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REVIEWED BLD2022-0646+Manufacturer_Specifications_and_Installation_Instructions+5.13.2022_2.05.30_PM+2869653Installer's Guide Upflow/Horizontal and Downflow Gas -Fired, Direct/Non-Direct Vent, 2-Stage Condensing Variable Speed Furnaces Upflow, Convertible to Horizontal Right or Horizontal Left A952V040BU3SAB A952V060BU3SAB A952V060BU4SAB A952V080BU4SAB A952V080CU5SAB A952V100CU4SAB A952V100CU5SAB A952V120DU5SAB Downflow Only A952V040BD3SAB A952V060BD3SAB A952V080BD4SAB A952V100CD4SAB A952V100CD5SAB A952V120DD5SAB Note: Graphics in this document are for representation only. Actual model may differ in appearance. f � � COIL REQUIREMENT! Failure to follow this Caution could result in property damage or personal injury. 4GXC* and 4MXC* coils installed on upflow furnaces in vertical, horizontal left, or horizontal right orientations without a factory installed metal drain pan shield must use a MAY*FERCOLKITAA kit. Coils installed on upflow furnaces must have drain pans that are suitable for 400' F (205°C) or have a metal drain pan shield. Downflow furnaces do not require a metal drain pan shield or the use of the MAY*FERCOLKITAA kit. See Installer's Guide for more information. Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment. October 2019 88-A952V001-1 C-EN ARD'Ingersoll Rand SAFETY SECTION- FURNACES Ingersoll Rand has a policy of continuous product and product data improvement and it reserves the right to change design and specifications without notice. Important: — This document pack contains a wiring diagram and service information. This is customer property and is to remain with this unit. Please return to service information pack upon completion of work FIRE OR EXPLOSION HAZARD! Failure to follow safety warnings exactly could result in a fire or explosion causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and 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's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency, or the gas supplier. EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, personal injury or death. Install a gas detecting warning device in case of a gas leak. NOTE: The manufacturer of your furnace does not test any detectors and makes no representations regarding any brand or type of detector. FIRE OR EXPLOSION HAZARD! Failure to follow the safety warnings exactly could result in serious injury, death, or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury, or loss of life. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD! Failure to follow this Warning could result in dangerous operation, property damage, severe personal injury, or death. Improper servicing could result in dangerous operation, property damage, severe personal injury, or death. • Before servicing, disconnect all electrical power to furnace. • When servicing controls, label all wires prior to disconnection. Reconnect wires correctly. • Verify proper operation after servicing. CARBON MONOXIDE POISONING HAZARDI Failure to follow this Warning could result in property damage, severe personal injury, or death. To ensure furnace is vented properly, do not replace factory supplied venting components with field fabricated parts. Fabricating parts can result in damaged vents and components allowing carbon monoxide to escape the venting system. CARBON MONOXIDE HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not attempt to change the venting system. Follow the installation and operation instructions for the venting system. ©2019Ingersoll Rand 88-A952V001-1C-EN SAFETY SECTION— FURNACES 9Iall Q:I_fOG1 H OIL Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow applications, subbase (BAYBASE205) must be used between the furnace and combustible flooring. When the downflow furnace is installed vertically with a cased coil, a subbase is not required. WARNING! This product can expose you to chemicals including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca. gov. EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Propane gas is heavier than air and may collect in any low areas or confined spaces. In addition, odorant fade may make the gas undetectable except with a warning device. If the gas furnace is installed in a basement, an excavated areas or a confined space, it is strongly recommended to contact a gas supplier to install a gas detecting warning device in case of leak. The manufacturer of your furnace does not test any detectors and makes no representations regarding any brand or type of detector. ELECTRICAL SHOCK HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not bypass the door switch or panel loop by any permanent means. ELECTRICAL SHOCK HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not touch any components other than the Menu and Option buttons on the IFC when setting up the system or during fault code recovery. FIRE OR EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do NOT attempt to manually light the furnace. CARBON MONOXIDE POISONING HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Follow the service and/or periodic maintenance instructions for the Furnace and venting system. CARBON MONOXIDE POISONING HAZARD! Failure to follow this Warning could result in serious personal injury or death. Make sure that the blower door is in place and not ajar. Dangerous fumes could escape an improperly secured door. ELECTRICAL SHOCK HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Disconnect power to the unit before removing the blower door. Allow a minimum of 10 seconds for IFC power supply to discharge to 0 volts. SAFETY HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. These furnaces are not approved or intended for installation in trailers or recreational vehicles. Installation in manufactured (mobile) housing is only approved with BAYMFGH Kit. 88-A952V001-1 C-E N SAFETY SECTION- FURNACES EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. In the event that electrical, fuel, or mechanical failures occur, shut gas supply off at the manual gas valve located on the supply gas piping coming into the furnace before turning off the electrical power to the furnace. Contact the service agency designated by your dealer. EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, serious personal injury, or death. Do not store combustible materials, gasoline, or other flammable vapors or liquids near the unit. SAFETY HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not use semi -rigid metallic gas connectors (flexible gas lines) within the furnace cabinet. INSTALLATION WARNING - HIGH VOLTAGE MOVING PARTS! Failure to follow this Warning could result in property damage, severe personal injury, or death. Bodily injury can result from high voltage electrical components, fast moving fans, and combustible gas. For protection from these inherent hazards during installation and servicing, the main gas valve must be turned off and the electrical supply must be disconnected. If operating checks must be performed with the unit operating, it is the technician's responsibility to recognize these hazards and proceed safely. SAFETY HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Do not install the filter in the return duct directly above the furnace in horizontal applications. Install the filter remotely. SAFETY HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Turn the power to the furnace off before servicing filters to avoid contact with moving parts. CARBON MONOXIDE HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. Furnace venting into an unlined masonry chimney or concrete chimney is prohibited. CARBON MONOXIDE HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. The chimney liner must be thoroughly inspected to insure no cracks or other potential areas for flue gas leaks are present in the liner. Liner leaks will result in early deterioration of the chimney. SHOCK HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. If a disconnect switch is present, it must always be locked in the open position before servicing the unit. ELECTRICAL SHOCK HAZARD! Failure to follow this Warning could result in an electrical shock, fire, injury or death. Ensure cabinet has an uninterrupted or unbroken ground in accordance with National Electrical Code, ANSI/ NFPA 70 —'latest edition' and Canadian Electrical Code, CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. 88-A952V001-1 C-E N SAFETY SECTION- FURNACES OVERHEATING AND EXPLOSION HAZARD! Failure to follow this Warning could result in property damage, personal injury or death. Should overheating occur, or the gas supply fail to shut off, shut off the gas valve to the unit before shutting off the electrical supply. IMPROPER VOLTAGE CONNECTION! Failure to follow this Caution could result in property damage. Do NOT connect the furnace line voltage to a GFCI protected circuit. CORROSION WARNING! Failure to follow this Caution could result in property damage or personal injury. Do not install the furnace in a corrosive or contaminated atmosphere. SAFETY HAZARD! Failure to follow this Caution could result in property damage or personal injury. The vent for this appliance shall not terminate; (1) Over public walkways; or (2) Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage; or (3) Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment. SHARP EDGE HAZARD! Failure to follow this Caution could result in property damage or personal injury. Be careful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. BACKUP WRENCH REQUIRED! Failure to follow this Caution could result in property damage or personal injury. Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and manifold assembly. FREEZE CAUTION! Failure to follow this Caution could result in property damage or personal injury. If complete furnace shutdown is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and water receptacles. FREEZE CAUTION! Failure to follow this Caution could result in property damage or personal injury. When the vent pipe is exposed to temperatures below freezing, i.e., when it passes through unheated spaces, etc., the pipe must be insulated with 1/2 inch (12.7 mm) thick Armaflex-type insulation or equal. If the space is heated sufficiently to prevent freezing, then the insulation would not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space. FREEZE CAUTION! Failure to follow this Caution could result in property damage or personal injury. Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. This is very important during freezing weather. If for any reason your furnace should fail to operate damage could result, such as frozen water pipes. FREEZE CAUTION! Failure to follow this Caution could result in property damage or personal injury. Caution should be taken to prevent drains from freezing or causing slippery conditions. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants. IGNITION FUNCTION! Failure to follow this Caution may result in poor ignition characteristics. Maintain manifold pressure in high altitude installations. 88-A952V001-1 C-E N SAFETY SECTION— FURNACES WATER DAMAGE! Failure to follow this Caution could result in property damage or personal injury. It is recommended that an external overflow drain pan be installed in all applications over a finished ceiling to prevent property damage or personal injury from leaking condensate. HOT SURFACE! Failure to follow this Caution could result in personal injury. Do NOT touch igniter. It is extremely hot. FURNACE SERVICE CAUTION! Failure to follow this Caution could result in property damage or personal injury. Label all wires prior to disconnection when servicing controls. Verify proper operation after servicing. Wiring errors can cause improper and dangerous operation. WIRING INFORMATION! Failure to follow this Caution could result in property damage or personal injury. The integrated furnace control is polarity sensitive. The hot leg of the 120 VAC power must be connected to the BLACK field lead. CARBON MONOXIDE POISONING HAZARD! Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: • Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1 Natural Gas and Propane Installation Code and these instructions. Determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition. • Close all doors and windows between the space in which the appliance(s) connected to the venting system are located. Also close fireplace dampers. • Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans such as range hoods so they are operating at maximum speed. Do not operate a summer exhaust fan. • Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously. • Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. • If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z221.1/NFPA 54 and/or CSA B149.1 Natural Gas and Propane Installation Code. • After it has been determined that each appliance connected to the venting system properly vents when tested, return all doors, windows, exhaust fans, etc. to their previous condition of use. 88-A952V001-1 C-E N SAFETY SECTION- FURNACES VENTING REQUIREMENT! Failure to follow this Caution could result in property damage or personal injury. For condensing furnaces, Do NOT run vent through chimney for wood burning or oil Furnaces or incinerators. If remaining free area between single wall flue pipe and masonry chimney is to be used for another gas appliance, venting area must be sufficient to vent that appliance and that appliance must be connected to chimney with separate entry openings. IMPORTANT— The single wall flue pipe joints musi be sealed. The 90' elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of masonry chimney. VENTING REQUIREMENT! Failure to follow this Caution could result in property damage or personal injury. Condensing furnaces may be vented through UNUSED chimneys. Do NOT run vent through chimney for wood burning or oil Furnaces or incinerators or any other gas appliance. IMPORTANT— The single wall flue pipe joints m be sealed. The 90° elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of masonry chimney. EQUIPMENT DAMAGE! UV light exposure can cause the plastic blower material to deteriorate which could lead to Blower Housing Damage. For units containing a plastic Blower Housing, Do NOT install third party Ultra -Violet Air Cleaners where the Blower Housing can be exposed to UV light. For more information, visit www.IRCO.com or contact your installing dealer. Ingersoll Rand 800 Beaty St. Davidson, NC 28036 Coil Caution COIL REQUIREMENT!! Failure to follow this Caution could result in property damage or personal injury. 4GXC* and 4MXC* coils installed on upflow furnaces in vertical, horizontal left, or horizontal right orientations without a factory installed metal drain pan shield must use a MAY*FERCOLKITAA kit. Coils installed on upflow furnaces must have drain pans that are suitable for 400° F (205' C) or have a metal drain pan shield. Downflow furnaces do not require a metal drain pan shield or the use of the MAY*FERCOLKITAA kit. See Installer's Guide for more information. 88-A952V001-1 C-E N Table of Contents Accessories ................................. 9 Document Pack Contents ................. 10 Furnace Installation Guidelines............ 11 Safety Practices and Precautions.......... 11 General Guidelines ...................... 11 Locations and Clearances ................ 12 Outline Drawings .......................... 13 Furnace General Installation ............... 19 A952V Furnace Panel Removal............ 19 Horizontal Installation in an Attic or Crawlspace ............................. 19 Gas Piping .............................. 20 Combustion and Input Check.......... 23 Gas Valve Adjustment ................ 24 High Altitude Derate.................. 25 General Venting ......................... 26 Special Case Venting ................. 27 Vent Terminations ................... 29 Attaching Vent Piping ................ 29 Maximum Vent Length Table ............. 32 Horizontal Venting ....................... 33 Horizontal Venting Through Wall with Concentric Vent Kit .............. 36 Venting Through The Roof............ 40 Air for Combustion and Ventilation........ 42 Duct Connections ........................ 45 Return Air Filters ........................ 57 Electrical Connections ................... 59 Field Wiring ......................... 59 Condensate Drain Instructions ............. 61 ........................................ 61 Vertical Applications ..................... 62 Horizontal Applications ............... 66 General Start-up and Adjustment.......... 67 Preliminary Inspections .................. 67 Lighting Instructions ..................... 67 Control and Safety Switch Adjustment ............................. 67 Furnace Combustion Air Exhaust Options.................................... 68 Upflow Furnace in Upflow Position — Top Vented Combustion Air .............. 70 Upflow Furnace in Upflow Position — Left Side Vented Combustion Air.......... 71 Upflow Furnace in Horizontal Left Position —Top Vented Combustion Air.................................. 75 Upflow Furnace in Horizontal Left Position — Side Vented Combustion Air.................................. 79 Upflow Furnace in Horizontal Right Position — Top Vented Combustion Air.................................. 83 Upflow Furnace in Horizontal Right Position — Left Side Vented Combustion Air ...................... 87 Downflow Furnace — Top Vented Combustion Air ...................... 92 Downflow Furnace — Left Side Vented Combustion Air ............... 93 Integrated Furnace Control Menu.......... 97 Integrated Furnace Control Display Codes....................................100 Fault Code Recovery .................... 101 Sequence of Operation ...................102 8 88-A952V001-1 C-E N Accessories Table 1. Accessories Model Number Description Use with BAYHANG Horizontal Hanging Kit All Upflow Furnaces BAYVENT200B Sidewall Vent Termination Kit All Furnaces BAYVENTCN200B Sidewall Vent Termination Kit (Canada — CPVC) All Furnaces BAYAIR30AVENTA Concentric Vent Kit All Furnaces BAYAIR30CNVENT Concentric Vent Kit (Canada — CPVC) All Furnaces BAYREDUCE Reducing Coupling (CPVC) All Furnaces BAYLIFTB Dual Return Kit (B size extension) B Cabinet Upflow Furnaces BAYLIFTC Dual Return Kit (C size extension) C Cabinet Upflow Furnaces BAYLIFTD Dual Return Kit (D size extension) D Cabinet Upflow Furnaces BAYBASE205 Downflow Subbase All Downflow Furnaces BAYFLTR206 Filter Access Door Kit (Downflow only) All Downflow Furnaces BAYSF1165AA (a) 1" Slim Fit Box with MERV 4 Filter All Upflow Furnaces BAYFLTR203 Horizontal Filter Kit B Cabinet Furnaces in Downflow/Horizontal BAYFLTR204 Horizontal Filter Kit C Cabinet Furnaces in Downflow/Horizontal BAYFLTR205 Horizontal Filter Kit D Cabinet Furnaces in Downflow/Horizontal BAYLPSS400B Propane Conversion Kit with Stainless Steel Burners All Furnaces BAYMFGH200B Manufactured/Mobile Housing Kit All Furnaces BAYCNDTRAP2A Inline Condensate Trap Kit used with Special Venting on 2" Vent Pipe All Furnaces BAYCNDTRAP3A Inline Condensate Trap Kit used with Special Venting on 3" Vent Pipe All Furnaces MAYBFERCOLKITA Heat Shield Kit for B-width 4GXCB or 4MXCB coils B width 4GXCB or 4MXCB Coils when installed with Upflow Furnace in all orientations MAYCFERCOLKITA Heat Shield Kit for C-width 4GXCC or 4MXCC coils C width 4GXCC or 4MXCC Coils when installed with Upflow Furnace in all orientations MAYDFERCOLKITA Heat Shield Kit for D-width 4GXCD or 4MXCD coils D width 4GXCD or 4MXCD Coils when installed with Upflow Furnace in all orientations (a) Airflow greater than 1600 CFM requires dual returns 88-A952V001-1 C-E N Accessories Document Pack Contents Item Qty. Description O ••• • •�•a• ° 4) O, ay,,,,,•,„,", ,,,,,,_„ Fj O 0 0 �.o" '""" '""" '• 11 12 13 14 . O ® 15 O O(A) O O ° p 10 O O 16 O 1 1 Condensate Drain Tube Assembly 2 1 Inlet Vent (a) 3 1 Inlet Vent Gasket 4 1 Outlet Vent Assembly 5 1 Outlet Vent Gasket 6 6 Screws 7 1 Condensate Trap Grommet 8 1 Plug — Condensate/Gas 9 1 Plug — Electrical 10 2 Grommet — Condensate/Gas 11 1 Installer's Guide 12 1 Service Facts 13 1 Owner Guide 14 1 Limited Warranty 15 1 2" to 3" Coupling — CPL00938 (b) 16 2 Brand labels (c) (a) 3" inlet vent supplied with A952V120DU5SAB and A952V120DD5SAB only. 2" inlet vent supplied with all other models. (b) Supplied with A952V120DU5SAB and A952V120DD5SAB only (c) Place appropriate brand label below the warning label on the front panel using stencil marks as guides. 10 88-A952V001-1C-EN Furnace Installation Guidelines The following sections give general guidelines for the installation of the gas furnaces. Safety Practices and Precautions The following safety practices and precautions must be followed during the installation, servicing, and operation of this furnace. 1. Use only with the type gas approved for this furnace. Refer to the furnace rating plate. 2. Install the furnace only in a location and position as specified in "Locations and Clearances" of these instructions. 3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air for Combustion and Ventilation" of these instructions. 4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the "Venting" section of these instructions. 5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the "Gas Piping" section of these instructions. 6. Always install the furnace to operate within the furnace's intended temperature -rise range with a duct system which has an external static pressure within the allowable range, as specified on the unit rating plate. Airflow within temperature rise for cfm versus static is shown in the Service Facts accompanying this furnace. 7. When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. 8. A gas -fired furnace for installation in a residential garage must be installed as specified in "Location and Clearances" section of these instructions. 9. The furnace may be used for temporary heating of buildings or structures under construction only when the following conditions have been met: a. The furnace venting system must be complete and installed per manufacturer's instructions. b. The furnace is controlled only by a room Comfort Control (no field jumpers). c. The furnace return air duct must be complete and sealed to the furnace. d. The furnace input rate and temperature rise must be verified to be within the nameplate marking. e. A minimum 4" MERV 11 air filter must be in place. f. 100% of the furnace combustion air requirement must come from outside the structure. g. The furnace return air temperature range is between 45 and 80 Fahrenheit. h. Clean the furnace, duct work, and components upon substantial completion of the construction process, and verify furnace operating conditions including ignition, input rate, temperature rise, and venting, according to the manufacturer's instructions. 10. In the Commonwealth of Massachusetts, this product must be gas piped by a Licensed Plumber or Gas Fitter. This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to .5" water column with all inlets, outlets, and drains sealed. General Guidelines The manufacturer assumes no responsibility for equipment installed in violation of any code or regulation. It is recommended that Manual J of the Air Conditioning Contractors Association (ACCA) or A.R.I. 230 be followed in estimating heating requirements. When estimating heating requirements for installation at Altitudes above 2000 ft., remember the gas input must be reduced. See Combustion and Input Check. Material in this shipment has been inspected at the factory and released to the transportation agency without known damage. Inspect exterior of carton for evidence of rough handling in shipment. Unpack carefully after moving equipment to approximate location. If damage to contents is found, report the damage immediately to the delivering agency. Codes and local utility requirements governing the installation of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 / NFPA 54 • National Installation Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org. These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 standards • CSA 2.3. Category IV furnaces operate with positive vent static pressure and with a flue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent furnaces are 88-A952V001-1 C-E N 11 Furnace Installation Guidelines approved for installation in Manufactured/ Mobile housing when used with BAYMFGH200B. A manufactured (mobile) home installation must conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or when this Standard is not applicable, the Standard for Manufactured Home Installations (Manufactured Home Sites, Communities and Set -Ups), ANSI/NCS A225.1. and/or MH Series Mobile Homes, CAN/CSA-Z240. Locations and Clearances The location of the furnace is normally selected by the architect, the builder, or the installer. However, before the furnace is moved into place, be sure to consider the following requirements: 1. Is the location selected as near the chimney or vent and as centralized for heat distribution as practical? 2. Do all clearances between the furnace and enclosure equal or exceed the minimums stated in Clearance Table below? Minimum clearance to combustible materials Closet Sides 0 in. Back 1 in. Top 1 in. Front 0 in. Bottom 0 in. Flue 0 in. 24 in. minimum front clearance recommended for service Horizontal Closet and Alcove Right Side 0 in. Left Side 0 in. Back 1 in. Top 1 in. Bottom 0 in. Flue 0 in. Horizontal Flue (discharge on left) Closet Right Side 0 in. Left Side 0 in. Rear 1 in. Top 1 in. Bottom 0 in. Flue 0 in. 3. Is there sufficient space for servicing the furnace and other equipment? A minimum of 24 inches front accessibility to the furnace must be provided. Any access door or panel must permit removal of the largest component. 4. Are there at least 3 inches of clearance between the furnace combustion air openings in the front panel and any closed panel or door provided? 5. Are the ventilation and combustion air openings large enough and will they remain unobstructed? If outside air is used, are the openings set 12" above the highest snow accumulation level? 6. Allow sufficient height in supply plenum above the furnace to provide for cooling coil installation, if the cooling coil is not installed at the time of this furnace installation. 7. The furnace shall be installed so electrical components are protected from water. 8. If the furnace is installed in a garage, it must be installed so that the burners, and the ignition source are located not less than 18 inches above the floor and the furnace must be located or protected to avoid physical damage from vehicles. 9. The gas furnace must not be located where excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid the following known contaminants: a. Permanent wave solutions b. Chlorinated waxes and cleaners c. Chlorine based swimming pool chemicals d. Water softening chemicals e. De-icing salts or chemicals f. Carbon tetrachloride g. Halogen type refrigerants h. Cleaning solvents (such as perch loroethylene) i. Printing inks, paint removers, varnishes, etc. j. Hydrochloric acid k. Cements and glues I. Antistatic fabric softeners for clothes dryers m. Masonry acid washing materials IMPORTANT: The furnace must be installed level. The only allowable variation would be slightly to the left and/ or forward in upflow installations or slightly toward the front in horizontal installations. This is necessary for proper condensate drainage. 12 88-A952V001-1 C-E N oc QC CT rr �i8 ili6� 5/8 —— — — — — — — — 15/16 — — — 1-11/16 �If1`ANGER OF I�1 UP 8.13/16 16-JI IS OUTLET ,I,N AIR 3 OUTLET Upflow Furnace BfNOui fLI.E B Size Cabinet INLET 1 IL 518 -118 i0.,/8 3.I /d T.3/i6 0U5L8 5-3/8 /3/ ¢A IGAS P 1.l4 S-UPPL AI 2-518 IERNAIFI ELECTRICAL fR[S 1-3/8 1-3/8 CONDENSATE TRAP INORI g11iAL RIGHT) ILUF f LUE MIT IT I x0A 1ZONTAL R1GN11 A`TEAT 1 NOR1IOpiAL LEFT) CONDF MITT TRAP I XORIZWIAL L[f11 p,/e ,LFCIR ICAL �I R[S AL I[RNATE) LUf I LFT I NOR IZONTAL RIGN11 3 1-5/8 CONDFNSA'F III NUF OUILFT ORI ZONTAL LfTTI UPIL IL AifE COND[NSAT )DRAIN " IAL 1[AN /8 INERUpS1Ai IR[S ImXF ERRj11'i #IRIS ZB�I/16 25.1// ZB-1/16 i/. 11/16 Ir15-5/16 S I DE R-,/R 1R SIDE IA-318 RETURN RETURN 1d"J'6 AIR i /d A 5/16 IR �..—..—..—..—..� 1- /dL A..—..—..—.. —..� 'Al 13116 18-5/16L 1 15116 I i8-I II 16 1R. D/16 1-15/16 " L 1311 INLET 15.3/4 AIR ve iD 18. I116 10-1IXI/d I F44ANGE 10.9/16 B[qi UP in; FLUE DXTL E, RET t1-1/I6 19 I1/16 OUTLET Upflow Furnace BN�G�; ' iV[T C Size Cabinet 3.3/d t0-1/B ,-ll l6 GAS SUPPLY 5-3/0 d3/d �A5 SUPPLY /.1/d IALTERNA,EI QQi/8 ELECTRICAL �IR[S 03 FLUE OUT LE I-l/B 13/0 C.DE SATE TRAP INDRI ONiAL RIGHT FLUT ICE IL MIT IONTAL RIGXTI ° NORIZ to L[iil [ONOE NSA if TRAP IXOAIZOR,AL L[m 0i/8 EL EC TIICAL �IRES IAL IE RNA,EI LUE I L[i I NDRIZONTAL RIGN,1 03 UOU,LET INORI ZONLAL LE FLI �I-5/8 CONDENSAI,ODRA�N �0I1I1 �I-5/8 CONDENSA,E DRAIN I AL YE RNA,EI 1/8 ,XERNOS,Ai IRES q� i0X[Rlb$$iAl �I RfS • O 3/ IAL,E AyAiEI — � t5-5/16 t8-I/16 � t0-I/16 15-I// 24-11116 d-3/a I E DE a.,/e REATRRN SIDE 6 Iean6 RETURN Id-3/8 � Iz-1/d � A I R � 11.5116 8 8 _.._.._.._.. 13116 18.5/16 I. 11S/16 21-1116 1.15116 L d 3/d ► d 5116 18-5/I6 I3/16 18-13/16 d.3/d 19-I/d INLET oc 118 AIR Cc 20 O c CD 5� cc cn oc QC CT 28. 1116 518 +F4-5/16 -------------r713/ 16 rr I I Y20-I/1 011H Gf R 03 12. 5116 BE`TI UP FLUE I I 23-3/16 OUTLET OU1LE1 ...9/16 Bf N>�UP A I R 03 INl[T Upflow Furnace I D Size Cabinet 1. 119 20-18 7-3163/d 01-518 01-5/8 GAS SUPPLY 5-3/8 d. lT6 GAS SUPPLY IAL iSUPPLY) i/8 /-I Id 2,631 ELECTRICAL IR[S I I-318 A02 OO OYSA1 1RAP RI A FLUE ONIAL RIGXI IXORIIO`EA04TALAGXT, (XOAIIL LEFT) Q 1/8 EONOEI{N,,SATE TRAP EL EGIRICAL WIRES IXOA'TONIAL L[F11 (AL TERNAIfI lYLUE INLET I HORIZONTAL RIGXI) RL UE OUTLET �I-5/8 (NORI ZONIAL LE FI] [ONDf NSA IUP`RA� N CI-5/8 UII 1ALTENSAIf DRAIN I AL T9ERNAIEI INERIIDSIAi A[S + • I FRIIOSTAT )WIRES • 281/16 3/ T IALTERNAIE) 25�5/16 28-I/16 2Y Ill 2/-II/16 SIDE 18 19 SIDE RETURN 8.3,16 RETURN Id-3/8 � 11-3/8 A I R I 2-1,d 5/I6 A I R I I I I �..—..—..—..—d 18-5116 I. 15/16 1"� 21-9/16 I-15/16 4.3/dd5/16 18.5116 IIT 13/16 13116 22.3,4 INLET AIR Ile 2D Downflow Furnace B Size Cabinet m m O c CD 0 o� cc Cn oc QC CT 28-13/I6 �d-5/16 -13116 rr 03 10-9/16 FLUE OU IL Ei 19-1/4 INLET 7/8 A'RT-FL Downflow Furnace C Size Cabinet 20 I -31d g� TTHERLIOSTAT 'OIRES ��ii7/gd-31d THERMOSTAT f . 'ALTER ATE) PLUG HOLE 1.15116 I-3/8 15/16 PLUG HOLE ELECTRICAL 'RESUE 'ALTER ATf) 03 INLET IALi ERNAT[1 FLUE OUTL�f3 8 ELECTRICAL 'WIRES 'ALTERNATE) MERNAi0 PLUG HOLE I f) ' 3/ d SDI - GAS SUP SUPPLY G518 AS SUPPLY 26 26 'ALTERNATE) 22-11/16 15.13/16 21.31A • 15 9-5116 5-IS/16 15-I /8 8-II/16 5-15/16 I-318 21.1116 I-3/d d-I/I 28 1/16 5/8 A -MA 5-3/8 19-II/16 OUTLET ' HE�I.5/8 FL GUP A I R DRAD[NSITE BEN A 20-I/d N ITx REAR BEN NUP 41 20-7/8 5/8 ---- 7-3/I6 +{ 28-13/16 d -5/16 1.13116 2-5/16 ' F FLUE N L E T OUTLET 22314 7l8 A I R Downflow Furnace INLET D Size Cabinet 20 3-III d-3/d QT/8 /-5/16 d-1/d THERMOSIIT wI RES (ALTER ATE) I-15/16 1.3/8 I-IS/16 PLUG HOLE--,--.gg� d 7 TTHER40STAT FIRES $gi/8 ELECTRICAL �'IRfS I AL TER NNATE) PLUG 03 ' HOLE FLUE OUTLET (ALTERNATE) 03 FLU' INL[i IALTERNATEI FLUE 14LET (ALTERNATE) �SUPPLB O 34 d ELECTRICAL FIRE: GAS (ALTERNATE) I T PLUG HOLE 26 22.11/16 26 21.3/4 ¢I.5/8 GAS SUPPLY ' 15 15-13/16 15-I/B 5-15116 8-3/d 8-II/16 5-15/16 2-5/8 1.3/8 24-9/16 4-3/d d-1/d 28 1116 5/8 d-3/d 5-3/8 _ ____________ 20-d I �IiN I/REAR F4AWGE BEA i UP CON E4ATE ORAIN I 23-3/16 OUTLET FLEA GEB A I R BEB� UP cc cc I I I-I/8 20 7/8 7-3116 rl c CD 0 1 5� cc cn Furnace General Installation The following sections give general instructions for the A952V Furnace Panel Removal installation of the gas furnaces. Note: Use a 1/4"nut driver to remove the two screws on the front panel. Horizontal Installation in an Attic or Crawlspace The S-Series upflow condensing furnace may be installed in an attic or crawl space in the horizontal let or right position for needed airflow direction. The horizontal furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the furnace. See "the Locations and Clearance section," p. 12. Line contact is only permissible between lines formed by intersections of the top and two sides of the furnace casing and building joists, studs, or framing. The furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture. The Furnace must be supported at both ends and the middle when installed horizontally. The Furnace must also be elevated approximately 6 inches to allow clearance for the condensate drain to exit the cabinet in the horizontal position. FURNACE MUST BE SUPPORTED AT ALL FOUR TO APPROVED CORNERS. BAYHANG - OPTIONAL HORIZONTAL OPEN / VENTED DRAIN HANGING BRACKET KIT Note: The overflow stand pipe termination must be even with or slightly below the bottom of the condensate trap. Note: Water from the overflow pipe must drain into the emergency drain pan. Horizontal Installation Hanging Using Straps The furnace may be installed hanging in a hanging position using straps. The furnace should be supported at both ends and have an additional support in the center of the furnace in front. 88-A952V001-1 C-E N 19 Furnace General Installation Gas Piping Important., When converting the gas piping from the factory default, the plug must be removed from the new gas piping location and swapped with the grommet from the default location. The upflow furnace default is left side gas piping. The downflow furnace default is right side gas piping. Upflow furnace with gas piping on left side Upflow furnace with gas piping on right side 1 /8" N PT 1 /8" N PT Test Fitting Test Fitting Automatic Gas Valve �. Automatic Gas Valve Main Manual with Manual Shut-off with Manual Shut-off Main Manual Shut-off Valve Shut-off Valve Gas Line Gas Line Ground Grommet e e o o Grommet Union \ Ground \y o 0 Joint ° ° Union Joint 6 Drip Leg o 0 0® of o Opo e 0 e e� o Opo Drip Leg o`er e60°Obo o`er e64°Obe o Downflow furnace with gas piping on left side Downflow furnace with gas piping on right side + � Test Fittin a Test Fitting r � ` � @�-�L 1 /8" NPT g J� Test Fitting Main Manual a •• Shut-offValve� 0. e°ooU�e� '�_ � oa�� Main Manual Gas Line o o e' ogo�po Shut-off Valve Grommet o" a e o 0 Ground ,® o Q o o Gas Line Grommet ,� Union , o Ground E Joint ® °s / Union •rep q Joint 0 0 Drip Leg 0 0 Drip Leg Automatic Gas Valve with Manual Shut-off Automatic Gas Valve with Manual Shut-off 88-A952V001- l C-E N Furnace General Installation Important., When converting the gas piping from the factory default, the plug must be removed from the new gas piping location and swapped with the grommet from the default location. The upflow furnace default is left side gas piping. The downflow furnace default is right side gas piping. Horizontal left furnace with gas piping out left side Horizontal left furnace with gas piping out right side 1 /8" N PT ® ? ° e Test Fitting Main Manual °pO�Qg Shut-off Valve Ground Union Gas Line Automatic Gas Valve e a Joint Grommet with Manual Shut-off 's �, 1/8"NPT ° ° Ej �® Drip Leg y, Test Fitting Main Manual Shut-off Valve Ground o 0 ° / Union o Joint eGas Line a Grommet °QpppQ° 0 —� Drip Leg Automatic Gas Valve with Manual Shut-off Horizontal right furnace with gas piping out left side Horizontal right furnace with gas piping out right side Main Manual Shut-offValve Automatic Gas Valve \ oo° 900o with Manual Shut-off 0-0 o • ee o�06 Oo Gas Line ° Grommet Ground Union 1/8"NPT ° ° Joint Test Fitting Ground Main Manual U o o Union Shut-off Valve Drip Leg Joint i Automatic Gas e �o0 9000 Valve with Gas Line Manual Shut-off Grommet e Drip Leg 1/8"NPT e � _ Test Fitting 88-A952V001-1 C-E N Furnace General Installation The upflow/horizontal furnace is shipped standard for left side installation of gas piping. An opening with plug is provided on the right side for an alternate gas piping arrangement. The installation of piping shall be in accordance with piping codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases. Important: If local codes allow the use of flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. Refer to the piping table for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve. National codes require a condensation drip leg to be installed ahead ofthe gas valve. The furnace and its individual shut-offvalve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa). The furnace must be isolated from the gas supply piping by closing its individual manual shut-off valve during any pressure testing ofthe gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa). Note: Maximum pressure to the gas valve for natural gas is 13.8" W. C. Minimum pressure is 5.0" W.C. Maximum pressure to the gas valve for propane is 13.8" W.C. Minimum pressure is 10.0" W. C. All gas fittings must be checked for leaks using a soapy solution before lighting the furnace. DO NOT CHECK WITH AN OPEN FLAME! For propane conversions on all S-Series Furnaces, use BAYLPSS400B conversion kit with stainless steel burners. When installing our furnaces in a manufactured house, use Manufactured Housing Accessory Kit, BAYMFGH2O06. NATURAL GAS ONLY TABLE OF CUBIC FEET PER HOUR OF GAS FOR VARIOUS PIPE SIZES AND LENGTHS PIPE LENGTH OF PIPE SIZE 30 20 30 40 50 60 70 1/2 131 90 72 62 55 50 46 3/4 273 188 151 129 114 104 95 1 514 353 284 243 215 195 179 1-1/4 1060 726 583 499 442 400 368 This table is based on Pressure Drop of 0.3 inch W.C. and 0.6 SP. GR. Gas ORIFICE SIZES INPUT RATING BTUH NUMBER OF BURNERS MAIN BURNER ORIFICE DRILL SIZE NAT.GAS PROPANE GAS 40,000 2 45 56 60,000 3 45 56 80,000 4 45 56 100,000 5 45 56 120,000 6 45 56 88-A952V001- l C-E N Furnace General Installation Combustion and Input Check 1. Make sure all gas appliances are off except the furnace. 2. Clock the gas meter with the furnace operating (determine the dial rating of the meter) for one revolution. 3. Match the "Sec" column in the gas flow table with the time clocked. 4. Read the "Flow" column opposite the number of seconds clocked. 5. Use the following factors if necessary: a. For 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow Reading _ 2 b. For 1/2 Cu Ft. Dial Gas Flow CFH = Chart Flow Reading - 4 c. For 5 Cu. Ft. Dial Gas Flow CFH = IOX Chart Flow Reading - 4 6. Multiply the final figure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating. Gas Flow in Cubic Feet Per Hour 2 Cubic Foot Dial Sec. Flow Sec. Flow Sec. Flow Sec. Flow 10 732 31 236 52 141 86 85 11 666 32 229 53 138 88 83 12 610 33 222 54 136 90 81 13 563 34 215 55 133 94 78 14 523 35 209 56 131 98 75 15 488 36 203 57 128 100 73 16 458 37 198 58 126 104 70 17 431 38 193 59 124 108 68 18 407 39 188 60 122 112 65 19 385 40 183 62 118 116 63 20 366 41 179 64 114 120 61 21 349 42 174 66 111 130 56 22 333 43 170 68 108 140 52 23 318 44 166 70 105 150 49 24 305 45 163 72 102 160 46 25 293 46 159 74 99 170 43 26 282 47 156 76 96 180 41 27 271 48 153 78 94 190 39 28 262 49 149 80 92 200 37 29 253 50 146 82 89 30 244 51 144 84 87 88-A952VO01-1 C-E N 23 Furnace General Installation Gas Valve Adjustment Changes can be made by adjusting the manifold pressure, or changing orifices (orifice change may not always be required). To adjust the manifold pressure: 1. Turn off all electrical power to the system. 2. Attach a manifold pressure gauge with flexible tubing to the outlet pressure boss marked "OUT P" on White- Rodgers gas valve model 363. 3. Loosen (Do Not remove) the pressure tap test set screw one turn with 3/32" hex wrench. a. The pressure tap adjustment kit (KIT07611) contains a 3/32" hex wrench, a 5/16" hose and a connector and can be ordered through Global Parts. 4. Turn on system power and energize valve. Important: Adjust 2nd stage on the gas valve before attempting to adjust 1 st stage. 5. Adjust 2nd stage gas heat by removing the high (HI) adjustment regulator cover screw. a. To increase outlet pressure, turn the regulator adjust screw clockwise. b. To decrease outlet pressure, turn the regulator adjust screw counterclockwise. c. Adjust regulator until pressure shown on manometer matches the pressure specified in the table. The input of no more than nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude. d. Replace and tighten the regulator cover screw securely. 6. Adjust 1st stage gas heat by removing the low (LO) adjustment regulator cover screw. a. To increase outlet pressure, turn the regulator adjust screw clockwise. b. To decrease outlet pressure, turn the regulator adjust screw counterclockwise. c. Adjust regulator until pressure shown on manometer matches the pressure specified in the table. The input of no more than nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude. d. Replace and tighten the regulator cover screw securely. 7. Cycle the valve several times to verify regulator setting. a. Repeat steps 5-7 if needed. 8. Turn off all electrical power to the system. 9. Remove the manometer and flexible tubing and tighten the pressure tap screw. 10. Using a leak detection solution or soap suds, check for leaks at the pressure outlet boss and pressure tap test screw. 11. Turn on system power and check operation of the unit. White -Rodgers 36J Gas Valve On/Off Inlet Pressure Toggle Switch Boss 2nd Stage (HI) Manifold Pressure Adjustment 1st Stage (LO) Manifold Pressure Adjustment Fuel Manifold Pressure Settings (inches w.c.) Fuel 2nd Stage Max. 1st Stage Max. Natural Gas 3.5" W.C. 1.7" W.C. Propane Gas 10.0" W.C. 6.0" W.C. 24 88-A952V001-1 C-E N Furnace General Installation High Altitude Derate Input ratings (BTUH) of these Furnaces are based on sea level operation and should not be changed at elevations up to 2,000 ft. (610 m). If the installation is 2,000 ft. (610 m) or above, the Furnace input rate (BTUH) shall be reduced 4% for each 1,000 ft. above sea level. Installations of this furnace at altitudes above 2,000 ft. (610 m) shall be made utilizing the Vent Length table and/or Part Numbers for Replacement Orifices table in these installation instructions. The Furnace input rate shall be checked by clocking the gas flow rate (CFH) and multiplying by the heating value obtained from the local utility supplier for the gas being delivered at the installed altitude. Input rate changes can be made by adjusting the Manifold Pressure (min 3.0 - max 3.7 in. W.C. - Natural Gas) or changing orifices (orifice change may not always be required). If the desired input rate can not be achieved with a change in Manifold Pressure, then the orifices must be changed. Propane installations will require an orifice change. Important. Reinstall the replacement orifices to the same depth as the orifices supplied with the equipment. See the table for help in selecting orifices if orifice change is required. Furnace input rate and temperature rise should be checked again after changing orifices to confirm the proper rate for the altitude. The vent length table shows the required vent lengths for installations at various altitudes. Installations above 12,000 feet are not allowed. Turn the main Gas Valve toggle switch within the unit to the "OFF' position. Turn the external gas valve to "ON". Purge the air from the gas lines. After purging, check all gas connections for leaks with a soapy solution - DO NOT CHECK WITH AN OPEN FLAME. Allow 5 minutes for any gas that might have escaped to dissipate. Propane Gas being heavier than air may require forced ventilation. Turn the toggle switch on the Gas Valve in the unit to the "ON" position. The table lists the main burner orifices used with the furnace. If a change of orifices is required to correct the furnace input rating refer to the part number for replacement orifices table. Installation of this furnace at altitudes above 2000 ft (610m) shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA 8149.1. PART NUMBERS FOR REPLACEMENT ORIFICES DRILL SIZE PART NUMBER DRILL SIZE PART NUMBER 44 ORF00501 54 ORF00555 45 ORF00644 55 ORF00693 46 ORF00909 56 ORF00907 47 ORF00910 57 ORF00908 48 ORF01099 58 ORF01338 49 ORF00503 59 ORF01339 50 ORF00493 Orifice Twist Drill Size If Altitude Above Sea Level and Orifice Required at Other Elevations Installed at Sea Level 2000 3000 4000 5000 6000 7000 8000 9000 10000 42 42 43 43 43 44 44 45 46 47 43 44 44 44 45 45 46 47 47 48 44 45 45 45 46 47 47 48 48 50 45 46 47 47 47 48 48 49 49 50 46 47 47 47 48 48 49 49 50 51 47 48 48 49 49 49 50 50 51 52 54 54 55 55 55 55 55 56 56 56 55 55 55 55 56 56 56 56 56 57 56 56 56 57 57 57 58 59 59 60 57 58 59 59 60 60 61 62 63 63 58 59 60 60 61 62 62 63 63 64 From National Fuel Gas Code —Table E.1.1(d) 88-A952V001-1 C-E N 25 Furnace General Installation General Venting FURNACE EXHAUST MUST BE VENTED TO THE OUTDOORS. THESE FURNACES ARE INDUCED DRAFT VENTED AND MUST NOT BE CONNECTED TO ANY VENT SERVING ANOTHER APPLIANCE. PLEASE NOTE THATTHESE FURNACES USE POSITIVE -PRESSURE VENT SYSTEMS. Proper venting is essential to obtain maximum efficiency from a condensing Furnace. Proper installation of the vent system is necessary to assure drainage ofthe condensate and prevent deterioration of the vent system. ETL has certified the design of condensing Furnaces for a minimum of 0" clearance from combustible materials to single wall plastic vent pipe. The recommended system is assembled from 2" or 3" plastic pipe and fittings found in the Approved Vent Pipe Materials Table. Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance, or where required by local codes, then 3" venting of Type 29- 4C stainless steel must be used in place of PVC material. These Furnaces have been classified as CATEGORY IV Furnaces in accordance with ANSI Z21.47 "latest edition" standards. Category IV Furnaces operate with positive vent pressure and with a vent gas temperature less than 1401Fabove the dewpoint. These conditions require special venting systems, which must be gas tight and water tight. 3" Venting requirements Important: To determine if your application requires 3" venting, see the Maximum Vent Length Table. Important: Horizontal venting application must use the 2"x 3"offset reducing coupling. Vertical venting applications do not require the reducing coupling to be offset. When the vent pipe is exposed to temperatures below freezing, e.g., when it passes through unheated spaces, etc., the pipe must be insulated with 112 inch (12.7 mm) thick Armaflex-type insulation or equal. If the space is heated sufficiently to prevent freezing, then the insulation will not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space. Note: If your furnace comes with a factory supplied 2"X 3" offset reducing coupling it is used for 3" vent pipe installation. Make sure the marking "TOP" is located on the top side ofthe pipe in horizontal venting applications. The straight side ofthe coupling must be on bottom for proper drainage of condensate Note: For Canadian applications, BA YREDUCE 2 "x 3 " offset reducing coupling meets ULC-S636 requirements. Make sure the marking "TOP" is located on the top side ofthe pipe. The straight side of the coupling must be on bottom for proper drainage of condensate in horizontal venting. Note: When an existing Furnace is removed from a venting system serving othergas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. Important: These Furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect Vent (single pipe). The Furnaces are shipped DIRECT VENT with sealed combustion. Important: Products installed in Canada must use vent systems that are certified to the Standard for Type BH Gas Venting Systems (ULC S636) for Class II -A venting systems (up to 650C). Components of the vent system must not be interchanged with other vent systems or unlisted pipe or fittings. Plastic components, specified primers, and glues must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts. In addition, the first three feet ofthe vent pipe must be visible for inspection. LABEL SAYS "TOP" CPL00938 FIELD SUPPLIED U 2"T03"COUPLING 2"COUPLING BAYREDUCE maybe CPL009381. FACTORY used in Canadian SUPPLIED ONLY WITHTHE applications to meet 120,000 BTUH UPFLOW ULC-S636 FURNACE MODELS CPL00938 O BAYREDUCE maybe 2" TO 3" COUPLING used in Canadian applications to meet ULC-S636 FIELD SUPPLIED 2" COUPLING CPL00938 IS FACTORY SUPPLIED ONLY WITH THE 120,000 BTUH UPFLOW FURNACE MODELS 88-A952V001- l C-E N Furnace General Installation Special Case Venting Special instructions for direct vent furnace air intake. In certain applications, particularly when the furnace is located in a basement, there are certain conditions that can be met where warm humid air from the outside is drawn into combustion air piping. If the area where the piping is located is conditioned below 700 F, condensation could occur inside the piping and ultimately drain into the furnace compartment, which could lead to premature component failure. We recommend following one of the options to prevent this condition from occurring and possibly damaging components within the furnace: Note: Inlet air piping is not considered to be part of the venting system. The inlet air piping may be made from PVC. Option 1 Option 1 If possible, slope the inlet combustion air piping away from the furnace. Condensation that may occur will now drain outside of the home. The combustion air outlet piping must remain sloped back to Combustion air the furnace. exhaust Combustion air intake Slope equals 1 /4" per foot Primary drain vent stack must O terminate below the bottom of the condensate trap To an approved vented drain f Optional In -line Condenser Trap Kit The BAYCNDTRAP2 and BAYCNDTRAP3 may be used for Option 1 Combustion air venting. The in -line condenser trap kit must be installed on the exhaust vertical section ofthe combustion air intake pipe. Note: The in -line condenser trap may only be installed one way. See Combustion air the imprint on the trap to ensure the arrow is pointing towards intake the furnace. The BAYCNDTRAP2 is used when the system uses 2" vent pipe. The BAYCNDTRAP3 is used when the system uses 3" vent pipe. BAYCNDTRAP2 BAYCNDTRAP3 '• ° Field fabricated trap Primary drain vent stack must O terminate below the bottom of the condensate trap To an approved vented drain F 88-A952V001-1 C-EN 27 Furnace General Installation Option 2 —Top combustion air intake Option 2 If sloping the combustion air intake pipe is not possible, install a DWV Tee as close to the furnace as possible with drain and trap to prevent condensation from occurring in the furnace cabinet. Do not tee AC condensate and combustion air condensate trap together. Combustion air exhaust Combustion air intake Approved DWV Tee Field fabricated trap C Primary drain vent stack must C terminate below the bottom of the condensate trap To an approved vented drain F Option 3 — Side combustion air intake Option 3 If sloping the combustion air intake pipe is not possible, install an Combustion air Combustion air approved DWV Tee as close to the furnace as possible with drain and intake exhaust trap. Approved DWV Tee Field fabricated trap - 0 Primary drain vent stack must terminate below the bottom of the condensate trap To an approved - vented drain E7 88-A952V001-1C-EN Furnace General Installation Vent Terminations For DIRECT VENT APPLICATION: The Furnaces must be vented to Vent terminations the exterior of the house and combustion air MUSTcome through the BAYVENT200B inlet air pipe from OUTSIDE AIR. Note: BAYVENT* accessories can be used for inlet and outlet ' BAYAIR30AVENTA Vent terminations — Canadian applications. Meets ULC-5636 terminals when the pipes do not exit the structure together. For requirements. Canadian applications, venting systems must meet ULC-S636 requirements. BAYVENTCN200B For NONDIRECT VENT APPLICATION: The Furnace shall be vented BAYAIR30CNVENT to the exterior of the house, but combustion air may enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR COMBUSTION AND VENTILATION) FURNACE VENT / INLET PIPE INSTALLATION IN TWO PRESSURE ZONE CONFIGURATIONS ARE NOT ALLOWED Note: For single pressure zone applications, see the Horizontal Venting section. The following are EXAMPLES ONLY. EX. 1— Vent Example 1 shows the vent pipe exhausting through the roof and the inlet air coming from the interior of the house. The inlet air coming from the interior of the house must meet combustion requirements for area, etc., as shown in the section AIR FOR COMBUSTION AND Air VENTILATION in this Installer's Guide. Inlet Note: If only the flue gas pipe is to the outside of the structure, a straight section of pipe (long enough to exit the Furnace cabinet) must be attached to the inlet air side with an elbow (which is 5 to 10 equiv, ft.) installed on the end to prevent dust Furnace and debris from falling directly into the Furnace. EX. 2 — Attic The inlet air does not have to come from outside the structure. Vent Vent Example 2 shows the inlet air, may come from the attic if the requirements for combustion air are met as shown in the section AIR FOR COMBUSTION AND VENTILATION. Note: If only the flue gas pipe is to the outside of the structure, a straight section of pipe (long enough to exit the Furnace cabinet) must be attached to the inlet air side with an elbow A i (which is 5 to 10 equiv. ft.) installed on the end to prevent dust r and debris from falling directly into the Furnace. Inlet (See Note) Furnace Attaching Vent Piping VENT FITTING MATERIAL— PLASTIC Gas and liquid tight single wall vent fittings, designed for resistance to corrosive flue condensate, MUST be used throughout. Listed in the Approved Vent Pipe Materials table are designations for different types of 2" and 3" size pipe and fittings that meet these requirements. The materials listed are various grades of PVC, CPVC, ABS, PolyProp by DuraVent , Z-Dens by Novaflex Group, Innoflue® by Centrotherm, and PolyFlue'" polypropylene venting systems. 88-A952V001-1 C-EN 29 Furnace General Installation ATTACHING VENT PIPING Important: Products installed in Canada must use vent systems that are certified to the Standard for Type BH Gas Venting Systems (ULC S636) for Class II -A venting systems (up to 650C). Components of the vent system must not be interchanged with other vent systems or unlisted pipe or fittings. Plastic components, specified primers, and glues must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts. In addition, the first three feet of the vent pipe must be visible for inspection. PIPE JOINTS: All joints must be fastened and sealed per manufacturer instructions and local and national codes to prevent escape of combustion products into the building. MANUFACTURED MODULAR VENTING SYSTEMS CARBON MONOXIDE POISONING CARBON MONOXIDE POISONING HAZARD! HAZARD! Failure to follow this Warning may result in property Failure to follow this Warning may result in property damage, severe personal injury, or death. damage, severe personal injury, or death. See the Approved Vent Pipe Materials table for Do not use cement on polypropylene venting manufactured modular venting systems that are systems. Follow the manufacturer's installation approved for use with this product. Follow the instructions when installing the venting system. manufacturer's installation instructions when installing the venting system. For manufactured modular venting systems that are approved with this product see PVC vent fitting material table. Do not drill into polypropelene venting pipes BONDING OF PVC Note: It is recommended that the first joints from the Furnace be Note: Follow venting instructions carefully when using PVC cement. connected and sealed with high temperature RTV. This will Important: All joints must be water tight. Flue condensate is enable the pipes to be removed later without cutting. somewhat acidic, and leaks can cause equipment Be sure to properly support these joints. damage. Commercially available solvent cement for PVC must be used to join PVC pipe fittings. Follow instructions on container carefully. Pipe and Fitting - ASTM D1785, D2466, D2661, & D2665 PVC Primer and Solvent Cement - ASTM D2564 Procedure for Cementing Joints - Ref ASTM D2855 1. Cut pipe square, remove ragged edges and burrs. Chamfer end of pipe, then clean fitting socket and pipe joint area of all dirt, grease, moisture or chips. Seal INLET AIR PIPE 2. After checking pipe and socket for proper fit, wipe socket and pipe With RTV sealant with cleaner -primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. DO NOTALLOW PRIMER TO DRY BEFORE APPLYING CEMENT. 3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert pipe into fitting with a slight twisting movement until it bottoms out. 4. Hold the pipe in the fitting for 30 seconds to prevent tapered socket from pushing the pipe out of the fitting. 5. Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time varies according to fit, temperature and humidity. Connection of the pipe and collar of the combustion air inlet should just be a friction fit. It is recommended that the inlet air joint be sealed with RTV type sealant to allow the joint to be separated for possible future service. The inlet and vent pipes must be properly supported throughout the entire length. 30 88-A952V001-1 C-E N Furnace General Installation APPROVED VENT PIPE MATERIALS PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors. ANSI/UL 1738 APPROVED VENT PIPE MATERIAL PVC ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE OF MARKING F891 CELLULAR CORE 158 ASTM F891 D2665 DWV PIPE 158 ASTM D2665 D1785 SCH 40, 80, 120 158 ASTM D1785 D2241 SDR SERIES 158 ASTM D2241 CPVC ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE OF MARKING D2846 CPVC 41 212 ASTM D2846 F441 SCH 40, 80 212 ASTM F441 F442 SDR SERIES 212 ASTM F442 ABS ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE OF MARKING D2661 SCH 40 DWV 180 ASTM D2661 F628 SCH 40 DWV CELLULAR CORE 180 ASTM F628 PolyPro® by DuraVent , Z-Dens by Novaflex Group, Innoflueg by Centrotherm, and PolyFluelm polypropylene venting systems. ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE OF MARKING N/A N/A 230 ULC-S636 88-A952V001-1 C-E N Furnace General Installation Maximum Vent Length Table Model Maximum Total Equivalent Length in Feet for Vent and Inlet Air (See Notes) 2 inch or 2.5 inch Pipe 3 inch or 4 inch Pipe Altitude 0-2,000 Feet A952V040BU3SAB,A952V040BD3SAB, A952V060BU3SAB,A952V060BD3SAB, 200 200 A952V060BU4SAB A952V080BU4SAB,A952V080BD4SAB, 100 200 A952V080CU5SAB A952V100CU4SAB,A952V100CD4SAB, 50 200 A952V100CU5SAB,A952V100CD5SAB A952V120DU5SAB,A952V120DD5SAB Note 200 Altitude 2,001-5,400 Feet A952V040BU3SAB,A952V040BD3SAB, A952V060BU3SAB,A952V060BD3SAB, 200 200 A952V060BU4SAB A952V080BU4SAB,A952V080BD4SAB, 80 120 A952V080CU5SAB A952V100CU4SAB,A952V100CD4SAB, 50 150 A952V100CU5SAB,A952V100CD5SA6 A952V120DU5SAB,A952V120DD5SAB Note 200 Altitude 5,401-7,800 Feet A952V040BU3SAB,A952V040BD3SAB, A952V060BU3SAB,A952V060BD3SAB, 100 150 A952V060BU4SAB A952V080BU4SAB,A952V080BD4SAB, 50 70 A952V080CUSSAB A952V100CU4SAB,A952V100CD4SAB, Notel 100 A952V100CU5SAB,A952V100CD5SAB A952V120DU5SAB,A952V120DD5SAB Note 100 Altitude 7,801-10,100 Feet A952V040BU3SAB,A952V040BD3SAB, A952V060BU3SAB,A952V060BD3SAB, 50 90 A952V060BU4SAB A952V080BU4SAB, A952V080BD4SAB, Note 1 50 A952V080CUSSAB A952V100CU4SAB,A952V100CD4SAB, Note 50 A952V100CU5SAB,A952V100CD5SAB A952V120DU5SAB,A952V120DD5SAB Note 50 Notes: 1. Not allowed 2. For PolyProp by Duravent, Z-DENS by Novaflex Group, InnoFlue@by Centrotherm, and PolyflueTM manufactured modular venting systems that are in the approved vent pipe material table, fitting equivalent vent lengths may be different from what is shown in Note 6. Refer to the venting system manufacturer's installation instruction for appropriate venting diameters and equivalent lengths. 3. Minimum vent length for all models: 15' equivalent. 4. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See note 7 below for exception). The inlet pipe can be of a larger diameter, but never smaller than the vent pipe. 5. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOTA COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH (Vent or Inlet air pipes). 6. One SHORTradius 900 elbow is equivalent to 10' of 4" pipe, 10' of 3" pipe, or 8' of 2" pipe. One LONG radius elbow is equivalent to 6' of 4" pipe, 7' of 3" pipe, or 5' of 2" pipe. Two 450 elbows equal one 900 LONG elbow. One MITERED elbow is equivalent to 12' of 3" pipe or 12' of 2" pipe. 7. The termination tee or bend must be included in the total number of elbows. If the BAYAIR30AVENTA or BAYAIR30CNVENT termination kit is used, the equivalent length of pipe is 5 feet. For BAYVENT200B and BAYVENTCN200B the equivalent length is 0 feet. 8. For Canadian applications, venting systems must meet ULC-S636 requirements. 9. The INLETAIR of one pipe systems require the installation of a minimum of one 900 elbow (to prevent dust and debris from falling straight into the furnace). 32 88-A952V001-1C-EN Furnace General Installation Horizontal Venting 3" Venting requirements Important: To determine if your application requires 3"venting, see FNo tioN a the Maximum Vent Length Table. Qos Important: Horizontal venting application must use the 2"x 3"offset LABEL a reducing coupling. Vertical venting applications do not SAYS l require the reducing coupling to be offset. "TOP" � _ When the vent pipe is exposed to temperatures below freezing, e.g., when it passes through unheated spaces, etc., q the pipe must be insulated with 112 inch (12.7 mm) thick l Armaflex-type insulation or equal If the space is heated sufficiently to prevent freezing, then the insulation will not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space. Note: If your furnace comes with a factory supplied 2 " X 3" offset 0 �� reducing coupling it is used for 3" vent pipe installation. Make sure the marking "TOP" is located on the top side of the pipe in CPL00938 FIELD SUPPLIED horizontal venting applications. The straight side of the 2" TO 3" COUPLING 2" COUPLING coupling must be on bottom for proper drainage of condensate. Note: For Canadian applications, BAYREDUCE 2"x 3" offset reducing BAYREDUCE may be used in Canadian CPL00938 IS FACTORY SUPPLIED ONLY WITH THE coupling meets ULC-S636 requirements. Make sure the applications to meet 120,000 BTUH UPFLOW marking "TOP" is located on the top side of the pipe. The ULC-S636 FURNACE MODELS straight side of the coupling must be on bottom for proper drainage of condensate in horizontal venting. CPL00938 2" TO 3" COUPLING O BAYREDUCE may be used in Canadian applications to meet ULC-S636 "COUPLING CPL00938 IS FACTORY SUPPLIED ONLY WITH THE 120,000 BTUH UPFLOW FURNACE MODELS 88-A952V001-1 C-E N 33 Furnace General Installation COMBUSTIBLE MATERIAL WALL A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal. Minimum dimensions are 12"x12". Shield must be fastened to both inside and outside of wall. Use screws or anchor type fasteners suited to the outside or inside wall surfaces. NONCOMBUSTIBLE MATERIAL WALL The hole through the wall must be large enough to maintain pitch of vent and properly seal. Use cement mortar seal on inside and outside of wall. i 34 88-A952V001-1 C-E N Furnace General Installation Table 2. Horizontal Venting Through Wall The vent for this appliance shall not terminate 1. Over public walkways; or 2. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage; or 3. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves. or other equipment. Possible configurations for two pipe venting system. Both terminations must be located in the same pressure zone. Important: Maintain 12"minimum clearance above highest anticipated snow level orgrade, whicheveris greater. Note: All distances are centerline to centerline. 12"Min. 15"Max. �� 12" Min. 15" Max 6" Min. 24" Max. INL INLET jT 6" VENT V y 9"Minimum minI.. from end of inlet 9" MinimumMAend minimum from and pipe 61• of exhaust pipe to / MAX end of inlet pipe 12" Min. 15"Max. i 6"Min.�� A— 24" Max. �\ 4"Min. f2" 24" Max. I INLET VENT INLET I VENT 9" Minimum minimum from end of exhaust pipe to \ end of inlet pipe `J 6" B" / MAX / MAX. Elbow and Tee Must be as close / together as \, 6" Max. to wall possible / 12" Min. between Inlet and vent 24" Max. I _ I terminations INLET / VENT VENT INLET / 6.. 4" Min. MAX 24" Max. I 88-A952V001-1 C-E N 35 Furnace General Installation Horizontal Venting Through Wall with Concentric Vent Kit These Furnaces may be installed as direct vent (as shipped) or as nondirect vent. Installation must conform to national, state, and local codes. The BAYVENT20013, BAYVENTCN200B, BAYAIR30AVENTA, and BAYAIR30CNVENTvent & inlet terminals kits must be located at least 12" minimum above normally expected snow accumulation level. Avoid areas where staining or condensate drippage may be a problem. Location of the vent/wind terminal should be chosen to meet the requirements for either direct or non -direct vent applications. PITCH — Venting through the wall must maintain 1/4" per foot pitched upward to insure that condensate drains back to the Furnace. FLUE GAS DEGRADATION —The moisture content of the flue gas may have a detrimental effect on some building materials. This can be avoided by using the roof or chimney venting option. When wall venting is used on any surface that can be affected by moisture, it is recommended that a corrosion resistant shield (24 inches square) be used behind the vent terminal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints within 3 feet of the vent terminal. The vent for this appliance shall not terminate 1. Over public walkways; or 2. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage; or 3. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves. or other equipment. For Canadian installations, if you used a ULC-S636 approved manufactured modular venting system, a copy of the manufacturer's instructions should remain with the system. The installation instruction can be obtained from the vent termination manufacturer. BAYVENTCN200B and BAYAIR30CNVENT meet ULC-S636 requirements. BAYVENT200B/BAYVENTCN200B Note: For Canadian applications, horizontal vent termination kits must meet ULC-S636. ANCHORS/ (4 req.) VENT i ENPLATE. % /VT 3.2" 12" MINIMUM TO OVERHANG COMBUS ION AIR SCREWS (4 req.) N1'Ll1lIW O VENT CENT 0 y CAP MAINTAIN 12" MINIMUM CLEARA CE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER BAYAIR30AVENTA/ BAYAIR30CNVENT(Sidewall) COMBUSTION AIR STRAP (FIELD SUPPLIED) R AIN CAP 1 \ O VENT 0 o � o 0 VENT 0 ELBOW COMBUSTION AIR (FIELD SUPPLIED) 12" MIN TO OVERHANG i °+1i2 COMBUSTION / AIR VENT "' MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SHOW LEVEL OR GRADE WHICH EVER IS GREATER 36 88-A952V001-1 C-EN Furnace General Installation Important: The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through -the - wall vented gas appliances as follows: For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OFALL OBSTRUCTIONS". 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2) (a)1 through 4. This appliance requires a special venting system. If BAYAIR30AVENTA or BAYVENT200B are used, a copy of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address: Ingersoll Rand 6200 Troup Highway Tyler, TX 75707 Attention: Manager of Field Operations Excellence Horizontal Vent Clearances D I E 0"I INSIDE CORNER DETAIL -G 1 _: H IS CLLy FIXED CLOSED B � 111 ��OPERABLE� -i_i i �� VENTTERMINAL ® AIR SUPPLY INLET ® AREA WHERE TERMINAL IS NOT PERMITTED 88-A952V001-1 C-E N 37 Furnace General Installation Non -Direct Vent Termination Clearances A= WE C= D= E= F= G= H= L= M= Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above meter/regulator assembly Clearance to service regulator vent outlet Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to a mechanical air supply inlet Clearance above a paved sidewalk or paved driveway located on public property Clearance under veranda, porch, deck, or balcony Canadian Installations 12 inches (30 cm) 6 inches (15 cm) for appliances <_ 10,000 BTUH (3 kw), 12 inches (30 cm) for appliances > 10,000 BTUH (3 kw) and <_ 100,000 BTUH (30 kw), 36 inches (91 cm) for appliances > 100,000 BTUH (30 kw) * * * * * 3 feet (91 cm) with a height 15 feet (4.5 m) above the meter/regulator assembly 3 feet (91 cm) 6 inches (15 cm) for appliances <_ 10,000 BTUH (3 kw), 12 inches (30 cm) for appliances > 10,000 BTUH (3 kw) and <_ 100,000 BTUH (30 kw), 36 inches (91 cm) for appliances > 100,000 BTUH (30 kw) 6 feet (1.83m) 7 feet (2.13 m) 12 inches (30 cm) US Installations 12 inches (30 cm) 4 feet (1.2m) below or to the side of opening; 1 foot (0.3m) above opening. * * * * * * * 4 feet (1.2 m) below or to side of opening; 1 foot (300 m) above opening 3 feet (91 cm) above if within 10 feet (3m) horizontally 7 feet (2.13 m) * Notes: 1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code. 2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. t. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. t. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions. 38 88-A952V001-1C-EN Furnace General Installation Direct Vent Termination Clearances A= WE C= D= E= F= G= H= L= M= Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above meter/regulator assembly Clearance to service regulator vent outlet Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to a mechanical air supply inlet Clearance above a paved sidewalk or paved driveway located on public property Clearance under veranda, porch, deck, or balcony Canadian Installations 12 inches (30 cm) 6 inches (15 cm) for appliances <_ 10,000 BTUH (3 kw), 12 inches (30 cm) for appliances > 10,000 BTUH (3 kw) and <_ 100,000 BTUH (30 kw), 36 inches (91 cm) for appliances > 100,000 BTUH (30 kw) * * * * * 3 feet (91 cm) with a height 15 feet (4.5 m) above the meter/regulator assembly US Installations 12 inches (30 cm) 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw) 3 feet (91 cm) 6 inches (15 cm) for appliances =/< 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 inches (30 cm) 10,000 Btuh (3 kw), 12 inches (30 cm) for for appliances > 10,000 Btuh (3 kw) and appliances > 10,000 Btuh (3 kw) and =/< =/< 100,000 Btuh (30 kw), 36 inches (91 100,000 Btuh (30 kw), 36 inches (91 cm) cm) for appliances > 100,000 Btuh (30 for appliances > 100,000 Btuh (30 kw) kw) 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally 7 feet (2.13 m) 12 inches (30 cm) * * Notes: 1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code. 2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. t. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. t. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions. 88-A952V001-1 C-E N 39 Furnace General Installation Venting Through The Roof Support Horizontal pipe every 3'0" with the first support as close to the furnace as possible. Induced draft blower, housing, and furnace must not support the weight of the flue pipe. p., �IIy Supports DD D �LBT INLET LRLEf INLET IJ rl I I I [PLASTIC YEM] � GTIDVG E::]� ��= 7T UPWARD PITCH - 1!4" PER FOOT I �BABINEf CABIN 3I4' UPFLOW OR DOWNFLOW FURNACE i HORIZONTAL AND VERTICAL VERTICAL BAYAIR30AVENTA/BAYAIR30CNVENT VENT VE8' MIN... M� ' 12 INCHES MIN. CLEARANCE MUST BE ' MAINTAINEDABOVE HIGHEST 72 *' ANTICIPAT D SNOW LEVEL. MAXIMUM NOT TO EXCEED DISTANCE FROM TOP 24 INCHES ABOVE ROOF. OF VENT M 1 OF AIR INIET BOTTOMUSE 41�, • / BE IT * I' MAINTAIN 12 IN. COMBUSTION (18 IN. FOR CANADA) AIR COM8l5TION MINIMUM CLEARANCE AIR fiEtI ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. Note: All measurements are from centerline to centerline. I BAYAIR30AVENTA / BAYAIR30CNVENT SEAL BETWEEN FLANGE, PIPE, MAINTAIN 12 IN. COUPLING AND METAL PANEL VENT (18 IN. FOR CANADA) WITH HI TEMP RTV SILICONE SEALANT REMOVE RIBS * MINIMUM CLEARANCE FROM CAP ABOVE HIGHEST FLUE PIPE ANTICIPATED SNOW COMBUSTION LEVEL. MAXIMUM OF COUPLING AIR \ 24 IN. ABOVE ROOF \\/� ROOF FLASHING BOOT (FIELD SUPPLIED) o �`> 000 SUPPORT 00000 0 SUPPORT FLANGE i (FIELD SUPPLIED) ELBOW i (FIELD SUPPLIED) GALVANIZED FIRESTOP SHOULD CEILING BE FABRICATED WITH 3-7/8" DIA. HOLE FOR SUPPORT FLANGE VENT COMBUSTION (12" x 12" PANEL OR 12" DIA MIN.) AIR CLEARANCE - 0" ACCEPTABLE FOR PVC VENT PIPE 1" ACCEPTABLE FOR TYPE 294C STAINLESS STEEL VENT PIPE VENTING THROUGH CEILING 40 88-A952V001- l C-E N Furnace General Installation When penetrating roof with PVC vent pipe, a flexible flashing may be used for a weather tight seal. Lubricate flexible seal on flashing before PVC pipe is pushed through the seal. (Field Supplied) Note: No vent cap is the preferred method for vertical vent termination in extremely cold climates. Note: In extreme climate conditions, insulate the exposed pipe above the roofline with Armaflex type insulation. SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL WITH HI TEMP RTV SILICONE SEALANT SUPPORT COUPLING FLANGE GALVANIZED PANEL (FIRESTOP) FLOOR FLUE PIPE CLEARANCE 0" ACCEPTABLE FOR PVC VENT PIPE 1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE VENTING THROUGH FLOOR Venting Through an UNUSED Chimney PVC PLASTIC VENTING Venting Routed Through a Masonry Chimney THROUGH UNUSED CHIMNEY STAINLESS Important: Refer to Section 12.6.8 of NFPA 54 / ANSI 223.1 2012 STEEL when routing vent piping through a chimney. VENT CAP (OPTIONAL) Important: The single wall flue pipe joints must be sealed. The 901 elbow connection to vertical pipe must be sealed SEE CAUTION - - e Irv. MIN• to prevent condensate leakage to base ofmasonry FLUE PIPE chimney. JIB/ SUPPORT THE SINGLE COUPLING TO SUPPORT WALL FLUE PIPE AND PIPE FROM ANGLES Yi CENTER IT IN THE OR OTHER SUITABLE CHIMNEY OPENING WITH SUPPORT METHOD ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER. COUPLING AS REQUIRED FLUE PIPE i i NOTE: HORIZONTAL VENTING TO VERTICAL VENTING Venting Through an UNUSED Chimney TYPE 29-4C STAINLESS STEEL VENTING Important: Refer to Section 12.6.8 of NFPA 54/ANSI223.1 2012 STAINLEsHROUGH UNUSED CHIMNEY when routing vent piping through a chimney. STEEL Important: The Single Wall flue pipejoints must be Sea/ed. VENT CAP (OPTIONAL) The 901 elbow connection to vertical pipe must be sealed SEE CAUTION 61N. MIN. to prevent condensate leakage to base of masonry _ I / chimney. - , 1_ VENT FITTING MATERIAL - STAINLESS STEEL Gas and liquid tight single wall metal vent fitting, designed for SUPPORT THE SINGLE WALL resistance to corrosive flue condensate such as Type 29-4C MUST be STAINLGSS STEELVENTINCENTER IT IN used throughout...., THE CHIMNEY OPENING WITH These fittings and fitting accessories are to be field supplied. ANGLES AS SHOWN OR DIRECTION OF STAINLESS STEEL FITTING ANOTHER EQUIVALENT y MANNER. All stainless steel fitting must be installed with male end towards the Furnace. All horizontal stainless steel sections must be positioned with the seam on top. All long horizontal sections must be supported to prevent sagging. All pipe joints must be fastened and sealed to prevent escape of combustion products into the building. NOTE: HORIZONTAL VENTING TO VERTICAL VENTING 88-A952V001-1 C-E N Furnace General Installation Downward Venting Downward Venting Furnace may be in vertical or horizontal configuration. Notes: 1. Condensate trap for vent pipe must be a minimum of 6 All horizontal pipes must be inches in height. imum of suppo4ft. 2. Condensate trap for vent and inlet pipe must be ls connected into a condensate drain pump; an open or vented drain; or it can be connected to the outlet hose ofDownward vent length the Furnace condensate trap. Outdoor draining of theis limited to a maximum 15 equivalent feet. Furnace and coil condensate is permissible if allowed byof local codes. SEE 3. The condensate trap should be primed at initial start upNOTES prior to heating season operation. Upflow or t. Downflow Furnace Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive Sl.draining ofcondensate may cause saturated ground conditions that 6' Min. may result in damage to plants. + Air for Combustion and Ventilation Adequate flow of combustion and ventilating air must not be obstructed from reaching the Furnace. Air openings provided in the Furnace casing must be kept free of obstructions which restrict the flow of air. Airflow restrictions affect the efficiency and safe operation of the Furnace. Keep this in mind should you choose to remodel or change the area which contains your Furnace. Furnaces must have a free flow of air for proper performance. Provisions for combustion and ventilation air shall be made in accordance with "latest edition" of Section 9.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1 / NFPA 54, or Sections 8.2, 8.3 or 8.4 of CSA B149.1 Installation Codes, and applicable provisions of the local building codes. Special conditions created by mechanical exhausting of air and fireplaces must be considered to avoid unsatisfactory Furnace operation. Furnace location may be in an unconfined space or confined space. Unconfined space are installations with 50 cu. ft. or more per 1000 BTU/hr input from all equipment installed. Unconfined spaces are defined in the table and illustration for various furnace sizes. These spaces may have adequate air by infiltration to provide air for combustion, ventilation, and dilution offlue gases. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air provided as described for confined space. Minimum Area in Square Feet for Unconfined Space Installations Furnace Maximum BTUH Input With 8 Ft. Ceiling, Rating Minimum Area in Square Feet of Unconfined Space 40,000 250 60,000 375 80,000 500 100,000 625 120,000 750 UNCONFINED o I50 CU. FT. OR MORE DOORS PER 1000 BTU/HR INPUT WATER CLOTHES ALL EQUIP. INSTALLED FURNACE HEATER DRYER 42 88-A952V001- l C-E N Furnace General Installation Confined spaces are installations with less than 50 cu. ft. of space per 1000 BTU/ hr input from all equipment installed. Confined spaces are defined in the table and illustration for various furnace sizes. Air for combustion and ventilation requirements can be supplied from inside the building. 1. The following types of installations will require use of OUTDOOR AIR for combustion, due to chemical exposures: * Commercial buildings * Buildings with indoor pools * Furnaces installed in commercial laundry rooms * Furnaces installed in hobby or craft rooms * Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply will also require OUTDOOR AIR for combustion: * Permanent wave solutions * Chlorinated waxes and cleaners * Chlorine based swimming pool chemicals * Water softening chemicals * Deicing salts or chemicals * Carbon Tetrachloride * Halogen type refrigerants * Cleaning solvents (such as perchloroethylene) * Printing inks, paint removers, varnish, etc. * Hydrochloric acid * Cements and glues * Antistatic fabric softeners for clothes dryers * Masonry acid washing material Note: Extended warranties are not available in some instances. Extended warranty does not cover repairs to equipment installed in establishments with corrosive atmospheres, including but not limited to, dry cleaners, beauty shops, and printing facilities. All air from inside the building The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to the Minimum Free Area in square inches for confined spaces table, for minimum open areas required. Minimum Free Area in Square Inches Each Opening (Furnace Only) in a Confined Space Furnace Max Air From Air From Outside BTUH.Input Inside Rtg. Vertical Duct Horizontal (a) Duct (b) 40,000 100 10 20 60,000 100 15 30 80,000 100 20 40 100,000 100 25 50 120,000 120 30 60 140,000 140 35 70 (a) 1 Square inch per 4000 BTU/hr Vertical Duct. (b) 1 Square inch per 2000 BTU/hr Horizontal Duct. CONFINED LESS THAN 50 CU. FT. PER 1000 BTU/HR INPUT ALL EQUIP. INSTALLED C( Al FURNACE 88-A952V001-1 C-E N 43 Furnace General Installation All air from outdoors The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. CONFINED SPACE The openings shall communicate directly, or by ducts, with the AIR FROM OUTDOORS outdoors or spaces (crawl or attic) that freely communicate with the I outdoors. Refer to the Minimum Free Area in square inches for confined spaces table, for minimum open areas required. CONFINED I I OUTLET SPACE OUTDOOR AIR DUCTS INLET CONFINED SPACE rj�\ AIR FROM VENTILATED ATTIC/CRAWL SPACE ATTIC LOUVERS NO TO OUTDOORS CONFINED I AIR IR SPACE L ET A RTE Y I I AIRS NDUCT CONFINED SPACE AIR FROM VENTILATEATTIC LOUVERS TO OUTDOORS Fj ROOTLET CONFINED AIR SPACE INLET AIR DUCT 44 88-A952V001-1C-EN Furnace General Installation Duct Connections Air duct systems should be installed in accordance with standards for When the furnace is located in a utility room adjacent to the living air conditioning systems, National Fire Protection Association area, the system should be carefully designed with returns which Pamphlet No. 90. They should be sized in accordance with ACCA minimize noise transmission through the return air grille. Although Manual D or whichever is applicable. Check on controls to make these winter air conditioners are designed with large blowers certain they are correct for the electrical supply. operating at moderate speeds, any blower moving a high volume of Central furnaces, when used in connection with cooling units, shall be air will produce audible noise which could be objectionable when the installed in parallel or on the upstream side of the cooling units to unit is located very close to a living area. It is often advisable to route avoid condensation in the heating element, unless the furnace has the return air ducts under the floor or through the attic. Such design been specifically approved for downstream installation. With a parallel permits the installation of air return remote from the living area (i.e. flow arrangement, the dampers or other means used to control flow of central hall). air shall be adequate to prevent chilled air from entering the furnace, When the furnace is installed so that the supply ducts carry air and if manually operated, must be equipped with means to prevent circulated by the furnace to areas outside the space containing the operation of either unit unless the damper is in full heat or cool furnace, the return air shall also be handled by a duct(s) sealed to the position. furnace and terminating outside the space containing the furnace. Flexible connections of nonflammable material may be used for return For furnaces not equipped with a cooling coil, it is recommended that air and discharge connections to reduce the transmission of vibration. the outlet duct be provided with a removable access panel. The Though these units have been specifically designed for quiet, vibration opening shall be accessible when the furnace is installed and shall be free operation, air ducts can act as sounding boards and could, if of such a size that the heat exchanger can be viewed for possible poorly installed, amplify the slightest vibration to the annoyance level. openings using light assistance or a probe can be inserted for sampling the air stream. The removable cover must be sealed to prevent air leaks. Where there is no complete return duct system, the return connection must be run full size from the Furnace to a location outside the utility room, basement, attic, or crawl space. Do Not install return air through the back of the Furnace cabinet. Do Not install return air through the side of the furnace cabinet on horizontal applications without following the guidelines in the Return Air section. Carbon monoxide, fire or smoke can cause serious bodily injury, Note: The manufacturer of your Furnace DOES NOT test any death, and/or property damage. A variety of potential sources of carbon monoxide can be found in a detectors and makes no representations regarding any brand building or dwelling such as gas -fired clothes dryers, gas cooking or type of detector. stoves, water heaters, furnaces and fireplaces. The U.S. Consumer Product Safety Commission recommends that users of gas -burning appliances install carbon monoxide detectors as well as fire and smoke detectors per the manufactures installation instructions to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide. These devices should be listed by Underwriters Laboratories, Inc. Standards for Single and Multiple Station Carbon Monoxide Alarms, UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19. Note: Seal per local codes 88-A952V001-1 C-E N 45 Furnace General Installation Table 3. Supply Duct Connections Upflow Furnace with Coil COIL REQUIREMENT!! Failure to follow this Caution could result in property damage or personal injury. 4GXC* and 41VIXC* coils installed on upflow furnaces in vertical, horizontal left, or horizontal right orientations without a factory installed metal drain pan shield must use a MAY*FERCOLKITAA kit. O Coils installed on upflow furnaces must have drain pans that are suitable for 400' F (205' C) or have a metal drain pan shield. Downflow furnaces do not m require a metal drain pan shield or the use of the MAY*FERCOLKITAA kit. See Installer's Guide for more information. 1. Bend furnace flanges up. 1. Set the coil on top of the furnace. 2. Screw through the coil cabinet into the furnace flange. Guide a 0 holes are located on the coil. Note: There are no longer guide holes located on the furnace flange. 3. Seal per local codes and requirements. a C CD Upflow Furnace without Coil 1. Bend furnace flanges up. 2. Seal per local codes and requirements. 3. Insulate the first 6-12 inches of the supply duct. Caution. The first 6-12 inches of the supply duct must be insulated to protect from high temperatures. O 46 88-A952V001-1 C-E N Furnace General Installation Furnace in Horizontal Left with Coil e COIL REQUIREMENT!! a Failure to follow this Caution could result in property damage or personal injury. a 4GXC* and 4MXC* coils installed on upflow furnaces in vertical, horizontal left, or horizontal / right orientations without a factory installed metal drain pan shield must use a MAY*FERCOLKITAA kit. Coils installed on upflow furnaces must have drain j pans that are suitable for 400' F (205` C) or have a metal drain pan shield. Downflow furnaces do not ,O require a metal drain pan shield or the use of the MAY*FERCOLKITAA kit. See Installer's Guide for more information. / C J. 1. Bend furnace flanges up. 1. Support the furnace and coil independently. 2. Screw through the coil cabinet into the furnace flange. Guide a a holes are located on the coil. a Note: There are no longer guide holes located on the furnace flange. 3. Seal per local codes and requirements. / ® O 0 0 88-A952V001-1 C-E N 47 Furnace General Installation Furnace in Horizontal Right with "A" Coil COIL REQUIREMENT!! a0 Failure to follow this Caution could result in property damage or personal injury. 'o a 4GXC* and 4MXC* coils installed on upflow furnaces in vertical, horizontal left, or horizontal right orientations without a factory installed metal $ drain pan shield must use a MAY*FERCOLKITAA kit. Coils installed on upflow furnaces must have drain pans that are suitable for 400* F (205° C) or have a metal drain pan shield. Downflow furnaces do not require a metal drain pan shield or the use of the o MAY*FERCOLKITAA kit. See Installer's Guide for more information. \ 1. Cut the back flange along perforation. 2. Starting at the back of the furnace, cut the side flanges along perforations until past the end of the heat shield to avoid interference when bending. 3. Bend furnace side flanges down. 4. Support the furnace and coil independently. Note: Flat or dedicated horizontal coils may require flanges to be bent upward. 1. Match the coil up flush to the back of the furnace. 2. Seal per local codes and requirements. e O o a• 0 48 88-A952V001-1 C-E N Furnace General Installation Downflow Furnace with Coil Note: 4GXC* or 4MXC* coils installed on a downflow furnace do not require a metal drain pan shield or the use of the MAY*FERCOLKITAA kit. 1. Cut the back flange along perforation. 2. Starting at the back of the furnace, cut the side flanges along �$ perforations until past the end of the heat shield to avoid interference when bending. �< 3. Bend furnace side flanges down. 4. Support the furnace and coil independently. 1. Set the furnace on top of the coil so that it is flush with the back of the furnace. 2. Seal per local codes and requirements. r O . 1. 0 /17 88-A952V001-1 C-E N 49 Furnace General Installation Horizontal Right and Downflow Furnace — no Coil Important: A BAYBASE is required when installing the furnace on a combustible floor. 1. Bend furnace flanges up. 2. Attach ducting. 3. Seal per local codes and requirements. 50 88-A952V001-1 C-E N Furnace General Installation Table 4. Return Duct Connections Return Ducting General Guidelines • Back returns are not allowed on any S-Series Furnaces • Side returns are not allowed on downflow or horizontal S-Series Furnaces • Mounting flanges must be located on ducting • Shoot screws through the mount flanges into the furnace cabinet • Always seal per local codes and requirements • Furnace, coil, and ducting must be supported separately • An external overflow drain pan must be installed in all applications over finished ceiling to prevent property damage Upflow Furnace with Bottom Return in Closet with Remote Filter 1. Remove the bottom plate. 2. Set the furnace on the base inside closet. 3. Install remote filter. 4. Seal per local codes and requirements. 0 Upflow Furnace with Bottom Return in Closet with Filter Box 1. Remove the bottom plate. 2. Set the furnace on the filter box inside closet. 3. Must have grill present for air. 4. Seal per local codes and requirements. 0 Filter 88-A952V001-1 C-E N Furnace General Installation Table 4. Return Duct Connections (continued) Upflow Furnace with Bottom Return Mounted on a Ducted Pedestal 1. Remove the bottom plate. 2. Set the furnace on the ducted pedestal. The ducted pedestal will use ducted air from a remote location. 3. Install filter at a remote location. 4. Seal per local codes and requirements. Upflow Furnace with Bottom Return Mounted on a Ducted Pedestal with Filter Box 1. Remove the bottom plate. 2. Set the furnace on the filter box. The ducted pedestal will use ducted air from a remote location. 3. Seal per local codes and requirements. 88-A952V001-1 C-E N Furnace General Installation Table 4. Return Duct Connections (continued) Upflow Furnace with Bottom and Side Returns Mounted on a Ducted Pedestal with Side Return and Filter Box Important: Make sure the condensate and thermostat wiring holes are sealed on the cabinet side with the side return. The plugs and grommets may need to be changed with those on the opposite side of the cabinet. Important: Make sure not to cut the cabinet in the "No Cut"area. 1. Remove the bottom plate. 2. Create ducting and set the furnace in place. Note: Use Optional BAYLIFT kit to lift furnace. Follow kit instructions. Note: The furnace bottom pedestal must be a minimum of 6"in height. 3. Match the filter cabinet flush to the back and bottom sides of the furnace cabinet and secure in place with screws. 4. Mark the two areas to be cut out for the return air. 5. Cut out the two sections of the cabinet and BAYLIFT kit to be removed. 6. Attach ducting to the filter box. 7. The ducted pedestal will use ducted air from a remote location. 8. Seal per local codes and requirements. 17.5" Filter Cabinet with BAYLIFT Kit 21" Filter Cabinet with BAYLIFT Kit o' o' O O O o O o o b o b ®O ®O b o o b o 0 - O O No No Cut Area Cutouts Flush with back Cut Area Cutouts Flush with back of furnace cabinet of furnace cabinet 88-A952V001-1 C-E N 53 Furnace General Installation Table 4. Return Duct Connections (continued) Upflow Furnace with Side Return 0 Important: Make sure the condensate and thermostat wiring holes are sealed on the cabinet side with the side return. The plugs and grommets may need to be changes with those on the opposite side of the cabinet. O Important: Make sure not to cut the cabinet in the "No Cut"area. Note: Return air on right side with the condensate on the left or return O air on left with the condensate on the right do not require a transition. ° ° 1. Using guides, remove the cutout for the side return. 2. Create ducting and set the furnace in place. Use screws to attach 0 6 ® O ducting to the furnace cabinet. y o 0 Note: If using a filter box, use a transition, if possible, to attach the ° � a filter box to the furnace cabinet. 3. Seal bottom panel per local codes and requirements. O 4. Seal all other panels per local codes and requirements. ° Use four corner guides X to create cutout � I 0 p 0 0 No Cut Area Upflow Furnace with Two Side Returns 0 Important: One of the sides must have a transition to allow the condensate and thermostat wiring to exit the cabinet. Important: Ifa transition is not a viable option, a hole may be drilled O in the bottom of the cabinet to allow the condensate to exit. Also, a hole will need to be drilled in the side of the 6 cabinet for the thermostat wiring to exit. O Important: Make sure not to cut the cabinet in the "No Cut"area. Note: If using one transition, the condensate and thermostat wiring 0 ° will exit on the transition side. 1. Using guides, remove the two cutouts for the side returns. O O 0 6 2. Create ducting and set the furnace in place. Use screws to attach ducting to the furnace cabinet. ° 4 Note: If using a filter boxes, use transitions, if possible, to attach the filter boxes to the furnace cabinet. If transitions are not used, O condensate may exit through the bottom of the furnace. 1 3. Seal bottom panel per local codes and requirements. ° Use four corner guides 0 4. Seal all other panels per local codes and requirements. to Create Cutout 9 p 0 0 No Cut Area 54 88-A952V001- l C-E N Furnace General Installation Table 4. Return Duct Connections (continued) Downflow Furnace with Top Return 1. Remove the top plate. 2. Attach the ducting to the top of the furnace. 3. Install remote filter. 4. Seal per local codes and requirements. Downflow Furnace with Top Return and Plenum 1. Remove the top plate. 2. Attach the plenum ducting to the top of the furnace. 3. Install remote filter. 4. Seal per local codes and requirements. 88-A952V001-1 C-EN Furnace General Installation Table 4. Return Duct Connections (continued) Downflow Furnace with Top Return and Plenum with Filter Box 1. Remove the top plate. 2. Attach the filter box to the top of the furnace. 3. Attach ducting. 4. Seal per local codes and requirements. 56 88-A952V001-1C-EN Furnace General Installation Return Air Filters TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS Filters are not factory supplied for upflow furnaces. Filter size needed will be dependent on type of filter and CFM requirement. Filters must be installed externally to the unit. Important: It is recommended to transition return ducting to the same size as the opening. It is acceptable for return duct or filter frame to extend forward of the opening but plastic plugs MUST be installed in any opening that the duct or filter frame may cover. Preparation for Upflow Bottom and Side Return Air Filter Installations All return air duct systems should provide for installation of return air filters. 1. Determine the appropriate position to set the furnace in orderto connect to existing supply and return ductwork. 2. For upflow side return installations, remove the insulation around the opening in the blower compartment 3. The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air, refer to the figure and the upflow furnace outline drawing for duct connection dimensions for various furnaces. 4. If a 3/4" flange is to be used for attaching the air inlet duct, add to cut where indicated by dotted lines. Cut corners diagonally and bend outward to form flange. 5. If flanges are not required, and a filter frame is installed, cut between locating notches as in illustration. 6. The bottom panel of the upflow furnace must be removed for bottom return air. Upflow Return Air Filters Furnace Width Filter Qty and Size 17-1/2" 1 — 16" x 25" x 1" 21" 1 — 20" x 25" x 1" 24-1/2" 1 — 24" x 25" x 1" Note: For upflow airflow furnaces where the airflow requirement exceeds 1600 CFM - Furnaces will require return air openings and filters on: (1) both sides, or (2) one side and the bottom, or (3) just on the bottom. UPFLOW FURNACES ONLY LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT SEE OUTLINE DRAWING FRONT OFFURNACE 88-A952V001-1 C-E N 57 Furnace General Installation 1. Upflow Furnaces: When the upflow furnace is installed in the horizontal right or left application and a return duct is attached to the top side, do not install a filter in the return duct directly above the furnace. Install the filter in a remote location. When the upflow furnace is installed in the horizontal right or left application and a close coupled (less than 36") return duct is attached to the bottom side of the furnace as shown above, securely attach a 1/2" mesh metal hardware cloth protective screen to the inside bottom of the filter grill to prevent personal injury from contacting moving parts when reaching into the return opening to replace the filter. Close coupled (less than 36") return (filter directly beneath bottom side return) is not recommended due to noise considerations. 2. Connect the duct work to the furnace. See Outline Drawing for supply and return duct size and location. Flexible duct connectors are recommended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable. 3. When replacing a furnace, old duct work should be cleaned out. Thin cloths should be placed over the registers and the furnace fan should be run for 10 minutes. Don't forget to remove the cloths before you start the furnace. 4. The horizontal installation of the upflow furnace requires an external filtersection. Filter kits are available for horizontal applications. RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION When the Upflow Furnace is installed in the horizontal configuration, the return airfilters must be installed exteriorto the furnace cabinet. Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the furnace. TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS Filters are not factory supplied for downflow furnaces. Filter size needed will be dependent on type of filter and CFM requirement. Filters must be installed externally to the unit. Figure 1. Horizontal upflow furnace with side return 0 LESS THAN 36" CLOSE COUPLED (LESS THAN 36") RETURN (FILTER DIRECTLY BENEATH BOTTOM SIDE RETURN) NOT RECOMMENDED DUE TO NOISE CONSIDERATIONS. IF USED, SECURELY ATTACH 1/2" MESH METAL HARDWARE CLOTH PROTECTIVE SCREEN TO THE INSIDE BOTTOM OF THE FILTER GRILL. Downflow Return Air Filters riiii■ ■■■■■■I Furnace Width Filter Qty and Size 17-1/2" 2 — 14" x 20" x 1" 21" 2 — 16" x 20" x 1" 24-1/2" 2 — 16" x 20" x 1" 88-A952V001-1C-EN Furnace General Installation Electrical Connections Make wiring connections to the unit as indicated on enclosed wiring diagram. As with all gas appliances using electrical power, this furnace shall be connected into a permanently live electric circuit. It is recommended that furnace be provided with a separate "circuit protection device" electric circuit. The furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code, ANSI/NFPA 70 or CSA C22.1 Electrical Code, if an external electrical source is utilized. The integrated furnace control is polarity sensitive. The hot leg of the 120V power supply must be connected to the black power lead as indicated on the wiring diagram. Refer to the SERVICE FACTS literature and unit wiring diagram attached to furnace. Field Wiring Two Stage Thermostat Two Stage Furnace FIELD WIRING DIAGRAM FOR TWO STAGE HEATING THERMOSTAT, TWO STAGE COOLING Outdoor Unit ----- -- W1 (No Transformer) Y2 ----- -- Y2 4�_Y1 ----- --Fv_1 L--------- NOTES: 1) For PWM (BK) enabled thermostats, cut the BK jumper on the IFC and connect wiring. 2) The factory Y1-O jumper must remain in place for proper LED read out in cooling mode. 3) Y1 and Y2 wiring from the thermostat must connect to the IFC for proper airflow and LED readout. 4) Single compressor and two compressor airflow is auto- matically set with the IFC Menu optionsin ODU section. 2-1=2 stage / 1 compressor (1 st stage airflow = 80%) 2-2=2 stage / 2 compressors (1 st stage airflow = 50%) fill" Il�oo .,.Mi'11`r'11UM-`I`�rl`�I`�I INTER -COMPONENT SEE • FACTORYBKJUMER TE 2 •. Thermostat Furnace BK -- ----- BK W2 -- ----- - W2 W1 - ----- -- W1 - ----- ----- -- 0 - r- SEE NOTE 2 FIELD WIRING DIAGRAM FOR TWO STAGE HEATING THERMOSTAT, TWO STAGE HEAT PUMP Outdoor Unit (No Transformer) _ X2 _ R -B/C L�-Y2 NOTES: 1) For PWM (BK) enabled thermostats, cut the BK jumper on the IFC and connect wiring. 2) Remove the factory Y1-0 jumper for HP systems for proper LED read out. 3) Y1 and Y2 wiring from the thermostat must connect to Y1 and Y2 of the IFC for proper airflow and LED readout. 4) Single compressor and two compressor airflow is automatically set with the IFC Menu options in ODU section. 2-1=2 stage / 1 compressor (1 st stage airflow = 80%) 2-2=2 stage / 2 compressors (1 st stage airflow = 50%) Furnace IFC ` o 0 0 0 I39 ®� 44 44� E3 u�w[ s 0 BK W2 W1 R G B/C Y YI INTER -COMPONENT WIRING R-BK 24 V FIELD WIRING TR SEE N NOTE 1 24 V FACTORY WIRING 88-A952V001-1 C-E N 59 Furnace General Installation Single Stage Thermostat Y1 -- Single Stage Stage Thermostat Furnace FIELD WIRING DIAGRAM FOR ---I SINGLE STAGE HEATING THERMOSTAT, SINGLE STAGE COOLING W2 -- --, SEE j NOTE 4 Outdoor Unit ❑ (No Transformer) _ �B/C ---- --R-71-1- ---------- M Furnace NOTES: 1) For PWM (BK) enabled thermostats, cut the BK jumper on the IFC and connect wiring. 2) The factory Y1 -0 jumper must remain in place for proper LED read out in cooling mode. 3) Y1 wiring from the thermostat must connect to Y1 of the IFC for proper airflow and LED readout. 4) Place field supplied jumper between W1 and W2 on the IFC. Interstage delay is factory set for 10 minutes but is field adjustable with the Menu option in the ISD section. 5) Single stage airflow is set with the IFC Menu options in ODU section. Select 1-1. 0 •,'D, ! 00 INTER -COMPONENT WIRING ZQQ11M T Ir'il`�'ilIili��il`�'il�M ST3 FIELDSEE • • ' NOTE 2 24 VY WIRING BKJUMPER SEE NOTE 1 FIELD WIRING DIAGRAM FOR SINGLE STAGE HEATING THERMOSTAT, SINGLE STAGE HEAT PUMP SEE Outdoor Unit NOTE 4 (No Transformer) W2 -- --, Y2 SEE NOTE 2 _ -X2 _ -R /C NOTES: 1) For PWM (BK) enabled thermostats, cut the BK jumper on the IFC and connect wiring. 2) Remove the factory Y1-O jumper for HP systems for proper LED read out. 3) Y1 wiring from the thermostat must connect to Y1 of the IFC for proper airflow and LED readout. 4) Place field supplied jumper between W1 and W2 on the IFC. Interstage delay is factory set for 10 minutes but is field adjustable with the Menu option in the ISD section. 5) Single stage airflow is set with the IFC Menu options in ODU section. Select 1-1. Furnace IFC 39 ®� 44 44Q E3 & J E BK W2 Wl R G B/C Y4 DY1 0 INTER-COMPON ENT WI RING BKJUMPER 24 V FIELD WIRING SEE NOTE 1 24 V FACTORY WIRING 60 88-A952V001-1 C-E N Condensate Drain Instructions The following sections give general instructions for the Repositioning of the condensate trap is covered in the installation of the gas furnace condensate drains. exhaust air options section. Cutouts with plugs and grommets are provided on the left and right hand side of the furnace cabinets for drain connections IN VERTICAL i • APPLICATIONS. The standard arrangement is for the drain connection on the left side. The tubing may have to be trimmed in this application Water Damage/Property Damage! to avoid kinking. The upflow (vertical application) also has provisions for right side It is recommended that a drain pan be installed drain connections. Exchange the grommet and plugs from the left and under the furnace to prevent property damage or right side. Trim all excess tubing to avoid kinking. It is always recommended that an auxiliary drain pan be installed personal injury from leaking condensate. under a horizontally installed evaporator or 90% Gas Furnace. Connect the auxiliary drain line to a separate drain line (no trap is needed in this line). Horizontal applications require repositioning the condensate canister trap. Additionally the drain tubing connected to the inducer housing may need to be repositioned for removing the plug and reconnecting the tubing to the lower connection on the inducer housing. Connections must be made to an OPEN/ VENTED DRAIN. Note: All condensate drain piping supplies included with the furnace are intended for internal piping only and should not be applied external to the furnace. All external piping must use 112" minimum size PVC pipe and fittings throughout for drain connections (fittings, pipe and PVC solvent cement not provided with furnace, must be field supplied). A 314" coupling is supplied to connect to systems that are using 314 " piping with an air conditioner coil. Note: A corrosion resistant condensate pump must be used if a pump is required for a specific drain system. Important: The condensate drain should be installed with provisions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, resulting in furnace shutdown. If the drain line cannot be installed in a conditioned space and/ or its surrounding ambient temperature is expected to fall below freezing, then heat tape should be applied as required to prevent freezing (per manufacturer's instructions). The heat tape should be rated at S or 6 watts per foot at 120 volts. Self- regulating (preferred) or thermostatically controlled heat tape is required. Typical sources of UL listed heat tapes are W.W. Granger, Inc. (Wintergard PlusTM Series), McMaster Carr Supply Co. (3554 Series), or your equipment supplier. The condensate drain may be cleaned or inspected by removal of the drain tube at the header. Evaporator and Furnace condensate drain piping may be manifolded together. A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection to prevent water from damaging Furnace controls if the primary drain outlet plugs up. Where the Furnace is installed above a finished ceiling, the primary drain vent stack must be installed such that overflow from the vent stack opening will flow into an auxiliary drain pan in order to prevent water damage to the finished ceiling below. 88-A952V001-1 C-E N Condensate Drain Instructions Vertical Applications VERTICAL APPLICATIONS Upflow furnace - Remove the plug from the side panel where the condensate will exit. Note: For easiest installation, remove the spring clip from the end of the condensate line and feed through the grommet. Install the condensate grommet into the side panel. Important: Condensate grommetmust be installed forproper Install the connection tubing from the trap to the side of the unit and operation. trim all excess tubing to avoid kinks. COIL PRIMARY DRAIN _ • O COIL PRIMARY O DRAIN CONDENSATE GROMMET CONDENSATE GROMMET — — LEFT SIDE DRAIN •�� RIGHT SIDE DRAIN 0 ® 8 O LEFT SIDE DRAIN COIL PRIMARY DRAIN �� ..�' COIL PRIMARY.. DRAIN RIGHT SIDE DRAIN IF THE FURNACE IS INSTALLED OVER A FINISHED IF THE FURNACE IS CEILING, OVERFLOW FROM INSTALLED OVER A FINISHED THE PRIMARY DRAIN VENT CEILING, OVERFLOW FROM STACK MUST FLOW INTO AN THE PRIMARY DRAIN VENT AUXILIARY DRAIN PAN TO STACK MUST FLOW INTO AN PREVENT DAMAGE TO THE AUXILIARY DRAIN PAN TO CONDENSATE PREVENT DAMAGE TO THE FINISHED CEILING BELOW GROMMET e - FINISHED CEILING BELOW CONDENSATE O O GROMMET PRIMARY DRAIN VENT STACK MUST TERMINATE BELOW THE BOTTOM OF THE CONDENSATETRAP _ _ Y DRAIN VENT UST TERMINATE THE BOTTOM OF THE O NSATETRAP tB� OR21 rB A CONDENSATE PIPED TO OPEN VENTED DRAIN CONDENSATE PIPES MUST CONDENSATE PIPED TO OPEN NOT BE BELOW WATER SURFACE VENTED DRAIN OR CONDENSATE PUMP CONDENSATE PUMP 62 88-A952V001- l C-E N Condensate Drain Instructions Downflow furnace -Cut the 90 degree section of the condensate tubing off and connect the tubing to the condensate trap. Install the condensate grommet into the bottom panel. Cut to length as needed. • LEFT SIDE DRAIN WITH Q EVAPORATOR AND CONDENSATE V DOWNFLOW FURNACES WITH BOTTOM DRAIN DRAIN PIPING MANIFOLDED ®� TOGETHER. IF THE FURNACE IS COIL PRIMARY INSTALLED OVER A FINISHED ❑ DRAIN+ CEILING, OVERFLOW FROM m THE PRIMARY DRAIN VENT CONDENSATE • • STACK MUST FLOW INTO AN GROMMET AUXILIARY DRAIN PAN TO PREVENT DAMAGE TO THE IF THE FURNACE IS FINISHED CEILING BELOW O INSTALLED OVER A FINISHED CEILING, OVERFLOW FROM THE PRIMARY DRAIN VENT _ STACK MUST FLOW INTO AN AUXILIARY DRAIN PAN TO CONDENSATE PREVENT DAMAGE TO THE GROMMET FINISHED CEILING BELOW 0 PRIMARY DRAIN VENT PRIMARY DRAIN VENT — STACK MUST TERMINATE BELOW THE BOTTOM OF THE STACK MUST TERMINATE BELOW THE BOTTOM OF THE ❑ n CONDENSATE TRAP CONDENSATETRAP OR 0 CONDENSATE PIPED kONDENSBBELMPIPEWA TO OPEN VENTED DRAIN MUST COIL PRIMARY�r DRAIN �,� NOT BE BELOW WATER SURFACE • • CONDENSATE PUMP CONDENSATE PIPED TO OPEN VENTED DRAIN Downflow furnace with Left Side Condensate - Drill a 1-5/8 inch diameter hole in the left side ofthe case at the dimensions shown. 0 0 O ® 0 0 00 O 1-5/8 m +' J 3.00 c 0 1 0 1 4.50 -- 88-A952V001-1 C-E N 63 Condensate Drain Instructions Plug the bottom hole with plug provided in document pack. e' qao �C� °000'o` 0 Attaching the condensate drain line. DOWNFLOW FURNACES 1. Locate the condensate grommet and the condensate drain line LEFT SIDE DRAIN assembly in the doc pack. 1-5/8" DIAMETER HOLE MUST 2. Insert the condensate grommet in the 1-5/8" hole in the side of BE CUT IN LEFT SIDE OF CASE. BOTTOM HOLE MUST BE PLUGGED. the cabinet. 3. Remove the fitting at the end of the drain line assembly and insert IF THE FURNACE IS ❑ it through the cabinet from the inside out. Attach the 90 degree INSTALLED OVER A FINISHED CEILING, OVERFLOW FROM m section of the hose to the condensate drain trap. THE PRIMARY DRAIN VENT 4. Cut off the excess tube and reinstall the end fitting to the drain STACK MUST FLOW INTO AN hose. AUXILIARY DRAIN PAN TO PREVENT DAMAGE TO THE 0 FINISHED CEILING BELOW . n CONDENSATE GROMMET Downflow furnace with Right Side Condensate - Drill an 11/16 0 0 inch diameter hole in the right side of the case at the dimensions shown. O o 0 0 m 00 0 m O 11/16"m 1.00 o ` +; 0 0 -4.60 - Plug the bottom hole with plug provided in document pack. a 4oao 6QaD� e 64 88-A952V001-1C-EN Condensate Drain Instructions Attaching the condensate drain line. 1. Locate the condensate drain line assembly in the doc pack. Important: It is best to cut the condensate drain hose assembly longer than 4 inches and then fit in place. It can then be trimmed to needed length. The 4 inch measurement is an approximation. 2. Cut the condensate drain line assembly as shown. 3. Use a field supplied hose clamp to secure the condensate drain line to the condensate trap. 4. Insert a field supplied piece of 1/2" CPVC pipe though the 11/16" hole drilled through the cabinet and insert into drain line hose. Secure with the spring clip. Note: Seal around the condensate drain tubing where it exits the cabinet. , , , Cut hose , Approx. 411 DOWNFLOW FURNACES RIGHT SIDE DRAIN 11/16" DIAMETER HOLE MUST BE CUT IN RIGHT SIDE OF CASE. BOTTOM HOLE MUST BE PLUGGED. CUT FACTORY SUPPLIED CONDENSATE ASSEMBLY HOSE AND ATTACH TO FIELD SUPPLIED CPVC TUBE. SECURE WITH SPRING CLIP AND FIELD SUPPLIED HOSE CLAMP. IF THE FURNACE IS INSTALLED OVER A FINISHED CEILING, OVERFLOW FROM THE PRIMARY DRAIN VENT STACK MUST FLOW INTO AN AUXILIARY DRAIN PAN TO PREVENT DAMAGE TO THE FINISHED CEILING BELOW 88-A952V001-1 C-E N 65 Condensate Drain Instructions Horizontal Applications HORIZONTAL APPLICATIONS Upflow models in horizontal - It is always recommended that the auxiliary drain pan be installed under a horizontally installed I ---- evaporator and/or 90% gas furnace. Connect the auxiliary drain pan I to a separate drain line (no trap is needed in this line). Connections must be made to an OPEN/VENTED DRAIN. Outdoor I draining of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants. I _ Note: Use 112" or larger PVC or CPVC pipe and fittings as required for drain connections connections (fittings, pipe and solvent cement not provided). Note: A corrosion resistant condensate pump must be used ifa pump is required for a specific drain system. Important: The condensate drain should be installed with provisions FURNACE MUST BE SUPPORTED AT ALL FOUR TO APPROVED to prevent winterfreeze-up of the condensate drain line. CORNERS. BAYHANG - OPTIONAL HORIZONTAL OPEN / VENTED DRAIN Frozen condensate will block drains, resulting in furnace HANGING BRACKET KIT shutdown. Ifthe drain line cannot be installed in a Note: The overflow stand pipe termination must be even with or slightly below conditioned space, then UL listed heat tape should be the bottom of the condensate trap. applied as required to prevent freezing (per Note: Water from the overflow pipe must drain into the emergency drain pan. manufacturer's instructions). The heat tape should be rated at 5 or 6 watts per foot at 120 volts. Self-regulating (preferred) or thermostatically controlled heat tape is required. To prevent AC condensate from backing up into the furnaces, follow these instructions for condensate drainage. Note: 1. The overflow standpipe termination must be even with or slightly below than the bottom of the condensate trap. ❑ Note: 2. Water from the overflow pipe must drain into the emergency drain pan. Note: 3. It is recommended to use the secondary drain. The secondary drain pipe must terminate over the emergency drain pan. 00 O Note: 4. Emergency drain pan. Horizontal Right 000AA O 00 Horizontal Left 88-A952V001- l C-E N General Start-up and Adjustment The following sections give instructions for the general Preliminary Inspections start-up and adjustment of the gas furnaces. With gas and electrical power "OFF", ensure: 1. Duct connections are properly sealed. 2. Filters are in place. 3. Venting is properly assembled. 4. Blower vestibule panel is in place and all screws in place Lighting Instructions Turn knob on main gas valve within the unit to the "OFF' position. Turn the external gas valve to "ON". Purge the air from the gas lines. After purging, check all gas connections for leaks with a soapy solution. — DO NOT CHECK WITH AN OPEN FLAME. Allow 5 minutes for any gas that might have escaped to dissipate. Turn the gas valve in the unit to the "ON" position. Propane Gas being heavier than air may require forced ventilation. Turn the toggle switch on the Gas Valve in the unit to the "ON" position. Lighting instructions appear on each unit. Each installation must be checked out at the time of initial start up to ensure proper operation of all components. Check out should include putting the unit through one I complete cycle as outlined below. FIRE OR EXPLOSION HAZARD! Turn on the main electrical supply and set the comfort control above the indicated temperature. The ignitor will automatically heat, then Failure to follow this Warning could result in the gas valve is energized to permit the flow of gas to the burners. property damage, Severe personal injury, or death. After ignition and flame is established, the flame control module monitors the flame and supplies powerto the gas valve until the Do NOT attempt to manually light the furnace. comfort control is satisfied. To shut off For complete shutdown: Turn the toggle or control switch located on the main gas valve inside the unit to the "OFF' position and the external main gas shutoff valve to the "OFF' position. Disconnect the electrical supply to the unit. Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. This is very important I • during freezing weather. If for any reason your furnace should fail to operate damage could result, such as frozen water pipes. FREEZE CAUTION Failure to follow this Caution could result in property damage or personal injury. If complete furnace shutdown is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and water receptacles. Control and Safety Switch Adjustment LIMIT SWITCH CHECK OUT The limit switch is a safety device designed to close the gas valve should the furnace become overheated. Since proper operation of this switch is important to the safety of the unit, it must be checked out on initial start up by the installer. To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indicated temperature to bring on the gas valve. Restrict the airflow by blocking the return air to the blower. When the furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty limit switch is probable and the limit switch must be replaced. After checking the operation of the limit control, be sure to remove the paper or cardboard from the return air inlet, or reconnect the blower. 88-A952V001-1 C-E N 67 Furnace Combustion Air Exhaust Options Important: All plugs must be in place for sealed combustion. Note: Default is left side for electric and natural gas connections. Default for the combustion air inlet and exhaust is top of the furnace. Important: If the locations are changed from the defaults, the default holes not being used must be plugged. The following sections give instructions for the different furnace orientations and the options for venting the inlet and exhaust combustion air. Table 5. Combustion Air Venting Options Note: If the electrical and natural gas connections are moved to the right side, remove the plugs and move them to the left side. The grommets will move from the left side to the right side. Note: The grommets are different for the natural gas and condensate connections. Important: When looking at the different orientations, the direction of the combustion air exhaust in the illustration's description is after the furnace has been rotated, if needed. Refer to the illustrations below to find the approved venting options for upflow and horizontal left furnace models. Important: The combustion air exhaust must be vented to the outdoors. Note: The combustion air inlet does not have to be on the same side as the combustion air exhaust. Note: Right side combustion air entry is allowed in upflow applications. Upflow Orientation or Installation Combustion air exhaust vented out top. Combustion air exhaust vented through left side. ❑ F-1 yr O Horizontal Left Orientation or Installation Combustion air exhaust vented out top. tCombustion air exhaust vented through left side. L -11*0 68 88-A952V001-1 C-E N Furnace Combustion Air Exhaust Options Table 6. Combustion Air Venting Options Continued Refer to the illustrations below to find the approved venting options for horizontal right furnace models. Important: The combustion air exhaust must be vented to the outdoors. Note: The combustion air inlet does not have to be on the same side as the combustion air exhaust. Horizontal Right Orientation or Installation Combustion air exhaust vented through left side. Combustion air exhaust vented out top. Note: Requires a hole to be drilled in the case. + + i, F1 --Gi. El 0❑ 1101, Refer to the illustrations below to find the approved venting options for downflow furnace models. Important: The combustion air exhaust must be vented to the outdoors. Note: The combustion air inlet does not have to be on the same side as the combustion air exhaust. Note: Right side combustion air entry is allowed. Downflow Orientation or Installation Combustion air exhaust vented out top. El Combustion air exhaust vented through left side. F-1 F-1 EA 88-A952V001-1 C-E N 69 Furnace Combustion Air Exhaust Options Upflow Furnace in Upflow Position — Top Vented Combustion Air No changes need to be made to the inducer when installing the upflow furnace with the combustion air vented through the top. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. . 0 ® . VIM. 111i) 0 1. Attach the vent outlet gasket to the vent outlet. 1 1 f 2. Install vent outlet to top of cabinet using 2 screws supplied in the 1 t 1 doc pack. 3. Install vent inlet gasket and vent inlet using 4 screws supplied in the doc pack. - 0 1. Slide PVC pipe through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the clamp on the end of the 45 degree elbow. 4. Tighten the clamp on the outlet vent adapter. Note: The vent outlet adapter is used forstrain relief against the ; weight of the venting. The clamp should be tightened after the internal connection is made. 5. Install the combustion air inlet PVC pipe. o� =oa Note: If required, transition to larger venting within 2' of the cabinet. ° CPL00938 - 2"x 3" offset coupling may be used and is factory supplied with 120 KBTUH furnaces. Canadian applications may use BAYREDUCE to meet ULC-S636 requirements. _ Ac B 70 88-A952V001-1 C-EN Furnace Combustion Air Exhaust Options Upflow Furnace in Upflow Position — Left Side Vented Combustion Air Changes need to be made to the inducer orientation when installing ° ° the upflow furnace with the combustion air vented through the side. Additional changes are needed for hose routing and PS2 rotation. The figure to the right shows the furnace as it is sent from the factory. ° ° Use the following steps to modify the furnace for upflow with side w , venting of combustion air. l Important., Right side vent outlet is not allowed because condensate , will not drain. e ° 0QQ�0Qo o O o Oa40Qb b > O.P O J o .S r l l l l III IIII 03 40 3 8 Before proceeding, lay unit on its back to make conversion easier. 1. Disconnect all drain tubes from condensate trap. Note: When removing condensate hoses from the condensate trap, 0° ° ° ° hold the trap with your hand to prevent the trap from breaking. Removing the trap before the hoses is also an option. 5 2. Remove drain tubing from bottom of inducer housing. 3. Remove rain gutter tubing from inducer outlet. } 4. Remove tubing from condensate pressure switch. O 00 5. Remove tubing from PS2 to cold header. o ° 4 ° C�'Oa ° o�40Qb � o a 3 2 88-A952V001-1 C-E N Furnace Combustion Air Exhaust Options 1. Remove two 3" plugs on left side of cabinet. To be used for combustion air and vent exhaust. 2. Install the two 3" plugs into the two 3" default openings on the top of the cabinet. O ® t m � < 0 1. Loosen the clamp holding the 450 elbow. Remove the elbow and discard. 0 0 0 0 yN�• o o C CO o " QoUU o0a ,o o`�• � 0�40�0 ' ® e 1. Remove the three inducer mounting screws. 2. Rotate inducer counter -clockwise so that the inducer outlet aligns with the exhaust vent outlet. o 0 3. Insert and re -tighten screws to 30 in.-lbs. Do not overtighten. 0 0 w• , R ?r. o - p0 40po ,• o v Q.o O o`er • ��boo a 'o o ® 9 72 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Remove the pressure switch bracket assembly. 2. Remove the screw that holds PS2, rotate 90 degrees clockwise, and reattach. 3. Reattach the pressure switch bracket assembly. o 0 Note: Illustration shows the PS2 pressure switch in the final rotated position. ° o ° ° „� o ° o - o0 4000 0 / 6 ® 1. Attach the vent outlet gasket to the vent outlet. 2. Install vent outlet to top of cabinet using 2 screws supplied in the o 0 dock pack. 3. Install vent inlet gasket and vent inlet using 4 screws supplied in m the dock pack. 4. Install the for the drain tube. The drain o grommet condensate may be located on either side of the cabinet. m o or J 88-A952V001-1 C-EN 73 Furnace Combustion Air Exhaust Options 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. ° ° 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. 4. Install the combustion air inlet pipe. Note: The vent outlet adapter is used forstrain relief against the weight of the venting. The clamp should be tightened after the internal connection is made. 0 Note: If required, transition to larger venting within 2' of the cabinet. o fl �o0 9�00 ° An 2"x 3" offset coupling is required if the transition is made in 000�oo e o a horizontal plane. Use coupling CPL00938 (Canadian applications may use BAYREDUCE to meet ULC-S636 e +ir • requirements.) See Horizontal Venting section for proper orientation of 2"x 3"offset coupling. ® e 1. Connect PS2 tubing to switch and sensing location. Important: Trim the condensate pressure switch tubing to length to 0 0 ensure there is no sag or trap created 2. Remove port cap at bottom of inducer and connect inducer 5 0 condensate tubing. Connect other end of inducer condensate tubing to top port on the condensate trap. Cut tubing to length, if O • • 6 necessary. 3. Install previously removed port cap onto bottom port of the inducer. (As viewed in upflow) 1� 4. Connect condensate pressure switch tubing to pressure port on e 1 0 •' f the condensate trap. Important: Trim the condensate pressure switch tubing to Q o length to ensure there is no sag or trap created. 5. Remove port plug from rain gutter and install in new position on opposite side of the rain gutter. Ej i 6. Connect rain gutter condensate hose to the rain gutter and the e lower port of the condensate trap. Cut to length, if necessary. 2 O r1I 74 88-A952V001- l C-E N Furnace Combustion Air Exhaust Options Upf low Furnace in Horizontal Left Position —Top Vented Combustion Air Changes need to be made to the inducer orientation when installing the upflow furnace in the horizontal left position with the combustion air vented through the side. Additional changes are needed for hose routing, condensate trap orientation, and inducer hoses. ° E The figure to the right shows the furnace as it is sent from the factory. ° Use the following steps to modify the furnace for horizontal left with side venting of combustion air. o o0 a - nR 0 0 ° I ®I Before proceeding, lay unit on its back to make the conversion easier. 1. Remove all drain hoses from condensate trap. o Note: When removing condensate hoses from the condensate trap, hold the trap with your hand to prevent the trap from breaking. Removing the trap before the hoses is also an option. 4 I 2. Remove tubing from PS2 to cold header. ° 3. Remove drain tubing from bottom of inducer housing. 4. Remove rain gutter tubing from inducer outlet. 2 ® v ®.. 5. Remove tubing from condensate pressure switch. Qp�0 6. Remove the screws that hold the condensate trap bracket. The ® o 0 o - condensate trap should not be removed from the condensate trap 064p0� o = bracket. Remove assembly and retain for later installation. _ Note: There is a plastic adapter with 0-rings located inside the cold ° `� 5 _ header that is held in place by the condensate trap bracket. Do not lose this adapter. This adapter needs to be in place when the condensate trap bracket is reattached. 0 0FM 0 0 1. Loosen the clamp holding the 45° elbow. Remove the elbow and discard. o 40 i 0 0 o ? a 0 0 '� �. 88-A952VOW I C-EN 75 Furnace Combustion Air Exhaust Options 1. Remove three inducer screws. 2. Rotate the inducer so that the outlet is pointing vertically. 3. Use the three screws to reattach the inducer to the cold header to 30 in.-lbs. Do not overtighten. 76 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Remove 3" plug on left side of unit. To be used for condensate trap. o 2. Install condensate trap grommet. 3. Remove two 3" plugs on right side of cabinet. To be used for combustion air exhaust and inlet. m 4. Reuse the two 3" plugs to seal the two 3" default openings on the top of the furnace. ° 1 \\ C',. oc 1. Attach the vent outlet gasket to the vent outlet. 2. Install vent outlet to top of cabinet using 2 screws supplied in the dock pack.. e e 3. Install vent inlet gasket and vent inlet using 4 screws supplied in the dock pack. $ e e ,e �J 88-A952V001-1 C-EN 77 Furnace Combustion Air Exhaust Options 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. 4. Install the combustion air inlet PVC pipe. Note: The vent outlet adapter is used forstrain relief against the weight of the venting. The clamp should be tightened after the internal connection is made. Note: If required, transition to larger venting within 2' of the cabinet. CPL00938 - 2"x 3" offset coupling may be used and is factory supplied with 120 MBTUH furnaces. Canadian applications may i, 1-01, T0 ®q s use BAYREDUCE to meet ULC-5636 requirements. o o 40 ® Q�oo o0o a�o W o °�,000eoo-�n. Condensate Trap Installation 1. Reinstall the condensate adapter if it was earlier removed or ensure adapter is still in place. ° Important: The condensate adapter must be present for proper condensate drain operation. �� 0 1 ' 2. Install condensate trap into new location by fitting into grommet and aligning the hole on the condensate trap with the hole labeled H L". �• Important: When installing a 21.0"wide S-Series furnace, the condenser trap grommet must be rotated so that the oy notch in the grommet faces the outer edge of the furnace o °0 cabinet as shown in the illustrations. This allows the rain gutter tubing to fully seat onto the lower condensate port O trap. O 3. Hand tighten screws. 6 �• O O O Q r K v up r v v v O O O 78 88-A952V001- l C-E N Furnace Combustion Air Exhaust Options 1. Connect PS2 tubing to switch and new sensing location. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. 2. Remove port cap on left of inducer and connect inducer condensate tubing. Connect other end of inducer condensate tubing to top port on the condensate trap. Cut tubing to length, if necessary. 3. Install previously removed port cap onto bottom port of the inducer. 4. Connect condensate pressure switch tubing to pressure port on the condensate trap. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created 5. Connect rain gutter condensate hose to the rain gutter and the lower port of the condensate trap. Upf low Furnace in Horizontal Left Position — Side Vented Combustion Air Changes do not need to be made to the inducer orientation when installing the upflow furnace in the horizontal left position with the combustion air vented through the top. Changes are needed for hose PE routing, condensate trap orientation, and inducer port caps. The figure to the right shows the furnace as it is sent from the factory. ° Use the following steps to modify the furnace for horizontal left with top venting of combustion air. c Q000�o . a I o _ 1 b ®I Before proceeding, lay unit on its back to make the conversion easier. 1. Remove all drain hoses from condensate trap. Note: When removing condensate hoses from the condensate trap, o hold the trap with your hand to prevent the trap from breaking. Removing the trap before the hoses is also an option. 4 I 2. Remove tubing from PS2 to cold header. ° 3. Remove drain tubing from bottom of inducer housing. 4. Remove rain gutter tubing from inducer outlet. 2 ®.. 5. Remove tubing from condensate pressure switch. Qp�U 6. Remove the screws that hold the condensate trap bracket. The ® �4��b = condensate trap should not be removed from the condensate trap C O bracket. Remove assembly and retain for later installation. _ Note: There is a plastic adapter with 0-rings located inside the cold 5 header that is held in place by the condensate trap bracket. Do not lose this adapter. This adapter needs to be in place when the condensate trap bracket is reattached. o o s ` 0 0 88-A952V001-1 C-EN 79 Furnace Combustion Air Exhaust Options 1. Remove plug from 3" hole. 2. Install condensate trap grommet. a _O U 0 0 . � p 1. Remove the pressure switch bracket assembly. 2. Remove the screw that holds PS2, rotate 90 degrees clockwise, and reattach. 3. Reattach the pressure switch bracket assembly. O Q n O O � O ' o ® O Oa � ® `0�Qp0�0 m 0 � O b o o ®82 0 0 0 a • ® oOa��Oo m 0 a. O 80 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Attach the vent outlet gasket to the vent outlet. 2. Install vent outlet to top of cabinet using 2 screws supplied in the [ 1 e doc pack. 1� 3. Install vent inlet gasket and vent inlet using 4 screws supplied in ( the doc pack. 1� [ Vol I 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. C^ 4. Install the combustion air inlet PVC pipe. 0 Note: The vent outlet adapter is used forstrain relief against the 0d o weight of the venting. The clamp should be tightened after the internal connection is made. Note: If required, transition to larger venting within 2' of the cabinet. An 2"x 3" offset coupling is required if the transition is made in 0 `; a horizontal plane. Use coupling CPL00938 (Canadian o applications may use BAYREDUCE to meet ULC-5636 ° o Q o requirements.) See Horizontal Venting section for proper ® d Q�� orientation of 2"x 3"offset coupling. 0o o 9 � B 0 0 .0 88-A952V001-1 C-E N Furnace Combustion Air Exhaust Options Condensate Trap Installation — 1. Reinstall the condensate adapter if it was earlier removed or ensure adapter is still in place. Important: The condensate adapter must be present for proper condensate drain operation. oo®9e 2. Install condensate trapinto new location b fitting into grommet Y 9 � 9 and aligning the hole on the condensate trap with the hole labeled "HL". When installing a 21.0"wide S-Series furnace, the condenser trap grommet must be rotated so that the notch in the grommet faces the outer edge of the furnace cabinet as shown in the illustrations. This allows the rain gutter tubing to fully seat onto the lower condensate \ \ port trap. 3. Hand tighten screws. . 1 O O UP r v v v O O 1. Connect PS2 tubing to switch and new sensing location. Important., Cut to length but insure there is a rise in the tubing to 5 avoid condensed flue gases from entering pressure switch. 2. Remove port cap on left side of inducer and connect inducer ° ° 6 condensate tubing. Connect other end of inducer condensate tubing to top port on the condensate trap. Cut tubing to length, if g necessary. 3. Install previously removed port cap onto bottom port of the p o - inducer. (As viewed in upflow) .aao� 4 4. Connect condensate pressure switch tubing to pressure port on = the condensate trap. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. 0 0 2 5. Remove port plug from rain gutter and install in new position on opposite side of the rain gutter. 6. Connect rain gutter condensate hose to the rain gutter and the 77 lower port of the condensate trap. Route rain gutter condensate hose to the right of the inducer motor. 82 88-A952V001- l C-E N Furnace Combustion Air Exhaust Options Upflow Furnace in Horizontal Right Position — Top Vented Combustion Air Changes need to be made to the inducer orientation when installing the upflow furnace in the horizontal right position with the combustion a a air vented through the left side. Additional changes are needed for hose routing, condensate trap location, and inducer port caps, and the condensate plug. The figure to the right shows the furnace as it is sent from the factory. m F �, ° ° Use the following steps to modify the furnace for horizontal right with left side venting of combustion air. ° •op0�po ^ a 1 �o v • e o ® El ® o 0 Before proceeding, lay unit on its back to make the conversion easier. 1. Remove all drain hoses from condensate trap. Note: When removing condensate hoses from the condensate trap, hold the trap with your hand to prevent the trap from breaking. Removing the trap before the hoses is also an option. o 0 2. Remove tubing from P52 to cold header. 3. Remove drain tubing from bottom of inducer housing. 4 5 J= 4. Remove rain gutter tubing from inducer outlet. _ o 5. Remove tubing from condensate pressure switch. __ ,#, o OpQo ® r 6. Remove the screws that hold the condensate trap bracket. The s _ 8 condensate trap should not be removed from the condensate trap MWW7 bracket. Remove assembly and retain for later installation. 2 7. Remove the adapter located inside the condensate trap connection on the cold header and retain for later installation. Note: The plastic adapter with 0-rings located inside the cold header o O that is held in place by the condensate trap bracket. Do not lose I o 0 this adapter. This adapter needs to be in place when the ,o, condensate trap bracket is reattached. 1. Remove 3" plug on right side of unit. To be used for condensate . • �� trap. • 2. Install condensate trap grommet. .� 3. Remove two 3" plugs on left side of cabinet. O 4. Reuse the two 3" plugs to seal the two 3" default openings on the • top of the cabinet. �- o s 1 .O C) 88-A952V001-1 C-E N 83 Furnace Combustion Air Exhaust Options 1. Attach the vent outlet gasket to the vent outlet. 2. Install vent outlet to top of cabinet using 2 screws supplied in the doc pack. 3. Install vent inlet gasket and vent inlet using 4 screws supplied in the doc pack. 1 t o CD. e qO o e o 1 1. Remove three inducer screws. 2. Rotate the inducer so that the outlet is pointing vertically. IIILILLI JI ® 5 3. Use the three inducer screws to reattach the inducer to the cold header. Torque to 30 in.-lbs. Do not overtighten. ®� ° ° �aaooe e ® El o o 0 �FMIIIL.IL.ILJI 0 0 0 p ®� I ='e a op09Dpo ^ , ed�oe M � e I �� e i b o 0 ® 84 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Remove condensate drain plug from top right location on cold header. 2 2. Place condensate drain plug onto the cold header outlet located on the bottom left of the cold header. o= 0 • :®®� U 0 0 •• J/ _ � Rood � , IUU � Apo A o w _ o 000�op � o ® i 1 Elo p�m 0 0 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. 4. Install the combustion air inlet PVC pipe. Note: The vent outlet adapter is used forstrain relief against the weight of the venting. The clamp should be tightened after the internal connection is made. Note: If required, transition to larger venting within 2' of the cabinet. CPL00938 - 2"x 3"offset coupling may be used and is factory supplied with 120 MBTUH furnaces. Canadian applications may D use BAYREDUCE to meet ULC-5636 requirements. 0 of = _ 'n u op040po � o _ eaQoe poo • :" 0 88-A952V001-1 C-E N 85 Furnace Combustion Air Exhaust Options Condensate Trap Installation 1. Reinstall the condensate adapter if it was earlier removed or ensure adapter is still in place. Important: The condensate adapter must be present for proper condensate drain operation. \ 2. Install condensate trap into new location by fitting into grommet and aligning the hole on the condensate trap with the hole labeled HR„ Important: When installing a 21.0"wide S-Series furnace, the ° condenser trap grommet must be rotated so that the notch in the grommet faces the outer edge of the furnace cabinet as shown in the illustrations. This allows the rain gutter tubing to fully seat onto the lower condensate port , trap. 3. Hand tighten screw. �. • a _ HR lip` � o 4j 4 1 1. Connect PS2 tubing to switch and new sensing location. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. EM �J_LJO ` 2. Remove portcap on the right side of the inducer and connect inducer condensate tubing. Connect other end of inducer condensate tubing to top port on the condensate trap. Cut tubing to length, if necessary. ; a ¢ . e 0 0 3. Install previously removed port cap onto bottom port of the ° inducer. • 4. Connect condensate pressure switch tubing to pressure port on the condensate trap. Important: Cut to length to ensure there is no sag or trap created. 3 ° 00 90po 0 • 5 5. Connect rain gutter condensate hose to the rain gutter and the lower port of the condensate trap. 8 o" 0 0 4 86 88-A952V001-1 C-EN Furnace Combustion Air Exhaust Options Upf low Furnace in Horizontal Right Position — Left Side Vented Combustion Air Changes need to be made to the inducer orientation when installing the upflow furnace in the horizontal right position with the combustion �® o a air vented through the bottom. Additional changes are needed for I • : hose routing, condensate trap location, and inducer port caps, and the condensate plug. a� w ° ° The figure to the right shows the furnace as it is sent from the factory. Use the following steps to modify the furnace for horizontal right with _ bottom venting of combustion air. ° 000Upo I (� _ � �Oa �a000e s • ® o 0 Before proceeding, lay unit on its back to make the conversion easier. 1. Remove all drain hoses from condensate trap. Note: When removing condensate hoses from the condensate trap, hold the trap with your hand to prevent the trap from breaking. Removing the trap before the hoses is also an option. o 0 2. Remove tubing from PS2 pressure switch. 3. Remove drain tubing from bottom of inducer housing. _ 4 o 5 Je 4. Remove rain gutter tubing from inducer outlet. _ s 5. Remove tubing from condensate pressure switch. _ # o� D�po ® +• 6. Remove the screws that hold the condensate trap bracket. The =_ _ 8 condensate trap should not be removed from the condensate trap bracket. Remove assembly and retain for later installation. 2 7. Remove the condensate adapter located inside the condensate trap connection on the cold header and retain for later installation. D. Note: The plastic condensate adapter with 0-rings located inside the • I o 0 cold header that is held in place by the condensate trap o, bracket. Do not lose this adapter. The condensate adapter needs to be in place when the condensate trap bracket is reattached. 1. Remove 3" plug on right side of unit. To be used for condensate �� < trap. • 2. Install condensate trap grommet. •® .� 3. Remove 3" plugs on the left side of the cabinet. To be used for combustion air inlet. 4. Reuse the two 3" plugs to seal the two 3" default openings on the O top of the furnace. 1 .O C U 88-A952V001-1 C-E N 87 Furnace Combustion Air Exhaust Options 1. Remove three inducer screws. 2. While the inducer is loose, remove condensate drain plug from top right location on cold header. 3. Place condensate drain plug onto the cold header outlet located on the bottom left of the cold header. 4. Rotate the inducer 180 degrees so that the elbow is pointing towards the left. 5. Use the three inducer screws to reattach the inducer to the cold header. Torque to 30 in.-lbs. Do not overtighten. �ao 0 O �• �- Rio 0 88 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Remove the pressure switch bracket assembly. 2. Remove the screw that holds PS2, rotate 90 degrees clockwise, and reattach. 3. Reattach the pressure switch bracket assembly. Note: The inducer is shown rotated into its final position in the illustration. � F. !.7 °J © J, +� o P82 0 m ►8 0�� o � c o o O� 0 O � .. 1. Cut 3" hole in bottom panel using large dimple as guide. U O ® v 1 1 1. Attach the vent outlet gasket to the vent outlet. a 2. Install vent outlet to top of cabinet using 2 screws supplied in the e doc pack. 3. Install vent inlet gasket and vent inlet using 4 screws supplied in e a the doc pack. _ e Note: The vent outlet adapter is used forstrain relief against the weight of the venting. The clamp should be tightened after the e internal connection is made. Note: If required, transition to larger venting within 2' of the cabinet. e An 2"x 3" offset coupling is required if the transition is made in horizontal Use CPL00938 a plane. coupling (Canadian e applications may use BAVREDUCE to meet ULC-5636 requirements.) See Horizontal Venting section for proper ve 0 orientation of 2"x 3"offset coupling. 7 a0ao90 88-A952V001-1 C-E N 89 Furnace Combustion Air Exhaust Options 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. 4. Install the combustion air inlet PVC pipe. ' o o Cj= low o60Obo 'M - CondensateTrapInstallation F �i 1. Reinstall the condensate adapter if it was earlier removed or ensure adapter is still in place. I m9 Important: The condensate adapter must be present for proper 0 condensate drain operation. \ 2. Install condensate trap into new location by fitting into grommet and aligning the hole on the condensate trap with the hole labeled „HR„ important: When installing a 21.0"wide S-Series furnace, the condenser trap grommet must be rotated so that the ` notch in the grommet faces the outer edge of the furnace cabinet as shown in the illustrations. This allows the rain gutter tubing to fully seat onto the lower condensate port , trap. 3. Hand tighten screw. e B � � 0 4 0 E« u� 0 0 a` 0 O. O O _ 0 88-A952V001- l C-E N Furnace Combustion Air Exhaust Options 1. Connect P52 tubing to switch and new sensing location. Use additional tubing in ship with bag, if necessary. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. 2. Remove port cap on the right side of inducer and connect inducer condensate tubing. Connect other end of inducer condensate tubing to top port on the condensate trap. Cut tubing to length, if necessary. 3. Install previously removed port cap onto bottom port of the inducer. (As viewed in upflow) 4. Connect condensate pressure switch tubing to pressure port on the condensate trap. Important: Cut to length to ensure there is no sag or trap created. 5. Remove port plug from rain gutter and install in new position on opposite side of the rain gutter. 6. Connect rain gutter condensate hose to the rain gutter and the lower port of the condensate trap. Route rain gutter condensate hose to the right of the inducer motor. 88-A952V001-1 C-E N 91 Furnace Combustion Air Exhaust Options Downf low Furnace — Top Vented Combustion Air No changes need to be made to the inducer when installing the downflow furnace with the combustion air vented through the top. Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. • o 'O a ti 1. Attach the vent outlet gasket to the vent outlet. 2. Install vent outlet to top of cabinet using 2 screws supplied in the ! doc pack. 1 3. Install vent inlet gasket and vent inlet using 4 screws supplied in 1 the doc pack. i 1 m 1. Slide PVC pipe through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps. 4. Install the combustion air inlet PVC pipe. Note: The vent outlet adapter is used forstrain relief against the weight of the venting. The clamp should be tightened after the internal connection is made. �v Note: If required, transition to larger venting within 2' of the cabinet. CPL00938 - 2"x 3" offset coupling may be used and is factory supplied with 120 MBTUH furnaces. Canadian applications may use BAYREDUCE to meet ULC-S636 requirements. e o, ° Qgoopo o� a o : �t e � 0 0 0 0 88-A952V001- l C-E N Furnace Combustion Air Exhaust Options Downflow Furnace — Left Side Vented Combustion Air Changes need to be made to the inducer orientation when installing the downflow furnace with the combustion air vented through the side. Additional changes are needed for hose routing and PS2 rotation. The figure to the right shows the furnace as it is sent from the factory. Use the following steps to modify the furnace for downflow with side (� 11111 ]111 , venting of combustion air. Important: Right side vent outlet is not allowed because condensate will not drain. a e ° Q�OOQo u 0. e = O A D O O O O Before proceeding, lay unit on its back to make conversion easier. E=U 1. Disconnect all drain tubes from condensate trap. 54bbo _ Note: When removing condensate hoses from the condensate trap, �' hold the trap with your hand to prevent the trap from breaking. ® 2. Remove drain tubing from bottom of inducer housing. 4 0 3. Remove rain gutter tubing from inducer outlet. °< o�OQoo 4. Remove tubing from condensate pressure switch. �64ppb ° o 5. Remove tubing from PS2 to cold header. ° �t ra 2 0 0 0 0 88-A952V001-1 C-E N 93 Furnace Combustion Air Exhaust Options 1. Remove two 3" plugs on left side of cabinet. To be used for combustion air exhaust and inlet. 2. Reuse the two 3" plugs to seal the two 3" default openings on the J ° top of the cabinet. m m oaop0� C m a 1. Loosen the clamp holding the 450 elbow. Remove the elbow and discard. u �� (® zs 00, o ° ppOL1Qo U ooo 0 `, 94 88-A952V001-1C-EN Furnace Combustion Air Exhaust Options 1. Remove the three inducer mounting screws. 2. Rotate inducer counterclockwise so that the inducer outlet aligns with the exhaust vent outlet. 3. Reinsert and tighten screws to 30 in.-lbs. Do not overtighten. ® o. ° • QpODQo o � ° °-a odaoo�o „s ° e1� O O O O lk _ ape®e i Q a o �p O O O O 1. Remove the pressure switch bracket assembly. 2. Remove the screw that holds PS2, rotate 90 degrees 0r r counterclockwise, and reattach. 3. Reattach the pressure switch bracket assembly. Note: The illustration shows PS2 in its final position after being rotated. o Booboo o�a C Q fly 88-A952V001-1 C-E N 95 Furnace Combustion Air Exhaust Options 1. Attach the vent outlet gasket to the vent outlet. ° 2. Install vent outlet to cabinet using 2 screws supplied in the doc 0 0 pack. 3. Install vent inlet gasket and vent inlet using 4 screws supplied in G the doc pack. 4. Install the grommet for the condensate drain tube. The drain may be located on either side of the cabinet. /a p 1. Slide PVC through vent outlet adaptor and insert into inducer outlet. 2. Twist to insure PVC is fully inserted. 3. Tighten the two clamps.LA _ ®® 4. Install the combustion air inlet PVC pipe. Note: The vent outlet adapter is used forstrain relief against the J a O o o �o0h ° weight of the venting. The clamp should be tightened after the ° a p ° internal connection is made. . o a Note: If required, transition to larger venting within 2' of the cabinet.=' An 2"x 3" offset coupling is required if the transition is made in a horizontal plane. Use coupling CPL00938 (Canadian applications may use BAYREDUCE to meet ULC-S636 -... L requirements.) See Horizontal Venting section for proper orientation of 2"x 3"offset coupling. o 0 0 0 1. Connect PS2 tubing to switch and sensing location. =0 Important: Trim the condensate pressure switch tubing to length to ensure there is no sag or trap created. 3 1 2. Remove port cap at bottom of inducer and connect inducer c?„ condensate tubing. Connect other end of inducer condensate = ®0 •' ®, © tubing to top port on the condensate trap. Cut tubing to length, if necessary. 3. Install previously removed port cap onto bottom port of the 000� p o inducer. 0 4. Connect condensate pressure switch tubing to pressure port on the condensate trap. Important: Cut to length to ensure there is no sag or trap created. 5. Remove port plug from rain gutter and install in new position on 2 • .N opposite side of the rain gutter. o 0 6. Connect rain gutter condensate hose to the rain gutter and the o 0 lower port of the condensate trap. Cut to length, as required. 96 88-A952V001- l C-E N a n A952V Control System Menu Example Example 1" stage Gas Heat 800 CFM '- ] dL HE I RrF 080 rUS MENU Example Example 2"Stage Pressure 1st Stage Pressure Switch Error Switch Error Err E3_4 IVE ERROR Example Example Example 2"a Stage Pressure 1st Stage Pressure Open Limit Switch Switch Error Switch Error Error L6F E3_4 E3_ I E04 iT 6 FAULTS Example Software Version # [r I Er-2 I :rol Release# Example seconds cad 000 090 160 SETTING UP YOUR SYSTEM: To change any factory default value, first remove any "call" from the furnace and allow any fan off delays to finish. (I �+ should be seen on the display) Scroll to the selected Menu item by momentarily depressing the "MENU" key and then depress the "OPTION" key to the desired setting. Then momentarily depress the "MENU" key again to save the change. Example Enhanced Mode EH 3_0 C_0 2_5 3-5 OD TOodnnage Example Example Example Single Stage 2 stage 1 compressor 2 stage 2 compressor adu 1- 1 2- 1 2- 2 OD Unit Type Example 50%Cooling Airflow [OF 050 025 :ontinuous Fa C PL Cooling CFM 350 L-Dj:�F 450 per Ton E-ple FM perTon [PH Heating CFM 350 390 450 per Ton x Seconds Hod 1111" 100 60 100 140 seat Off Delay Ex Seconds ISdeZt�-Stage D 2n° sta a Heatin CFM 9H` 103 113 146 093 as Heating CFM rst Mode tun Test See Run Test Menu Model ODT Options [ ]= Default Upflow A952VO40BU3SAB 3T[3T], 1.5T, 2T, 2.5T A952VO60BU3SAB 3T[3T], 1.5T, 2T, 2.5T A952VO60BU4SAB 4T[4T], 2.5T, 3T, 3.5T A952VO80BU4SAB 4T[4T], 2.5T, 3T, 3.5T A952VO80CU5SAB 5T[5T], 3.5T, 4T, 4.5T A952V100CU4SAB 4T[4T], 2.5T, 3T, 3.5T A952V1000U5SAB 5T[ST], 3.5T, 4T, 4.5T A952V120DU5SAB 5T[5T], 3.ST, 4T, 4.5T Downflow A952VO40BD3SAB 3T[3T], 1.5T, 2T, 2.5T A952VO6OBD3SAB 3T[3T], 1.5T, 2T, 2.5T A952VO8OBD4SAB 4T[4T], 2.5T, 3T, 3.5T A952V100CD4SAB 4T[4T], 2.5T, 3T, 3.5T A952V100CD5SAB 5T[5T], 3.5T, 4T, 4.5T A952V1201DDSSAB 5T[5T], 3.5T, 4T, 4.5T CFM per Ton selections range from 290 - 450 Important: When applied with zoning or a VSPD outdoor unit, the CFM/Ton must be set to 400 CLEARING THE LAST6 FAULTS: To clear the stored faults, scroll to the last 6 faults menu, enterthe menu by scrolling to the right and hold the "Option" key for at least 5 seconds. Release and a set of 3 dashes will be seen 3 times. This confirms the faults have been cleared Gas Heating CFM shown is 2n" stage airflow. 1" stage airflow is -80% of the selected 2na stage airflow and cannot be adjusted. Gas heating CFM can be adjusted while the unit is operating in gas heat mode to enable the technician to quickly adjust to the manufacturer's suggested heat rise across the heat exchanger. Multiply the value shown by 10 for actual airflow Model Gas Heating CFM [ ]=Default Upflow A952VO4OBU3SAB 088 [088], 140, 065,083 A952V06OBU3SAB 103 [103], 113, 130, 080 A952V06OBU4SAB 116 [116], 130, 099, 109 A952V08OBU4SAB 126 [1261, 133, 146,120 A952V08OCU5SAB 145 [1451, 156, 208, 119 A952V10OCU4SAB 183 [1831, 145, 162, 172 A952V1000USSAB 206[2061, 215, 159,198 A952V12ODU5SAB 195 [195], 225, 156, 185 Downflow A952VO4OBD3SAB 088 [088], 095, 125, 065 A952V06OBD3SAB 103 [103], 113, 080, 090 A952V08OBD4SAB 126[126],133,148,120 A952V100CD4SAB 183 [1831, 189, 150, 162 A952V10OCD5SAB 210 [2101, 152, 180, 187 A952V120DD5SAB 225 [225], 175, 185, 195 rf M cc iV r+ 0. mn iV M 0 O O - 9 00 M Z A952V Examples of System Status Example Example Example Airflow Requested 800 CFM 1st Stage Pressure Switch Error �-N I dL = Idle, no demand for cooling, heating, or fan HE 1= Demand for 15Y stage gas heat HE2 = Demand for 2"d stage gas heat EL 1 = Demand for 15Y stage cooling EL = Demand for 2"d stage cooling HP 1 = Demand for 1st stage heat pump HF'2 = Demand for 2"d stage heat pump EOF = Demand for continuous fan dFE = Demand for outdoor unit defrost, furnace running in gas heat mode Ar-F / 080 = Airflow request is for 800 cfm. Airflow display is rounded down to the nearest 10 cfm NOTES: (1) The menu status displayed is solely dependent on the input of 24VAC that is applied to the low voltage terminal strip. (2) The status will alternate between the system mode and the airflow request every 2 seconds. (3) If an error occurs, an E*.* will alternately flash with the system mode and airflow request. See first example (4) Multiply the value shown by 10 for actual airflow Integrated Furnace Control Menu Note: During run test mode, depressing the option key will allow the user to hold (HLD) that test sequence if measurements want to betaken. The exception is RU3 (ignitor). rUrt rr i — rU i Run Test Mode Run Test Mode: To enter Run Test Mode, scroll to run using the Menu key, then push the option key. The LED will flash rJn three times, then begin the test. To exit the test mode, momentarily push the Menu key, cycle power to the furnace, or make a valid thermostat call for capacity or fan. Sequence of Run Test Mode rU I -Turns the inducer on in 1" stage for 30 seconds rut —Turns on the inducer on 2"d stage for 30 seconds rL13 — Turns the ignitor on for 10 seconds rU`i — Turns the circulating blower on 1st stage compressor speed for 10 seconds rU5 — Turns the circulating blower on 2nd stage compressor speed for 10 seconds rL16 — Turns the circulating blower on 1�` stage gas heat speed for 10 seconds rUl — Turns on the circulating blower on 2"d stage gas heat speed for 10 seconds The above sequence will repeat two more times unless the Run Test Mode is exited, see above Important: The Run Test Mode does not test fire the furnace or bring the outdoor unit on. It is designed to allow the technician to observe each mode to ensure the IFC, inducer, and circulating blower are performing as intended. 88-A952V001-1 C-E N 99 Integrated Furnace Control Display Codes 2 Stage Inducer with ECM Blower Motor Status Codes 1 dL Idle HE! First Stage Heating HE2 Second Stage Heating RrF Airflow times 10 (080=800 CFM) C0F Continuous Fan CLI First Stage Cooling CL2 Second Stage Cooling HPI First Stage Heat Pump HP2 Second Stage Heat Pump dFt Defrost Mode Menu Options €r, Active Alarm Menu LSF Last 6 Faults (To clear — Hold Option button down for 5 seconds) C Code Release Number Cod Cooling Off Delay (Seconds) Odt Outdoor Tonnage 0dU Outdoor Unit 'OF Blower Constant Fan Airflow Multiplier (Percentage) CPC Cooling (CFM/Ton) CPH Heat Pump Heating (CFM/Ton) Hod Heat Off Delay (Seconds) I Sd Inter -Stage Delay (Seconds) 9HC Gas Heating CFM 2nd Stage (1st Stage is not adjustable) Run Test Mode Error Codes Alarm Error Code Alarm Explanation €01 Loss of the IRQ or other internal failures (Internal IFC error) €2_1 Retry Exceeded (Flame never sensed, one hour lockout after 3 times) €2_2 Recycles Exceeded (Flame sensed then lost, one hour lockout after 10 times) €2_3 1st Stage Gas Valve Not Energized When It Should Be exceeded after 10 times €3_1 Shorted Pressure Switch, 1st Stage €3_2 Open Pressure Switch, 1st Stage €3_3 Shorted Pressure Switch, 2nd Stage €3_9 Open Pressure Switch, 2nd Stage €0H Open Limit (Main Thermal, Rollout Switch, or Reverse Airflow Switch) €05 Flame detected, should not be present 100 88-A952V001-1 C-EN Integrated Furnace Control Display Codes E5-I Voltage reversed polarity E13_2 Bad grounding ES-3 (1) Igniter relay fails (2) Igniter open El_I 1st stage gas valve (MVL) is energized when it should be off E08 Flame current is low, but still strong enough to allow operation E09 Open Inducer Limit Switch or Condensate Pressure Switch El 1 (1) 1st stage gas valve not energized when it should be (2) 1st stage gas valve relay stuck closed (3) 2nd stage gas valve relay stuck closed (4) 2nd stage gas valve energized when it should not be (5) 2nd stage gas valve not energized when it should be El 2 Open fuse El 3 Blower HP/OEM ID El a No PM and local copy bad El 5 Both of unit Data File in PM and local Unit Data File are corrupt El 1 Blower motor no communication response El 8 Blower communication failure on the control Fault Code Recovery Fault Code Recovery 1. To view the last 6 faults, press the "Menu" key until the "Last 6 Faults" (LSF) menu appears. 2. Enter the menu by pressing the "Option" key. 3. The last 6 faults can be viewed. EAC, HUM Dry Contacts LINE Neutral Connections Connections Inducer/Igniter Connector 4$4 E1z ¢ E$'$°$°$ ® ND ® IND-N Clearing the Last 6 Faults p�.,�� ®W ® " ® IND-LD 1. To clear the last 6 faults, press the "Menu" key until the "Last 6 Flame Current 0 IND-HI Faults" (LSF) menu appears. 2. Enter the menu by pressing the "Option" key. 00 7 Segment LED 3. Hold the "Option" key for at least 5 seconds. MVH ® M .0 4. Release and a set of 3 dashes with be seen 3 times. This confirms GND ® S MENU and OPTION the faults have been cleared. 112 ® TM Mac" H E„ `NU OPTION Select Buttons Motor HLO Communications Resetting Factory Defaults Ps, TR 1. Display must be in Idle Mode. ILI Personality 2. Push the "Menu" and "Option" buttons at the same time for 15 Module seconds then release. 12 Pin 3. The 7 segment will flash "Fd" 3 times. This confirms the unit has Connector e been reset to the factory defaults. BK wz w1 B G Bic vz v1 BKJumper Low Voltage Terminal Strip 5 Amp Fuse 88-A952V001-1 C-E N 101 Sequence of Operation Note: The seven segment LED readout is based on Note: There are two flame sense pads located on thermostat input. During a simultaneous call for the IFC, marked "FP". To measure the flame W1 and W2, the seven segment LED will read current, use a VOM set to DC volts. 1 VDC = 1 "H,L2", although the IFC will process the call for micro -amp. Flame current will vary 1st stage heat first. depending on the type of meter used. Typical Note: Numbers in Parenthesis () refer to the 12 pin flame current ranges from 0.75 — 3.0 micro - terminal positions. amps (0.75 — 3 VDC). 7. Once flame sense has been achieved, a timer on the EAC and HUM Timing IFC starts and after the "Blower On" delay has • EAC relay closes approximately 2 seconds after the completed, the indoor blower will energize and run blower starts. at the 1st stage gas heating speed. The seven • EAC relay opens when the blower motor stops. segment LED for example will alternately read: • HUM relay closes on any heating call (HP/Gas) approximately 1 second after the blower motor starts. • HUM relay opens when any heating call (HP/Gas) is removed. 1st Stage Gas Heating 1. R — W1 contacts close on the thermostat sending 24VAC to the W1 low voltage terminal of the IFC. Technician should read 24VAC from W1 to B/C. The seven segment LED will read "HE 1". 2. The IFC performs a self -check routine and then confirms: a. Condensate pressure switch and Inducer limit switch are closed by sending 24VAC out the HLO terminal and monitoring the ILI (1) input. b. Flame roll -out switches (FRS) 1 & 2, main thermal limit (TCO), and any reverse air flow (RAF) switches are proved closed by sending 24VAC out the HLO (4) terminal and monitoring the HLI (11) input. c. Pressure switch 1 (PS1) and pressure switch 2 (PS2) are proved open by sending 24VAC out the HLO terminal, through the limit switches, and monitoring the PS1 (3) and PS2 (7) inputs. Note: If a thermal limit is open, 24VAC will not be present at either pressure switch. 3. After steps a, b, and c are confirmed, the inducer relay is closed energizing 1st stage inducer. As the inducer ramps up, PS1 will close. 4. When PS1 closes, the ignitor relay on the IFC will close. The ignitor is energized and warm up is approximately 20 seconds. 5. After the ignitor warm up, the 1st stage gas valve relay is closed, energizing the 1st stage gas valve solenoid to allow ignition. 6. The first burner will ignite and flame will crossover to the remaining burners, establishing current to the flame sensor. Flame sensing must take place within 4 seconds. HE! = Gas heating, Stage 1 RrF = Airflow U50 = 600 requested cfm (value shown x 10) 8. When the temperature raises enough to satisfy the thermostat setting, contacts R-W1 will open. 9. The gas valve relay will open, closing the gas valve. The inducer will continue to run for approximately 5 seconds to remove any combustion byproducts from inside the furnace. 10. The indoor blower continues to run to remove heat from the heat exchangers. The blower off time is field adjustable through the IFC menu setup option. The seven segment LED will read "I dL" = Idle, no thermostat demand. 2nd Stage Gas Heating Note: 2nd stage heating cannot operate without 1st stage operation. 1. R — W1 contacts close on the thermostat sending 24VAC to the W1 low voltage terminal of the IFC. Technician should read 24VAC from W1 to B/C. The seven segment LED will read "HE 1" 2. The IFC performs a self -check routine and then confirms: a. Condensate pressure switch and Inducer limit switch are proved closed by sending 24VAC out the HLO terminal and monitoring the ILI (1) input. b. Flame roll -out switches (FRS) 1 & 2, main thermal limit (TCO), and any reverse air flow (RAF) switches are closed by sending 24VAC out the HLO (4) terminal and monitoring the HLI (11) input. c. Pressure switch 1 (PS1) and pressure switch 2 (PS2) are proved open by sending 24VAC out the HLO terminal, through the limit switches, and monitoring the PS1 (3) and PS2 (7) inputs. Note: If a thermal limit is open, 24VAC will not be present at either pressure switch. 3. After steps a, b, and care confirmed, the inducer relay is closed energizing 1st stage inducer. As the inducer ramps up, PS1 will close. 102 88-A952V001-1 C-E N Sequence of Operation 4. When PS1 closes, the ignitor relay on the IFC will close. The ignitor is energized and warm up is approximately 20 seconds. 5. After the ignitor warm up, the 1st stage gas valve relay is closed, energizing the 1st stage gas valve solenoid to allow ignition. 6. The first burner will ignite and flame will crossover to the remaining burners, establishing current to the flame sensor. Flame sensing must take place within 4 seconds. Note: There are two flame sense pads located on the IFC, marked "FP". To measure the flame current, use a VOM set to DC volts. 1 VDC = 1 micro -amp. Flame current will vary depending on the type of meter used. Typical flame current ranges from 0.75 — 3.0 micro - amps (0.75 — 3 VDC). Once flame sense has been achieved, a timer on the IFC starts and after the "Blower On" delay has completed, the indoor blower will energize and run at the 1 st stage gas heating speed. The seven segment LED for example will alternately read: HL 1 = Gas heating, Stage 1 RrF = Airflow 060 = 600 requested cfm (value shown x 10) 8. R-W2 contacts close on the thermostat sending 24VAC to the W2 low voltage terminal of the IFC. Technician should read 24VAC from W2 to B/C. The seven segment LED will read "HL2". 9. The IFC then energizes the 2nd stage inducer relay. The inducer ramps to 2nd stage, the second stage gas valve relay on the IFC closes, energizing second stage gas valve. The indoor blower motor will ramp up to the 2nd stage gas heating speed. The seven segment LED for example will alternately read: HL2 = Gas heating, Stage 2 RrF =Airflow 123 = 1230 requested cfm (value shown x 10) 10. The IFC monitors PS2 for closure and if PS2 does not close within 45 seconds, a PS2 open error will be declared and the furnace will operate in 1st stage. If PS2 closes, 2nd stage gas heating will continue until the thermostat R-W2 contacts open. Note: If PS2 does not close within the 45 second time, the IFC will wait 10 minutes and repeat step 9. If on the third attempt during the same heating call, PS2 does not close within the 45 second proving time, the unit will lock out 2nd stage until the heating calls are removed or the power is cycled to the furnace. 11. When the temperature raises enough to satisfy the thermostat setting, contacts R-W2 will open, 2nd stage gas valve will close, the indoor blower motor will ramp down to 1st stage, and the unit will continue to run until R-W1 contacts open. 12. When the temperature raises enough to satisfy the thermostat setting, contacts R-W1 will open. 13. The gas valve relay will open, closing the gas valve. The inducer will continue to run for approximately 5 seconds to remove any combustion byproducts from inside the furnace. 14. The indoor blower continues to run to remove heat from the heat exchangers. This blower off time is field adjustable through the IFC menu setup option. The seven segment LED will read "I dL" = Idle, no thermostat demand. Single Stage Cooling 1. R-Y1-G contacts on the thermostat close sending 24VAC to the Y1 and G low voltage terminals on the IFC. Technician should read 24VAC between Y1-B/C and between G-B/C. Note: Factory supplied Y1-0jumper must remain in place for proper seven segment LED readout. If removed, seven segment LED will read "PIP l". 2. 24VAC is sent to the OD unit via thermostat wiring. 3. The indoor blower ramps to the cooling airflow. The seven segment LED for example will alternately read: LL 1 = Cooling, Stage 1 RrF = Airflow USO = 800 requested cfm (value shown x 10) 4. When the temperature is lowered enough to satisfy the thermostat setting, contacts R-Y1-G will open. 5. The OD unit shuts off and the indoor blower shuts off, unless a blower off delay has been enabled in the IFC setup menu options. The seven segment LED will read "1 dL" = Idle, no thermostat demand. Two Stage Cooling 1. R-Y1-G contacts on the thermostat close sending 24VAC to the Y1 and G low voltage terminals on the IFC. Technician should read 24VAC between Y1-B/C and between G-B/C. Note: Factory supplied Y1-O jumper must remain in place for proper seven segment LED readout. If removed, seven segment LED will read "HP / ". 2. 24VAC is sent to the OD unit via thermostat wiring energizing 1st stage compressor operation. 3. The indoor blower ramps to the 1st stage cooling airflow. The seven segment LED for example will alternately read: LL 1 = Cooling, Stage 1 RrF = Airflow 080 = 800 requested cfm (value shown x 10) 4. R-Y2 contact on the thermostat closes sending 24VAC to Y2 low voltage terminal on the IFC. Technician should read 24VAC between Y2 and B/C. 5. 24VAC is sent to the OD unit via thermostat wiring. 6. The indoor airflow ramps to 2nd stage cooling airflow. The seven segment LED for example will read: LL2 = Cooling, Stage 2 88-A952V001-1 C-E N 103 Sequence of Operation ArF =Airflow 160 = 1600 requested cfm (value shown x 10) 7. When the temperature is lowered enough to satisfy the thermostat setting, contacts R-Y1-Y2-G will open. 8. The OD unit shuts off and the indoor blower shuts off, unless a blower off delay has been enabled in the IFC setup menu options. The seven segment LED will read "I dL" = Idle, no thermostat demand. 104 88-A952V001-1 C-E N Notes 88-A952V001-1 C-E N 105 Notes 106 88-A952V001-1C-EN Notes 88-A952V001-1 C-E N 107 4B)Ingersoll Rand® Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands — including Club Caro, Ingersoll Rand@, Thermo King@ and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results. 40)lngersoil Rand T, THERMO KING 0 TXWE® ingersollrand.com Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices. 88-A952V001-1C-EN 210ct2019 Supersedes88-A952V001-1B-EN (August2019) ©2019Ingersoll Rand