HIGH-EFFICIENCY UPFLOW FURNACE INSTALLER'S INFORMATION MANUAL

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HIGH-EFFICIENCY UPFLOW FURNACEINSTALLER'S INFORMATION MANUALD ES IG NCEATTENTION, INSTALLER!After installing thefurnace, show the user how to turn off gas and electricity tothe furnace. Point out control and switch locations forturning off gas and electricity. Go over the User’sInformation Manual and Section 23, “Maintaining FurnaceIn Good Working Order" in this manual with the user. Makesure the user understands the importance of following allsafety precautions, including what could happen if they donot.Attach the following documents to or adjacent to thefurnace. Tell the user where these documents are located. User's Information ManualInstaller's Information ManualParts ListWarranty InformationWhile these instructions have been written as accuratelyand thoroughly as possible, they can not cover everysystem variation or contingency.Questions ofinterpretation may arise. For more information, solutions toparticular problems or clarification, contact your localdistributor or the manufacturer.R TI F I EDATTENTION, USER!Your furnace installer shouldgive you the documents listed on opposite side. Youshould immediately read the User’s Information Manual forimportant safety information to keep you and your familysafe. Keep these as long as you keep your furnace. Passthem on to future furnace purchasers or users. If any of thedocuments are missing or illegible, contact your installer orfurnace manufacturer for replacement. Throughout thismanual, when we use the word "you" we refer to thequalified service technician who is responsible forapplication, installation and service of your furnace.? ? Do not store or use gasoline or other flammable vaporsand liquids in the vicinity of this or any other appliance.? ? WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance.Do not touch any electrical switch.Do not use any phone in your building.Immediately call your gas supplier from a neighbor'sphone. Follow the gas supplier's instructions.If you cannot reach gas supplier, call the firedepartment.WARNING: Individuals who install this fu rnace, must have the training and experience necessary to install gasfurnaces. They must also have training and experience necessary to install related comfort air conditioning appliances.Improper installation could create a hazard, resulting in the possibility of damage, injury or death.422690 I

TABLE OF CONTENTSSECTION 1. IMPORTANT SAFETY RULES. 2SECTION 2. MEETING CODES . 3SECTION 3. DETERMINING BEST FURNACE LOCA TION . 3SECTION 4. PROVIDING VENTING AND COMBUSTION AIR. 5SECTION 5. CONDENSATE DRAIN.14SECTION 6. INSTALLING GAS PIPING.14SECTION 7. INSTALLING ELECTRICAL WIRING .15SECTION 8. SEQUENCE OF OPERATION .17SECTION 9. INSTALLING DUCT SYSTEM .18SECTION 10. SELECTING AND INSTALLING FILTER CABINETS .18SECTION 11. CHECKS BEFORE STARTING FURNA CE .20SECTION 12. GAS SUPPLY PRESSURE AND PILOT ADJUSTMENT.20SECTION 13. MANIFOLD PRESSURE ADJUSTMENT .21SECTION 14. CHECKING GAS INPUT RATE .21SECTION 15. DERATING FOR HIGH ALTITUDE .22SECTION 16. DETERMINING CORRECT ORIFICE SIZE .22SECTION 17. CHANGING MAIN BURNER ORIFICES .23SECTION 18. ADJUSTING BLOWER SPEED.24SECTION 19. MEASURING DUCT SYSTEM STATIC PRESSURE .24SECTION 20. MEASURING AIR TEMPERATURE RISE .25SECTION 21. CHECKING CONTROLS .25SECTION 22. SETTING BLOWER TIMINGS.26SECTION 23. MAINTAINING FURNACE IN GOOD WORKING ORDER.26SECTION 24. ACCESSORIES .27SECTION 25. OTHER INFORMATION AND PUBLICATIONS .27SECTION 1. IMPORTANT SAFETYRULESTo alert you to potential hazards, we use the signal words"WARNING" and "CAUTION" throughout this manual."WARNING" alerts you to situations that could cause orresult in serious injury or death. "CAUTION" alerts you tosituations that could cause or result in minor or moderateinjury or property damage. For a safe and reliableinstallation be sure to read and follow all warnings andcautions.We also use the words "must" and "should" in this manual."Must" is mandatory. "Should" is advisory.WARNING: Read and follow the safety rules inthis section and throughout this manual. Failure to do socould cause improper fu rnace operation, resulting indamage, injury or death.Rule 1. Use only gas approved for use in this fu rnace, asindicated on furnace rating plate. Use only natural gas infurnaces designed for natural gas. Use only propane (LP)gas in furnaces designed for propane (LP) gas. Make surefurnace will operate properly on the gas type available touser. Do not use butane gas in this fu rnace.WARNING: Use of a non-approved gas (such asbutane) in this furnace could cause sooting or overheatingof heat exchanger.Rule 2. Do not install this fu rnace outdoors or in a mobilehome, trailer or recreational vehicle. It is not designcertified for these installations. This furnace is suitable fora home built on site or a manufactured home completed atthe final site.Rule 3. Air for combustion must not come from a corrosiveor contaminated atmosphere. Make sure all combustionand ventilation air requirements are adhered to in additionto local codes and ordinances.Rule 4. This furnace is not to be used for temporaryheating of buildings or structures under construction.Rule 5. Provide adequate combustion and ventilation air tospace where furnace is being installed unless combustionair is provided directly through an inlet air pipe. Connectthis furnace to an approved vent system--ventingcombustion products outdoors.Rule 6. Check for gas leaks anytime work is done on gassupply line, furnace gas control, pilot and pilot line or mainburner manifold.Rule 7. Never test for gas leaks with an open flame. Use acommercial soap solution made specifically for leakdetection to check all connections.Page 2Installer’s Information Manual

Rule 8. Completely seal supply and retu rn air ducts tofurnace casing. Duct system must run to an area outsidefurnace room or closet. Seal duct work wherever it runsthrough walls, ceilings or floors of fu rnace room or closet.SECTION 2. MEETING CODESThis furnace complies with American National Standardand National Standard of Canada for Gas Fired CentralFurnaces, ANSI Z21.47 ? CAN/CGA-2.3. It is certified foroperation with either natural gas or propane (LP) gas forindoor installation in a building constructed on site. It meetsthe requirement for a 100% shut-off gas control system.Provide ample space for servicing and cleaning. Locationmust allow 30 inches minimum front clearance for service.WARNING:Some insulating materials arecombustible. When a furnace is installed in an attic or otherinsulated space, keep all insulating materials at least 12inches away from furnace and combustion air inlet. Failureto do so could cause a fire.You may install furnace on non-combustible flooring or onwood flooring.Before installing this furnace, make sure you know allapplicable codes. Be sure to consult local authoritieshaving jurisdiction over furnaces for information onelectrical wiring, gas piping and venting. The installation ofthis furnace must conform with local building codes or in theabsence of local codes, with ANSI Z223.1, National FuelGas Code or CAN/CGA B149, Canadian Installation Codes.WARNING: Do not install furnace on carpeting,tile or other combustible material except wood flooring.Doing so could cause a fire.Electrical wiring must conform with local building codes orin the absence of local codes, with the current NationalElectrical Code, ANSI/NFPA 70 or current CanadianElectrical Code, CSA C22.1.Level furnace from front to back and from left to right within1/4 inch. Furnace must be installed level for propercondensate drainage.Furnace will not operate ifcondensate does not drain.SECTION 3. DETERMINING BESTFURNACE LOCATIONYou may install this upflow furnace in an alcove, attic,basement, closet, garage or utility room. Do not installfurnace in an area subject to freezing temperatures.This furnace operates best when return-air temperature isbetween 55 F and 80 F. Do not install furnace in a locationsubject to continuous higher or lower temperatures.Continuous operation outside of this range may shortenfurnace life.WARNING: Do not install furnace in any otherposition other than upflow. Doing so could cause heatexchanger blockage and damage to heat exchanger.Select a location that meets all requirements described inthis manual for the following:?SafetyMinimum ClearancesCombustion and Ventilation AirVentingDuct SystemGas PipingElectrical WiringLocate furnace as near to the center of the air distributionsystem as possible.Installer’s Information ManualInstall furnace so all electrical components are protectedfrom water.When furnace is located within the heated space, exhaustfans can adversely affect its operation. Exhaust fans inkitchen, bathrooms, clothes dryers or anywhere withinheated space, increase combustion air requirements ofnon-direct vented furnaces. This is because exhaust fansreduce the amount of combustion air available to thefurnace. A fireplace also reduces amount of combustionair.Sufficient air must be provided to ensure there will not be anegative pressure in furnace room or space. In addition,there must be a positive seal between fu rnace and returnair duct to avoid pulling air from burner area.When a cooling unit is installed with this fu rnace, thefurnace must be installed parallel with or on the upstreamside of the cooling unit to avoid condensation in furnaceheat exchanger. With a parallel flow arrangement, thedampers or other means used to control flow of air must beadequate to prevent chilled air from entering the furnaceand, if manually operated, must be provided with a meansto prevent operation of either unit unless damper is in thefull heat or cool position.When furnace is in a residential garage, it must be installedso that pilot and main burners are located no less than 18inches above the floor. Also, furnace should be protectedfrom physical damage by vehicles.When furnace is in a public garage, airplane hanger, orother building having hazardous atmosphere, install unit inaccordance with recommended good practice requirementsof the National Fire Protection Association, Inc. Consultlocal code authorities for additional location requirements.See Figure 1 for furnace dimensions and clearances.Page 3

GASMOTORFURNACERETURN AIR SUPPLY AIRCLEARANCE TO COMBUSTIBLES***VENT (HP)“A”“B”“C”TOPSIDESBACK FRONTVENT(INCHES)54,0001/317 1/215 3/4”15 15/16”10020272,0001/217 1/215 3/4”15 15/16”100202 OR 372,0003/420 1/218 3/4”18 15/16”100202 OR 390,0001/217 1/215 3/4”15 15/16”100202 OR 390,0003/420 1/218 3/4”18 15/16”100202 OR 3108,0003/423 1/221 3/4”21 15/16”100203126,0003/423 1/221 3/4”21 15/16”100203* See Furnace Rating Plate located on blower door.** These are furnace dimensions. See Sections 9 and 10 for proper ductwork and floor opening dimensions.*** Certified for installation on wood flooring. 30-inch front clearance required for service. 18-inch front clearance required in an alcove.Figure 1. Furnace Dimensions and Clearances.Page 4Installer’s Information Manual

SECTION 4. PROVIDING VENTINGAND COMBUSTION AIR?Some models are shipped with a 3-inch to 2-inchreducer bushing. When venting with two-inch pipe,install reducer bushing in flue outlet fitting.This furnace must be connected to a plastic venting systemadequate to remove flue gases to the outside atmosphere.It must be vented in accordance with these instructions andlocal building codes.The furnaces covered by this manual are design-certifiedas Category IV appliances. Category IV appliances operatewith a positive vent static pressure and with a flue gastemperature that will produce significant condensate in thevent. The vent system for this furnace must be installed soas to prevent leakage of flue gases into the building. Thisfurnace may be installed using either direct venting or nondirect venting.WARNING: Do not connect this furnace to a ventsystem shared by any other appliance. Do not connect it toany other type of vent system other than described by theseinstructions. Improper venting could allow combustionproducts to collect in building during use resulting in nauseaor death by asphyxiation.GENERAL VENTING GUIDELINES?Vent system and combustion air supply componentsmust be constructed of schedule 40 PVC, PVC-DWV,SDR26, SDR 21 or ABS plastic pipe, fittings, sealants,and installation procedures that conform to thefollowing ANSI/ASTM standards:Figure 2. Vent Connection to Furnace.PVC PIPE INSTALLATION INSTRUCTIONS1.Cut ends of pipe square using a miter box, power sawor PVC tubing cutter. Put a 10 to 15 degree chamferon end of pipe. Remove any burrs, dirt, grease, andmoisture. Check joint for proper fit.2.Freely coat outside end of pipe and inside of fittingsocket with cleaner-primer. The purpose of the primeris to dissolve and penetrate the surface of the pipe.Several coats may be necessary to do this.3.While primer is still wet, apply a heavy coat of solventcement to outside of pipe. Next, using outward strokesto keep excess cement out of socket, apply a generouscoat of cement to the inside of socket.4.While both surfaces are still wet with cement, insertpipe into fitting socket until it bottoms out, using a slighttwisting motion (1/4 turn). Hold pipe in socket 30seconds to allow cement to set.Allow joint to cure before handling.PVCASTM D-1785SDR26, SDR21ASTM D-2241PVC-DWVASTM D-2665PVC-DWV Cellular CoreASTM F-891PVC Primer And Solvent CementASTM D-2564ABS Pipe And FittingsASTM D-22355.Procedure For Cementing JointsASTM D-2855Caution: Keep solvent cement container sealed when notin use. Do not use solvent cement that has thickened or isgel-like.All condensate formed in the vent must run backtoward furnace for proper drainage. Install vent pipewith no less than a 1/4 inch per foot slope from fu rnaceto vent terminal.?Install vent pipe without dips or sags that may holdwater. Support horizontal portions of vent pipe every 5feet (3 feet for SDR-21 or SDR-26 pipe).?Protect vent from freezing. Long runs of vent pipeinstalled in an unconditioned space may requireinsulation to prevent freezing of condensate.?Furnace can be vented from either left or right side.See Figure 2. As shipped, furnace is setup for ventingthrough the left side.Right side venting isaccomplished by rotating flue outlet fitting and adding astreet elbow to the drain fitting. Street elbow andinstructions are supplied in the furnace parts package.Installer’s Information ManualWARNING: PVC cements are highly flammable.Do not use near open flames. A fire or explosion couldresult. Avoid prolonged breathing or contact with skin oreyes.Page 5

TERMINATION LOCATION AND CLEARANCESVent pipe and combustion-air-supply pipe (when directvented) may terminate through a roof or through a sidewall.Roof termination has the advantages of better pipeprotection and fewer condensate-damage concerns. Usethe following guidelines when choosing a vent location:The following steps shall be followed with each applianceconnected to the old venting system placed in operation,while any other appliances connected to the venting systemare not in operation:1.Seal any unused openings in the venting system ;2.Inspect the venting system for proper size andhorizontal pitch, as required in the National Fuel GasCode, ANSI Z223.1/NFPA 54 or the CAN/CGA B149Installation Codes.Determine that there is noblockage or restriction, leakage, corrosion and otherdeficiencies which could cause an unsafe condition;?Flue gases can be corrosive. When sidewall venting,protect walls with a corrosion resistant material. Also,terminate away from plants and shrubs.?Locate termination consistent with the National FuelGas Code, ANSI Z223.1/NFPA 54 or the CAN/CGAB149 Installation Codes.3.Locate termination away from other air intake orexhaust vents such as dryer vents, other gas appliancevents, or plumbing vents. Allow at least 3 foot to anyother vent.In so far as is practical, close all building doors andwindows and all doors between space in whichappliance(s) connected to the venting system arelocated and other spaces of building.4.Close fireplace dampers.5.Turn on clothes dryers and any appliance notconnected to the venting system. Turn on any exhaustfans, such as range hoods and bathroom exhausts, sothey shall operate at maximum speed. Do not operatea summer exhaust fan.6.Follow the lighting instructions. Place the appliancebeing inspected in operation. Adjust thermostat soappliance shall operate continuously;7.Test for drafthood equipped appliance spillage at thedrafthood relief opening after 5 minutes of main burneroperation. Use the flame of a match or candle;8.After it has been determined that each applianceconnected to the venting system properly vents whentested as outlined above, return doors, windows,exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;9.If improper venting is observed during any of the abovetests, the venting system must be corrected. Followthe National Fuel Gas Code, ANSI Z223.1/NFPA 54 orCAN/CGA B149 Installation Codes to correct impropervent operation. Any "common vent" re-sizing mustapproach minimum size determined using currentventing tables.?Terminal must not be located above a walkway,driveway or within 10 feet of an adjacent building.?Do not locate termination underneath a veranda,porch, or deck.IN THE UNITED STATES:?Allow a minimum clearance of 4 feet from electricmeters, gas meters, regulators, and relief equipment.When non-direct venting, terminal must be at least 4feet below, or 4 feet horizontally from o

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