-primer. Applya liberal coat of primer to inside sur-face of socket and outside of pipe.READ INSTRUCTIONS INCLUDEDWITH THE PRIMER FOR PROPERINSTALLATION.

! WARNING

PIPE & FITTING MATERIAL ASTMSPECIFICATION

Schedule 40 PVC (Pipe) D1785Schedule 40 PVC (Cellular Core Pipe) F891Schedule 40 PVC (Fittings) D2466SDR-21PVC (Pipe) D2241SDR-26 PVC (Pipe) D2241Schedule 40 ABS Cellular Core DWV (Pipe) F628Schedule 40 ABS (Pipe) D1527Schedule 40 ABS (Fittings) D2468ABS-DWV (Drain Waste & Vent)(Pipe & Fittings) D2661

PVC-DWV (Drain Waste & Vent)(Pipe & Fittings) D2665

20

COMBUSTION AIR

ALWAYS PROVIDE THIS FUR-NACE AND ANY OTHER FUELBURNING APPLIANCEWITHENOUGH FRESH AIR FORPROPER COMBUSTION ANDVENTILATION OF THE FLUEGASES. MOST BUILDINGCODES REQUIRE THAT OUT-SIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAIL-URE TO DO SO CAN CAUSEDEATH FROM CARBONMONOXIDE POISONING.Provide adequate facilities for com-bustion and ventilation air in accor-dance with section 5.3, Air forCombustion and Ventilation of theNational Fuel Gas Code, ANSIZ223.1 - latest edition; CAN/CGAB149.1 and .2, or applicable provi-sions of the local building codes.These combustion and ventilationfacilities must not be obstructed.IMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any furnacefailure due to corrosive elements inthe atmosphere is excluded fromwarranty coverage.

The following types of installation (butnot limited to the following) REQUIREOUTDOOR AIR for combustion, dueto chemical exposures:• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundryrooms

• Furnaces in hobby or craft rooms• Furnaces installed near chemicalstorage areas.

Exposure to the following substancesin the combustion air supply (but notlimited to the following) alsoREQUIRE OUTDOOR AIR for com-bustion:• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming poolchemicals

• Water softening chemicals• De-icing salts or chemicals• Carbon Tetrachloride• Halogen type refrigerants• Cleaning solvents (such as per-chloroethylene)

• Printing inks, paint removers,varnishes, etc.

• Hydrochloric acid• Cements and glues• Anti-static fabric softeners forclothes dryers

• Masonry acid washing materialsCombustion air must be free of acidforming chemicals such as sulphur,fluorine, and chlorine. These ele-ments are found in aerosol sprays,detergents, bleaches, cleaning sol-vents, air fresheners, paint and var-nish removers, refrigerants and manyother commercial and householdproducts. Vapors from these productswhen burned in a gas flame form acidcompounds. The acid compoundsincrease the dew point temperatureof the flue products and producehighly corrosive condensate.

TABLE 1UNCONFINED SPACE DIMENSIONS

ALL FURNACE INSTALLATIONSMUST COMPLYWITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDE ADE-QUATE COMBUSTION AND VENTI-LATION AIR FOR THE FURNACE.FAILURE TO DO SO CAN RESULTIN EXPLOSION, FIRE, PROPERTYDAMAGE, CARBON MONOXIDEPOISONING, PERSONAL INJURYOR DEATH.Combustion air requirements aredetermined by whether the furnaceis in an open (unconfined) area or ina confined space such as a closet orsmall room.

FURNACE LOCATED IN ANUNCONFINED SPACEUsing indoor air for combustion.An unconfined space must have atleast 50 cubic feet for each 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. Thesizes are based on 8 foot ceilings.See Table 1.

If the open space containing the fur-nace is in a building constructed toseverely limit outside air infiltration(contemporary energy efficient con-struction methods), outside air maystill be required for the furnace tooperate and vent properly. Outsideair openings should be sized thesame as for a confined space.

BTUH Minimum Sq. Feet Typical Room SizeInput With 8 foot Ceiling60,000 375 15' x 25' OR 19' x 20'75,000 469 15' x 32' OR 20' x 24'90,000 563 20' x 28' OR 24' x 24'105,000 657 20' x 33' OR 26' x 25'120,000 750 25' x 30' OR 24' x 32'

! WARNING

! WARNING

NON-DIRECTVENT PIPE INSTALLATION(FORVERTICALTERMINATIONS ONLY)

21

FURNACE LOCATED IN ACONFINED SPACE.A confined space (any space small-er than shown before as “uncon-fined”) must have openings intothe space, which are located inaccordance with the require-ments set forth in the followingsubsections A and B. The open-ings must be sized by how theyconnect to the heated area or to theoutside, and by the input of allappliances in the space.If the confined space is within abuilding with tight construction,combustion air must be taken fromoutdoors or areas freely communi-cating with the outdoors.

FIGURE 14AIR FROM HEATED SPACE

A. USING INDOOR AIR FORCOMBUSTION

IMPORTANT: DO NOT take air froma heated space with a fireplace,exhaust fan or other device that mayproduce a negative pressure.

If combustion air is taken from theheated area (see Figure 14), theopenings must each have at least100 square inches of free area.Each opening must have at leastone square inch of free area foreach 1,000 BTUH of total input inthe space. See Table 2.

TABLE 2INDOOR AIR OPENING DIMENSIONS

BTUH Free AreaInput Each Opening60,000 100 square inches

75,000 100 square inches




B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: Do not take air froman attic space that is equipped withpower ventilation.

The confined space must communi-cate with the outdoors in accordancewith Methods 1 or 2. The minimumdimension of air openings shall notbe less than 3 inches. Where ductsare used, they shall be of the samecross-sectional area as the free areaof the openings to which they con-nect.

Method 1Two permanent openings, one locat-ed within 12 inches of the top andone located within 12 inches of thebottom of the enclosure, shall be pro-vided. The openings shall communi-cate directly, or by ducts, with the out-doors or spaces (crawl or attic) thatfreely communicate with the out-doors.

a. Where directly communicatingwith the outdoors or where com-municating to the outdoorsthrough vertical ducts as shown inFigure 15, each opening shallhave a minimum free area of 1square inch for each 4000 BTUHof total appliance input rating inthe enclosure. See Table 3.

BTUH Free Area Round PipeInput Each Opening Size60,000 15.00 square inches 5"

75,000 18.75 square inches 5"




AO77501

TABLE 3VERTICAL OUTDOOR AIR OPENINGDIMENSIONS

22

b. Where communicating with out-doors through horizontal ducts,each opening shall have a minimumfree area of 1 square inch for each2000 BTUH of total input rating ofall equipment in the enclosure. SeeTable 4 and Figure 16.

Method 2One permanent opening, locatedwithin 12 inches of the top of theenclosure, shall be permitted wherethe equipment has clearances of atleast 1 inch from the sides and backand 6 inches from the front of theappliance. The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors, andshall have a minimum free area of:

a. One square inch for each 3000BTUH of the total input rating ofall equipment located in theenclosure (see Table 5), and

b. Not less than the sum of theareas of all vent connectors in theconfined space.

If the unit is installed where there isan exhaust fan, sufficient ventilationmust be provided to prevent theexhaust fan from creating a negativepressure.

FIGURE 15AIR FROM ATTIC/CRAWL SPACE

FIGURE 16OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

TABLE 4HORIZONTAL OUTDOOR AIROPENING DIMENSIONS

BTUH Free Area Round PipeInput Each Opening Size60,000 30.00 square inches 7"





TABLE 5VERTICAL OR HORIZONTALOUTDOOR AIR OPENING DIMENSIONS

Combustion air openings must not berestricted in any manner.CONSULT LOCAL CODES FOR SPE-CIAL REQUIREMENTS.

A077601

A077701

BTUH Free Area Round PipeInput Each Opening Size60,000 20.00 square inches 6"75,000 25.00 square inches 6"90,000 30.00 square inches 7"105,000 35.00 square inches 7"120,000 40.00 square inches 8"

23

INSTALLATION GUIDELINESIMPORTANT: When installed as a non-direct furnace, only vertical terminationsare allowed. Do not use horizontal termi-nations when the furnace is installed witha non-direct vent.All exhaust vent piping must be installedin compliance with Part 7, Venting ofEquipment, of the latest edition of theNational Fuel Gas Code NFPA 54/ANSIA223.1, or CAN/CGA-B149.1 and .2,local codes or ordinances and theseinstructions.

VENTING GUIDELINES - Non-DirectVent1. IMPORTANT: Do not common ventwith any other appliance. Do notinstall in the same chase or chim-ney with a metal or high tempera-ture plastic pipe from another gas orfuel-burning appliance unless therequired minimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

2. Use only medium or long radiussweep elbows, such as PVC-DWVelbows.NOTE: For upflow and downflowinstallations, extend the exhaustpipe a minimum of 18" verticallyabove the furnace cabinet beforeturning the vent.

3. Vertical vent piping is preferred.4. Install all horizontal piping as fol-lows:• Slope horizontal vent pipingupward a minimum of 1/4" perfoot of run so that condensatedrains toward the furnace.

• Support horizontal vent piping atleast every four feet. No sags ordips are permitted.

5. Insulate all vent runs throughunconditioned spaces where below-freezing temperatures are expected,with 1" thick medium density, foilfaced fiber glass or equivalentRubatex/Armaflex insulation. Forhorizontal runs where water maycollect and freeze, wrap the ventpipe with self-regulating, 3 or 5 Wattheat tape. The heat tape must beU.L. listed and installed per themanufacturer’s instructions.

6. All piping between the furnace andthe roof penetration is 2" or 3" asspecified in Table 6. Table 6 lists themaximum allowable exhaust ventpipe length for the number ofelbows used, based on the furnacesize.IMPORTANT: Use Only standardvertical terminations when installingthe modulating furnace as a non-direct vent appliance.

7. The minimum vent length is 5 feet.8. All piping through the roof is 2".When using 3" pipe, reduce to2" within 18" of the inside of theroof.

9. Vertical through-the-roof installa-tions do not require any specialvent termination. Use 2" PVCpipe extending a minimum of 12

inches above the anticipatedlevel of snow accumulation.

10. Elbows must be a minimum of15” apart.

11. No screens may be used tocover combustion air orexhaust.

➤ TABLE 6NON-DIRECT VENT APPLICATIONSMAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE

UPFLOW FURNACES (-)GFD

FURNACEINPUT

PIPESIZE

TERMINATION(VERTICAL VENTTERMINATIONS

ONLY)

NUMBER OF ELBOWS22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1 - 2 3 - 4 5 - 6

60,0002"

3"

40'

120'

35'

120'

30'

120'

STANDARD

STANDARD

75,0002"

3"

20'

120'

15'

120'

10'

120'

STANDARD

STANDARD

90,000

105,000

3"

3"

110'

110'

105'

105'

95'

95'

STANDARD

STANDARD

120,000 3" 45' 35' 30'STANDARD

75,0002"

3"

20'

120'

15'

120'

10'

120'

STANDARD

STANDARD

90,000

105,000

3"

3"

90'

45'

80'

40'

75'

35'

STANDARD

STANDARD

120,000 3" 40' 35' 30'STANDARD

DOWNFLOW AND HORIZONTAL FURNACES (-)GGD & (-)GJD

FURNACEINPUT

PIPESIZE

TERMINATION(VERTICAL VENTTERMINATIONS

ONLY)

NUMBER OF ELBOWS22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1 - 2 3 - 4 5 - 6

60,0002"

3"

30'

120'

25'

120'

20'

120'

STANDARD

STANDARD

NOTES:1. N.R. - NOT RECOMMENDED.2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.

MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. CONCENTRIC TERMINATION NO. RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.5. USE KITS RXGY-D02 OR D02A (2") OR RXGY-D03 OR D03A (3") FOR STANDARD OR ALTERNATE

THRU-THE-WALL VENTING.6. USE KITS RXGY-D04 OR D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.* A = 171⁄2” CABINET WIDTHB = 21” CABINET WIDTH

24

DIRECTVENT PIPE INSTALLATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SEC-TION. FAILURE TO PROPERLYVENT THIS FURNACE CANCAUSE CARBON MONOXIDEPOISONING OR AN EXPLOSIONOR FIRE, RESULTING IN PROP-ERTY DAMAGE, PERSONALINJURY OR DEATH.Direct vent installations require a dedi-cated combustion air and venting sys-tem. All air for combustion is takenfrom outside and all combustion prod-ucts are discharged to the outdoors.Therefore, no ventilation or combus-tion air openings are required.

INSTALLATIONGUIDELINESAll exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA 54, 90Aand 90B ANSI Z223.1-, local codes orordinances and these instructions.1. IMPORTANT: Do not commonvent with any other appliance. Donot install in the same chase orchimney with a metal or high tem-perature plastic pipe from anothergas or fuel-burning applianceunless the required minimumclearances to combustibles aremaintained between the approvedPVC pipe and other pipes.

2. Use only medium or long radiussweep elbows.NOTE: For all installations. Extendthe combustion air exhaust pipe aminimum of 18" vertically abovethe furnace cabinet before turningthe vent.

3. Vertical piping is preferred.4. Install all horizontal piping as fol-lows:• Slope horizontal vent pipingupward a minimum of 1/4" per footof run so that condensate drainstoward the furnace.• Support horizontal vent piping atleast every four feet. No sags ordips are permitted.

! WARNING

Standard RXGY-D02/RXGY-D02A/RXGY-G02

2” Concentric RXGY-E03A, RXGY-G0240 35 30

60,000Alternate RXGY-D02, RXGY-D02A 30 25 20

Standard RXGY-D03/RXGY-D03A,RXGY-G02120 120 120

3” Concentric RXGY-E03A, RXGY-G02

Alternate RXGY-D03, RXGY-D03A 110 105 100

2” Standard RXGY-D02, RXGY-D02A, RXGY-G02 20 15 10

Standard RXGY-D03/RXGY-D03A120 120 12075,000

3” Concentric RXGY-E03A/RXGY-G02


Standard RXGY-D03, RXGY-D03A, RXGY-G02110 105 95

90,000 3” Concentric RXGY-E03A/RXGY-G02



105,000 3” Concentric RXGY-E03A, RXGY-G02



120,000 3”Concentric RXGY-E03A, RXGY-G02

Alternate RXGY-D03, RXGY-D03A 20 N/A N/A


DOWNFLOW (-)GGD AND HORIZONTAL (-)GJD FURNACES

FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS22.5, 45 or 90 Degrees

Medium / Long Radius ONLY

TABLE 7DIRECT VENT APPLICATIONS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE

FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS22.5, 45 or 90 Degrees

Medium / Long Radius ONLY

NOTES:1. N.R. - NOT RECOMMENDED2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3. A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALLVENTING.

5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATETHRU-THE-WALL VENTING.

6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.(A*) = 171⁄2” CABINET(B*) = 21” CABINET**ALTERNATE VENT NOT PERMITTED ON DOWNFLOW/HORIZONTAL MODELS.

2”Standard RXGY-D02, RXGY-D02A, RXGY-G02 30 25 20

Concentric RXGY-E03A, RXGY-G02 30 25 2060,000

3”Standard RXGY-D03, RXGY-D03A, RXGY-G02 120 120 120

Concentric RXGY-E03A, RXGY-G02 120 120 120

Standard RXGY-D02, RXGY-D02A, RXGY-G02 20 15 10

75,000

2”Concentric RXGY-E03A, RXGY-G02 20 15 10

Standard RXGY-D03, RXGY-D03A, RXGY-G02 120 120 1203”


90,000 3”Standard RXGY-D03, RXGY-D03A, RXGY-G02 70 60 55





Concentric RXGY-E03A/RXGY-G02 40 35 30

25

FIGURE 17STANDARD VERTICAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

10. Elbows must be a minimum of 15”apart.

11. No screens may be used to covercombustion air or exhaust.

VERTICAL TERMINATIONSSTANDARD VERTICAL TERMINA-TIONS (See Figure 16)Combustion Air Piping: Use two medi-um-radius sweep elbows to keep theinlet downward and prevent the entry ofrain. The inlet opening of the com-bustion air termination must be aminimum of 12" above the anticipat-ed level of snow accumulation.Exhaust Vent Piping: The exhaust ventmust terminate at least 12 inchesabove the combustion air terminationinlet. The 2" vent pipe used to pene-trate the roof must be reduced to 1 1/2"PVC for the last 12" for the 60,000 and75,000 BTUH furnace models. Noreduction of the 2" pipe is necessary forthe 90,000 through 120,000 BTUHmodels. The maximum length of theexposed vent pipe above the roof is30".

ST-A0407-00

5. Insulate all vent runs throughunconditioned spaces wherebelow-freezing temperatures areexpected with 1" thick mediumdensity, foil faced fiber glass orequivalent Rubatex/Armaflex insu-lation. For horizontal runs wherewater may collect, wrap the ventpipe with self-regulating, 3 or 5Watt heat tape. The heat tapemust be U.L. listed and installedper the manufacturer’s instruc-tions.

6. All piping between the furnaceand the roof or outside wall pene-tration is 2" or 3" as specified inTable 7. Table 7 lists the maxi-mum allowable length for theexhaust vent pipe and intake airpipe for the number of elbowsused, based on the type of termi-nation and furnace size.

7. The minimum vent length is 5feet.

8. All piping through the roof or out-side wall is 2". When using 3"pipe, reduce to 2" within 18" ofthe inside of the roof or outsidewall (except 120,000 BTUHmodel using the RXGY-D04 orD04A Horizontal Vent Kit).

9. Terminate the vent using one ofthe following termination options.

NOTES:

1 THE COMBUSTION AIR PIPEMUST TERMINATE IN THESAME PRESSURE ZONE ASTHE EXHAUST PIPE.

2 INCREASE THE 12-IN. MINIMUMTO KEEP TERMINAL OPENING ABOVEANTICIPATED LEVEL OF SNOW ACCU-MULATIONWHERE APPLICABLE.

3 WHEN 3-IN. DIAM. PIPE IS USED,REDUCETO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUM OF18 IN. OF 2-IN. PIPE MAY BE USEDBEFORE PASSING THROUGH ROOF.

4 SUPPORT VERTICAL PIPE EVERY 6FEET.

5 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHESWITH 2” PVCPIPE ON 90,000 AND 120,000 BTUHMODELS. REDUCE ANDTERMINATETHE LAST 12 INCHESWITH 11/2” PVCPIPE ON 60,000 THROUGH 75,000 BTUHMODELS.SEE DETAIL A.

4

1

2

3

5

5

5

5

12”

DETAIL A

EXHAUSTTERMINATION

26

FIGURE 18CONCENTRIC VENT KIT NO. RXGY-E03A(DIRECT VENT INSTALLATIONS)

HORIZONTAL INSTALLATION

VERTICAL INSTALLATION

1" MAXIMUM

FIELD-SUPPLIEDSTRAP

NOTE: AIR INTAKE NOTORIENTATION SENSITIVE.

ITEM No. DESCRIPTION1 2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG2 4" PVC PIPE SCHEDULE 40 -- 24" LONG3 3" x 3" x 4" SPECIAL CONCENTRIC FITTING4 3" x 45° STREET ELBOW (FIELD SUPPLIED)5 PVC RAINCAP

CONCENTRIC TERMINATIONSCONCENTRIC VENT KITNO. RXGY-E03A (SEE FIGURE 18)This kit is for vertical and horizontalintake air/vent runs. One5-in. diameter hole is required forinstallation. See Figure 18 for the gen-eral layout. Complete installationinstructions are included with the kit.

MAINTAIN 12 IN.MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOWLEVEL. MAXIMUM OF24 IN. ABOVE ROOF.

A

A

A NOTE: Drain tee is not needed for the inlet pipe.

NOTE: The following IPEX brand con-centric terminations (System 636) maybe purchased in the field and used inplace of factory supplied kits:3” Concentric Kit – Item # 196006

27

INSTALLATION – RXGY-G02 Side Wall Vent This termination for horizontal venting only. This termination for direct vent application only. Important: Do no install on the prevailing winter wind side of the structure

NOTE: Install the vent and air intake piping into the vent plate openings. Seal all gaps between the pipes and wall. Be Sure To Use Silicone Sealant to seal the vent pipe to the vent cap to permit field disassembly for annual inspection and cleaning. Also seal all pipe penetrations in wall. To prevent possibility of condensate freeze-up or recirculation, do not install vent kits one above the other.

For 90000 thru 120000 BTUH models- reduce to a length between 12 inches and 30 inches of 2 inch pipe. For 60000 thru 75000 BTUH models- when 3 inch pipe is used: reduce last 30 inches to 18 inches of 2 inch pipe and 12 inches of 1-1/2 inch pipe to maintain velocity. Note: Vent should protrude a maximum of 2-1/4” beyond vent plate. Air intake should protrude a maximum of 1inch beyond vent plate.

Seal all wall cavities

? ?? ? ? ?

ST-A1075

EXHAUST

AIR INTAKE

Note: Multi-venting-No common venting.

FIGURE 19VENT KIT INSTALLATION OPTIONS

FIGURE 20TYPICAL INSTALLATION

28

HORIZONTAL TERMINATIONS

STANDARD HORIZONTAL TERMINA-TIONS (SEE FIGURE 21)

NOTE: All furnaces with horizontal airintakes (except those using horizontalconcentric vent kit RXGY-E03A) musthave a drain tee assembly and trapinstalled in the combustion air pipe asclose to the furnace as possible. This isto drain any water that may enter thecombustion air pipe to prevent it fromentering the furnace vestibule area.These parts are included in horizontalvent kits RXGY-D02, RXGY-D03 andRXGY-D04.

NOTE: The combustion air and exhaustterminations must be at least 12 inchesabove grade or anticipated snow levels.Use alternate horizontal terminationswhen termination locations are limitedand higher snow levels are anticipated.

NOTE: Ensure the location of the com-bustion air inlet with respect to theexhaust vent terminal complies withFigure 21, detail C.

Combustion Air Piping: Use a 2" PVCcoupling with a wind deflector vane (pro-vided) installed as follows:

1. Install a 2" coupling to the combus-tion air pipe at the outside wall toprevent the termination from beingpushed inward.

2. Cut a 2 1/4" length of 2" PVC pipeand connect this to the coupling.

3. Connect another 2" coupling to theend of the 2 1/4" length of pipe.Terminate this outer coupling 4inches from the wall.

4. Attach the vane in the final 2" cou-pling in the vertical position withPVC cement.

IMPORTANT: To insure proper fur-nace operation, install the vane in thevertical position as shown in Figure21, Detail B. Failure to install the vaneproperly can result in nuisance trip-ping of the pressure switch.

Exhaust Vent Piping:60,000 and 75,000 BTUH models:Install a 2" to 1 1/2" reducer cou-pling at the outside wall to preventthe termination from being pushedinward. Reduce the 2" vent pipeused to penetrate the wall to 1 1/2"PVC for the last 12" of the run.Terminate the 1 1/2" PVC exhaustvent at least 12 inches from the out-side wall.

90,000 through 120,000 BTUHmodels: Install a 2" coupling at theoutside wall to prevent the termina-tion from being pushed inward. Noreduction of the 2" pipe used topenetrate the wall is necessary.Terminate the 2" PVC exhaust ventat least 12 inches from the outsidewall.

FIGURE 21STANDARD HORIZONTAL DIRECT VENTINGUPFLOW MODEL SHOWN(TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

ST-A0407-00

12”

4NOTES:

➀ SUPPORT HORIZONTALPIPE EVERY FOUR FEET.

➁ WHEN 3 IN. PIPE IS USED REDUCE TO2 IN. BEFORE PENETRATING OUT-SIDEWALL.

➂ 18 IN. MAXIMUM. 2 IN. DIAMETERPIPE MAY BE USED INSIDE THEWALL.

➃ DETAIL “A” - EXHAUST TERMINATIONTERMINATE THE LAST 12 INCHESWITH 2” PVC PIPE ON 90,000 AND120,000 BTUH MODELS. REDUCEANDTERMINATE THE LAST 12 INCH-ESWITH 11/2” PVC PIPE ON 60,000THROUGH 75,000 BTUH MODELS.

➄ INCREASE THE 12 IN. MINIMUMABOVE GRADE TO KEEP TERMINALOPENINGS ABOVE ANTICIPATEDLEVEL OF SNOW ACCUMULATIONWHERE APPLICABLE.

➅ DETAIL “B”, INSTALLWIND DEFLEC-TOR VANE IN 2 IN. PVC COUPLING INVERTICAL POSITION USING PVCSOLVENT.THE COMBUSTION AIR TERMINATIONMUST BE IN THE SAME PRESSUREZONE AS THE EXHAUST TERMINA-TION.

DETAIL A

EXHAUSTTERMINATION

DETAIL BCOMBUSTION AIR TERMINATION

2

DETAIL CEXHAUST/INTAKE RELATIONSHIP

1 3

5

6

NO SCREENS OR ELBOWSAT THE END OF THE PIPES

DETAIL C

29

FIGURE 22ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

60" MAX.

PIPESUPPORTSTRAP

3" MAX.NOTE: 3-1/2"MAX.WHEND04 KIT ISUSED.

EXHAUST VENT FORMODELSWITH INPUT OF60,000 AND 75,000 BTU

EXHAUST VENT21/2" PVC FOR MODELSWITH 120,000 BTUH INPUT(KIT NO. RXGY-D04)2" PVC FOR MODELSWITH INPUTS OF 90,000 THRU 120,000BTUH. REDUCETO 11/2" FOR MODELSWITH INPUTS OF 60,000AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELSWITH120,000 BTUH INPUT.2" PVC ELBOWS AND RISERMODELSWITH INPUTS OF 75,000THRU 120,000 BTUH.USE KIT NO. RXGY-D02 OR D02AWHEN 2"PIPE IS USED BETWEEN FURNACE ANDOUTSIDEWALL. USE KIT NO. RXGY-D03OR D03AWHEN 3" PIPE IS USED.

I339

12" FROMWALL

ALTERNATE HORIZONTAL TERMI-NATIONS (See Figure 22)

NOTE: This method is not permittedon modulation downflow ((-)GGD) orhorizontal ((-)GJD) furnace models.

NOTE: The combustion air andexhaust terminations must be at least12 inches above grade or anticipatedsnow levels. Alternate horizontal ter-minations allow the combustion airand exhaust terminations to be raiseda maximum of 60 inches above thewall penetrations to maintain therequired clearance.

NOTE: If combustion air vent pipe isextended more than 24 inches, insu-late the vent pipe between the twooutside 90° elbows with closed cellinsulation such as rubatex, armaflexor equivalent.

NOTE: Ensure the location of thecombustion air inlet with respect tothe exhaust vent terminal complieswith Figure 22.

Combustion Air Piping: Use a 2" PVCelbow with a wind deflector vane (pro-vided) installed as follows:

1. Install a 2" elbow to the combustionair pipe at the outside wall to preventthe termination from being pushedinward.

2. Cut an adequate length of 2" PVCpipe as needed to clear the antici-pated snow level and connect this tothe elbow.

3. Connect another 2" elbow to theend of the pipe such that the inlet isfacing away from the wall. This outercoupling must terminate 4 inchesfrom the wall.

4. Attach the vane in the final 2" elbowin the vertical position with PVCsolvent.

IMPORTANT: To insure proper fur-nace operation, the supplied vanemust be installed in the vertical posi-tion as shown in Figure 21, Detail B.

Exhaust Vent Piping:

1. Install a 2" elbow to the exhaust ventpipe at the outside wall to prevent thetermination from being pushedinward.

2. Cut an adequate length of 2" PVCpipe as needed to insure proper loca-tion of the exhaust vent terminationwith respect to the combustion airinlet and connect this to the elbow.

3. Connect another 2" elbow to the endof the pipe such that the inlet is fac-ing away from the wall.

Exhaust Vent Termination:

60,000 and 75,000 BTUH models:Reduce the 2" vent pipe used topenetrate the wall and extend theterminations to 1 1/2" PVC for thelast 12" of the run. Install a 2" to 11/2" reducer bushing in the last 2"elbow. Connect a length of 1 1/2"PVC pipe such that the exhaust ventterminates at least 12 inches fromthe outside wall. See Figure 22,Detail A.90,000 through 120,000 BTUH mod-els: No reduction of the 2" pipe usedto penetrate the wall is necessary.Terminate the 2" PVC exhaust ventat least 12 inches from the outsidewall.120,000 BTUH model with theRXGY-D04 or D04A Horizontal VentKit: Venting and terminations installthe same as above except the 2"pipe and connectors are replacedwith 2 1/2" pipe and connectors.

DETAIL A

DETAIL CEXHAUST/INTAKE RELATIONSHIP

NOTE: If combustion air vent pipe is extended morethan 24 inches, insulate the vent pipes between thetwo outside 90° elbows with closed cell insulationsuch as rubatex, armaflex, or equivalent.

30

LOCATION REQUIREMENTSHORIZONTAL DIRECTVENTS

THE COMBUSTION PRODUCTSAND MOISTURE IN THE FLUEGASESWILL CONDENSE ASTHEY LEAVE THE TERMINATION.THE CONDENSATE CAN FREEZEON THE EXTERIORWALL,UNDER THE EAVES AND ONSURROUNDING OBJECTS.SOME DISCOLORATION TO THEEXTERIOR OF THE BUILDING ISTO BE EXPECTED. HOWEVER,IMPROPER LOCATION ORINSTALLATION CAN RESULT INSTRUCTURAL OR EXTERIORFINISH DAMAGE TO THE BUILD-ING AND MAY RECIRCULATEPRODUCTS OF COMBUSTIONINTO THE COMBUSTION AIRTERMINAL AND FREEZE.NOTE: In Canada vent terminationsmust be in accordance with the currentCSA-B149 Gas Installation Code and/orlocal codes.The vent must be installed with the fol-lowing minimum clearances. SeeFigures 23 and 24.1. Locate the bottom of the vent ter-

minal and the air inlet at least 12inches above grade. Increase the12-in. minimum to keep the termi-nal openings above the level ofsnow accumulation, where applica-ble.

2. Do not terminate the vent over pub-lic walkways or over an area wherecondensate or vapor could create anuisance or hazard.

3. Locate the vent terminal at leastone foot from any opening throughwhich flue gases could enter abuilding.

4. Locate the vent terminal at least 3feet above any forced air inletlocated within 10 feet, except thecombustion air inlet of a direct ventappliance.

5. Allow the vent terminal minimumhorizontal clearance of 4 feet fromelectric meters, gas meters, regula-tors and relief equipment.

6. Locate the furnace combustion airinlet a sufficient distance from thevent of any other gas or fuel burn-ing appliance or electric clothesdryer to prevent recirculation of theflue gases into the furnace com-bustion air inlet. The only exceptionto this requirement is the case ofmultiventing two or more furnaces,which is covered in the section onmultiventing in these instructions.

In addition to the minimum clearanceslisted above, the vent location shouldbe governed by the following guide-lines.1. Do not terminate under any kind of

patio or deck. If running the ventunder a deck, insulate it to insureno condensate freezes and blocksthe pipe. The insulation must bewaterproof.For vent considerations, the edgeof the deck must be consideredthe outside wall.

2. Do not terminate behind any areathat may allow the flue products tobecome stagnant and recirculate.

3. Do not locate on the side of abuilding with prevailing winterwinds. This will help prevent mois-ture from freezing on walls andoverhangs (under eaves).

4. Do not extend vent directlythrough brick or masonry sur-faces. Use a rust-resistant sheetmetal or plastic backing platebehind vent. See Figure 17.

5. Do not locate too close to shrubsas condensate may stunt orkill them.

6. Minimum vertical clearances of 1foot are recommended for over-hangs up to 1 foot horizontal.The vertical clearance should beincreased equally for each addi-tional increase in horizontal over-hang to a maximum verticalclearance of 6 feet.

7. Caulk all cracks, seams andjoints within 6 feet horizontallyas well as 6 feet above andbelow vent. See Figure 23.

FIGURE 23MOISTURE ZONES

! CAUTION

2 FT. SQ. SHEET METAL PLATE ON BRICK ORMASONRY SURFACE RECOMMENDED, BUTNOT REQUIRED BY CODE.

31

FIGURE 24DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pane

Inst

alla

tion

Cod

eN

atio

nalF

uelG

asC

ode

Can

adia

nIn

stal

latio

nsU

SIn

stal

latio

nsC

anad

ian

Inst

alla

tions

US

Inst

alla

tions

32

FIGURE 26TWO FURNACE VENTING THROUGHWALL

FIGURE 25TWO FURNACE VENTING THROUGH ROOF

8. Painted surfaces must be soundand in good condition with nocracking, peeling, etc. Paintedsurfaces will require mainte-nance.

9. Do not expose 3" x 2" reducer/bushing to outdoor ambient tem-peratures.

MULTIVENTINGIF VENTINGTWO OR MORE FUR-NACES NEAR EACH OTHER ISREQUIRED, EACH FURNACEMUST BE INDIVIDUALLY VENTED –NO COMMON VENTING IS PERMIT-TED. See Figures 25 and 26 for posi-tioning of the terminations. Whenmore than two furnaces are to bevented, there must be at least 4 feetbetween the first two furnaces andthe third, etc.

EXHAUST VENTMODELS 06-07TO BE REDUCED TO1-1/2” PVC LAST 12”.

3” MININUM24” MAXIMUM

CONNECTINGTOFURNACEIMPORTANT: Clean and deburr allpipe cuts. The shavings must not beallowed to block the exhaust, inlet orcondensate drain pipes.IMPORTANT:When indoor combus-tion air is used, the inlet air openingat the furnace must be protectedfrom accidental blockage. On down-flow models, install a double elbow inthe top inlet air opening. See Figure29.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MINIMUM 12" ABOVE AVERAGE SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

SEE CONCENTRICVENT SECTIONON PAGE 23FOR MOREINFORMATION.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MAXIMUM 1"DISTANCE

FROM WALL

MINIMUM 12"ABOVE GRADE

6' MINIMUM10' RECOMMENDED

SEE CONCENTRIC VENT SECTIONON PAGE 23 FOR MORE INFORMATION.




33

FIGURE 27UPFLOW MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION

I515

FIGURE 28UPFLOW MODELS -- COMBUSTION AIR FITTING

➤ FIGURE 29DOWNFLOW AND HORIZONTAL MODELS -- COMBUSTION AIR AND VENT PIPECONNECTION

UPFLOW MODELSThe exhaust air pipe connection is a 2-in. female PVC pipe fitting extendingthrough the left side of the furnace topplate. See Figure 27. This opening has aprotective cap which should be removedjust prior to installing the exhaust pipe.When 2-in. pipe is used, connect itdirectly to this fitting. When 3-in. pipe isused, connect a 2 to 3-in. coupling tothis fitting with a short piece of 2-in. PVCpipe.The inlet combustion air connectionis at the right side of the top plate.An alternate combustion inlet air connec-tion may be made on the right side ofthe jacket. The alternate connectionopening has a plastic cap. A combustioninlet air connection fitting is supplied withthe furnace and it must be installed inthe furnace by screwing it into the open-ing. Make sure the rubber “O-ring” sup-plied with the furnace is used with thisfitting. See Figure 27.IMPORTANT:When using indoor com-bustion air, the furnace air opening mustbe protected from accidental blockage.Install a 2-inch 90° elbow pointing down-ward on the side or a double elbowpointing downward in the top opening.See Figure 28.

➤DOWNFLOW & HORIZONTALMODELSNOTE: Combustion air inlet and exhaustoutlet air pipes are reversed for down-flow and horizontal models from that ofupflow.The exhaust pipe connection is a 2-in.PVC pipe fitting extending through theright side of the furnace top cover. Thisopening has a protective cap whichshould be removed just prior to installingthe exhaust pipe. When 2-in. pipe isused, connect it directly to this fitting.When 3-in. pipe is used, connect with a2- to 3-in. coupling directly to the 2-in.pipe.The combustion inlet air connection is a2-in. extruded hole on the left side of thetop plate. When a 2-in. pipe is used,attach a 2-in. PVC coupling over thishole with RTV sealant and also add twosheet metal screws through the couplinginto the extrusion to secure it in place,and add the required piping. When 3-in.pipe is required, use a 2- to 3-in. cou-pling and add the required piping. SeeFigure 29.IMPORTANT: Always pre-drill holesbefore securing with screws. Using self-tapping screws without first pre-drillingcauses the PVC fitting to crack.

“O” RINGTOP PLATE

VENT CAP/PLUGEXHAUST AIR PIPE

EXHAUST TRANSITION

CONNECTOR

CONDENSATE TRAP

INDUCED DRAFTBLOWER

COMBUSTIONAIR ADAPTER

NOTE:WHEN COMBUSTION AIR INLET IS INOPTIONAL POSITION SWAP LOCATIONOF INLET AIR ADAPTER AND “O” RINGWITH PLUG.

PLUG OPT. COMBUSTIONAIR INLET POSITION

34

CONDENSATE DRAIN/OPTIONAL NEUTRALIZERFIGURE 30UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS.FREEZING OF CONDENSATE CANCAUSE PROPERTY DAMAGE.IMPORTANT: Do not connect into a com-mon drain line with an air conditionerevaporator coil drain located below thefurnace. A blocked or restricted drain linecan result in overflow of the coil pan andnegate the furnace blocked-drain shutoffcontrol.➤ IMPORTANT: If installing the unit overa finished ceiling or living area, be certainto install an auxiliary condensate drainpan under the entire unit extending outunder the condensate tee. With the mini-mum 51⁄2" riser for upflow modelsor 13⁄4" for downflow models installedabove the tee, a blocked drain will resultin overflow from the riser. if the furnace isinstalled in an attic, crawlspace or otherarea where freezing temperatures mayoccur, the furnace drain can freeze whileshut off for long periods of time.If required by local codes, install a con-densate neutralizer cartridge in the drainline. Install cartridge in horizontal positiononly. Also install an overflow line if routingto a floor drain (see Figures 30 & 31). Ifavailable, install a condensate pump thatis resistant to acidic water. Pumps areavailable from your local distributor. Ifpump used is not resistant to acidic water,a condensate neutralizer must be usedahead of the pump. The condensatepump must have an auxiliary safetyswitch to prevent operation of the furnaceand resulting overflow of condensate inthe event of pump failure. The safetyswitch must be wired through the “R” cir-cuit only (low voltage) to provide operationin either heating or cooling modes.When selecting neutralizer cartridges andcondensate pumps, use the followingdata:CONDENSATE PRODUCTION:MAX (ALL MODELS) = 1-2 gallons per hr.

pH LEVEL:3.2 - 4.5 using OUTDOOR air2.2 - 4.5 using INDOOR air(neutral pH = 7.0)

UPFLOW MODELSThe condensate drain trap is located inthe blower compartment on the left- handside of the jacket. A short piece of 1⁄2-in.PVC pipe and a 1⁄2-in. tee are provided.Connect the 1⁄2-in. pipe to the elbow onthe trap and the tee to this pipe so thatthe open end is upward. Run a drain tubefrom the bottom of the tee to a floor drainor condensate pump.IMPORTANT: If installing the unit over afinished ceiling or living area, be certainto install an auxiliary condensate drainpan under the entire unit extending outunder the condensate tee.

! CAUTION

AO51601

➤ FIGURE 31DOWNFLOW CONNECTION

A085001

NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE: SEE DOWNFLOWMODEL NOTES

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

CONDENSATE TRAP

CONDENSATE TRAP

DRAIN LINE

DRAIN LINE

TO FLOOR DRAIN OR CONDENSATE PUMP

TO FLOOR DRAIN OR CONDENSATE PUMP

NEUTRALIZER CARTRIDGE(OPTIONAL)

NEUTRALIZER CARTRIDGE(OPTIONAL)

35

FIGURE 32UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION(NO KIT REQUIRED)

IMPORTANT: There are two optionswhen choosing a height for the con-densate riser:CONDENSATE OVERFLOW:With a51⁄2 inch riser installed above the tee,a blocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To causethe furnace to shut down when ablocked drain is present, install a riserwhich is a minimum of 1013⁄16”. If thefurnace is installed in an attic, crawl-space or other area where freezingtemperatures may occur, the furnacedrain can freeze while shut off for longperiods of time.Use a solvent cement that is compati-ble with PVC material. Cut the drainhoses to the appropriate length andconnect to the trap with hose clamps.Tighten the clamps with pliers andcheck for leaks after attaching.

DOWNFLOW MODELSIMPORTANT: There are two optionswhen choosing a height for the con-densate riser:CONDENSATE OVERFLOW:With a13⁄4 inch riser installed above the tee,a blocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To causethe furnace to shut down when ablocked drain is present, install a riserwhich is a minimum of 51⁄2”. If the fur-nace is installed in an attic, crawl-space or other area where freezingtemperatures may occur, the furnacedrain can freeze while shut off for longperiods of time.Use a solvent cement that is compati-ble with PVC material.

REVERSINGTHETRAPUPFLOW MODELSThe trap may be moved to the rightside for right-side drainage. Open theknockout for the drain on the right sideof the cabinet. Remove the bracketholding the trap from the left side.Seal the left side drain hole with aplug provided in the cloth bag with thefurnace. Position the mounting bracketand trap so that the drain elbow iscentered in the hole on the right. SeeFigure 32.Drill two holes in the cabinet to mountthe bracket. Mount the trap and brack-et to the right side with the drainelbow pointing through the knockout.Connect the 1⁄2" pipe and tee as notedabove. Route the drain hoses behindthe top of the electric box, cut to theappropriate length, and connect to thetrap with hose clamps.IMPORTANT: Do not connect into acommon drain line with an air condi-tioner evaporator coil drain locatedabove the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked drain shutoff control.

RXGY-H01CONVERTING TO LEFTDRAIN FOR DOWNFLOWMODELSTo convert downflow models to left-hand drain, a kit (RXGY-H01) must beordered from the distributor. The kitincludes a 24” piece of 1⁄2” black PVCpipe, a 2-9/16” length of black hose, a2” rubber grommet, a 1-5/8” plug andinstructions. Note the location of thealternate drain hole as shown in Figure33.To convert to left side drainage, removethe long molded hose from the trap.Remove the double-elbow black mold-ed hose from the trap and exhaust tran-sition and discard. Remove the trapfrom its mounting bracket, rotate it 180degrees and mount in place with thedrainage elbow pointing to the left.Reattach the long black molded hose.Use the 2-9/16” length of black hoseincluded in the RXGY-H01 kit betweenthe trap and exhaust transition. Clamphoses tight with white nylon clamps.Remove the plug from the 2” alternatedrain hole (see Figure 33) and replace

A051701

it with the 2” rubber grommet sup-plied in the RXGY- H01 downflowalternate drain kit. Also, remove the1-5/8” grommet supplied in the prima-ry drain hole and replace it with the1-5/8” diameter plug that is also sup-plied in the RXGY-H01 downflowalternate drain kit. Both the hole-plugand grommet must be in place toinsure a good seal in the burner com-partment.A length of 1/2” black PVC pipe is alsoprovided in the RXGY-H01 downflowalternate drain kit. Glue one end ofthe pipe to the elbow in the trap. Cutthe pipe so that it extends throughthe alternate drain hole in the left sideof the cabinet one inch (see Figure33). Connect the1/2” PVC tee (sup-plied with the furnace) to the pipewith a 1-3/4” riser. Use the 1-5/8”plug supplied in the RXGY-H01downflow alternate drain kit to sealthe right side drainage hole.IMPORTANT: Do not connect into acommon drain line with an air condi-tioner evaporator coil drain locatedabove the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked-drain shutoff control.

51/2” MINIMUMHEIGHT OPEN

END

FIGURE 33DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION(REQUIRES RXGY-H01 KIT)

TEE

DRAINEXTENSION

DRAIN VENT

CONDENSATE TRAP

TO FLOORDRAIN OR

CONDENSATE PUMP

ALTERNATE DRAIN HOLELOCATED HERE ON JACKET.(REMOVE PLASTIC PLUG ANDREPLACE WITH GROMMET).

EXISTING DRAIN HOLE.PLUG WITH 15⁄8” PLUGSUPPLIED IN KIT

ROTATE TRAP 180° ANDINSTALL RIGID PIPE FROMELBOW TO OPPSOITE SIDEOF JACKET AS SHOWN

I394

36

CONDENSATE DRAINFOR HORIZONTAL((-)GJD) INSTALLATION

HORIZONTAL ((-)GJD) MODELSARE SHIPPEDWITHOUT A DRAINTRAP ATTACHED. IT MUST BEATTACHED (AS DESCRIBEDBELOW) IN THE FIELD. FAILURE TOINSTALL THE DRAIN TRAP ASDESCRIBED CAN CAUSE THE FUR-NACE TO SHUT DOWN UNEXPECT-EDLY.NOTE:The following steps shouldtake place with the furnace in thehorizontal position.Refer to Figure 36 for Steps 1-8.1. Locate the parts bag in the burner

compartment.2. Remove the red vinyl covers that

cover the vent drain and heatexchanger drain (see Figure 34).

3. Fill the trap assembly with acup of water.

4. Attach the gasket onto the trapassembly so that the gasket holeson the gasket line up with theholes on the trap assembly.

5. Insert the trap assembly with gas-ket up through the existing hole inthe jacket and secure from insidethe jacket. Use two screws pro-vided. Screw down into the two“ears” molded into either side ofthe trap. Snug the trap assemblyagainst the furnace jacket com-pressing the gasket slightly toeliminate any air leaks. Do notovertighten!

6. Attach the black molded rubber90° elbow to the straight spouton the trap top using a whitenylon clamp . Attach the otherend of the rubber elbow to thespout located on the exhausttransition using a white nylonclamp.

7. Cut 1.0 inch from the long end ofthe black molded hose . Attachthe 90° end of the hose to thecollector box. Then attach theother end of the black moldedhose to the 45° elbow molded intothe top of the trap assembly.Clamp the hose tight with whitenylon clamps.IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks after conver-sion is complete.

8. IMPORTANT: There are twooptions when choosing a heightfor the condensate riser:CONDENSATE OVERFLOW:With a 13⁄4 inch riser installedabove the tee, a blocked drain willresult in overflow from the riser.FURNACE SHUTDOWN: Tocause the furnace to shut down

when a blocked drain is present,install a riser which is a minimumof 51⁄2”. If the furnace is installedin an attic, crawlspace or otherarea where freezing temperaturesmay occur, the furnace drain canfreeze while shut off for long peri-ods of time. Provisions must bemade to prevent freezing of con-densate.Use a solvent cement that is com-patible with PVC material.

NOTE: See location requirementsand combustion section for additionalrecommendations.

FILLINGTHETRAPFILL THE TRAP ASSEMBLYWITHWATER BEFORE OPERATING THEFURNACE. Do this by removing thedrain hose from the trap or from theconnection to the secondary coil.Pour about a cup of water into thevent trap. Any excess water flows intothe house drain when the trap is full.

FIGURE 35HORIZONTAL CONDENSATE DRAIN

FIGURE 34REMOVE VINYL CAPS BEFORE INSTALLING THE DRAIN SYSTEM.

! WARNING

REMOVE THESERED VINYLCOVERS TOINSTALL THEDRAIN SYSTEM

G

H

I

J

KE

LL

37

FIGURE 36HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATIONFOR HORIZONTAL OPERATION

I534

CONDENSATETRAP CONVERSION FROM DOWNFLOWTOHORIZONTAL INSTALLATION

38

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPEDAT THE FACTORY FOR USE ONNATURAL GAS ONLY. CONVER-SION TO LP GAS REQUIRES ASPECIAL KIT AVAILABLE FROMTHE DISTRIBUTOR. FAILURE TOUSE THE PROPER CONVER-SION KIT CAN CAUSE FIRE,CARBON MONOXIDE POISON-ING, EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.See the conversion kit index sup-plied with the furnace. This indexidentifies the proper LP GasConversion Kit required for eachparticular furnace.IMPORTANT: Any additions, changesor conversions required for the furnaceto satisfactorily meet the applicationshould be made by a qualified installer,service agency or the gas supplier,using factory-specified or approvedparts.IMPORTANT: Connect this furnaceonly to gas supplied by a commercialutility.IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) are rec-ommended in all applications, and theirinstallation should be in accordancewith the manufacturer’s recommenda-tions and/or local laws, rules, regula-tions or customs.

GAS PIPINGInstall the gas piping according to alllocal codes and regulations of the utili-ty company.If possible, run a separate gas supplyline directly from the meter to the fur-nace. Consult the local gas companyfor the location of the manual mainshut-off valve. The gas line and man-ual gas valve must be adequate insize to prevent undue pressure dropand never smaller than the pipe size

! WARNING

FIGURE 37GAS PIPING -- UPFLOW INSTALLATION

STA0518-01

TOP VIEW OF GAS LINE AND VALVEIN OPTIONAL POSITION

OPTIONAL GAS LINEPOSITION

PLUG(IN NORMALPOSITION)

MANIFOLDPRESSURE TAP

MANIFOLD

GROMMET

GAS VALVEDRIP LEG

4 TO 5 FEETABOVE FLOORREQ’D BY SOMEUTILITIES.

NOTE:WHEN GAS LINE IS INOPT. POSITION, SWAP LOCA-TION OF GROMMET ANDPLUG.

MAIN GAS VALVE

IMPORTANT: Do not run a flexible gas connector inside the unit.

A087301-01-00

TOP VIEW OF GAS LINE AND VALVEIN OPTIONAL POSITION

BURNERS

GROMMET(IN NORMALPOSITION)

UNION(TYPICAL INSTALLATION)

➤ FIGURE 39GAS PIPING -- DOWNFLOW INSTALLATION

MAIN GAS VALVE

GAS VALVE

DRIP LEG

BURNERSUNIONMANIFOLD

GROMMET

MANIFOLDPRESSURE TAP

NOTE:WHEN GAS LINE IS IN OPT.POSITION, SWAP LOCATIONOF GROMMET AND PLUG.

PLUG(IN NORMALPOSITION)

GROMMET(IN NORMALPOSITION)

4 TO 5 FT.ABOVEFLOOR

REQ’D BYSOME

UTILITIES.

➤ FIGURE 38GAS PIPING -- HORIZONTAL INSTALLATION

39

GAS PRESSURENatural gas supply pressure shouldbe 5" to 10.5" w.c. LP gas supplypressure should be 11" to 13" w.c.This pressure must be maintainedwith all other gas-fired appliances inoperation.

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAMEOR ANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURETO ADHERE TO THISWARNINGCAN CAUSE A FIRE OR EXPLO-SION RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.To check for gas leakage, use anapproved chloride-free soap and watersolution, an electronic combustible gasdetector, or other approved method.

! WARNING FIGURE 40GAS VALVE

MANUAL CONTROL

to the combination gas valve on thefurnace. Refer to Table 8 for the recom-mended gas pipe size for natural gasand Table 9 for L.P. See Figures 37, 38& 39 for typical gas pipe connections.Install a ground joint union betweenthe manual gas stop and the maingas valve to easily remove the con-trol valve assembly. Install a manualgas stop in the gas line outside thefurnace cabinet. The gas stop shouldbe readily accessible to turn the gassupply on or off. Install a drip leg in thegas supply line as close to the furnaceas possible. Always use a pipe com-pound resistant to the action of liquefiedpetroleum gases on all threaded con-nections.IMPORTANT:When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve.Any strains on the gas valve canchange the position of the gas orifices inthe burners. This can cause erratic fur-nace operation.IMPORTANT: Do not run a flexible gasconnector inside the unit. If local codesallow the use of a flexible gas applianceconnector, always use a new listed con-nector. Do not use a connector whichhas previously serviced another gasappliance. Massachusetts law requiresthat all flexible gas connectors be lessthan 36”.The gas pipe grommet in the cabinetdoes not seal around a flexible gas con-nector. It is important to have allopenings in the cabinet burner com-partment sealed for proper furnaceoperation.IMPORTANT: To insure a good seal, thegas pipe that runs through the grommetmust be 1/2” schedule 40 black pipe.IMPORTANT: Ensure that the furnacegas control valve is not subjected tohigh gas line supply pressures (13.5”w.c. or above).DISCONNECT the furnace and its indi-vidual shut-off valve from the gas supplypiping during any pressure testing thatexceeds 1/2 PSIG (3.23 kPa or 13"w.c.).

GAS VALVEThis furnace has a 24-volt operatedvalve. It has ports for measuringsupply pressure and manifold pres-sure. A manual control is on thevalve body. It can be set to only the“ON” or “OFF” positions. SeeFigure 40.

40

TABLE 8NATURAL GAS PIPE CAPACITYTABLE (CU. FT./HR.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. andspecific gravity of 0.60 (natural gas).Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170

1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubicfeet per hour required for the gas input rating of the furnace. By formula:

Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas(BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

TABLE 9LP GAS PIPE CAPACITYTABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11inches water column inlet pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 633/4 567 393 315 267 237 217 196 182 173 162 146 1321 1,071 732 590 504 448 409 378 346 322 307 275 252

1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 5111-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 7872 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.

LP COPPERTUBE SIZINGTABLESizing between single or second stage (low pressure) regulator and appliance. Maximum capacity of pipe in thousands of BTUper hour of undiluted propane gases (at 11" w.c. setting).

Outside Diameter Length of Pipe, FeetCopper Tubing,Type L 10 20 30 40 50 60 80 100 125 150

3/8" 49 34 27 23 20 19 16 14 11 10

1/2" 110 76 61 52 46 42 36 32 28 26

5/8" 206 141 114 97 86 78 67 59 52 48

3/4" 348 239 192 164 146 132 113 100 89 80

7/8" 536 368 296 253 224 203 174 154 137 124

41

LP CONVERSIONIMPORTANT: LP gas from trucks usedto transport liquid-based fertilizers cancontain chemicals that will damage thefurnace. Verify that your gas supplierdoes not use the same truck to trans-port materials other than LP.This furnace is shipped from the facto-ry for use on natural gas only. For useon LP gas, a proper conversion isrequired.Conversion of this furnace for use onLP gas requires conversion kit RXGJ-FP07 for U.S. and RXGJ-FP08 forCanada. This kit includes an LP gasvalve.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE.THE BURNER ORI-FICES MAY (OR MAY NOT) NEED TOBE CHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDE INSTALLA-TIONS” OF THIS BOOK FORINSTRUCTIONS.NOTE: Order the correct LP conver-sion kit available from the local distrib-utor. Furnace conversion to LP gasmust be performed by a qualifiedinstaller, service agency, or the gassupplier.To change orifice spuds for either con-version to LP or for elevation:1. Shut off the manual gas valve and

disconnect the gas line at theunion ahead of the unit gas valve.

SUPPLY-LINEPRESSURE TAP

2. Remove the gas valve and mani-fold assembly.

3. Replace the orifice spuds.4. Remove the natural gas valve from

the manifold assembly and replacewith the LP valve included in thekit.

5. Re-attach the manifold assembly tothe unit and connect the gas line tothe gas valve.

6. Place the conversion label, includ-ed in the kit, adjacent to the CSArating plate.

FIGURE 41SUPPLY-LINE PRESSURE TAP

7. Check unit for leaks.8. Follow lighting instructions to

put the furnace into operation.9. Check manifold pressure.Consult Table 11, if there is anyquestion concerning orifice sizing.NOTE: No LP orifices are includedin the kit. LP orifices must be select-ed based on the altitude of theinstallation. See orifice chart.

CAUTION!

42

SETTING GAS PRESSUREA properly calibrated pressure gaugeor U-Tube manometer is required foraccurate gas pressure measure-ments.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDANDTHAT THE SIZE OF THEBURNER ORIFICES BE RE-CAL-CULATED BASED ON ELEVATIONAND GAS HEATING VALUE.THEBURNER ORIFICES MAY (OR MAYNOT) NEED TO BE CHANGED. SEETHE SECTION TITLED “HIGH ALTI-TUDE INSTALLATIONS” OF THISBOOK FOR INSTRUCTIONS.Supply Gas Pressure Measure-ment.1. With gas shut off to the furnace

at the manual gas valve outsidethe unit, remove the linepressure tap plug on the gasvalve. See Figure 41.

2. Connect a U-Tube manometer tothe pressure tap.

3. Turn on the gas supply andoperate the furnace at 100% andall other gas-fired units on thesame gas line as the furnace.

4. Note or adjust the supply-linepressure to give:A. 5" - 10.5" w.c. for natural gas.B. 11" - 13" w.c. for LP gas.

5. Shut off the gas at the manualgas valve and remove theU-Tube manometer.

6. Replace the supply-line pressuretap plug before turning on thegas.

7. Check unit for leaks.If the supply-line pressure is abovethese ranges, install an in-line gasregulator to the furnace for naturalgas units. With LP gas, have the LPsupplier reduce the supply-line pres-sure at the regulator.If supply-line pressure is below theseranges, either remove any restrictionsin the gas supply piping or enlargethe gas pipe. See Tables 8 and 9.

FIGURE 42MANIFOLD PRESSURE TAP LOCATION

With LP gas, have the LP supplieradjust the supply-line pressure at theregulator.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDANDTHAT THE SIZE OF THEBURNER ORIFICES BE RE-CAL-CULATED BASED ON ELEVATIONAND GAS HEATING VALUE.THEBURNER ORIFICES MAY (OR MAYNOT) NEED TO BE CHANGED. SEETHE SECTION TITLED “HIGH ALTI-TUDE INSTALLATIONS” OF THISBOOK FOR INSTRUCTIONS.

➤ MANIFOLD GAS PRESSUREMEASUREMENT.

1. With the gas to the unit shut offat the manual gas valve, removethe outlet pressure tap plug inthe gas valve. See Figure 42.

2. Connect the positive pressurehose to the pressure tap.

3. Note the manifold gas pressureto be:A. 3.5" w.c. (±.3) for naturalgas .B. 10.0" w.c. ( ±.5) for LP gas.

4. To adjust the pressure regulator,remove the regulator cap.NOTE: Only small variations ingas pressure should be made byadjusting the pressure regulator.

5. Turn the adjustment screw, usinga 3⁄32" allen wrench, clockwise toincrease pressure, or counter-clockwise to decrease pressure.See Figure 43.

6. Check manifold gas pressure.7. Repeat step 5 & 6 if needed.8. Securely replace the regulator

cap.NOTE: Shut off gas at the manu-al gas valve and remove the U-Tube manometer.

9. Replace the manifold pressuretap plug before turning onthe gas.

10. Check unit for leaks.NOTE: Do not use gas valve pres-sure adjustment as a means toadjust temperature rise. The blowermotor will change speed to maintaina reasonably constant temperaturerise.

OUTLET MANIFOLD PRESSURETAP

FIGURE 43GAS VALVE PRESSURE ADJUSTMENT (3/32" ALLENWRENCH)

REGULATOR CAP

CAUTION!CAUTION!

43

the electrical disconnect to the junctionbox on the left side of the furnace, insidethe blower compartment. See Figure 44.For the proper connection, refer to theappropriate wiring diagram located on theinside cover of the furnace control boxand in these instructions.NOTE: The electrical junction box maybe moved to the right side if necessary. Aknockout is provided. Seal the oppositehole with plug provided.IMPORTANT: L1 terminal and neutral ter-minal polarity must be observed whenmaking field connections to the furnace.The ignition control will NOT sense flameif 120 vac and neutral terminalsreversed.

Make all electrical connections inaccordance with the latest edition ofthe National Electrical CodeANSI/NFPA70 – or in Canada, theCanadian Electrical Code Part 1-CSA Standard C22.1 and local codeshaving jurisdiction.These may be obtained from:National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269Canadian Standards Association178 Rexdale BoulevardRexdale, Ontario, Canada M9W 1R3

ELECTRICALWIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANY ELECTRI-CAL CONNECTIONS. FAILURE TODO SO CAN CAUSE ELECTRICALSHOCK RESULTING IN PERSON-AL INJURY OR DEATH.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDINGTOTHE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/NFPA70-, OR IN CANADA,THECANADIAN ELECTRICAL CODE,CSA-C22.1 OR LOCAL CODESTHAT APPLY. A GROUND SCREWIS PROVIDED IN THE JUNCTIONBOX. FAILURE TO PROPERLYCONNECT THE GROUNDWIRECAN CAUSE ELECTRICALSHOCK RESULTING IN PERSON-AL INJURY OR DEATH.

THIS FURNACE IS EQUIPPEDWITH A BLOWER DOOR SAFETYSWITCH. DO NOT DISABLE THISSWITCH. FAILURE TO FOLLOWTHISWARNING CAN RESULT INELECTRICAL SHOCK, PERSON-AL INJURY OR DEATH.IMPORTANT: The furnace must beinstalled so that the electrical compo-nents are protected from water.A grounding wire is provided to connectto the incoming grounding wire fromline power. The furnace must be perma-nently grounded in accordance with allnational and local codes.Before proceeding with the electricalconnections, be certain that the servicepanel voltage, frequency and phase cor-responds to that specified on the fur-nace rating plate. Maximum over-currentprotection is 15 amperes.Use a separate, fused branch electricalcircuit containing a properly sized fuse orcircuit breaker. Run this circuit directlyfrom the main switch box to an electricaldisconnect that is readily accessible andlocated near the furnace. Connect from

! WARNING

! WARNING

! WARNING

FIGURE 44JUNCTION BOX LOCATION

UPFLOWMODELS

➤ DOWNFLOW/HORIZONTAL

MODELS

44

ELECTRICAL CHECKSLine Power CheckThe furnace must have a nominal 115volt power supply for proper opera-tion. If there is not a consistent powersupply, contact a licensed electricianto correct the problem.1. With the blower compartment door

off, manually hold the push buttondoor switch in.

2. Call for heat at the thermostat.3. With the unit operating, use a volt-

meter to measure the voltage fromany 120 VAC terminal to any neu-tral connection.

4. The voltage should be a nominal115 volts (acceptable 105-120VAC).

This test should be made with the unitin full operation.Polarity CheckProper line voltage polarity, or phas-ing, is a must for this furnace to oper-ate. Use a volt meter to make thischeck.1. With the blower compartment door

off, manually hold the push buttondoor switch in.

2. Use a voltmeter to measure thevoltage from any 120 VAC terminalto any bare metal ground on thefurnace.

3. The voltage should be a nominal115 volts (acceptable 105-120VAC).

4. Use a voltmeter to measure thevoltage from any neutral terminalto the bare metal ground on thefurnace.

5. The voltage should be less than1.0 VAC.

6. If the voltage from any 120 VACterminal to ground is less than 1.0VAC volts and the voltage from aneutral to ground is a nominal 115volts, the polarity is reversed.

7. To correct the problem, eitherreverse the hot and neutral wiresto the furnace or have a licensedelectrician check the buildingwiring.

Control Voltage Check1. With the blower compartment

door off, manually hold the pushbutton door switch in.

2. Call for heat at the thermostat.3. With the unit operating, use a

voltmeter to measure the voltagefrom control voltage terminal “W”to terminal “C” on the furnacecontrol board.

4. The voltage should be a nominal24 volts (Acceptable 18-30 VAC).

This test should be made with theunit in full operation.

45

FIGURE 4524-VOLT TERMINALS

THERMOSTATWIRINGNOTE: For fully modulating function,the furnace must be installed with the(-)HC-TST401MDMS ModulatingTouch-Screen Thermostat.NOTE: Do not use 24 volt control wiresmaller than No. 18 AWG.Wire all thermostats to the 24V connec-tions on the integrated furnace control.See Figures 46, 47, 48, 49, and 50.NOTE: A larger wire gage may be berequired for longer lengths of thermo-stat wire.For proper installation of the VariableOutput Thermostat, follow the“Thermostat Installation, Programmingand Troubleshooting Manual” includedas section II of this manual. For properinstallation of a Single-Stage or Two-Stage Thermostat, see the InstallationInstructions included with the thermo-stat.➤ FURNACE OPERATION USINGMODULATING, SINGLE-STAGE, ANDTWO-STAGE THERMOSTATSThe modulating furnace with the UTElectronic Controls IFC is also capableof operating with a single-stage or atwo-stage thermostat as well as themodulating thermostat. Furnacesequipped with part # 62-24174-01 (rev-02 or newer) or 62-24174-02 (all revi-sions) will operate with either single-stage or two-stage thermostats as amodulating system using an algorithmthat utilizes three distinct firing rates;40%, 65% and 100% of the furnaceheating capacity (See below for opera-tion of each).Figures 46, 47, 48, 49 and 50 detailhow to wire the modulating furnace foroperation with a modulating thermo-stat, a single-stage thermostat or atwo-stage thermostat.➤ FURNACE OPERATIONWITH AMODULATING THERMOSTATAs described previously in this manual,operation with a modulating thermostatwhen installed as shown in Figure 46is fully modulating between 40% and100% of furnace capacity. The firingrate is first determined by the thermo-stat and then sent to the furnace. Thisis the optimum mode of operation andwill give the best temperature controlwith minimal temperature variationfrom the desired set point.➤ FURNACE OPERATIONWITH ASINGLE STAGE THERMOSTATTo operate the furnace with a single-stage thermostat, set switches 1 & 2 ofSW2 (See Figure 56) to the “OFF”position. Note that these switches

should be in the “OFF” position from thefactory. The lack of the modulating “V”signal will automatically be sensed as asingle-stage thermostat and the furnacewill operate accordingly.With a single-stage thermostat (installedas shown in Figure 49), during a call forheat, the furnace will operate as fol-lows:Phase 1: 0 to 5 minutes = 40% of fur-nace capacityPhase 2: 5 to 12 minutes = 65% of fur-nace capacityPhase 3: After 12 minutes = 100 % offurnace capacityNOTE: If the call for heat ends duringany phase, the furnace will terminateimmediately at the firing rate of thatphase.If switches 1 & 2 of SW2 are in the“ON” position (See Figure 56), the fur-nace will always operate at 40% with asingle-stage thermostat installed asshown in Figure 40. THIS CONFIGU-RATION IS NEITHER RECOMMEND-ED NOR APPROVED.

THERMOSTATS

46

FIGURE 47FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION – SINGLE STAGE HEAT PUMP

➤

FIGURE 46WIRING DIAGRAM FOR MODULATING HEAT (NO DUAL FUEL)

V / W2

MODULATING THERMOSTAT

YH (Y2) Y (Y2)

YL* (Y1) YL (Y1)* *

Y Y2

(1) FOR REMOTE SENSOR INSTALLATION(1) SEE THERMOSTAT INSTALLATION INSTRUCTIONS

THERMOSTAT MODEL: (-)HC-TST401MDMSREMOTE SENSOR: F1451378

+S

– 12FT

OU

TDO

OR

SEN

SOR

(1)

*2 STAGE COOLING ONLY

47

➤

FIGURE 49WIRING DIAGRAM FOR SINGLE-STAGE HEAT

* NO MECHANICAL THERMOSTATS.** 40%, 65%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION (DIP SWITCH SET SW2 — SWITCHES 1 & 2 OFF).*** 2 STG. COOLING ONLY.

1-STAGE ELECTRONIC THERMOSTAT*

YL (Y1)*** YL (Y1)

Y (Y2)

***

YH (Y2)

Y Y2

FIGURE 48FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION - TWO STAGE HEAT PUMP

48

FIGURE 51(-)HC-TST401MDMSMODULATING TOUCHSCREEN THERMOSTAT

FURNACE OPERATIONWITH A TWO-STAGE THERMOSTATTo set the furnace for operation withtwo-stage thermostats, set switches 1 &2 of SW2 to the “ON” position (SeeFigure 56). Note that these switchesshould be in the “OFF” position fromthe factory. With both switches in the“ON” position, the furnace can still rec-ognize a “V” signal present and will stilloperate with a modulating thermostat.However, with both switches of SW2 inthe “ON” position, the furnace is set tooperate with a two-stage thermostat aswell.With a two-stage thermostat (installedas shown in Figure 50) and switch set-tings configured as described above,during a call for heat, the furnace willoperate as follows:First Stage(“W”=ON and “W2”=OFF)40% of furnace capacity alwaysSecond Stage(“W”=ON and “W2”=ON)Phase 1: 0 to 5 minutes = 65% of fur-nace capacityPhase 2: After 5 minutes = 100% offurnace capacity

NOTE: If the call for heat ends duringany phase and/or stage, the furnacewill terminate immediately at the firingrate of that phase and/or stage.

FIGURE 50WIRING DIAGRAM FROMTWO-STAGE HEAT

* NO MECHANICAL THERMOSTATS.** 40% FIRING RATE IN TWO-STAGE OPERATION (DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).*** 65% and 100% FIRING RATE IN TWO-STAGE OPERATION (W & W2 ENERGIZED).**** 2 STAGE COOLING ONLY.

2-STAGE ELECTRONIC THERMOSTAT*2-STAGE ELECTRONIC THERMOSTAT*

YH (Y2) Y (Y2)

YL (Y1) YL (Y1)**** ****

Y Y2

Description

Heat Pump (with Aux. or Emergency Heat), 2 StageYes

Systems with up to 3 Stages Heat, 2 Stages CoolYes

Heat Only SystemsYes

Wired Remote Temperature Sensor (Indoor/Outdoor)Yes

Dual Fuel Feature (Heat Pump Mode)YesYes

THERMOSTAT APPLICATION GUIDE

M

Modulating PWM output, gas furnace

Model Programming Choices

(-)HC-TST401MDMS Non-Programmable 5/1/1 Day 7 Day

M

APPLICATIONSMODULATINGTOUCH-SCREENTHERMOSTAT

INSTALLATION

THERMOSTAT INSTALLATIONAND ALL COMPONENTS OFTHECONTROL SYSTEM SHALL CON-FORMTO CLASS II CIRCUITS PERTHE NEC CODE.REMOVE OLDTHERMOSTATA standard heat/cool thermostat con-sists of three basic parts:1. The cover, which may be either asnap-on or hinge type.

2. The base, which is removed byloosening all captive screws.

3. The switching subbase, which isremoved by unscrewing themounting screws that hold it onthe wall or adapter plate. Beforeremoving wires from old ther-mostat, label each wire with theterminal designation from whichit was attached. Disconnect thewires from the old thermostat oneat a time. Do not let wires fallback into the wall.

INSTALLING NEWTHERMOSTAT1. Pull the thermostat body off thethermostat base. Forcing or pryingon the thermostat will cause dam-age to the unit. Rear view of ther-mostat

2. Place base over hole in wall andmark mounting hole locations onwall using base as a template.

! WARNING

For complete product specifications, seethe Installation Instructions supplied withthermostat.

49

WIRING CONNECTIONSRefer to equipment manufacturers’instructions for specific system wiringinformation. After wiring, see CONFIGU-RATION section for proper thermostatconfiguration. For wiring diagrams, seeFigures 46, 47 & 48.Wiring diagrams shown are for typicalsystes and describe the thermostat ter-minal functions.

3. Move base out of the way. Drillmounting holes. If you are using exist-ing mounting holes and the holesdrilled are too large and do not allowyou to tighten base snugly, use plasticscrew anchors to secure the base.

4. Fasten base snugly to wall usingmounting holes shown in Figure 52and two mounting screws. Leveling isfor appearance only and will not affectthermostat operation.

5. Connect wires to terminal block onbase using appropriate wiringschematic (see Figures 46, 47 & 48).

6. Push excess wire into wall and plughole with a fire resistant material(such as fiberglass insulation) to pre-vent drafts from affecting thermostatoperation.

7. Carefully line the thermostat up withthe base and snap into place.

BATTERY LOCATION2 “AA” alkaline batteries are included inthe thermostat at the factory with a bat-tery tag to prevent power drainage.Remove the battery tag to engage thebatteries. To replace batteries, set sys-tem to OFF, remove thermostatfrom wall and install the batteries in therear along the top of the thermostat(see Figure 52).

2 "AA" Batteries

MountingHole

MountingHole

Place LevelacrossMounting Tabs(for appearance only)

Place Levelacross

Mounting Tabs(for appearance only)

+S

-

W/E

V

Y2

W2

Rear view of thermostat

FIGURE 52(-)HC-TST401MDMS BASE

Terminal Designation DescriptionB . . . . . . . . . . . . . . . . . . Changeover valve for heat pump energized constantly in heatingO . . . . . . . . . . . . . . . . . . Changeover valve for heat pump energized constantly in coolingY2 . . . . . . . . . . . . . . . . . . 2nd Stage CompressorY . . . . . . . . . . . . . . . . . . Compressor RelayG . . . . . . . . . . . . . . . . . . Fan Relay

RC . . . . . . . . . . . . . . . . . . Power for CoolingRH . . . . . . . . . . . . . . . . . . Power for HeatingC . . . . . . . . . . . . . . . . . . Common wire from secondary side of coolingV . . . . . . . . . . . . . . . . . . PWM Output

W/E . . . . . . . . . . . . . . . . . Heat Relay/Emergency Heat Relay (Stage 1)W2 . . . . . . . . . . . . . . . . . . 2nd Stage Heat (3rd Stage Heat in HP2)

- . . . . . . . . . . . . . . . . . . . Common (DC) for wired remote temperature sensorS . . . . . . . . . . . . . . . . . . Frequency signal from remote temperature sensor+ . . . . . . . . . . . . . . . . . . Power (DC) to remote temperature sensor

TERMINAL DESIGNATION DESCRIPTIONS

50

Time of Day

Day of WeekRoomTemperature

SystemSwitch

FanSwitch

Indicates whenthermostat is callingfor Heat or Cool

Battery Level IndicatorIndicating the current power level

Full power remaining. Half power remaining.Change The batteries should be replaced at this time.

Menu key for enteringdifferent modes such asCleaning, Configuration, SetTime and Set Schedule

Enters comforttemperature settingsinto the schedule

TemperatureUP/Down used formodifying set pointas well as tonavigating the menus

Set Temperature

THERMOSTAT QUICK REFERENCEHome Screen Description

13 "Copy" indicates the copy program feature is beingused during programming.

14 A steady "Cool Savings" display indicates the featureis enabled in the installer menu. A flashing "CoolSavings" display indicates the feature is active.

12 "System On" indicates when heating or cooling stageis energized. "+2" also indicates when a second stageis energized.

11 The words "Hold At" are displayed when the thermo-stat is in the HOLD mode. "Temporary Hold At" isdisplayed when the thermostat is in a temporary HOLDmode.

10 "Hours" and "Days" displays during steps in installerconfiguration.

9 "Hold Until" indicates the time when a temporary holdperiod will end.

8 Used in programming to set time and in configurationmenu to change selections.

7 CLEAN DISPLAY button allows 30 seconds to wipe offthe display or ADVANCE DAY button for programming.

6 COPY button or INSTALLER CONFIG button.

5 Displays "Change Filter" when the system has runfor the programmed filter time period as a reminderto change or clean your filter.

2 Indicates period of day being programmed.

3 RUN SCHEDULE (run program) button.

4 SET TIME button or HOLD temperature button.

1 Displays and "Keypad Lockout" when in keypadlockout mode.Displays and "Temperature Limit" and "KeypadLockout" when limited range is activated and locked.Displays only "Temperature Limit" when limited rangeis activated.

Programming and Configuration Items

15 "Remote" indicates that the indoor remote temperaturesensor, is being accessed. "Outdoor Remote" indi-cates the outdoor remote temperature sensor is beingaccessed.

15

1413 12

1110

9

8

7 6 5 4

3

2

1

Figure 52 – Home Screen Display

Figure 53 – Programming & Configuration Items

Figure 53 – Home Screen Display

Figure 54 – Programming & Configuration Items

51

CONFIGURATION MENUNon- Displayed Press or

Program- Program- Press (Factory to select frommable mable Button Default) listed options Comments

1 1 MS 2 HP 1, HP 2, SS 1 Selects Multi-Stage (MS 2, No Heat Pump), Heat Pump 1

(HP 1, 1 compressor), Heat Pump 2 (HP 2, 2 compressor

or 2 speed compressor), or Single Stage.

2 2 (GAS) ELE GAS setting: furnace controls blower.

ELE setting: thermostat controls blower.

3 3 Days, (7) P 5-1-1 or 0 Programs per week. (0 = non-programmable)

4 NA PS (4) 2 Program periods per day.

Morning, Day, Day, Night 4 = Morning, Day, Evening, Night

Evening, Night 2 = Day, Night

5 4 Cool-Off- Cool-Off-Heat, System switch configuration in non heat pump mode.

Heat-Auto Off-Heat, Cool-Off

Cool-Off-Heat- Cool-Off-Heat-Emer, System switch configuration, heat pump mode.

Emer-Auto Off-Heat-Emer, Cool-Off

6 NA E (On) OFF Selects Energy Management Recovery, E (with programming option on)

7 5 Cr, Heat (FA) SL Selects Adjustable Anticipation, cycle rate, Heat

8 6 Cr, Cool (FA) SL Selects Adjustable Anticipation, cycle rate, Cool

9 7 Cr/AU, Emer (FA) SL Selects Adjustable Anticipation, cycle rate auxiliary, (This item is

only to appear if HP 1 or HP 2 is selected above).

10 8 CL (OFF) On Selects Compressor Lockout.

11 9 dL (On) OFF Selects Continuous Display backlight & intensity.

12 10 dL (LO) HI Selects Backlight Intensity.

13 11 0 4, LO to 4, HI Selects Adjustable Ambient Temperature Display [range -4 (LO) to

+4 (HI)].

14 12 F C Selects F/ C Displa y (temperature units in Fahrenheit or Celsius).

15 13 b (On) OFF Selects audible Beeper On/Off.

16 14 dS (On) OFF Selects Daylight Saving Time calculation.

17 15 AS, Heat (OFF) On Selects Automatic Schedule for comfort temperature Programming,

heat mode.

18 16 AS, Cool (OFF) On Selects Automatic Schedule for comfort temperature Programming,

cool mode.

19 17 CS, (OFF) 1-2-3-4-5-6 Selects Cool Saving Feature & amount.

Cool Savings

20 18 HL, Heat (99) 62-98 TEMPERATURE LIMIT, HEAT (max. heat set point).

21 19 LL, Cool (45) 46-82 TEMPERATURE LIMIT, COOL (min. cool set point).

22 20 OFF, L (total), P (partial), Selects Keypad Lockout.

Keypad Lockout Temperature Limit

(limited temperature range)

000 001-999 Selects Keypad Lockout Combination (active only if keypad Lockout

is selected).

23 21 FS, Heat (On) OFF Fast second stage of heat (not available if SS1 is selected above).

24 22 FS, Cool (On) OFF Fast second stage of cool (not available if SS1 or HP1 is selected

above).

25 23 Remote (OFF) On Remote temperature sensor, enable/disable.

In, Remote Outdoor Remote Remote temperature sensor (Indoor/Outdoor).

LS (On) OFF Local temp. Sensor enable/disable (only when Indoor Remote is

selected On).

26 24 dF (5) 5-50 Selects Dual Fuel Feature & setpoint (in Fahrenheit) (applicable only

when HP1 or HP2 is selected).

Cd (15) 0-99 Selects Compressor delay in seconds (only when dF is selected >5).

27 25 AO (80) 35 to 80 Selects Auxiliary Off setpoint (applicable only when HP1 or HP2

is selected).

28 26 Change Filter On Selects Change filter feature

(OFF)

200 Hours 25-1975 (in increments Change filter, duration hours.

of 25 hours)

INSTALLER/CONFIGURATION MENUTo enter the menu: Press the Menu touch key. Press and hold for 5 seconds the Installer Config touch key. This displaysmenu item #1 in the table below. Press to advance to the next menu item or to return to a previous menu item. Press or to change a menu item.

MenuReferenceNumber

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

52

INSTALLER/CONFIGURATION MENU11) Select Continuous Backlight In low lighting condi-

tions, display backlight improves the display contrast.When C terminal is connected, selecting dL On will turnthe backlight on continuously. Selecting dL Off will turnthe backlight on momentarily after any key is pressed.When C terminal is not powered (battery only), dL Onenables the momentary backlight whenever a key ispressed.

12) Select Backlight Intensity This ther mostat has theability to provide two selectable intensities of the back-light: HI and LO. Using or touch keys you cantoggle the selection between HI and LO.

13) Select Temperature Display Adjustment 4 LO to 4 HIThis allows you to adjust the room temperature displayby an amount in the range of -4 F to +4 F in 1 steps b yusing the or touch keys. Your thermostat wasaccurately calibrated at the factory, however you have theoption to change the display temperature value to matchyour previous thermostat, if you so prefer.

14) Select °F or °C Readout Select the desired temper -ature unit by pressing or . Factory default is F.

15) Select Audio Prompting (Beeper) On or Off F actorydefault setting is on (b, On). If you wish to turn off thebeeper select OFF.

16) Select Daylight Saving Time Calculation T his featurewill allow the thermostat to calculate the DST automati-cally and apply it to the Real Time Clock display. DefaultOn. Use or touch keys to select the feature, OFF.

17 & 18) Select Automatic Schedule With just one touc hof the Auto Schedule key this feature allows you toprogram a desired comfort temperature into all theprogram periods along with a 6 set back for nightperiods of both Heat and Cool programs. Factory defaultis "On" for both. When Heat AS On and Cool AS On areactivated while in Heat or Cool mode, select desiredsetpoint temperature and press Auto Schedule. AutoSchedule will flash, press it again to copy. This value willbe copied into all the morning, day and evening programperiods. The night program periods will be with a 6 F setback.

19) Select Cool Savings™: With Cool Savings ena bled,the thermostat will make small adjustments to the sensedtemperature during periods of high demand to reduce ACsystem running time and save energy. When the coolingsystem has been running for more than 20 minutes,humidity in the home will be lower and a highertemperature will feel comfortable. After 20 minutes of runtime, the thermostat will start decreasing the sensedtemperature in steps of less than one degree as thesystem continues to run. These adjustments will eventu-ally cause the system to satisfy the thermostat to turn thesystem off and reduce the energy consumption. Whenthe Cool Savings f eature is active and making adjust-ments, the display will flash CoolSavings”. The amountof the adjustments to the sensed temperature is depen-dent on the Cool Savings v alue that is set, 1 being theleast adjustment and 6 being the most adjustment. Withthis feature set to OFF, no change will occur when the ACsystem is continuously running during the periods of highdemand. Periods of high demand will normally occurduring the late afternoon and early evening on the hottestdays of the summer. As demand lessens the adjustmentsto sensed temperature are reversed until sensedtemperature returns to normal and “CoolSavings” nolonger flashes.

1) This control can be configured for:MS2 Multi-Sta ge System (2 heat/2 cool)HP1 Hea t Pump with one stage of compressor(2 heat/1 cool)HP2 Hea t Pump with two stage compressor or twocompressor system, Gas or Electric backup; (Dual Fuelsee menu item 35) (3 heat/2 cool)SS1 Sing le Stage System (3 wire zone see wiringdiagram 37-6808A)

2) GAS or Electric (ELE) fan operation. If the heatingsystem requires the thermostat to energize the fan,select ELE. Select GAS if the heating system energizesthe fan on a call for heat. Note: Resetting the thermo-stat switches the option to ELE.

3) Programs per week This control can be configured for7 independent day or 5/1/1 day programming or non-programmable modes. Default is 7-day mode. Thedisplay indicates "7 Days" as default. Other options "5Days" or "0 Days" can be selected by pressing touchkeys, or . If "0 Days" is selected for non-program-mable mode, the step for EMR will be skipped, as thisfeature will not be available in this mode.

4) Program Steps per day This control can be config-ured for 4 or 2 program steps per day. Default is "4 PS"and can be toggled between 4 PS and 2 PS by pressingthe or touch keys.

5) System Switch Configuration (MS2/SS1) Thisthermostat is configured for Heat and Cool with Autochangeover default (Cool-Off-Heat-Auto). Can beconfigured as Heat & Cool (Cool-Off-Heat), or Heat Only(Off-Heat), or Cool Only (Cool-Off).When the control is in heat pump configuration (HP1/HP2), the system switch configuration will have anadditional mode available namely, Emer for EmergencyMode.

6) Energy Management Recovery (EMR) (this step isskipped if configured as non-programmable).When set to "On" causes the thermostat to start heatingor cooling early to make the building temperature reachthe program setpoint at the time you specify.Example: Let us say, the heating program is 65 F a tnight and 70 a t 7 AM. If the building temperature is 65 F,the difference is 5 F. Allowing 5 minutes per F rise, thethermostat setpoint will change to 70 a t 6:35 AM.Cooling allows more time per F, because it takeslonger to reach temperature.

7, 8 & 9) Cycle Rate Selection The factor y default settingis fast cycle (FA Cr) in all modes (Heat, Cool, Emer). Toslow cycling (SL, Cr), press touch keys or togglebetween FA & SL. The cycle rates are as below differentselections:Mode Fast rate Slow rateHeat 0.6 F 1.2 FCool 1.2 F 1.7 FEmer 1.2 F 1.7 F

10) Select Compressor Lockout (CL) Selecting CL Onwill cause the thermostat to wait 5 minutes betweencooling cycles. This is intended to help protect thecompressor from short cycling. Some of the newercompressors have already got a time delay built in anddo not require this feature to be activated in the thermo-stat. Your compressor manufacturer can tell you ifthis lockout feature is already present in their system.When the thermostat compressor time delay is activated,it will flash the set point for up to five minutes.

53

20) Heat Temperature Limit Range This f eature adjuststhe highest setpoint temperature for heat. The defaultsetting is 99 F. It can be changed between 62 F and98 F by pressing the or key. The "temperaturelimit" icon will be displayed to the left of your setpointtemperature when using this feature. The "temperaturelimit" icon will flash if an attempt is made to adjust thetemperature beyond the range selected.

21) Cool Temperature Limit Range T his feature adjuststhe lowest setpoint temperature for cool. The defaultsetting is 45 F. It can be changed between 46 F and82 F by pressing the or key. The "temperaturelimit" icon will be displayed to the left of your setpointtemperature when using this feature. The "temperaturelimit" icon will flash if an attempt is made to adjust thetemperature beyond the range selected.

22) Keypad Lockout This step allows y ou to select thetype of lockout or limited range security required. If nolockout or limited range security is required, press toadvance the menu.Three security settings are available in this menu item.Use the or keys to select the lockout desired.Lockout selections are:"Keypad Lockout and L" = Total Lockout. Total Lockoutlocks all keys."Keypad Lockout and P" = Partial Lockout. Partial Lock-out allows only the or keys to operate within yourset temperature limits."Temperature Limit/Keypad Lockout" preventschanging the temperature limits in the ConfigurationMenu.Keypad Lockout Combination Number SelectionDisplay will read "OFF" "Keypad Lockout".Skip this step and continue through the configurationmenu items 19 thru 22 if you require an Air Filter Changeout indicator or Humidifier Pad Change out indicator bypressing the button to advance.Return to this point when you are ready to start yourselected lock-out and continue by:Pressing or keys to select ON.Press . Display will read "000".Pressing or keys to select your keypad lockoutcombination number. Note: "000" is not a validcombination choice.Record the number you select for future use.Press to exit the menu. The security feature youselect will start in 10 seconds. The system button willremain active for 10 seconds to allow setting Heat, Off,Cool or Auto.

23 & 24) Select Fast Second Stage ON or OFF In the r unmode, with the fast Heat feature enabled (FA Heat On), ifthe Heat setpoint temperature is manually raised by 3 F(2 C) or more above the actual temperature using thesecond stage will energize immediately. With FA OFF,second stage will not energize until the setpoint tempera-ture is 1 F or more above actual temperature for morethan ten minutes. The Fast Cool feature (FA Cool)provides the same controls when the setpoint tempera-ture is lowered.

INSTALLER/CONFIGURATION MENU25) Select Remote Temperature Sensor This control

allows one wired remote temperature sensor (indoor oroutdoor) be connected to it and indicates the measuredtemperature in clock digits. This menu enables you toselect the remote sensor and also configure it as indooror outdoor temperature sensor. Factory default is off.Select Remote On and Remote in (for indoor) orOutdoor Remote.Local Temperature Sensor disable This is applica bleonly when indoor remote temperature sensor is enabled.Factory default is On LS. You can make it Off LS if youdesire by using or touch keys.Then, only theindoor remote temperature reading will be used forcontrol.

26) Select Dual Fuel Feature and Setpoint This f eatureis applicable only in heat pump modes. When the featureis selected, the thermostat will switch to gas heat andinhibit the compressor when the outside temperature(monitored by the outside remote sensor), falls below theDF setpoint. By using or touch keys, select x, DFwhere x=5 to 50; factory default is 5 which disables thefeature. This feature requires an outdoor remote temp-erature sensor (WR# F145-1378), however does notneed a fossil fuel kit.Select Compressor Delay When the DF feature isenabled, the shut down of the compressor stage(s) aredelayed by a programmable time after the auxiliary stageis energized to minimize the duration during which thesystem may blow cooler air. Default delay is 60 seconds(60, Cd). By using or touch keys any value be-tween 0 and 99 can be selected.

27) Select Auxiliary Offset Point T his feature is applic-able only in heat pump modes. When the outdoor temp-erature is above the Auxiliary Off (AO) setpoint, theauxiliary stages will be inhibited so the temperature willbe maintained by only the heat pump. Factory default is80, which disables the feature. AO setpoint cannot be setat or below Dual Fuel (DF) setpoint. By using or touch keys, select x, AO where x=35 to 80.

28) Select Change Filter Run Time The ther mostatwill display "Change Filter" after a set time of bloweroperation. This is a reminder to change or clean your airfilter. This time can be set from 25 to 1975 hours in 25hour increments. A selection of OFF will cancel thisfeature. When "Change Filter" is displayed, you canclear it by pressing Clean Display. In a typical application,200 hours of run time is approximately 30 days.

54

OPERATING YOUR THERMOSTATChoose the Fan Setting (Auto or On or Prog)Fan Auto is the most commonly selected setting and runsthe fan only when the heating or cooling system is on.Fan On selection runs the fan continuously for increased aircirculation or to allow additional air cleaning.Fan Prog will cycle the fan for -10 minutes on and 20minutes off if the thermostat has not called for heat or coolduring the past 60 minutes.

Choose the System Setting(Cool, Off, Heat, Emer, Auto)Press the SYSTEM button to select:Heat: Thermostat controls only the heating system.Off: Heating and Cooling systems are off.Cool: Thermostat controls only the cooling system.Auto: Auto Changeover is used in areas where both heatingand cooling may be required on the same day. AUTO allowsthe thermostat to automatically select heating or coolingdepending on the indoor temperature and the selected heatand cool temperatures. When using AUTO, be sure to set theCooling temperatures more than 1 Fahrenheit higher thanthe heating temperature.Emer: Setting is available only when the thermostat isconfigured in HP1 or HP2 mode.

Manual Operation forNon-Programmable Mode ThermostatsPress the SYSTEM button to select Heat or Cool and usethe or buttons to adjust the temperature to yourdesired setting. After selecting your desired settings you canalso press the SYSTEM button to select AUTO to allowthe thermostat to automatically change between Heat andCool.

IMPORTANT!

PROGRAMMINGSet Current Time and Day1) Press Menu key to enter installer menu. Then press

Set Time once to indicate hour & A or P designation inclock display.

2) Press and hold either the or touch key until youreach the correct hour and A or P designation.

3) Press Set Time again to display minutes only in clockdisplay.

4) Press and hold either the or touch keys until youreach the correct minutes.

5) Press Set Time once again to display year.6) Press and hold either the or touch key until you

reach the correct year.

Manual Operation (Bypassing the Program)Programmable ThermostatsPress or and the HOLD button and adjust the tempera-ture wherever you like. This will override the program. TheHOLD feature bypasses the program and allows you toadjust the temperature manually, as needed. Whatevertemperature you set in HOLD will be maintained 24 hours aday, until you manually change the temperature or press RunSchedule to cancel HOLD and resume the programmedschedule.

Program Override (Temporary Override)Press or buttons to adjust the temperature. This willoverride the temperature setting for a (default) four houroverride period. The override period can be shortened bypressing or lengthened by pressing . Program Overrideperiod can range from 15 minutes to 7 days.Example: If you turn up the heat during the morning pro-gram, it will be automatically lowered later, when the tempo-rary hold period ends. To cancel the temporary setting at anytime and return to the program, press Run Schedule.If the SYSTEM button is pressed to select AUTO thethermostat will change to Heat or Cool, whichever ran last. Ifit switches to heat but you want cool, or it changes to coolbut you want heat, press both or buttons simulta-neously to change to the other mode.

7) Press Set Time once again to display month.8) Press and hold either the or touch key until you

reach the correct month.9) Press Set Time once again to display date of the month

along with day of the week at top row (which is auto-matic).

10) Press and hold either the or touch key until youreach the correct day of the month. The correct day ofthe week is displayed at the top row.

11) Press Run Schedule once; now the display will show thecorrect time and room temperature.

Special Test Mode for PWM (V) output(Installer function only)The PWM (V) output controls the modulating gas valve.Amplitude of this signal is about 10 VDC, frequency is 1 HZand the pulse width is variable 350 to 950 in steps of 50msec.

To activate the modulating test mode, press and hold theInstaller Config touch key until the display changes to showdC (in actual temperature digits) and 05 (default) in clockdigits (at least 10 seconds). If the touch key is releasedbefore the display changes the test mode will not be acti-vated and the installer menu mode will be active. On enteringthe modulating test mode, the display (05) will indicate theduty cycle of 5% (pulse width of 50 msec) corresponding tono call for heat.

Press key to change the display to 35 (duty cycle 35%).The W output will energize and within one second the pulsewidth modulated V output will also be activated with a pulsewidth of 350 msec.

Use or touch keys to increase or decrease the pulsewidth in steps of 50 milliseconds (5% change in duty cycle).The maximum duty cycle is 95% (maximum pulse width of950 milliseconds).

This special test mode will be exited by pressing RunSchedule touch key or when there is no keypad activity forover 60 minutes.

55

Enter the Heating Program1) Press the Menu button and then press Set Schedule.

Press SYSTEM button to select either "Heat" or "Cool" inthe system switch area indicating the active mode beingprogrammed. You can switch to the other mode bypressing the system switch at any time.

2) The top of the display will show the day(s) being pro-grammed. The time and set at temperature are alsodisplayed. "Morning" will also be displayed to indicatethe period.

3) Press or key to change the temperature to yourselected temperature for the 1st heating period (Morning).

4) Press or key to adjust the start time for period.The time will change in 15 minute increments.

5) Press FAN to select Auto or Prog.6) After you have set the time and the temperature for the

period to begin, press Set Schedule to advance to thenext program period.

7) Repeat steps 2 through 6 until all of the program timesand temperatures are set for all program periods onthat day.

8) Press "Advance Day" to change to the next day andrepeat steps 2 through 8.

9) When programming is complete and all of the times andtemperatures match your desired heating schedule, pressRun Schedule. The thermostat will now run your program.

Enter the Cooling Program1) Press the SYSTEM button until the Cool icon appears.2) Follow Enter Heating Program instructions for entering

cooling times and temperatures.

PROGRAMMING

Fill in the blank schedule on the next page then:

Automatic ScheduleThis feature provides a method to program every day withthe most popular time and temperature profile using one keypress. For this feature to be available, the Auto scheduleoptions (AS Cool or AS Heat) should be set on in theinstaller configuration.

Select the desired Comfort Temperature in the setpoint.When the Auto Schedule touch key is pressed, it will startflashing indicating that it is now ready to insert the displayedtemperature setpoint as the Comfort Temperature for theselected system mode currently in (Heat/Cool). A secondpress of the Auto Schedule touch key will complete theprocess. A 6 o F setback temperature will also be inserted forthe night step. Once it is done, the touch key display AutoSchedule will disappear disabling any further operation ofAuto Schedule touch key. If desired it can be enabled againin the installer configuration menu.

Entering Fan ProgramThe FAN touch key is used to select FAN Auto operation(fan energized with a call for cool but not on with a call forheat) to FAN On (fan on continuous) or FAN PROG (fanprogrammed to cycle fixed time automatically). Each press ofthe FAN touch key will change the mode from Auto to On toProg. FAN Auto or FAN On or FAN On Prog will display inthe run mode for as long as the fan is in that position. WhenFAN Prog position is selected and the system is in the Cool,Heat or Auto mode, the circulator blower (fan) will cycle ONfor 10 minutes, OFF for 20 minutes when the thermostat hasnot called for cooling or heating for the past 60 minutes.

To improve indoor air quality, the system circulator can beprogrammed to run during any program time period bytouching the FAN touch key in the appropriate program timeperiod when in the Menu mode for that particular day.The display shall indicate Prog (under the FAN icon) when inMenu mode and the fan is programmed to come on duringthat time.

In the menu mode, each time the fan key is pressed, the fanoperation and display will change from FAN Auto to FANProg. The display shall indicate FAN On Prog when in runmode and the fan is programmed to run for that particulartime period.

When in Run Schedule mode and the FAN touch key ispressed, it will override the schedule, and the display and fanoperation shall change to FAN Auto and the fan is stopped.Further key depression will change it to FAN On (continuousblower on) and to FAN Prog (cycling 10 minutes on and 20minutes off if there is no call for heat or cool for 60 minutes).The Run Schedule touch key will also be indicated, meaningthat it is an override on the scheduled program. The overridewill last until next schedule comes up or the Run Scheduletouch key is depressed.

Programming Tip: Copy ButtonYou may copy any daily program to another day or group ofdays by pressing the Copy button. In 7 day programmingmode when the Copy button is pressed, the other 6 days ofthe week will flash. To copy the current program into theremaining six days, simply press the Copy button again. Tocopy the current program to another day of the week, pressAdvance Day to select the day and press Copy to paste theprogram. In 5/1/1 day programming mode the copy functionis similar. The weekday (Mon-Fri) program can be copied toSat and Sun (both flashing) or use Advance Day to chooseSat or Sun and press the Copy button to paste the program.

Automatic Daylight Saving CalculationThe Real Time Clock will adjust automatically for daylightsavings time, in the following manner until 2007:Increment one hour at 2 AM on the first Sunday of April anddecrement one hour at 2 AM of the last Sunday of Octoberevery year.From March 2007, the adjustment will occur every year asfollows: Increment one hour at 2 AM on the second Sundayof March and decrement one hour at 2 AM on the firstSunday of November.The daylight saving feature can be enabled or disabled ininstaller configuration mode.After entering installer configuration mode, momentarilypress or touch key until the display indicates dS (inactual temperature digits) and on (default in c lock digits).

and keys will toggle display and operation from On toOFF.

56

PROGRAMMINGEnergy Saving Factory Pre-ProgramThe (-)HC-TST401MDMS thermostats are programmed with the energy saving settings shown in the table below for all daysof the week. If this program suits your needs, simply set the thermostat clock and press the RUN button.The table below shows the factory set heating and cooling schedule for all days of the week.

* Wake Up Leave For Work * Return Home Go To Bed(Morning) (Day) (Evening) (Night)

HeatingProgramCoolingProgram

6:00 AM 70 F 8:00 AM 62 F 5:00 PM 70 F 10:00 PM 62 F

6:00 AM 78 F 8:00 AM 85 F 5:00 PM 78 F 10:00 PM 82 F

* You can eliminate these two program periods in the configuration menu (reference #3) if the building is occupied all day.Day will change to 6:00 am and can be programmed as required.

Planning Your Program – ImportantThe Heating and Cooling Program schedules below allow you to pencil in your own program times and temperatures.The (-)HC-TST401MDMS comes configured for 7 day programming and can also be configured for 5+1+1 programming (seeconfiguration section).Factory settings are listed on Monday, Saturday and Sunday. If you are re-programming a 5+1+1 day schedule, pencil in yourown times and temperatures directly below the factory times and temperatures.

If you are re-programming a 7 day fill in all lines with the times and temperatures you want.

Keep the following guidelines in mind when planning your program.In Heating, lower temperatures will save energy.In Cooling, higher temperatures will save energy.If you plan on using Auto Changeover, do not program the heating higher than the cooling.

Wake Up Leave For Work Return Home Go To Bed(Morning) Fan (Day) Fan (Evening) Fan (Night) Fan

6:00 AM 70 F Auto 8:00 AM 62 F Auto 5:00 PM 70 F Auto 10:00 PM 62 F Auto


HeatingProgram

MON

TUE

WED

THU

FRI

SAT

SUN 6:00 AM 70 F Auto 8:00 AM 62 F Auto 5:00 PM 70 F Auto 10:00 PM 62 F Auto

Worksheet for Re-Programming 5+1+1 and 7 Day Program

Wake Up Leave For Work Return Home Go To Bed(Morning) Fan (Day) Fan (Evening) Fan (Night) Fan



CoolingProgram

MON

TUE

WED

THU

FRI

SAT

SUN 6:00 AM 78 F Auto 8:00 AM 85 F Auto 5:00 PM 78 F Auto 10:00 PM 82 F Auto

57

PROGRAMMINGWired Remote Temperature SensingOne remote temperature sensor can be installed indoor oroutdoor and connected to the thermostat by a maximumcable length of 100 meters (300 ft). Three terminals, +, S & -are provided on the terminal block to connect to the White-Rodgers standard wired remote sensor. This sensor will beread by the thermostat only when 24VAC is present.When used as indoor sensor, the readings can be weightedwith the local sensor for specific program periods. User canenable or disable the remote sensor in the installer configu-ration mode and also the outdoor temperature can beselected to show on the display.

Once in the installer configuration mode, momentarily pressthe or touch key until display indicates Remote (at thetop left of the LCD) and OFF (default in clock digits).Pressing or touch key will toggle the operation anddisplay from Remote OFF to Remote On.When Remote On is selected, press key for the display toindicate Remote In (for indoor remote).The or keys will toggle the operation and display fromRemote In to Outdoor Remote.When any remote is selected the temperature will display inthe clock digits for one second alternating with the currenttime for three seconds when in Run Schedule mode.Outdoor Remote will indicate at the top left of display foroutdoor remote reading.Only Remote will show at top left for indoor remote reading.(oF or oC will not indicate with remote temperature readings).

Sensing Range:Outdoor temperature range is -40 to 140oFIndoor temperature range is 32 oF to 99 oF

Weight of Remote Reading:When in view schedule mode the weight of the indoor remotesensor will be shown in the left actual temperature digitsdesignated as A2 (default for average weight), H4 (highweight) or L1 (low weight). The period (Morning, Day,Evening, Night) will also be shown to the right of the weightvalue in the actual temperature digits.When in view schedule mode, press and keys at thethe same time to sequence the indoor remote temperaturesensor weight from A2 to H4 to L1 and back to A2 for each ofthe program period times for each day. (The H4 weight istwice the weight of A2 and A2 is twice the weight of L1).

When Remote In is selected (with Remote selected to On),press key for the display to indicate the status of the localsensor LS On (default for thermostat local sensor opera-tional). The and keys will toggle the function anddisplay from LS (shown in actual temperature digits) and On(shown in clock digits) to LS OFF to designate the localsensor is disabled.

The local sensor may be disabled only if the indoor remotesensor is enabled and functional.If the indoor remote sensor is disabled or not functional, thelocal sensor will automatically enable and display in the runschedule mode.The actual temperature displayed in the run mode is themathematical weighted sum of the two temperature sensors local and indoor remote.(Outdoor remote sensor is not used for this computation).If the remote sensor is absent or not enabled then the actualtemperature will be as measured by the local sensor.

Dual Fuel Temperature Set PointThe Thermostat can monitor outside temperature through anoutdoor remote sensor if installed and switch to gas heat andinhibit the compressor when in heat pump mode and outsidetemperature is below a user selectable value. This tempera-ture is called the dual fuel temperature set point. Thiseliminates the need for a fossil fuel kit.For this feature to be functional the following conditions areto be met:1. The thermostat must be in heat pump mode;2. The outdoor temperature sensor must be enabled and

operational.

Once in the installer configuration mode, step through themenu items until the display indicates dF (for dual fuel) in theactual temperature digits and 5 (default) in clock digits.Pressing the or touch keys will increment the dual fueltemperature setpoint from 5 to 50 (default unit is Fahrenheit).When the dual fuel temperature setpoint is any value above5oF this feature is enabled. If the actual outdoor temperatureis lower than this temperature setpoint the heat pump will beinhibited. If the balance point temperature setpoint is 5oF thefeature is disabled.When the dual fuel feature is enabled, the shut down of thecompressor stage(s) are delayed a programmable time witha default of 60 seconds after the auxiliary stage is energizedto minimize the time that the system may blow cooler air.Only when the dual fuel feature is enabled and the ispressed after the dual fuel feature dF is selected, the displaywill indicate Cd (for compressor delay) in actual temperaturedigits and 60 (default) in clock digits.Pressing the or touch keys will increment the compres-sor delay time to 99 seconds or decrement down to 0second.If the or touch keys are held depressed, the setpointwill increment or decrement one degree at the rate of onedegree every one half second for the first three seconds andthereafter at double the speed.

58

TROUBLESHOOTINGReset OperationNote: When thermostat is reset, installer configuration menu settings and programming will reset to factory settings.If a voltage spike or static discharge blanks out the display or causes erratic thermostat operation, you can reset the thermostat by removingthe wires from terminals R and C (do not short them together) and removing batteries for 2 minutes. After resetting the thermostat, replacethe wires and batteries. If the thermostat has been reset and still does not function correctly contact your heating/cooling service person orplace of purchase.Note: Be sure to review the installer configuration menu settings.To reset the programming, clock and configuration settings, press and and the SYSTEM button simultaneously. The thermostatshould go blank and then all segments will be displayed momentarily.

Symptom

No Heat/No Cool/No Fan(common problems)

No Heat

No Cool

Heat, Cool or FanRuns Constantly

Thermostat Setting &Thermostat ThermometerDisagree

Furnace (Air Conditioner)Cycles Too Fast or Too Slow(narrow or widetemperature swing)

Forgot KeypadLockout Code

Possible Cause

1. Blown fuse or tripped circuit breaker.2. Furnace power switch to OFF.3. Furnace blower compartment door or

panel loose or not properly installed.4. Loose connection to thermostat or system.

1. Pilot light not lit.2. Furnace Lock-Out Condition. Heat

may also be intermittent.

3. Heating system requires service orthermostat requires replacement.

1. Cooling system requires service orthermostat requires replacement.

1. Possible short in wiring.2. Possible short in thermostat.3. Possible short in heat/cool/fan system.4. FAN Switch set to Fan ON.

1. Thermostat thermometer settingrequires adjustment.

1. The location of the thermostat and/orthe size of the Heating System maybe influencing the cycle rate.

Corrective Action

Replace fuse or reset breaker.Turn switch to ON.Replace door panel in proper position to engage safetyinterlock or door switch.Tighten connections.

Re-light pilot.Many furnaces have safety devices that shut down when alock-out condition occurs. If the heat works intermittentlycontact the furnace manufacturer or local HVAC serviceperson for assistance.Diagnostic: Set SYSTEM Switch to HEAT and raise thesetpoint above room temperature. Within a few secondsthe thermostat should make a soft click sound. This soundusually indicates the thermostat is operating properly. Ifthe thermostat does not click, try the reset operation listedabove. If the thermostat does not click after being resetcontact your heating and cooling service person or placeof purchase for a replacement. If the thermostat clicks,contact the furnace manufacturer or a HVAC serviceperson to verify the heating is operating correctly.

Same as diagnostic for No Heat condition except set thethermostat to COOL and lower the setpoint below theroom temperature. There may be up to a five minute delaybefore the thermostat clicks in Cooling.

Check each wire connection to verify they are not shortedor touching together. No bare wire should stick out fromunder terminal block. Try resetting the thermostat asdescribed above. If the condition persists the manufacturerof your system or service person can instruct you on howto test the Heat/Cool system for correct operation. If thesystem operates correctly, replace the thermostat.

The thermometer can be adjusted +/- 4 degrees. SeeTemperature Display Adjustment in the ConfigurationMenu section.

Digital thermostats provide precise control and cycle fasterthan older mechanical models. The system turns on andoff more frequently but runs for a shorter time so there isno increase in energy use. If you would like an increasedcycle time, choose SL for slow cycle in the Configurationmenu, step 6 (heat) or 7 (cool). If an acceptable cycle rateis not achieved, contact a local HVAC service person foradditional suggestions.

Press the menu button (button will disappear) and hold infor 20 seconds. This unlocks the thermostat.

59

HUMIDIFIERThe humidifier contacts (labeledHUMIDIFIER on the IFC) are “dry” con-tacts on the IFC. This means that theterminals are connected directly to thecontacts of a board-mounted relay. Thecoil of the relay is controlled by themicroprocessor of the IFC. The coil isengaged roughly any time the heatspeed blower is engaged so thathumidification is active any time theheat blower is running. In addition tothis control, on 24 VAC humidifiers or

ACCESSORIESFIELD-INSTALLEDOPTION ACCESSORIESTWINNING: Twinning is NOT permittedon any modulating ((-)GFD, (-)GGD or(-)GJD) furnace model.

ELECTRONIC AIR CLEANERLine voltage power can be supplied fromthe screw terminal “EAC”, see Figure 55,and a line voltage neutral screw terminalon the control board. This will power theelectronic air cleaner whenever theECM2+ blower is operating and deliver-ing the recommended minimum CFM.The 60 and 75 KBTU models, which arecapable of a maximum delivery of 1200CFM, will operate the electronic aircleaner at 500 CFM and above. The 90,105 and 120 KBTU models, which arecapable of a maximum delivery of 2000CFM, will operate the electronic aircleaner at 800 CFM and above. Theselimits are set to prevent excessive pro-duction of ozone at the lower airflows ofthe modulating furnace and are basedon average requirements of commercial-ly available electronic air cleaners. Thecontinuous fan speeds are set to alwaysprovide adequate airflow for electronicair cleaner operation.

FIGURE 55EAC TERMINAL

FIGURE 56WIRING FOR OPTIONAL HUMIDIFIER

I681

LOW VOLTAGECONTROL WIRING

LOW VOLTAGECONTROL WIRING

LINE VOLTAGE

humidifiers controlled by a 24 VACcontrol circuit, an optional 24 VAChumidistat can be installed (seeFigure 56). With the optional humidi-stat, two separate conditions mustbe met before humidification of theconditioned space can begin: 1)There must be a heat call and theheat speed blower must be runningand 2) The humidistat must deter-mine that there is a need for humidi-fication.

60

Method B: ON-DEMAND DE-HUMIDI-FICATION–REFERENCE FIGURES 57THRU 59On UTECH IFC Revision –03 (62-24174-01 rev 03)or newer (After May12, 2004) or all revisions of 62-24174-02, an additional method for dehumidifi-cation was added to the function of theIFC. This method is not available onunits constructed before this date.The following methods for dehumidifica-tion utilize the most accurate means forsensing humidity. A humidistat shouldbe installed to the control board “YL” or“DEHUM” and “R” terminals.ON DEMAND DEHUMIDIFICATIONON UTECH IFC #62-24174-01REVISION 03 (62-24174-01 Rev -03)A humidistat should be installed to thecontrol board “YL” and “R” terminals.PLEASE NOTE THAT TWO-STAGECOOLING AND ON-DEMAND DE-HUMIDIFICATION CANNOT BE USEDAT THE SAME TIME (IFC REV. 03ONLY). The dip switch position #6 ofbank SW-1 is used to select betweeneither two-stage cooling or on-demandde-humidification, both features can notbe used at the same time becausethere is only one input used for both.Also, if neither feature is to be used, itdoes not matter if the dip switch is inthe “ON” or “OFF” position. Any humidi-stat can be used provided it is of thetype that can handle 24 volts andopens the contacts when there is aneed for de-humidification.

For proper installation of On-Demand De-Humidification, ensurethe following:A. Install one wire from one humidi-

stat contact terminal to the IFC“YL” terminal and another wirefrom the remaining humidistatcontact terminal to the IFC “R”terminal.

B. When installing, be sure to use ahumidistat and NOT a de-humidi-stat.

C. Position dip switch #6 of bankSW-1 to the “ON” position.

D. It is not possible to use two-stage cooling and de-humidifica-tion feature at the same time.

NOTE: When the dip switch position#6 of bank SW-1 is in the on posi-tion, a 24 volt signal from thehumidistat must be supplied at alltimes to keep the blower running atthe correct cooling speed. When the24 VAC signal is absent, the IFCassumes there is a need for de-humidification and operates theblower at the reduced rate. This iswhat is known as “reverse-logic”. Inother words, when a 24 VAC signalis present, normal operation occurs(100% cooling CFM), however,when there is no signal present, theIFC goes into the dehumidificationmode and reduces the airflow by15%. This could be confusing andwill cause the cooling speed to bereduced by 15% if the dip-switch isin the “on” position but no humidistatis connected.

DEHUMIDIFICATION IN COOLINGOPERATIONDehumidification in the cooling modecan be accomplished by two differentmethods. Both methods will reduce theamount of airflow in cooling by 15%.This reduced airflow will cause morewater to condense on the evaporatorcoil thus reducing the humidity in theconditioned space.IMPORTANT: The manufacturerrequires that all cooling systemsinstalled with either dehumidificationfeature enabled MUST have a coil of thetype with an expansion valve. In additionto these requirements, evaporator coilsmust have a freeze-stat (part #RXRX-AM01) installed to prevent possible coilfreeze-up. Note that the RCBA coilsmust have BOTH an expansion valve kitand a freeze-stat installed per manufac-turer’s instructions.Method A:THERMOSTAT DEMANDDE-HUMIDIFICATIONThis method for dehumidification relieson an algorithm in the modulating ther-mostat (part #41-24312-04) to calculatea need for dehumidification based onthe number and frequency of coolingcalls over a specified period of time.The feature is enabled on the thermo-stat interface panel. Please read andfollow the instructions for the modulat-ing thermostat to enable this feature.Please note that the thermostat canonly estimate when there is a need fordehumidification by looking at therecent history of cooling calls. This isnot a true measurement of humidity.For true humidity measurement, ahumidistat must be installed per theinstructions in method B below.

FIGURE 57UT Electronic Controls IFC. 62-24174-02Shown with Nec. Jumper location for acti-vation of dehumidification control.

(C.)Removethis jumper(J5) toenabledehumidifi-cation

SW1 SW2 SW3

61

FIGURE 59WIRING FOR OPTIONAL DEHUMIDIFIERWITH HUMIDIFIER

FIGURE 58WIRING FOR OPTIONAL DEHUMIDIFIER

ON DEMAND DEHUMIDIFICATIONIFC #62-24174-02IMPORTANT: Do not remove thejumper at J5 unless a humidistat isinstalled to the “DEHUM” terminal ofthe IFC. In addition, the controlallows the use of two-stage coolingand dehumidification at the sametime and separate cooling airflowsfor high efficiency (up to16 SEER)cooling. (see section labeled “FUR-NACE INSTALLATION WITH HIGHEFFICIENCY PREMIUM COOLINGSYSTEMS”).For IFC Revision #62-24174-02(AVAILABLE 2ND QUARTER 2005)or later, a new dehumidification ter-minal has been added to the ther-mostat terminal block. This terminalwill permit the user to install dehu-midification without the need tomanipulate any dip-switches.However, to activate the ODD fea-ture, a jumper located at position J5(between the thermostat terminalblock and dip switch bank SW-2 onthe IFC – see Figure 57) must beremoved and discarded. This jumperapplies 24 volts to the “dehum” ter-minal at all times in order to preventthe control from reverting to thelower (dehumidification) speed whenno voltage is applied.

HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING

IFC 62-24174-01 REV. 03 ONLY! POSITION #6OF SW1 MUST BE IN “ON” POSITION

IFC 62-24174-02: REMOVE THIS JUMPER(J5) TO ENABLE DEHUMIDIFICATION

(IFC 62-24174-01 REV. 03) OR DEHUM (IFC 62-24174-02 -ALLREVISIONS)

REM

OVE

FOR

DEH

UM

ENABLE

J5

HUMIDISTAT(24V)

(CONTACTS OPENWHEN HUMIDITY

IS ABOVE SET POINT)


(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02-ALL REVISIONS)

NEUTRAL OR COMMON

IFC

+110VAC OR 24VAC

HUMIDIFIER WITHINTERNALPOWER SUPPLY

J5

IFC 62-24174-02: REMOVETHIS JUMPER (J5) TO ENABLEDEHUMIDIFICATION

REM

OVE

FOR

DEH

UM

ENABLE

J5

HUMIDISTAT(24V)

(CONTACTSOPEN WHENHUMIDITY ISABOVE SETPOINT)

SPST RELAYW/ N.O CONTACTSRATED 24V COILAND 24V OR 110VCONTACTS ASNECESSARY FORHUMIDIFIER

HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATINGAND DEHUMIDIFIER IN COOLING (HUMIDIFIER WITH INTEGRALPOWER SUPPLY)

62

FIGURE 60WIRING FOR OPTIONAL DEHUMIDIFICATIONWITH HUMIDIFIER AND SEPARATE POWERSUPPLY.WIRING DIAGRAM FROMTWO-STAGE HEAT

HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATINGAND DEHUMIDIFIER IN COOLING (110V HUMIDIFIER WITHOUTINTEGRAL POWER SUPPLY)


(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02-ALL REVISIONS)

NEUTRAL OR COMMON

+110VAC OR 24VAC

HUMIDIFIER WITHEXTERNAL 110VOR 24V POWERSUPPLY

IFC 62-24174-02: REMOVETHIS JUMPER (J5) TO ENABLEDEHUMIDIFICATION

REM

OVE

FOR

DEH

UM

ENABLE

J5

HUMIDISTAT(24V)

(CONTACTSOPEN WHENHUMIDITY ISABOVE SETPOINT)

110V OR 24VPOWER SUPPLYAS NECESSARYFOR HUMIDIFIER

SPST RELAYW/N.O CONTACTSRATED 24V COILAND 24V OR 110VCONTACTS ASNECESSARY FORHUMIDIFIER

For proper installation of On-Demand De-Humidification, ensurethe following:A. Install one wire from one humidi-

stat contact terminal to the IFC“DEHUM” terminal and anotherwire from the remaining humidis-tat contact terminal to the IFC“R” terminal.

B. When installing, be sure to use ahumidistat and NOT a de-humidi-stat.

C. The jumper at position J5 on thecontrol (see Figure 57) has beenremoved.

OTHER ACCESSORIESAVAILABLEThese kits are available through thefinished goods department.CONCENTRIC VENTTERMINATIONKIT = RXGY-E03AHORIZONTAL,TWO-PIPETERMINA-TION KIT = RXGY-D02/D02A,RXGY-D03/D03A, OR RXGY-D04/D04AVENTTERMINATION KIT: RXGY-G02CONDENSATE PUMP KIT: RXGY-B01NEUTRALIZER KIT: RXGY-A01EXTERNAL BOTTOM FILTER RACK:RXGF-CBEXTERNAL SIDE FILTER RACK:RXGF-CAThese parts are available throughProStock parts department.ALTERNATE (LEFT-SIDE) DRAINKIT (DOWNFLOW MODELS ONLY):RXGY-H01

THERMOSTAT AND ACCESSORIES FOR THERMOSTAT

Programmable Modulating Thermostat:(-)HC-TST401MDMS

Remote Sensor:(For Mod Thermostat Above Only)F1451378

Thermostat Wall Plate For Mod Thermostat Above Only:F61-2600

63

TABLE 10Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace.Burner Input (per burner) 15,000 BTU @ Sea Level

Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 toto 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 6999 ft 7999 ft 8999 ft47 48 48 49 49 49 50 5048 49 49 49 50 50 50 5149 50 50 50 51 51 51 5250 51 51 51 51 52 52 5251 51 52 52 52 53 53 53

(-)GFD/(-)GGD/(-)GJD -HIGHALTITUDE OPTION #278

FOR (-)GGD-06 AND (-)GJD-06 MOD-ELS, A PRESSURE SWITCH CHANGEIS NOT NECESSARY AT ANY ELEVA-TION. FOR (-)GGD-07 AND (-)GJD-07MODELS, A PRESSURE SWITCHCHANGE IS REQUIRED AT ELEVA-TIONS ABOVE 8,000 FT. FOR ALLOTHER (-)GFD/(-)GGD/(-)GJD FUR-NACES, A PRESSURE SWITCHCHANGE IS REQUIRED AT ELEVA-TIONS ABOVE 5,000 FT. OPTIONCODE -278 OR THE APPROPRIATEHIGH-ELEVATION KIT WILL CONVERTTHE FURNACE FOR USE ABOVE THEAPPROPRIATE ELEVATION STATEDHERE. DO NOT INSTALL THE -278OPTION FURNACE OR THE HIGHALTITUDE KIT BELOWTHE STATEDELEVATION. DOING SO CAN CAUSESERIOUS PERSONAL INJURY ORDEATH OR EQUIPMENT FAILURE.Furnaces can be ordered from the facto-ry already converted for high altitudeelevations. The factory option for highaltitude elevations would be ordered asa 278 option (example: a 105k BTUupflow furnace which is factory convert-ed for high altitude elevations wouldhave the model number (-)GFD-10EZCMS278). These factory convertedfurnaces come with pressure switchesfor high-altitude elevations alreadyattached. Also, different burner orificesare installed at the factory which are onedrill size smaller (#51 DMS) than stan-dard (-)GFD/(-)GGD/(-)GJD gas fur-naces (#50 DMS). The smaller orifice isinstalled to accommodate for averageheating values expected in most highaltitude areas and a required 4% perthousand feet reduction in input as spec-ified by the National Fuel Gas Code(NFGC). Specific orifices should alwaysbe recalculated for all high altitudeinstallations as outlined below. Orificesshould be changed, if necessary, basedon gas heating value and elevation.

HIGH ALTITUDE CONVERSIONKITS AND OPTIONS

FOR (-)GGD-06 & (-)GJD-06 MODELS,A PRESSURE SWITCH CHANGE ISNOT NECESSARY AT ANY ELEVA-TION. FOR (-)GGD-07 & (-)GJD-07MODELS, A PRESSURE SWITCHCHANGE IS REQUIRED AT ELEVA-TIONS ABOVE 8,000 FT. FOR ALLOTHER (-)GFD/(-)GGD/(-)GJD FUR-NACES, A PRESSURE SWITCHCHANGE IS REQUIRED AT ELEVA-TIONS ABOVE 5,000 FT. OPTIONCODE -278 OR THE APPROPRIATEHIGH-ELEVATION KIT WILL CONVERTTHE FURNACE FOR USE ABOVE THEAPPROPRIATE ELEVATION STATEDHERE. DO NOT INSTALL THE -278OPTION FURNACE OR THE HIGHALTITUDE KIT BELOWTHE STATED

ELEVATION. DOING SO CAN CAUSESERIOUS PERSONAL INJURY ORDEATH OR EQUIPMENT FAILURE.HIGH ALTITUDE FIELDCONVERSION KITS (GFD MODELS)MODEL INPUT(BTU) KIT NO.(-)GFD-06XXXXX 60,000 RXGY-F06(-)GFD-07XXXXX 75,000 RXGY-F07(-)GFD-09XXXXX 90,000 RXGY-F06(-)GFD-10XXXXX 105,000 RXGY-F05(-)GFD-12XXXXX 120,000 RXGY-F05

HIGH ALTITUDE FIELDCONVERSION KITS (GGD & GJDMODELS)MODEL INPUT(BTU) KIT NO.(-)GGD/(-)GJD-06XXXXX 60,000 No Kit

Required(-)GGD/(-)GJD-07XXXXX 75,000 RXGY-F23

(8000 ft andabove only)

(-)GGD/(-)GJD-09XXXXX 90,000 RXGY-F24(-)GGD/(-)GJD-10XXXXX 105,000 RXGY-F25(-)GGD/(-)GJD-12XXXXX 120,000 RXGY-F26

Orifice Selection for High AltitudeApplicationsNatural Gas

INSTALLATION OF THIS FURNACEAT ALTITUDES ABOVE 2000 FT (610m) SHALL BE IN ACCORDANCEWITH LOCAL CODES, OR IN THEABSENCE OF LOCAL CODES, THENATIONAL FUEL GAS CODE, ANSIZ223.1/NFPA 54 OR NATIONALSTANDARD OF CANADA, NATURALGAS AND PROPANE INSTALLATIONCODE, CAN B149.1.INSTALLATION OF THIS APPLIANCEAT OR ABOVE 5000 FT (1525 m)SHALL BE MADE IN ACCORDANCEWITH THE LISTED HIGH ALTITUDECONVERSION KIT AVAILABLEWITHTHIS FURNACE.34” 90 Plus furnaces (except for opt-278 models) installed at high eleva-tions require the installation of a highaltitude kit for proper operation. Thehigh altitude kit consists of a high alti-tude pressure switch that replaces thepressure switch attached to the induceddraft blower.The pressure switch must be installedat elevations above those listed.Elevations above 2000 ft. require thefurnace to be de-rated 4% per thou-

Annual Avg. HeatValue (btu per ft3)

850900

100010751170

sand feet. NOTE: Factory installedorifices are calculated and sizedbased on a sea level Natural Gasheating value of 1075 BTU per cubicft. Regional reduced heating valuesmay nullify the need to change ori-fices except at extreme altitudes.Table 10 shows some quick conver-sions based on elevation and gasheating value. This table is com-bined and simplified from Tables F1and F4 of the NFGC.

EXAMPLESThe following are examples of orificesizing using the National Fuel GasCode Appendix F. For a simplifiedestimation of orifice size based onheating value and elevation useTables 10 and 11. However, calcula-tions are the best method.Example: 900 BTU/ft3 RegionalNatural Gas Heating ValueI / H = Q15000 / 900 = 16.68 ft3/hrI = Sea Level input (per burner):15000H = Sea Level Heating Value: 900Q = 16.68 ft3 Natural Gas per hour.From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5! w.c. col-umn)Orifice required at Sea Level: # 48From Table F.4 of National fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft): # 50Orifice required at 8000 ft. elevation(4% de-rate per thousand ft): # 51Example: 1050 BTU/ft3 RegionalNatural Gas Heating ValueI / H = Q15000 / 1050 = 14.63 ft3/hrI = Sea Level input (per burner):15000H = Sea Level Heating Value: 1050Q= 14.28 ft3 Natural Gas.From Table F.1 of National Fuel Gascode Handbook, 2002 (3.5! w.c. col-umn)Orifice required at Sea Level: # 50From Table F.4 of National Fuel Gascode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft): # 51Orifice required at 8000 ft. elevation(4% de-rate per thousand ft): # 52

CAUTION!

! WARNING

! WARNING

HIGH ALTITUDE INSTALLATIONS

64

TABLE

11SUPPLEMENTALORIFICESIZE

CHART

90Plus

ONLY

modelswith

15,000Btu'sperBurner.DONOTUSE

THISCHART

FORANY80PLUSMODEL.

NATURAL

GAS

QUICKREF

EREN

CECHAR

TFO

RORIFICESE

LECTION,AT3.5"W.C.ANDAP

PROXIMATEFINAL

FIRINGRATES

FinalFiring

RateperB

urner

Sea

Level

Orifice

Size

SeaLevel

Cubic

Footat

3.5"W.C.

90Plus

Heat

Valueat

15,000

Btu’s

perB

urner

0-999

1000-1999

2000-2999

3000-3999

4000-4999

5000-5999

6000-6999

7000-7999

8000-8999

9000-9999

ELEVATIONCHAR

T(NFG

recommendedorifice

basedon

4%derateforeach1000

footofelevation,based

ontheintersectionoftheorifice

requiredatSeaLeveland

theelevationrequiredbelow)

4618.57

808

4646

4747

4748

4849

4950

4717.52

856

4747

4848

4949

4950

5051

4816.36

917

4848

4949

4950

5050

5151

4915.2

987

4949

5050

5051

5151

5252

5013.92

1078

5050

5151

5151

5252

5253

5112.77

1175

5151

5152

5252

5253

5353

15,000

14,400

13,800

13,200

12,600

12,000

11,400

10,800

10,200

9,600

Allcalculations

areperformed

byusingthefirstthreecolumns

ofinformationonly.Beforebeginninganycalculations,determinethe

individualburnerBtusizeandheatingvalueatSeaLevelfortheinstallationsite.EachvalueshownintheHeatValue

columnisper

burnerat3.5"W.C.

NOTE:

HeatValue

atSeaLevel,forthe

locationoftheinstallation,isavailablefromtheNaturalGas

Suppliertothatsite.O

rifices

forallaltitudes

arebased

onSeaLevelvalues.

Dividetheindividualburnercapacity(15,000for90plus)bytheHeatValue

forthe

sitetodeterminetheCubicFootvalueatSeaLevel,ordivide

burnercapacityby

theCubicFootvalueforthe

HeatValue.O

nceyouhave

eithertheCubicFootValueortheHeatValue

youcanestim

atetheSea

Levelorificeforthe

site.Toselectthecorresponding

high

altitudeorifice,locatethesiteelevationon

thechartabove

andtheorifice

requiredatSea

Levelfromyourcalculationinthefirstcolumn.Thecorrecthigh

altitudeorifice

thatmustbeinstalledineach

individualburneristheintersectionof

thesetwopointson

thechartabove.

65

LP GAS AT HIGH ALTITUDEELEVATIONSLP Gas is a manufactured gas that hasconsistent heating value across mostregions.The NFGC guidelines are used with thefollowing exception:The recommended LP Gas high altitudeorifice selections differ slightly in thatthe NFGC LP orifice chart, as they arenot accurate for the (-)GFD or (-)GGDgas furnace. The National Fuel GasCode LP orifices are based on an 11” ofwater column pressure at the orifice,which differs from products that use 10”of water column at the orifice. This dif-ference requires a deviation from theNFGC orifice size recommendations.The Sea Level input should still bereduced by 4% per thousand ft. and theorifice size must be selected based onthe reduced input selection shown inTable 12.

Orifice Ordering InformationOrifice sizes are selected by addingthe 2-digit drill size required in the ori-fice part number. Drill sizes availableare 39 through 64; metric sizes avail-able 1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:#60 drill size orifice requiredPart #62-22175-60Example 2:1.15mm drill size orifice requiredPart #62-22175-91

TABLE 12LP Gas Orifice Drill Size and per burner de-rate by elevation basedon 15,000 btu 90+ burners.IMPORTANT: For 90+ Furnaces only. Do not use this chart for any80+ Furnace.

Input (per OrificeAltitude burner) 15000 Size

0 to 2000 ft. 15000 1.15 mm (factory)2001" to 3000" 13200 1.15 mm3001" to 4000" 12600 1.10 mm4001" to 5000" 12000 #585001" to 6000" 11400 #596001" to 7000" 1080 #607001" to 8000" 10200 #628001" to 9000" 9600 #639001" to 10000" 9000 #64

66

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.(See condenser spec. sheet, I&O and other literature for evaporator selection)

Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.(See condenser spec. sheet, I&O and other literature for evaporator selection)

TABLE 14AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (2 STAGE COOL ONLY)

TABLE 13AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (1 STAGE COOL ONLY)

ZONING SYSTEMSThe manufacturer does not currentlyprovide or support zoning with modulat-ing furnace. However, zoning systemscan be installed with the system as longas the zoning equipment manufacturersspecifications and installation instruc-tions are met and followed.The preferred zoning method is to usea “bypass” system which is properlyinstalled for maximum efficiency. Inthese systems, excess air is routedback through the system to be usedagain – this is opposed to a “dump”system in which excess air is routed toa zone where it is expected that theextra heat or cooling would be leastnoticed.If installed as a “bypass” system, theinstallation must have an optionalfreeze stat installed to prevent the coilfrom icing with excess bypass cooling.Also, if the zoning equipment manufac-turer provides a limit switch (usuallyprovided by the zoning manufacturer),this limit must be installed in the systemto prevent the furnace from overheat-ing.

FURNACE INSTALLATIONWITH HIGH-EFFICIENCYPREMIUM COOLINGSYSTEMSFurnace installation with Rheem/Ruud-ARA or -ARL outdoor condensing unitscan provide high efficiency (up to 16SEER) cooling operation when com-bined with proper evaporator coil. Forlisted cooling equipment combinations,see the -ARA or -ARL specificationsheets and Figure 62 of this document.Using Tables 13 and 14 and literatureprovided with the cooling equipment,the installer needs to make sure thatthe proper evaporator coil, condensingcoil and airflow is configured to achieverated efficiency.In accordance with Rheem/Ruud cool-ing equipment installation instructions,do not install an evaporator coil or coilcasing to the furnace which is smallerin width than the furnace cabinet.UP TO 16 SEER COOLINGOPERATIONCheck the revision number of the inte-grated furnace control (IFC) to deter-mine how best to configure your fur-nace for high SEER operation.

TONSFURNACE

MODEL WIDTH

APPROX.AIRFLOW

(CFM) SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4CONDENSING

UNITMOD. FURNACE IFC DIP-SWITCH SETTINGS

2 (-)GFD/GGD/GJD-06 & -07 17.5" 800 -ARA-24 OFF ON OFF OFF2-1/2 (-)GFD/GGD/GJD-06 & -07* 17.5" 1000 -ARA-30 ON OFF OFF OFF

3 (-)GFD/GGD/GJD-09 & -10* 21" 1200 -ARA-36 ON ON OFF OFF3-1/2 (-)GFD/GGD/GJD-09 & -10* 21" 1400 -ARA-42 ON ON OFF OFF

3 (-)GFD/GGD/GJD-12 24.5" 1200 -ARA-36 ON ON OFF OFF3-1/2 (-)GFD/GGD/GJD-12 24.5" 1400 -ARA-42 ON ON OFF OFF

TONSFURNACE

MODEL WIDTH

APPROX.AIRFLOW

(CFM) SW-1,#1 SW-1,#2 SW-1,#3 SW-1,#4CONDENSING

UNITMOD. FURNACE IFC DIP-SWITCH SETTINGS

2 (-)GFD/GGD/GJD-06 & -07 17.5" 800 -ARL/ASL-24 OFF ON OFF OFF3 (-)GFD/GGD/GJD-06 & -07 17.5" 1200 -ARL/ASL-36 OFF OFF OFF OFF3 (-)GFD/GGD/GJD-09 & -10 21" 1200 -ARL/ASL-36 ON ON OFF OFF3 (-)GFD/GGD/GJD-12 24.5" 1200 -ARL/ASL-36 ON ON OFF OFF4 (-)GFD/GGD/GJD-09 & -10 21" 1600 -ARL/ASL-48 ON OFF OFF OFF4 (-)GFD/GGD/GJD-12 24.5" 1600 -ARL/ASL-48 ON OFF OFF OFF5 (-)GFD/GGD/GJD-12 24.5" 1800 -ARL/ASL-60 OFF OFF OFF OFF

IFC #62-24174-02To achieve high SEER operation,turn dip switch #6 of bank SW1 tothe “on” position. This will enable thefurnace operation for 16 SEER.Actual SEER values will vary anddepend on the equipment combina-tion. Consult the specificationssheets and installation instructionsof the cooling equipment purchasedfor a listing of the SEER ratings fora specific combination.

ALL OTHER INTEGRATEDFURNACE CONTROLSHigh SEER operation with IFC’sother than 62-24174-02 may notachieve rated performance ordesired comfort levels. For theseolder models, there are no additionaladjustments necessary to the fur-nace. For optimum performance,replace with IFC #62-24174-02.

A NOTE ABOUTDEHUMIDIFICATION:High SEER systems may require theuse of the onboard dehumidificationfeature of this system. Be sure toconsult the section titled “ONDEMAND DEHUMIDIFICATION” onpage 45 of this document.

67

GENERALThe UT Electronic Controls IFC board(see Figure 61) is a recent addition tothe furnace and will be a direct replace-ment for all Johnson Controls IFCboards. New features have beenadded to the IFC board to improve air-flow performance in the heating mode.The new board also adds two-stagecapability in addition to the existingmodulating and single-stage operation.Also, the locations of the original dipswitches (SW1 & SW2), and the loca-tion of the seven segment display aredifferent than the previous JohnsonControls IFC board. The function ofthese components has not changed.

➤ IMPORTANT: The dip switches onSW2 (used for test mode and for oper-ation with two-stage thermostats) mustbe in the “OFF” position for modulatingor single-stage operation. If bothswitches are in the “ON” position, amissing “V” signal with a call on “W” willcause the furnace to run only at 40%.However, with both switches in the“ON” position, the furnace will functionwith a two-stage thermostat when con-nected as shown in Figure 55.

DIP SWITCH SET SW1For proper setting of the airflow switchesto meet requirements, see Figure 62.

➤ DIP SWITCH SET SW2The UT Electronic Controls IFC boardhas added two-stage capabilities. Thisfeature is activated by changing theswitches 1 & 2 of SW2 to the “ON” posi-tion and installing a two-stage thermo-stat as shown in Figure 55. This featureallows the furnace to be used with astandard two-stage thermostat. Withswitches 1 & 2 of SW2 set to the “ON”position, the furnace will go to 40% ofcapacity when “W” is energized alone.In this configuration, when “W” and “W2”are energized, the furnace runs at 65%for five minutes and then changes to100%. If the call for heat ends at anytime the furnace terminates immediatelyat the present firing rate.

DIP SWITCH SET SW3The UT Electronic Controls IFCboard has an added set of dipswitches labeled SW3 (see Figure61). The function of these dip switch-es is to fine-tune airflow in the heat-ing mode. The dip switches will beset to either the 40% or 100% (orboth) firing rate, and will adjust everypoint in between accordingly.SW3 will allow for airflow adjust-ments at high altitude, improper tem-perature probe locations, or no tem-perature probe applications. If tem-perature rise range is a problem, thetechnician must use temperatureprobes to determine the rise rangeand adjust the airflow using SW3’sdip switches until the temperaturerise is within the specified range.

ADJUSTING AIRFLOWAll airflow adjustments on SW3should be made with the main powerOFF. Dip switches 1 through 3 willadjust airflow at the 100% firing rateand dip switches 4 through 6 willadjust the airflow at the 40% firingrate.

100% Firing RateTo use SW3 to change the airflow atthe 100% rate:1) Dip switch 1 must be “ON” (or“ADJ”). This instructs the IFC thatthe high firing rate airflow will beoverridden.

2) Dip switch 2 in the “OFF” positionwill decrease airflow at 100% fire,and in the “ON” position willincrease airflow at 100% fire.

3) If dip switch 3 is “OFF” the amountairflow will be adjusted by 7.5%. Ifit is “ON” amount of airflow will beadjusted by 15%.

40% FIRING RATETo use SW3 to change the airflow atthe 40% rate:1) Dip switch 4 must be “ON” (or“ADJ”). This instructs the IFC thatthe high firing rate airflow will beoverridden.

2) Dip switch 5 in the “OFF” positionwill decrease airflow at 40% fire,and in the “ON” position willincrease airflow at 40% fire.

3) If dip switch 6 is “OFF” the amountairflow will be adjusted by 7.5%. Ifit is “ON” amount of airflow will beadjusted by 15%.

INTEGRATED FURNACE CONTROL

FIGURE 61UT ELECTRONIC CONTROLS IFC BOARD

Mode Switch 1 Position Switch 2 PositionModulating/Single-Stage OFF OFF

Test 40% ON OFFTest 100% OFF ON

Two-Stage ON ON

TABLE 15SW2 MODE SELECTION SETTINGS

SW2

SW1 SW3

68

FIGURE 62AIRFLOW SWITCHES (SW1)

SW1, Pos 6 YH YL YL+YH(16 SEER) Single stage Low 2 stage High 2 stage

OFF OFF OFF 1200 CFM 600 CFM 1200 CFM 3 Ton A/COFF OFF ON 1000 CFM 500 CFM 1000 CFM 2.5 Ton OFF ON OFF 800 CFM 400 CFM 800 CFM 2 Ton A/COFF ON ON 600 CFM 300 CFM 600 CFMON OFF OFF 1200 CFM 900 CFM 1200 CFM 3 Ton A/CON OFF ON 1000 CFM 750 CFM 1000 CFM 2.5 Ton ON ON OFF 800 CFM 600 CFM 800 CFM 2 Ton A/CON ON ON 600 CFM 450 CFM 600 CFM

SW1, Pos 6 YH YL YL+YH(16 SEER) Single stage Low 2 stage High 2 stage

OFF OFF OFF 2000 CFM 1000 CFM 2000 CFM 5 Ton A/COFF OFF ON 1600 CFM 800 CFM 1600 CFMOFF ON OFF 1400 CFM 700 CFM 1400 CFM 3.5 TonOFF ON ON 1200 CFM 600 CFM 1200 CFM 3 TonON OFF OFF 2000 CFM 1400 CFM 1800 CFM 5 Ton A/CON OFF ON 1600 CFM 1200 CFM 1600 CFMON ON OFF 1275 CFM 1050 CFM 1400 CFM 3.5 TonON ON ON 1200 CFM 900 CFM 1200 CFM 3 Ton

Standard Cooling (approx. 50% of High-Stage Cooling on Low Stage) This

matches cooling airflow of the original IFC.

HIGH SEER (16+) Premium Cooling airflow (SW1, Position 6 is ON)

Notes

MODULATING FURNACE COOLING AIRFLOW RATES, 1 HP (2000 CFM) motor settingsSW1, Pos.

2SW1, Pos.

1

MODULATING FURNACE COOLING AIRFLOW RATES, 1/2 HP (1200 CFM) motor settings

HIGH SEER (16+) Premium Cooling airflow (SW1, Position 6 is ON)

Notes

Standard Cooling (approx. 50% of High-Stage Cooling on Low Stage) This

matches cooling airflow of the original IFC.

SW1, Pos. 2

SW1, Pos. 1

4 Ton A/C

4 Ton A/C

69

FIGURE 63EXAMPLE 1

AIRFLOW ADJUSTMENTEXAMPLESThree examples of airflow adjustmentare shown below.

NOTE: All dip switches on SW3 will beshipped in the “OFF” position.

Example 1 (see Figure 63)

PROBLEM: Temperature rise is too highat 40% firing rate although it is withinthe published range at 100% firing rate.

SOLUTION: More airflow is needed tolower the temperature rise at 40%.1) Set dip switches 4 and 5 of SW3 tothe “ON” position. This will produce a7.5% increase in blower output.

2) Allow furnace to run for several min-utes at 40% firing rate until tempera-ture probes reach equilibrium.

3) If the temperature rise is still abovethe published range, set switch 6 ofSW3 to the “ON” position. This willincrease the airflow rate from +7.5%to +15% above the standard value.

EXAMPLE 2 (see Figure 64)

PROBLEM: Temperature rise is too lowat 100% firing rate although it is withinthe published range at 40% firing rate.

SOLUTION: Less airflow is needed toincrease temperature rise at 100%.1) Set dip switch 1 of SW3 to the “ON”position, which overrides standardairflow.

2) Leave switches 2 and 3 in the“OFF” position to decrease airflowby 7.5%.

3) Allow furnace to run for severalminutes at 100% rate until tempera-ture probes reach equilibrium.

4) If the temperature rise is still belowthe published range, set switch 3 tothe “ON” position. This willdecrease the airflow rate from -7.5% to -15% below the standardvalue.

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switches 4 & 5 to “ON” position toincrease airflow by 7.5% at the 40%fire rate.

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. If +7.5% is not enough, increase airflowby setting switch 6 to “ON” position togive +15%.

FIGURE 64EXAMPLE 2

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switch #1 to “ON” position andleave #2 and #3 in the “OFF” positionto decrease airflow by 7.5% at the100% fire rate.

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. If -7.5% is not enough, decreaseairflow by setting switch 3 to “ON”position to give -15%.

FIGURE 65EXAMPLE 3

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

A. Set switch #4 to “ON” and leave #5and #6 set to “OFF” to decrease air-flow by 7.5% at the 40% fire rate. Ifnecessary, set switch #6 to “ON” todecrease airflow by 15%.

12

34

56

ONOFF

40%

100%SW3

STD

--

7.5%

STD

--

7.5%

ADJ

+

15%

ADJ

+

15%

B. Set switches #1 and #2 to “ON” andleave #3 set to “OFF” to increaseairflow by 7.5% at the 100% firerate. If necessary, set switch #3 to“ON” to increase airflow by 15%.

EXAMPLE 3 (see Figure 65)

PROBLEM: Temperature rise is too lowat 40% firing rate and is too high at100%.

SOLUTION: Less airflow is needed toincrease temperature rise at 40% fir-ing rate and more is needed todecrease temperature rise at 100%.1) Set dip switch 4 of SW3 to the“ON” position to override standardairflow at 40% firing rate. Leaveswitches 5 and 6 in “OFF” positionto decrease airflow by 7.5%.

2) Allow furnace to run for severalminutes at 40% rate until tempera-ture probes reach equilibrium.

3) If temperature rise is still lowerthan the published range, setswitch 6 to the “ON” position todecrease the airflow rate from-7.5% to -15% below the standardvalue.

4) Set dip switches 1 to the “ON”position to override standard air-flow at 100% firing rate. Set switch2 to the “ON” position to increaseairflow by 7.5%.

5) Allow furnace to run for severalminutes at 100% rate until temper-ature probes reach equilibrium.

6) If temperature rise is still higherthan the published range, setswitch 3 to “ON” position toincrease the airflow rate from 7.5%to 15% above the standard value.

70

FURNACETEST MODEFURNACE TEST SWITCHESNOTE: The integrated furnace controldoes not recognize switch settingchanges while energized. To changesettings, remove power to the board,make changes, then return power.The Integrated Furnace Control isequipped with three sets of field selec-table switches. The set with five switch-es (SW1) (See Figure 60) is for select-ing airflow operation options (AirflowSwitches). The set with two switches(SW2) is for placing the furnace into testmode for initial set-up and troubleshoot-ing and for choosing between modulat-ing, single-stage and two-stage func-tions. (see Figure 61).The Test Switches (SW2) will place theIFC into a test mode, operating the fur-nace at continuous input rates of either100% of full rate (maximum fire) or 40%of full rate (minimum fire and 2-stageoperation). This is accomplished by set-ting the Test Switches as indicated inTable 16.

To enter the Furnace Test Mode, pro-ceed as follows:1. Switch the 115 volt power to the fur-nace OFF. Do not change settingswith control energized.

2. Position Test Switches 1 and 2 forthe desired test mode.

3. Switch the 115 volt power to the fur-nace ON.

4. Set the thermostat mode to HEAT,adjust the setpoint at least 4°Fabove room temperature to demanda call for heating.

When the furnace is powered with thetest switches in a position other thanmodulating/single-stage or in 2-stagemode, the first call for heat within thefirst hour after power-up will instruct thefurnace to perform as follows:1. Normal ignition sequence2. A calibration cycle will be performedunless the Test Switches are set forTest 40%. The LED status indicatorwill flash “H” or “h” during the cali-bration cycle (see Table 18).

START-UP PROCEDURESTO STARTTHE FURNACEDIRECT SPARK IGNITION LIGHTINGINSTRUCTIONSThis appliance is equipped with a direct-spark ignition device. This device lightsthe main burners each time the roomthermostat calls for heat (connects R toW). See the lighting instructions on thefurnace.During initial start-up, it is not unusual forodor or smoke to come out of any roomregisters. To ensure proper ventilation, itis recommended to open windows anddoors, before initial firing.The furnace has a negative pressureswitch that is a safety during a call forheat. The induced draft blower must pulla negative pressure on the heatexchanger to close the negative pressureswitch. The induced draft blower mustmaintain at least the negative pressureswitch set point for the furnace to oper-ate. If the induced draft blower fails toclose or maintain the closing of the nega-tive pressure switch, a “no heat call”would result.1. Remove the burner compartment

control access door.2. IMPORTANT: Be sure that the man-

ual gas control has been in the“OFF” position for at least five min-utes. Do not attempt to manuallylight the main burners.

3. Set the room thermostat to its lowestsetting and turn off the furnace elec-trical power.

4. Turn the gas control knob to the“ON” position.

5. Replace the burner compartmentcontrol access door.

FAILURETO REPLACETHEBURNER DOOR CAN CAUSEPRODUCTS OF COMBUSTIONTOBE RELEASED INTOTHE CONDI-TIONED AREA RESULTING INPERSONAL INJURY OR DEATH.6. Turn on the manual gas stop.7. Turn on the furnace electrical power.8. Turn thermostat to “Heat” mode and

set the room thermostat at least 4° Fabove room temperature to light themain burners.

9. After the burners are lit, set theroom thermostat to a desired tem-perature.

Mode Switch 1 Position Switch 2 PositionModulating/Single-Stage OFF OFF

Test 40% ON OFFTest 100% OFF ON

Two-Stage ON ON

TABLE 16SW2 MODE SELECTION SETTINGS

NOTE: The return air sensor (fac-tory installed) and the supply airsensor (field installed) arerequired for the furnace calibrationcycle. If the air sensors are faulty,or not properly connected, the fur-nace will not attempt a calibrationcycle and will operate on factorydefault parameters pre-pro-grammed into the microprocessor.

3. After calibration, the furnace willthen adjust to the desired Testcapacity. This allows time for thetechnician to check steady-stateoperation and evaluate furnaceperformance.NOTE: Refer to Figure 70(Furnace Test Mode Sequence ofOperation/ Troubleshooting), andFurnace Performance Data Table17.

4. The furnace will operate at thefixed Test capacity until one of thefollowing conditions:a. The thermostat is satisfied and

the call for heat is removed.b. The furnace has been in test

mode continuously for sixtyminutes, at which time thecontroller will go into modulat-ing/single-stage operation.

NOTE: The IFC will only checkthe test mode switches on powerup. Terminating the test mode byeither 4a or 4b will place the fur-nace into modulating or single-stage operation regardless ofthe test mode switch positions.

To set the furnace for normal oper-ation:1. Set the thermostat mode to OFF.

Always allow furnace to completethe cool down cycle.

2. Switch the 115 volt power to thefurnace OFF. Do not change set-tings with control energized.

3. Position Test Switches 1 and 2 formodulating/single-stage mode or2-stage mode.

4. Switch the 115 volt power to thefurnace ON.

5. Set the thermostat as desired.

THERMOSTATTESTMODESEE THERMOSTAT SECTION OFTHESE INSTRUCTIONS FOR TEST-MODE DIRECTIONS.

! WARNING

71

TABLE 18NORMAL OPERATION INDICATORS - DIAGNOSTIC LED

LEDSYMBOL DESCRIPTION COMMENTS

All symbols indicate furnace control board is properlypowered.

O System OFF There is no demand from the thermostat. Thereare no active faults.

F System FAN ONLY The IFC is receiving 24V on the “G”terminal ONLY. There are no active faults.

C System COOL The IFC is receiving 24 V on the “YL”and/or “YH” terminals. There are no active faults.

H System HEAT The IFC is receiving 24 V on the “W”terminal. The modulating signal is present on the“V” terminal. There are no active faults.

h System HEAT The IFC is receiving 24 V on the “W”terminal. The modulating signal is NOT present onthe “V” terminal. There are no active faults.

“H” Calibration Cycle The IFC is receiving 24 V on the “W”Flashing terminal. The modulating signal is present on the

“V” terminal. The furnace is in calibration mode.There are no active faults.

“h” Calibration Cycle The IFC is receiving 24 V on the “W”Flashing terminal. The modulating signal is NOT present on

the “V” terminal. The furnace is in calibrationmode. There are no active faults.

TABLE 17FURNACE PERFORMANCE DATA

Operating Inducer Servo ValveManifold Pressure

TemperatureLevel Speed Current Rise

100% High ~180 milliampsNatural - 3.5" w.c. (±0.3")

40°-70° FLP - 10.0" w.c. (±0.5")


40°-70° FLP - 8.1" w.c. (±0.5")

80% High ~144 milliampsNatural - 2.2" w.c. (± 0.3")

40°-70°FLP - 6.4" w.c. (± 0.5")


40°-70°FLP - 4.9" w.c. (± 0.5")


40°-70°FLP - 3.6" w.c. (± 0.5")


40°-70°FLP - 2.5" w.c. (± 0.5")

40% Low ~72 milliampsNatural - 0.6" w.c. (± 0.3")

40°-70°FLP - 1.6" w.c. (± 0.5")

Calibration High ~135 milliampsNatural - 2.0" w.c. (± 0.3")

40°-70°FLP - 5.6" w.c. (± 0.5")

NOTE: Gas valve milliamp readings may vary ± 05%.

72

TO SHUT DOWNTHE FURNACE1. Set the room thermostat to its low-

est setting and turn to “OFF” posi-tion.

2. Turn off the manual gas stop andturn off the electrical power to thefurnace.

3. Remove the burner compartmentcontrol access door.

4. Shut off the gas to the main burnersby turning the gas control knob tothe “OFF” position.

5. Replace the burner compartmentcontrol access door.

SHOULD OVERHEATING OCCUROR THE GAS SUPPLY FAIL TOSHUT OFF, CLOSE THE MANUALGAS VALVE FOR THE APPLI-ANCE BEFORE SHUTTING OFFTHE ELECTRICAL SUPPLY. FAIL-URE TO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULT-ING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

SEQUENCEOFOPERATIONHeating Cycle InitiationThe heating cycle is always initiated bya 24 volt signal on W of the thermostat.When the controller senses 24 volts onW, the following sequence occurs:• High and low pressure switches arechecked to insure contacts are open.

• Inducer is powered on high speed fora thirty (30) second prepurge.

• Pressure switches are monitored asthe inducer creates the vacuum toclose the contacts.

• The servo valve on the gas valve isenergized with ~180 milliamps current.(No flow yet.)

• The controller sends 120 volts to theignition control, which sparks acrossthe electrodes.

• The main solenoids on the gas valveare energized allowing gas to flow tothe burners.

• When flame is proven, the ignitioncontrol is de-energized - 8 secondmaximum trial time.

• The gas valve maintains 100% ratethrough the warm-up period - 20 sec-onds.Heating Cycle ResponseThe heating cycle is always initiated by a24 volt signal on W1. When the controllersenses 24 volts on W1, the followingsequence occurs:MODULATING FUNCTION:(“W” and “V” signal inputs, refer to dipswitch set SW2 on IFC)After the warm-up period, the furnacewill respond to the thermostat demandby adjusting the gas valve pressure

and blower speed anywhere between40% to 100% heating capacity.

➤TWO-STAGE FUNCTION:(Two-stage function only applies whenboth switches of SW2 are in the “ON”position and a two-stage thermostat isinstalled as shown in Figure 50.)After the warm-up period, the furnacewill respond to the thermostat demandby adjusting the gas valve pressure andblower heating speeds to the “W” signalvalues. “W” only = 40% gas valve pres-sure and blower heating speed. “W2” =65% gas valve pressure and blowerheating speed for first five minutes and100% thereafter. Also, if the call for heatends, the furnace terminates at the pre-sent rate.

➤ SINGLE-STAGE FUNCTION:(“W” signal only)After the warm-up period, the furnacewill respond to the thermostat demandby altering the gas valve pressure andblower speed as follows:

Phase 1: 0 to 5 minutes = 40% of furnacecapacity (gas valve output and blowerspeed)

Phase 2: 5 to 12 minutes = 65% of fur-nace capacity (gas valve output andblower speed)

Phase 3: After 12 minutes = 100% of fur-nace capacity (gas valve output andblower speed)

NOTE: If the call for heat ends during anyphase, the furnace will terminate imme-diately at the firing rate of that phase.

Heating CycleTermination(“W” signal only, refer to dip switch setSW2 on IFC)

When the 24 volt signal is removed fromW1, the heating cycle will end and the fur-nace will shut down and return to theproper off cycle operation.

TABLE 19METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACESEQUIPPED FOR NATURAL OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.METER 900 1000 1040 1100 2500 (LP)INPUT SIZE

BTU/HR CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

ONE 0 54 1 0 1 3 1 6 2 3060,000 TEN 9 0 10 0 10 24 11 0 25 0

ONE 0 44 0 48 0 50 0 53 2 075,000 TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 36 0 40 0 42 0 44 1 4090,000 TEN 6 0 6 40 7 0 7 20 16 40

ONE 0 31 0 34 0 36 0 38 1 26105,000 TEN 5 10 5 40 6 0 6 20 14 20

ONE 0 27 0 30 0 31 0 33 1 15120,000 TEN 4 30 5 0 5 10 5 30 12 30

DRY Heating Value of Gas (BTU/FT3) x 3600Formula: Input BTU/HR = x C • F

Time in Seconds (for 1 cu. ft.) of Gas

SETTING INPUT RATEChecking furnace input is importantto prevent over firing beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE. Use the follow-ing table or formula to determineinput rate. Prior to checking the fur-nace input, make certain that allother gas appliances are shut off,with the exception of pilot burners.Time the meter with only the furnacein operation. Start the furnace, inFurnace Test Mode, 100% rate, andmeasure the time required to burnone cubic foot of gas.The furnace is shipped from the fac-tory with #50 orifices. They are sizedfor natural gas having a heatingvalue of 1075 BTU/cu. ft. and a spe-cific gravity of .60. For high-altitudemodels (option 278) the furnacecomes equipped with #51 orificesinstalled for elevations 5,000 to5,999 ft. These orifices may still needto be changed based on both eleva-tion and gas heating value. Consultthe section of this book titled “HighAltitude Installation” for details.Since heating values vary geographi-cally, the manifold pressure and/orgas orifice size may need to bechanged to adjust the furnace to itsnameplate input. The rate will alsovary with altitude. Consult the localgas utility to obtain the yearly aver-age heating value and orifice sizerequired to fire each individual burnerat 15,000 BTUH. For high altitudeinstallations, also consult the sectionof this manual titled “High AltitudeInstallations” for details on how tocalculate the correct orifice size.

Gas Pressure (inch • Hg) x 520 (˚F)Where C • F = Gas Temperature (˚F) x 30 (inches • Hg)

! WARNING

73

DISCONNECT MAIN ELECTRICALPOWERTOTHE UNIT BEFOREATTEMPTING ANY MAINTE-NANCE. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

FILTERSKeep the filters clean at all times.Remove the filter. Vacuum dirt from filter,wash with detergent and water, air drythoroughly and reinstall.NOTE: Some filters must be resized to fitcertain units and applications. See Table20 and Figures 66, 67, 68, 69 & 70.1. 21" - 90,000 & 105,000 BTUH units

require removal of a 31/2-in. segmentof filter and frame to get the properwidth for a side filter.

2. 241/2" - 120,000 BTUH unit requiresremoval of a 7" segment of filter andframe to get the proper width for aside filter.

! WARNINGTABLE 20FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH KBTUH SIZE SIZE

171/2" 60 AND 75 153/4" X 25" 153/4" X 25" 121" 90 AND 105 191/4" X 25" 153/4" X 25" 1241/2" 120 223/4" X 25" 153/4" X 25" 1

FIGURE 67RESIZING FILTERS AND FRAME

MAINTENANCE

FIGURE 66UPFLOW — FILTER REPLACEMENT

REMOVE SEGMENT TO SIZEAS REQUIRED

2409401

542201

FILTER MAINTENANCEInstruct the user or homeowner onhow to access the filters for regularmaintenance.Filter application and maintenanceare critical to airflow, which mayaffect the heating and cooling systemperformance. Reduced airflow canshorten the life of the system’s majorcomponents, such as motor, limits,heat exchanger, evaporator coil orcompressor. Consequently, it is rec-ommended that the return air ductsystem have only one filter location.The most common location will beinside the furnace or a filter base.Systems with a return-air filter grilleor multiple filter grilles, can have a fil-ter installed at each of the return-airopenings. Installers are instructed toshow the homeowner or end userwhere the filter has been installed.If high efficiency filters or electronicair cleaners are used in the system, itis important that the airflow is notreduced in order to maximize systemperformance and life. Always verifythat the system’s airflow is notimpaired by the filtering system thathas been installed. This can be doneby performing a temperature rise andtemperature drop test.Instruct the homeowner or end-userto keep the filter(s) clean at all times.Instruct them to vacuum dirt from thefilter, wash with detergent and water,air dry thoroughly and reinstall.The installer may install a return-airfilter in place of the furnace filter.DO NOT DOUBLE-FILTER THERETURN-AIR DUCT SYSTEM. DONOT FILTER THE SUPPLY AIRDUCT SYSTEM.

74

FIGURE 68UPFLOW -- SIDE FILTER LOCATIONS

CUT-OUT AND DRILL DETAIL ROD & FILTER SUPPORT ANGLE ASSEMBLY 1332

FIGURE 69DOWNFLOW -- FILTER INSTALLATION((-)GGD MODELS)

A087001.S01

FIGURE 70HORIZONTAL -- FILTER INSTALLATION((-)GJD MODELS)

A087101.S01

AIRFLOW

AIRFLOW

AIRFLOW

75

IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the flame sensor be cleaned withsteel wool by a qualified installer, ser-vice agency or the gas supplier.IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the condensate trap be inspect-ed for debris or blockage. A blockedcondensate trap can cause water toback up into the primary heatexchanger and lead to nuisance trip-ping of the over temperature switchesand/or pressure switches.IMPORTANT: It is recommended thatat the beginning of the heating sea-son, the condensate neutralizer (ifused) be replaced by a qualifiedinstaller, service agency or the gassupplier.IMPORTANT: Drain traps will oftendry out over a summer. During annualinspection the service person mustverify that the trap still has water. Ifthere is not enough water (or nowater) in the trap, the service personmust fill it to the appropriate level.

IMPORTANT: It is recommended thatan annual inspection and cleaning ofall furnace markings be made toassure legibility. Attach a replacementmarking, which can be obtainedthrough the distributor, if any arefound to be illegible or missing.

REPLACEMENT PARTSContact your local distributor for acomplete parts list.

TROUBLESHOOTINGFigure 71 is a troubleshooting flow-charts for the sequence of operation.Table 21 is for fault-code descriptions.

WIRING DIAGRAMFigure 72 is a complete wiring dia-gram for the furnace and powersources.

DO NOT OPERATE THE SYSTEMWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAYTEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. ANYRECIRCULATED DUST PARTI-CLESWILL BE HEATED ANDCHARRED BY CONTACTWITHTHE FURNACE HEAT EXCHANG-ER. THIS RESIDUEWILL SOILCEILINGS,WALLS, DRAPES,CARPETS AND OTHER HOUSE-HOLD ARTICLES.

LUBRICATIONIMPORTANT: Do Not attempt to lubri-cate the bearings on the blower motor orthe induced draft blower motor. Additionof lubricants can reduce the motor lifeand void the warranty.The blower motor and induced draftblower motor bearings are prelubricatedby the manufacturer and do not requirefurther attention.The blower motor and induced draftblower motor must be cleaned periodi-cally by a qualified installer, serviceagency, or the gas supplier to preventthe possibility of overheating due to anaccumulation of dust and dirt on thewindings or on the motor exterior. Theair filters should be kept clean. As dirtyfilters can restrict airflow. The motordepends upon sufficient airflowingacross and through it to keep from over-heating.

SYSTEM OPERATIONINFORMATIONAdvise The CustomerIMPORTANT: Replace all blower doorsand compartment covers after servicingthe furnace. Do not operate the unitwithout all panels and doors securely inplace.1. Keep the air filters clean. The heat-

ing system will operate more effi-ciently and more economically.

2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.

3. Close doors and windows. This willreduce the heating load on the sys-tem.

4. Avoid excessive use of kitchenexhaust fans.

5. Do not permit the heat generatedby television, lamps or radios toinfluence the thermostat operation.

6. Explain proper operation of thesystem with constant air circulation.

ANNUAL INSPECTIONThe furnace should operate for manyyears without excessive scale build-upin the flue passageways. However, it isrecommended that a qualified installer,service agency, or the gas supplierannually inspect the flue passageways,the vent system and the main burnersfor continued safe operation. Pay partic-ular attention to deterioration from cor-rosion or other sources.During the annual inspection, all electri-cal power to the furnace should beturned off and then restored. This willput the furnace into a calibration cycleon the initial call for heat. This is a fiveminute (or until the heat call is satisfied)cycle which allows the furnace to evalu-ate conditions It should be noted, thata calibration cycle will occur on the ini-tial call for heat each time after line volt-age has been interrupted to the unit.IMPORTANT: It is recommended that atthe beginning and at approximately halfway through the heating season, a visu-al inspection be made of the main burn-er flames for the desired flame appear-ance by a qualified installer, serviceagency or the gas supplier. If the flamesare distorted and/or there is evidence ofback pressure, check the vent and inletair system for blockage. If there is car-bon and scale in the heat exchangertubes, the heat exchanger assemblyshould be replaced.

HOLES IN THE VENT PIPE OR HEATEXCHANGER CAN CAUSE TOXICFUMES TO ENTERTHE HOME,RESULTING IN CARBON MONOXIDEPOISONING OR DEATH.THE VENTPIPE OR HEAT EXCHANGER MUSTBE REPLACED IF THEY LEAK.

! CAUTION

! WARNING

76

FIGURE 71SEQUENCE OF OPERATION TROUBLESHOOTING FLOWCHART

Start1. De-energize furnace IFC2. Set test switches (SW2) to

desired setting: 100% or 40%3. Re-energize furnace IFC4. Set thermostat to heat, set 4°

above room temperature

LED status display shows "H"or “h”LED status display is blank1. Check transformer secondary voltage2. Check line voltage3. Check transformer secondary fuse

If 1, 2, and 3 check OK, replace IFCLED status display shows "0", "C", or "F"1. Call for heat at the thermostat, cycle furnace power, go to

"start"LED status display shows numeric function code1. See function code troubleshooting guide

Induced draft motor (IDM) startson high speed for 30 secondprepurge

Motor does not start1. Check status display - FUNCTION CODE 44 or 55, Check

pressure switches. FUNCTION CODE 45 or 57, Check IDM2. Check voltage to IDM high speed tap3. Check IDM run capacitor

If 2 & 3 check OK, replace IDM assembly4. Check wiring5. Check voltage on IDM pin on IFC

If 5 checks bad, replace IFCMotor runs for 60 seconds, then cycle terminates1. Check status display - FUNCTION CODE 45 or 57 expected,

see function code troubleshooting guideMotor starts on low speed1. Check wiring

Gas valve servo valve set to100% rate (~180 milliamps D.C.)

Direct spark igniter is activated(8 second trial for ignition)

continued on next page

yesno

yesno

yesno

yes

no

Servo current measures less than 170 milliamps D.C.1. Check status display - possible codes 77 or 78, see function

code troubleshooting guide

No spark present at igniter1. Check status display - FUNCTION CODE 45 or 57 expected2. Check pressure switches3. Check 120 volts to igniter control during trial for ignition (30

seconds after IDM starts). If 3 checks OK, go to step 6. If120 volts not present, then

4. Check wiring5. Check 120 volts on IFC spark igniter pins, if bad replace IFC6. Check spark wire connection7. Check spark wire & electrode ceramic8. Check spark gap (0.10 inches), if 6, 7, and 8 check OK

replace spark control

77

Burners light Ignition trial duration is 8 seconds. The gas valve will be ener-gized (24 volts between M/P & C) for this period and will remainenergized only if the flame sense signal is above a minimumthreshold by this time. If the first trial is not successful, three addi-tional trials will be made with IDM purge periods of 30 seconds athigh speed between retries.If the burners do not light:1. Check status display - FUNCTION CODE 11 expected2. Check for 24 volts between "M/P" and "C" - if 24 volts not

present, go to step 53. Check gas line inlet pressure4. Check manifold pressure - if steps 2 & 3 are OK, but 4 is bad

- replace gas valve5. Check wiring6. Check for 24 volts on the IFC valve pins - if 6 checks bad -

replace IFC7. Check spark electrode position

Burners remain lit beyond 8 sec-ond trial time

Failure to sense flame:1. Check status display - FUNCTION CODE 11 expected - see

function code troubleshooting guide

Indoor blower motor starts 20seconds after gas valve opens

Motor does not start:1. Check status display -FUNCTION CODE 67 or 68 expected2. Check for 120 volts to motor (5 pin plug)3. Check wiring4. Test motor with ECM2+ motor tester (see ECM2+ motor test

procedures)If 2, 3, and 4 test OK, replace IFC

If furnace test switches are setto 100%, calibration cycle exe-cutes and status display blinks"H" or ''h''. Duration is 5 minutes.Calibration is performed with thefurnace operating at 75% capac-ity. The inducer will run on highspeed, the servo valve currentwill be set at about 135 mil-liamps resulting in a manifoldpressure of around 2.0" w.c. Nat.(5.6" w.c. L.P.)

Supply air sensor faulty or not installed1. Check status display - FUNCTION CODE 82 expected2. Ensure supply air sensor is installed in the plenum and is

properly wired to the IFC3. Check resistance of supply air sensor - if step 3 checks bad,

replace sensorReturn air sensor faulty or not installed1. Check status display - FUNCTION CODE 81 expected2. Check return air sensor wiring3. Check resistance of return air sensor - if step 3 checks bad,

replace sensor

continued on next page

noyes

no

yes

yes

no

no

yes

78

FURNACE TEST SWITCHES SETAT 100 %

Furnace runs at 100% rate, statusdisplay shows "H" or “h”, induceron high speed, servo current is~180 milliamps, manifold pressureis ~3.5 " w.c. and temperature riseis 40 - 70 ºF

Monitor status display for abnormal indications, see function codetroubleshooting guide

FURNACE TEST SWITCHES SETAT 40 %

Furnace runs at 40% rate, statusdisplay shows "H" or “h”, inducer onlow speed, servo current is ~ 72milliamps, manifold pressure is~0.6 " w.c. and temperature rise is40 - 70°F

Monitor status display for abnormal indications, see function codetroubleshooting guide

Terminate test mode1. Test mode times out in 60

minutes.2. Remove the call for heat

from the W terminal

Induced draft motor stops after 5seconds

Induced draft motor doesn't stop1. Check status display - FUNCTION CODE 22 or 33 expected2. Check over-temperature switch(es)3. Check wiring

If steps 2 & 3 check OK, replace IFC

ECM2+ indoor blower motor stopsafter 90 seconds

ECM2+ indoor blower motor does not stop running1. Check status display - FUNCTION CODE 22, 23 or 33 expect-

ed2. Check main limit and over temperature switch(es)3. Test motor with ECM2+ motor tester (see ECM2+ motor test

procedures)If steps 2 & 3 check OK, replace IFC

Troubleshooting endsTo return system to modulating/single-stage operation (SW2):1. De-energize IFC2. Set furnace test switches (SW2) for desired operation3. Re-energize IFC4. Set thermostat for desired operation

REPEAT PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED IN100% AND 40% TEST MODES

no

no

yes

noyes

no

yes

no

yes

Status display shows "C", "F", or "H"1. Ensure thermostat is off2. Check thermostat wiring

Flames remain on1. Check 24 volts to gas valve solenoids (M/P) - if present, go to

step 2, if 24 volts is not present, shut off gas and replace thegas valve

2. Check wiring3. Check 24 volts on IFC valve pins (MV) - if status display

shows "O" and 24 volts is present in step 3, replace IFC

LED status display shows "O" gasvalve off, flames off

yes

20

79

TABLE 21FAULT CODE TROUBLESHOOTING CHART

LowFlameSense

Flamesenselevelisbelow

predeterminedthresholdbut

aboveminimum

operatingthresh-

old.Remainsdisplayeduntilflame

senselevelrisesabovethreshold

levelorheatdemandisremoved.

1.Checkformis-wiringinfurnace

2.ReplaceIFC

1.Insuregassupplyisconnectedtofur-

naceandcheckforproperlinepressure

1.Turngasvalvetothe“ON”position

1.Check24VACtogasvalve.

2.Checkfor170-190mAmpstoservo

valve.

3.Adjustvalveforpropermanifoldpres-

sureat100%

rate

4.Ifgasvalvewillnotadjust,replacegas

valve.

1.Check120VACatignitercontrolduring

ignitiontrial.

2.Checksparkwireconnectionatigniter

controltransformerandelectrode.

3.Checkforshorttogroundofelectrode

(crackedceramic,touchingburners,etc.)

4.Checkigniterwire

fordamage.

5.IfallchecksOK,replaceignitercontrol

1.Checkforpropermountingandplace-

mentsparkelectrodeassembly.

2.Checkforpropermountingofburner

assembly.

1.Checkforproperpolarityoflinevolt-

age.

2.Checkflamesensorwiringandconnec-

tions.

3.Checkforimproperlymountedflame

sensor(positionedoutofflame,

grounded).

4.Checkflamesensecurrent.

5.Cleanflamesensorrod.

1.Cleanflamesensorrod

1.Re-install/replaceflamesensor,check

wiringandconnections.

Failedmicroprocessorselftestor

maingasvalvesafetycircuitfault.

Hardlockout

Noflamesenseduringignitiontrial.

Remainsdisplayeduntilsuccessful

ignition,onehourretryisstartedor

heatdemandisremoved

Faultisstoredinbufferafterfour

consecutivefailedignitiontrialsin

asingleheatcall

A.VoltagesensedontheMVoutput

B.SoftwareSelf-testoutput

A.Insufficientlinegaspressure

B.Gasvalvecontrolturned“OFF”

C.Insufficientmanifoldpressure,gas

valve“ON”

D.Nosparkatelectrodes

E.Burnersdon’tlight

F.Burnerslight,butextinguishafter8

secondsorless

A.Flamesensorcontaminated

B.FlameSensorimproperlymountedor

grounded

– 11 12

Internalfault

FailedIgnitionTrial

1.Checkforfunctioncode11inbuffer.

Seesolutionsforfunctioncode11.

2.Checkforfunctioncode13inbuffer.

Seesolutionsforfunctioncode13.

Afurnacefaulthascausedthe

controllertoexecuteaone-hour

retrymode.

A.Failedignitiontrialfourtimes(code11)

B.Lostflamesensefourtimes(code13)

rOne-HourRetry

Solutions

FunctionCode

Description

ResponseComments

ProbableCauses

80

TABLE 21FAULT CODE TROUBLESHOOTING CHART, CONT.

1.Cleanflamesensorrod

1.Re-install/replaceflamesensor,check

wiringandconnections.

1.Checkthatallburnerassemblycompo-

nentsareproperlyinstalled.

2.Checkthatallsealsbetweenthe

vestibuleareaandtheheatexchanger

areaaretight

3.Insurethatthecombustiondoorgasket

isinplaceandthedoorisproperly

installed.

1.Repairmis-wiringtoremovecontinu-

ous24V

tovalve.

2.Gasvalvestuckopen-removeand

replace.

1.ReplaceIFCboard

1.CheckFaultBufferforECMmotor

fault

history

2.CheckECMmotorwiringtothecon-

trolboard.

3.TestECMmotorandreplaceiffaulty.

1.CheckFaultBufferforECMmotorfault

history

2.CheckECMmotorwiringtothecontrol

board.

3.TestECMmotorandreplaceiffaulty.

1.ReplaceLimit.

1.CheckFaultBufferforECMmotor

faulthistory

2.Checkfiltersandductworkforrestric-

tions

3.Checkrateandoutletairtemperature

at100%,and40%,comparetomaxi-

mum

onnameplate

4.Runfurnacecalibrationandre–check

outletairtemperature

1.Replacelimitcontrol

1.Insureproperlysizedorificesinstalled.

2.Checkmanifoldpressureandadjustas

needed.

1.Repairjumperbetweenpins5&11

onJ1.

Flamesenseisbelowminimum

operatingthresholdduringaheating

cycle.Remainsuntilasuccessful

ignitionsequence,onehourretryis

startedortheheatdemandis

removed.

Faultisstoredinbufferafterfour

ignitionretriesinasingleheatcall.

Flamesensedwhengasvalveisoff.

Remainsdisplayeduntilflame

sense

signalisgone.

Highlimitcircuitisopen.Remains

displayeduntilcircuitissensed

closed.

Auxiliarylimitcircuitisopen.

Remainsdisplayeduntilcircuitis

sensedclosed.

A.Flamesensorcontaminated

B.Flamesensorimproperlymountedor

grounded

C.Unstableflamepattern

A.Flameremainslitin“OFF”cycle

B.Flamegoesoutin“OFF”cycle

A.Noairflow

B.Insufficientairflow

C.Faultylimitcontrol

D.Inputratetoohigh.

A.Onupflowfurnacesjumperloose,

brokenormissing

B.Ondownflowfurnace,faultyHALC.

C.Ondownflowfurnaces,noairflow

13 14 22 23

LostFlameSense

ImproperFlameSense

HighLimit

AuxiliaryLimit

(HALC)

Solutions

FunctionCode

Description

ResponseComments

ProbableCauses

81


C.Abnormallyhighnegativepressure

presentonventsystem

Lowpressureswitchcircuitis

closedwhennocallforheat.

Remainsdisplayeduntilcircuit

opensorheatdemandisremoved.

44LPS–ContactsClosed

1.Replacelimitcontrol.

1.Checkthatinducerisoperatingat

properspeedandRPM.

2.Insureventingdoesnotexceedthe

maximum

lengthsspecifiedinthe

ventinginstructions.

3.Checkthatallgasketsbetweenthe

inducerandthecenterpanel/heat

exchangerareproperlyinstalledand

noleaksexist

1.Checkthatallburnerassemblycom-

ponentsareproperlyinstalled.

2.Checkthatallsealsbetweentheburn-

er compartmentandtheheatexchanger

areaaretight.

3.Insurethatthedoorsealsareinplace

andthedoorisproperlyinstalled.

4.Checkthattheheatexchangerhasnot

beendamaged;ie.crushedtubes,

breachedcollectorboxes

1.Checkforshortedwirestothelow

pressureswitch

1.Replacelowpressureswitch

1.Checkforproperventingandtermina-

tionasdefinedinthefurnaceinstalla-

tioninstructions

Over–temperaturelimitcircuitis

open.Remainsdisplayeduntilcir-

cuitissensedclosed.

A.Faultylimitcontrol

B.Insufficientcombustionair

C.Unstableflamepattern

A.Faultywiring

B.Faultyswitch

33Over–TemperatureLimit

1.Checkforleakinghosesorleaking

gasketattheinduceddraftblower

1.ReplaceLowPressureSwitch

Lowpressureswitchcircuitisopen

duringhighspeedIDMoperation.

Remainsdisplayeduntilasuccess-

fulignitionsequenceortheheat

demandisremoved

B.Insufficientcombustionair

C.Improperpressureswitchsetting

45LPS–Open–IDM=HI

Solutions

FunctionCode

Description

ResponseComments

ProbableCauses

A.Insufficientcombustionairflow

82


Highpressureswitchcircuitisopen

duringhighspeedIDMoperation.



demandisremoved.

57HPS–Open–IDM=HI

1.Checkthatthewirestothehighpres-

sureswitchhavenotbeenshorted

together

1.Replacehighpressureswitch

1.Checkthatthemaximum

ventlength

fortheapplicationhasnotbeen

exceededandthattheventisproperly

terminated

2.Checkthatthecombustionairinlet

andventpipesarenotrestricted

3.Checkthattheinduceddraftmotoris

operatingattheproperspeed.

1.Checkdrainlinesforblockage,kinks

ordoubletraps

2.Insuredraintraphasbeenfilledwith

waterbeforeoperation



1.ReplaceHighPressureSwitch

1.ReplaceHighPressureSwitch

Highpressureswitchcircuitis

closedwithnocallforheat.

Remainsdisplayeduntilcircuit

opensorheatdemandisremoved.

A.Faultywiring

B.Faultyswitch


B.Condensatenotdrainingfromheat

exchanger

C.Insufficientpressuresensedatswitch

D.Improperpressureswitchsetting

E.Faultyswitch

55HPS–ContactsClosed

1.Insureventsystemhasminimum

recom-

mendedventlengths.

2.Insureventsystemisproperlyterminated.

3.Insurecombustioncompartmentdooris

properlyinstalled.

1.Ifhighaltitudepressureswitchis

installedandinstallationsiteelevationis

near5,000feet,checkcoldpressureson

highspeedinducertoinsurepressure

switchchangewasnecessary.

2.Replacehighpressureswitchasneeded.

Highpressureswitchcircuitis

closedduringlowspeedIDMoper-

ation.

Remainsdisplayeduntilheat

demandisremoved

A.M

inimum

ventrequirementsnotfol-

lowed

B.Improperswitchsetting

56HPS-Closed-IDM=LO

1.Checkthatthemaximum

ventlengthfor

theapplicationhasnotbeenexceeded

andthattheventisproperlyterminated

2.Checkthatthecombustionairinletand

ventpipesarenotrestricted

3.Checkthattheinduceddraftmotoris

operatingattheproperspeed.

1.Checkdrainlinesforblockage,kinks

ordoubletraps

2.Insuredraintraphasbeenfilledwith

waterbeforeoperation





Lowpressureswitchcircuitisopen

duringlowspeedIDMoperation.



demandisremoved


B.Condensatenotdrainingfromheat

exchanger

C.Insufficientpressuresensedatswitch

D.Improperpressureswitchsetting

E.Faultyswitch

46AuxiliaryLimit

LPS-Open-IDM=LO

Solutions

FunctionCode

Description

ResponseComments

ProbableCauses

83


1.Checkfordirtyfilter

2.Checkforinadequatereturnairsupply

3.Checkforunder–sizedductwork

4.Checkforlooseblowerwheel

5.Unitinstallationisatenvironmentallim-

itsof:altitude,systemstaticpressures,

highefficiencyairfilters,etc.Blower

demandrequiresoperationatRPMlimit.

ECMfeedbacksignalindicatedthe

indoorblowermotorRPMisabove

1200.RemainsdisplayeduntilRPM

returnstonormaloperatingrangeor

bloweroperationrequirementis

removed.

A.ECM

motoroperatingatRPMlimit.

B.Unitinstalledina“normalextreme”

installation(seesolution#5)

66ECM–RPMRange

1.EnsuretheECMwiringharnessis

completeandconnected

1.Testmotorforfeedbacksignal,replace

motoriffaulty.

1.Replacecontrolboardifnecessary

1.Checkresistanceofservo–valvecoil.

Replacevalveifoutoftolerance.

1.Replacecontrolboardiffaulty.

1.Conductthefollowingtest:

a.Turnthegasvalvecontrolknobto

theoffposition.

b.Disconnectservovalveconnector

andplacea100-Ohm,10-Watt

resistoracrossthetwowiresfrom

thefurnacewiringharness(notthe

wiresfrom

thegasvalve).

c.Setthefurnacetoattemptanother

ignitioncycle.

d.IfFunctioncode78appears,replace

theIFC.

e.IfFunctioncode11appears,replace

thegasvalve

1.Ensurecontinuityfrom

boardconnector

togasvalveandtoground,checkall

connections

1.Checkresistanceofthermistor.

Replacesensorifoutoftolerance

2.Reconnectsensorifused.Ifnotused,

thenfurnaceisoperatingnormally.

ECMfeedbacksignalmissing.

Remainsdisplayeduntilfeedbackis

correctedorbloweroperation

requirementis

removed.

Gasvalveservocircuitissensed

open.Remainsdisplayeduntilcir-

cuitisclosedorheatdemandis

removed.

Gasvalvecurrentsensingcircuit

testsoutofrange.Remainsdis-

playeduntilcircuittestsOKorheat

demandisremoved.

Return/Supplyairsensoroutof

range.Remainsdisplayedfor1.5

minutesafterpoweron.Afterthat

timecodesremaininmemorybut

arenotdisplayed.Recyclingthe

powerwillredisplaycodes.

A.Faultywiring

B.FaultyECMmotor

C.Faultycontrolboard

1.Ensurecontinuityfrom

boardconnec-

tortogasvalveandtoground,check

allconnections.

A.Faultywiring

B.Faultygasvalve

C.Faultycontrolboard

A.Gasvalveservocoiloutofspecifica-

tion

A.Faultywiring

B.FaultyThermistorAssembly

68 77 78 81/82

ECM–NoSignal

GVServo–Open

GVServo–ControlFault

RAS/SAS–OutofRange

C.SensorNotConnectedornotused

1.Checkmotorpartnumber,replace

motorifneeded.

2.Testmotorfeedbacksignal,replaceif

faulty

ECMFeedbacksignaldoesnotfollow

definedprotocol–RPM

/CFM

blink.

Remainsdisplayeduntilfeedbackis

correctedorbloweroperation

requirementisremoved.

A.W

rongECMmotorinstalled

67ECM–ImproperSignal

Solutions

FunctionCode

Description

ResponseComments

ProbableCauses

84

FIGURE 72WIRING DIAGRAM

CM 0809

Documents

92-24161-22 Rev. 21 High Efficiency Modulating Gas Furnace ...The (-)GFD,(-)GGD and (-)GJD series furnaces are design-certified by CSA for use with natural and L.P. gases as follows: