icp confidential not for further publication condensing furnace distributor technical training 1
TRANSCRIPT
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Condensing FurnaceDistributor
Technical Training
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Model Nomenclature System
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Model Nomenclature System
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Agenda
Product Line OverviewNew FeaturesInstallationAdjustmentServicing
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Overview
• 95.5 AFUE • 4-way multipoise
– 100 & 120 size– 140 size limited to Upflow & Horizontal
• Aluminized steel primary and stainless steel secondary heat exchangers
• Direct Vent or Non-Direct Venting
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New Features
• Lower height, now 35”• Standard widths
– 21” for 100 and 120 sizes – 24 ½” for 140 sizes
• Through-the-top venting• Multiple venting options• Internal Condensate system
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New Features
• Slide out blowers• Ease of access for control board• Two outer doors• Easy door attachments
– No sharp edges– Quarter-turn knobs and latches
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New Features
• Redesigned primary heat exchanger– More compact– No eyelets
• Updated tube-and-fin secondary– Better efficiency– Eliminated U-bend – Easier to service with
slide-out rails
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New Technologies
• True installation flexibility– Venting flexibility
• Vent pipes can exit cabinet in three different directions
– Low-profile horizontal drain trap position• Easy to re-position the drain trap• Fewer tubes to connect• Drain trap and tubes removed from the blower
compartment
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Casing
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Casing
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Casing
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Casing
Combustion Air Opening
Gas Entry
Horizontal Drain Trap Opening
Vent or Combustion Air Opening
Condensate Drain K.O.
J Box K.O.
Return Air Opening
35”
Combustion Air Opening
Gas Entry
Vent or Combustion Air Opening
Horizontal Drain Trap Opening
Condensate Drain K.O.
J Box K.O.
Return Air Opening
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Outer Door Assembly
• Two piece door design• ¼ turn door knob attachment• Doors are gasketed
– Eliminates door rattling and leakage
– Vestibule is sealed• Door does NOT change with
furnace orientation– Logo rotates for upflow and
downflow positions
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Outer Door Assembly
• Vestibule functions as the burner compartment– Combustion air piped directly to the vestibule– Multiple locations to connect combustion air pipe
• Sealed burner box is not required• Simplifies set-up
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Upflow Return Air Connections
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Downflow Return Air Connections
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Horizontal Return Air Connections
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Upflow Venting
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100,000 BTUH & 120,000 BTUH Downflow Venting
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Horizontal Left Venting
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Horizontal Right Venting
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• Direct Vent– Concentric Vent– Field-fabricated 2-pipe
• Ventilated Combustion Air– Vent to outdoors– Combustion air from attic or crawlspace
• Single Pipe– Uses indoor air for combustion
Terminations
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Ventilated Combustion Air Option
The combustion air pipe for the Ventilated Combustion Air Option cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent / 2-Pipe system.
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Indoor Air For Combustion Option
• Use a (minimum) 12-inch piece of PVC– Maximum of 5 feet
• Tight radius elbow– Face away for better sound
control• Secure pipe to adapter
– Pilot drill 1/8” hole– Install sheet metal screw– Seal with silicone
12” (min)
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Alternate Indoor Air For Combustion Connection
12” (min)
12” (min)
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Supply Air Flanges
• Flanges shipped flat– If flanges are not bent, nuisance
limit trips could occur• Bend flanges UP for upflow or
horizontal coil installations• Remove or bend flanges DOWN
for downflow coil installations– No downflow for 140,000 input
• Supply opening match current coil opening sizes
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Supply Air Flanges
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Return Air Connections• Upflow
– Either Side– Bottom– Any combination of Sides and Bottom
• Downflow (100,000 BTUH & 120,000 BTUH)– Bottom only (“bottom” as referenced to furnace in upflow position)
• Horizontal – Bottom– Side (side facing down only)
• Airflow above 1800 cfm may require both side/bottom return or bottom only return
• Remove closure panel for bottom return air
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Return Air Connections
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Gas Piping• Gas pipe can enter
from either side• Remove K/O on either
side gas entry• Install grommet in
casing• Flex lines must
connect outside of the casing per the NFGC
Sediment trap required per NFGC
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Optional Right Side Gas Entry
• No special fittings for left side entry
• Valve inlet is ½” NPT• Install Street Ell, 2” nipple and
90º elbow together• Install Street Ell into gas valve• Remove K/O from casing• Install gas pipe grommet in
casing– (Required For Direct Vent)
• Install gas line into elbow• Tighten gas line
Use backup wrench on gas valve!
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J-Box Installation
• J-box bracket and cover shipped in loose parts bag
• J-box can be relocated to opposite side
• Other electrical knock-outs are available
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J-Box Installation
• Remove 7/8” knockout in casing
• Install J-box bracket• Attach ground wire to
green ground screw• Install cover after all
other connections are made
• Other electrical knock-outs are available
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Typical Disconnect At Furnace
Power Cord Installation in Furnace J-Box (Where permitted)
NOTE: Power cords must be able to handle the electrical requirements listed in Table 6. Refer to power cord manufacturer’s listings.1. Remove 7/8” K.O. in casing.2. Attach J box bracket to casing.3. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing.4. Attach power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.5. Attach field ground wire to green ground screw on J-Box bracket.6. Connect line voltage leads as shown in wiring diagram7. Install cover to J--Box. Do not pinch wires between cover and bracket.
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Upflow
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Downflow - Trap UnconvertedPSC Inducer Models
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Downflow - Trap ConvertedPSC Inducer Models
Route tube through
Switch Tube to PortOn Collector Box
To 15 ib-in
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Horizontal Left - Trap UnconvertedPSC Inducer Models
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Horizontal Left - Trap ConvertedPSC Inducer Models
Route Pressure Switch
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Horizontal Right - Trap UnconvertedPSC Inducer Models
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Horizontal Right - Trap ConvertedPSC Inducer Models
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Horizontal Trap Grommet
• Required accessory for Direct Vent applications (only)
• Maintains a sealed vestibule
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Repositioning Vent Elbow
• Loosen the Vent Elbow Clamp. • Remove the Vent Elbow. • Re-install in the desired position. • Torque clamp 15 lb-in.
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Condensate Trap and Drain Elbow
• Clear trap– Shown for clarity
• Production Trap– White, Opaque front/Clear back
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Condensate Trap
Expanded View Outlet Relief Port Inlets Front View Back View
Mounting Screw Hole
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Right Side Drain
• Production trap will be opaque front/clear back• Connect field supplied CPVC fittings to drain tube• Clamp may be located inside casing• Connect condensate drain to code approved drain or condensate
pump approved for furnace condensate
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Right Side Drain
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Left Side Drain• Cut the tube as shown• Install formed end of
grommet in the left side of the casing
• Connect the elbow to the short end of Z pipe
• Slide clamps on elbow and pipe
• Route Z pipe behind inducer• The inducer can be removed
if necessary to install the Z pipe
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Left Side Drain
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Left Side Drain
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Vent Sizing
• New tables based on Maximum Equivalent length– Starts with a maximum length– Deduct for type of fitting used– No restriction on number of elbows
• Diameters up to 4 inches on larger sizes• Expanded exposed vent pipe tables
– Winter design down to -40 deg. F (C) – ½ inch insulation added
• Closed cell Armaflex type
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Maximum Equivalent Length Table
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Deductions Table and Example
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Vent Table Notes
1. Use only the vent pipe sizes shown for each furnace. It is NOT necessary to choose the smallest diameter pipe possible for venting.
2. NA – Not allowed. Pressure switch will not close, or flame disturbance may result.
3. Size both the combustion air and vent pipe independently, then use the larger size for both pipes.
4. Assume the two 45_ elbows equal one 90_ elbow. Wide radius elbows are desirable and may be required in some cases.
5. Elbow and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.
6. The minimum pipe length is 5 ft. (2 M) linear feet (meters) for all applications.7. Use 3–in. (76 m) diameter vent termination kit for installations requiring 4–in.
(102 mm) diameter pipe.
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Sizing The Vent Pipe
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Sizing The Vent Pipe
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Vent Pipe Support
• Helps support vent pipe• Notches in coupling slide
over buttresses on adapter• Adds to unit serviceability
– Provides an optional disconnect point
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Combustion Air Adapter
• Attach to K.O. on casing– Any unused top or side K.O.
may be used • Connect 2” combustion air
pipe to casing• Gluing is not recommended
– Pilot drill 1/8” hole and secure with ½” #7 sheet metal screw
– Seal with silicone
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Comparing the Two Adapters(Both fit 2” PVC pipe)
Combustion Air Pipe Adapter
Vent Pipe Support
2 3/8”2”Internal pipe stop No pipe stop
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Vent Coupling & Adapter
• Coupling is notched• Provides for proper
orientation of coupling
• Notches slide over buttresses on adapter
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Vent Pipe Coupling & Combustion Air Pipe Adapter
Gaskets
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Continuous Vent PipeVent pipeInserts through coupling to vent elbow
Vent coupling w/clampsSlides over adapter
Vent coupling adapterAttaches to furnace casing
Vent pipePasses through adapter Inserts into Vent Elbow
360° Vent ElbowConnects to vent pipe
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Flush Mount Vent Pipe
Vent pipeInserts ½ way into coupling
Vent coupling w/clampsSlides over adapter
Vent coupling adapterAttaches to furnace casing
Vent pipe from inducerPasses through adapter Inserts ½ way into coupling
360° Vent coupling Vent pipe connects to coupling
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• Measure the vent pipe– Insert pipe through K.O and
adapter w/gasket installed– Insert pipe into vent elbow
• Slide adapter down on furnace casing– Mark the pipe at the top of the
adapter• Remove pipe from vent elbow
– Cut pipe square
Flush Mount Vent Pipe
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Optional Flush Mount Vent Pipe
• Clean and prime vent pipe• Pipe is inserted in vent elbow
– Clean and prime pipe
• Adapter with gasket is glued to vent pipe– Insert vent pipe into vent elbow– Apply cement to pipe and
adapter– Slide adapter over vent pipe
• If pipe is not glued to the adapter, the pipe will leak water!
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• Attach vent pipe adapter to furnace casing with screws
• Install vent coupling– Align notches in vent
coupling over stand-offs on vent pipe adapter
– Push down to seat coupling
• Seat coupling on adapter• Torque clamp 15 lb-in.
Optional Flush Mount Vent Pipe
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• Insert remaining vent pipe into coupling
• Torque clamp on coupling 15 lb-in.
• Torque clamp on vent elbow 15 lb-in.
Optional Flush Mount Vent Pipe
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Vent Through Casing Side
• Install adapter/gasket• Install coupling-
– Align notched and fully seat on vent pipe adapter
• Attach remaining vent pipe• Torque all clamps 15 lb-in.
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• Requires a (minimum) 12-inch pipe w/tight radius elbow• Pipe can be attached to any un-used 2-inch K.O.• Orient elbow or pipe away from front
– No combustion air disk required– Can be screened using ½” metal or plastic screening
Combustion Air Pipe (Non-Direct Vent)
12” 12”12”
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Single-Stage and Two-Stage PSC Inducer Assembly
360°Inducer outlet coupling
PSC inducer motor
Capacitor
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Single- and Two-StageInducer Assemblies
• Three unique sizes for each– PSC ball bearing motor– Provides optimum performance
• Adjustable vent coupling– Adjusts to 4 positions– Loosen the clamp, rotate the coupling, re-tighten the clamp
• Integral condensate drainage– No external hoses required
• Service replacement will be fully assembled
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Key Features Inducer Assembly
Drain outlets with gaskets
Mounting tabs
Inlet gasket
Flue gas inlet
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PSC Inducer Inlet ChokeFactory Installed
Inlet Choke Plate(when used)
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Integrated Inducer Vent/DrainFlue gases exit through the inner opening
The larger opening channels condensate from the vent through the inducer and out the drain openings in the back of the inducer.
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Vent Condensate DrainageFlue gases exit through the inner opening
The larger opening channels condensate from the vent through the inducer and out the drain openings in the back of the inducer.
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Collector Box-Front View
Inducer drain openings
Inducer attachment points w/brass inserts (red circles)
Condensate trap gasket
Condensate trap gasket
Condensate trap openings for upflow and horizontal right
Condensate trap openings for downflow and horizontal left
Pressure Switch/Relief port
Outlet to inducer
Pressure Switch/Relief port
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Single Stage Pressure Switches
• Single stage furnaces have 2 pressure switches– Housing Pressure Switch (HPS)
• Tapped into Inducer Housing• Connects electrically to the CPU of the furnace control board
– Collector Box Pressure Switch (LPS)• Tapped into Collector Box• Connects electrically to GVR via furnace control board
• The HPS has a lower set point than the LPS– HPS functions as a blocked vent switch– LPS functions as a blocked drain switch
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Single Stage Pressure Switches
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Single Stage Wiring Diagram
• Refer to the legend• HPS
– Inducer Housing Pressure Switch, SPST (N.O.)
• LPS– Collector Box Pressure
Switch, SPST (N.O.)
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Single Stage Pressure Switches
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Pressure Switch Settings
Single Stage Pressure Switches
Input Part Number Collector Box Pressure Switch Housing Pressure Switch
Max Make-IWC Nom Break-IWC Max Make-IWC Nom Break-IWC
100 &
120HK06NB030 0.45 0.30 +/- 0.05 0.45 0.30 +/- 0.05
140 HK06NB031 0.45 0.30 +/- 0.05 0.60 0.45 +/- 0.05
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Heat Exchanger AssemblyFront View
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Heat Exchanger AssemblyRear View
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Primary Assembly
• Completely redesigned heat exchanger• Compact multi-pass design• Aluminized• Service replacement sold fully assembled to the Primary Cell Inlet Plate
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Condensing Heat Exchanger
• Fin and tube type design • Stainless steel tubes• Aluminum fins• Tubes are straight through• Turbulators are “locked” in each tube
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Burners, HSI and Flame Sensor
• One piece burner design for each size• Burners are “ganged” together• Eliminates burner misalignment
– Note igniter and flame sensor locations• Igniter mounts from the top of the burner assembly• Flame sensor mounts through tab on burner• Flame sensor is positioned underneath burner
– Igniter resistance at room temp• 40 to 70 ohms
– Flame sensing current• 4 to 6 micro amps DC
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Manifold Assembly Features(Top plate removed for clarity)
Manifold is the same type for all families
Four screws attach manifold here
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Burner Assembly
Igniter resistance is 40 to 70 ohms @ room temperature and is stable over the life of the igniter
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Burner Assembly
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Single-Stage Gas Valve - Features
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Blower Assemblies
• Improved blower rails• Forward-facing mounting
screws• Longer main harness
(not shown)– Blower can be removed
without harness removal• Forward-facing control
board
Mounting Screw Locations
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Torsion-Flex Blower Motors
• Mounting arms attached to motor• Isolated with rubber grommets
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Typical Blower Assembly (Expanded)
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There are 2 sets of holes in the blower so if one set gets stripped, the whole motor can be rotated to the other set of holes.
For example:
One or more of the screws were stripped in the blower marked with a blue circle.
Remove all 4 mounting screws, rotate the motor to the holes with the arrows and re-install the screws.
Motor Mounting Holes
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Remember!
• Either set of screw holes can be used to mount the blower as long as…– The same hole position is used for each
mounting arm– Do not use a left-side hole for one mounting
leg then a right side hole for another mounting leg.• This stresses the mounting arms and can
cause them to break
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Propane Conversion
• Regulator spring change required for all models• Low Gas Pressure Switch (LGPS) required for
ALL models• Burners will use “Mixing Screws”
– 1 screw is installed in each burner venturi– Provide better mixing of propane and combustion air– Includes drill bit to drill the correct size hole
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Converting The Gas Valve
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Spoiler Screw
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LGPS Installation– 14 3/16” casing– Or, vent passes across
vestibule– Install switch as shown
• Manifold removed• Add wires to switch• Install manifold
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Low Gas Pressure Switch Installation
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Low Gas Pressure Switch InstallationOptional Location
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Setup and Service
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Single-stage PSC
24vac Thermostat Connections
R, W, Y, G Inducer Pre/Post Purge 15 Sec/5 Sec
Heat On Delay 25 Sec EAC Yes
Heat Off Delay 90, 120, 150, 180 Hum 24 vac Q.C.
Cool On Delay 3 Sec Hum Method When Pressure Switch Closes
Cool Off Delay 90 Sec Blower Speeds Up to 4 speed taps at motor, 2 are controlled
Optional Cool Off Delay Cut J1 Jumper (non reversible)
Heat Airflow Selectable Heat
Component Self Test Yes Cool Airflow Selectable High Cool Only
Non-Volatile Memory Yes Continuous Fan Same as Heat
Control Board Features
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Single-Stage PSC ControlComponent Layout
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Optional 3-Second Cooling Off Delay
CUT J2 JUMPER TO REDUCE
90 SECOND COOLING OFF-DELAY TO 3 SECONDS
(NON-REVERSIBLE)
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Single-Stage PSC ControlFan Speed Selection
SELECT HEATING AND COOLING SPEEDS REQUIRED
CONTINUOUS FAN SPEED IS HEATING SPEED
STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS
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Heating Off DelaySingle-Stage Control
2 PIN JUMPER: 1 TO 2 90 SECONDS 2 TO 3 120 SECONDS
3 TO 4 150 SECONDS 4 TO 5 180 SECONDS
90
150
120
180
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Single-Stage ControlComponent Self Test
To initiate the component last sequence, shut OFF the room thermostat or disconnect the “R” thermostat lead. Briefly short the TEST/TWIN terminal to the COM/24V terminal (Red Arrow)Once initiated the Status LED will flash the last Status Code and then turn ON the inducerThe inducer motor will run for the entire component test. The hot surface igniter, blower motor FAN speed (if equipped), blower motor Heat speed and blower motor COOL speed will be turned ON for 15 seconds each. Gas Valve and Humidifier will not be turned on.
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Status CodesCode Description
Heartbeat NO PREVIOUS CODE • Stored status codes are erased automatically after 72 hours or as specified above.
2 PRESSURE SWITCH DID NOT OPEN. Check for: Obstructed pressure switch tubing, Pressure switch stuck closed.
3 PRESSURE SWITCH DID NOT CLOSE OR RE-OPENED. Check for: If LPS is open longer than 6 minutes, inducer shuts off for 18 minutes before re-try. If HPS remains open for 72 seconds after the gas valve closes (after 3 successive trials) the furnace control will lockout for 3 ½ hours before re-try
4 LIMIT CIRCUIT FAULT. Indicates a limit or flame rollout switch is open. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #7. If open less than 3 1/2 minutes status code #4 continues to flash until blower shuts off. Flame rollout switch requires manual reset. Check for: Dirty filter or restricted duct system-Improper limit switch or no limit gasket. Defective switch or connections- Improper gas input adjustment- Loose blower wheel
5 ABNORMAL FLAME PROVING SIGNAL, Flame is proved while gas valve is de-energized. Inducer will run until fault is cleared. Check for: Leaky gas valve; Stuck-open gas valve; Dirty flame sensor insulator
6 IGNITION PROVING FAULT -Control will try three more times before lockout #14 occurs. If flame signal lost during blower time limits. Thirty seconds after being turned ON or ten seconds during steady-state operation. Check for:- Oxide buildup on flame sensor (clean with fine steel wool) - Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal) Manual valve shut-off- Control ground continuity- Gas valve defective fumed 'OFF'- Low inlet gas pressure-Defective hot surface igniter-Flame sensor must not be grounded-Green/yellow wire MUST be connected to furnace sheet metal.
110
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Code Description
7 LIMIT CIRCUIT LOCKOUT. Lockout occurs If a limit or flame rollout switch is open longer than 3 ½ minutes. Control will auto-reset in 3 hrs. Refer to Code 4.
8 GAS HEATING LOCKOUT • Control will NOT auto reset. Check for - Mis-wired gas valve -Defective control (valve relay)
9 POLARITY Line voltage (220 VAC) polarity reversed.
1 + 2 BLOWER ON AFTER POWER UP (115VAC or 24VAC)- Blower runs for 90 seconds, if unit is powered up during a call for heat (R to W/W1 closed) or (R to W/W1) opens during the blower on delay period.
6 + 1 IGNITION LOCKOUT Control will auto reset in 3 ½ hours. Refer to Code 6
OFF SECONDARY VOLTAGE FUSE IS OPEN • Check for - Short circuit in secondary voltage (24VAC) wiring.
On (solid) CONTROL CIRCUITRY LOCKOUT Auto reset after 72 minutes. Lockout due to: Gas Valve relay stuck open. Flame sense circuitry failure. Software check error. Reset power to clear lockout. Replace control if status code repeats.
Status Codes
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Sequence Of Operation
• NOTE: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw. Using the schematic diagram in Fig. 64, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.
• NOTE: If a power interruption occurs during a call for heat (W), the control will start a 108–sec blower–only ON period two sec after power is restored, if the thermostat is still calling for gas heating. The Green LED light will flash Code 1+2 during the 108–sec period, after which the LED will be flashing a heartbeat, as long as no faults are detected. After the 108–sec period, the furnace will respond to the thermostat normally.
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ThermostatThermostat
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ThermostatThermostat
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ThermostatThermostat
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ThermostatThermostat
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Start-up
• Refer to the installation instructions for specific start-up details
• Start-up procedures are:– Verify installation is complete– Verify the correct orifices are installed– Prime the condensate trap– Purge the gas supply line– Check the inlet gas pressure
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Start-up Continued
• Start-up procedures (continued) are:– Adjust the manifold pressure– Set the temperature rise– Set the blower off delay– Set the cooling airflow– Check safety control operation– Review installation checklist
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Priming The Condensate Trap1. Remove upper and middle collector box drain plugs oppositeof the condensate trap.2. Connect field-supplied 5/8--in. (16 mm) ID tube with attached funnel to upper collector box drain connection.3. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap,and flow into open field drain.4. Remove funnel; replace collector box drain plug.5. Connect field-supplied 5/8-in. (16 mm) ID tube to middle collector box drain port.6. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap,and flow into open field drain.7. Remove funnel and tube from collector box and replace collectorbox drain plug.
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Start-up Continued• Start-up procedures are:
– Check the inlet gas pressure• Use a good quality fluid-filled manometer to measure
the inlet pressure at the gas valve• Set the furnace to call for heat
– Verify inlet gas pressure does not drop below minimum inlet pressure
» 4.5 IWC for Natural Gas» 12.0 for Propane
– Adjust the manifold pressure• Manifold/orifice tables are provided• Use a good quality fluid-filled manometer to measure
the manifold pressure at the gas valve– Adjust manifold pressure at the regulator of the gas valve
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Single-Stage Gas Valve - Features
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Start-up Continued• Start-up procedures (cont.) are:
– Set the temperature rise• Temperature rise shown on the unit rating plate• Run the furnace at steady state• Measure the temperature in the supply air and the return air
– Measure supply temperature away from the line of sight of the heat exchanger
• Subtract the return air temperature from the supply air temperature
• Change blower speed to increase or decrease the temperature rise
• Change blower speed at the heating relay on the furnace control board
– Ideal point is at the mid-point of the rise or slightly above the midpoint.
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Start-up Continued
• Start-up procedures (cont.) are:– Set the blower off delay
• Move the jumper on the control board to the desired off delay time
– Set the cooling airflow• Blower airflow tables are in the installation
instructions.– Typical cooling speed is high speed
• Change motor speeds at the cooling relay on the furnace control board
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Single-Stage PSC ControlComponent Layout
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Single-Stage PSC ControlFan Speed Selection
SELECT HEATING AND COOLING SPEEDS REQUIRED
CONTINUOUS FAN SPEED IS HEATING SPEED
STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS
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Heating Off DelaySingle-Stage Control
2 PIN JUMPER: 1 TO 2 90 SECONDS 2 TO 3 120 SECONDS
3 TO 4 150 SECONDS 4 TO 5 180 SECONDS
90
150
120
180
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Start-up Continued
• Start-up procedures (cont.) are:– Check safety control operation
• Pressure switch operation• Limit switch operation• Flame sensing circuit
– Review installation checklist