Distributor Technical Training Condensing Furnace Distributor Technical Training

Model Nomenclature System

Model Nomenclature System

Agenda Product Line Overview New Features Installation Adjustment Servicing

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

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

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

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 Up to 97 AFUE. Eliminates “gurgle” in downflow Eliminates hiding places for process oils

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

Casing This is a typical dimensional drawing. Note the intake and vent pipe knock-outs on the top plate of the casing. Not all families will have a 40,000 btuh model and not all 60,000 and 80,000 models will be in a 17 ½” wide casing. Refer to the product data for specific casing details.

Casing This is a typical dimensional drawing. Note the intake and vent pipe knock-outs on the top plate of the casing. Refer to the product data for specific casing details.

Casing This is a typical dimensional drawing. Note the intake and vent pipe knock-outs on the top plate of the casing. Refer to the product data for specific casing details.

Casing 35” 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 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

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

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

Upflow Return Air Connections In the upflow position, any combination of return air connections may be used. Each connection at the furnace must have a field supplied filter and filter rack installed at external to furnace unless filters are located in the return grills. There are no provisions for an internal filter rack.

Downflow Return Air Connections In the downflow position, only connect return air to the factory opening in the casing. Do not use the sides of the casing as a return air connection! Erratic limit switch operation may result. A field supplied filter and filter rack must be installed at the furnace or in the return grills of the duct system. There are no provisions for

Horizontal Return Air Connections In the horizontal position, only connect return air to the factory opening in the casing, or in the side of the casing facing down. Do not use the top side of the casing as a return air connection! Erratic limit switch operation may result. A field supplied filter and filter rack must be installed at each return connection or in the return grills of the duct system. an internal filter rack. Horizontal right installations are similar.

Upflow Venting

100,000 BTUH & 120,000 BTUH Downflow Venting

Horizontal Left Venting

Horizontal Right Venting

Terminations Direct Vent Ventilated Combustion Air Single Pipe 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

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.

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)

Alternate Indoor Air For Combustion Connection 12” (min) 12” (min)

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

Supply Air Flanges

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 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 The furnace sides are the return air openings at the blower compartment as you view the furnace. The bottom of the furnace is where the closure pan is installed when viewed in the upflow position. The return air can never be connected to the back of the furnace. Never connect any ductwork or accessories to the heat exchanger compartment of the furnace.

Return Air Connections In the horizontal position, only the side facing down can be used as a return air connection.

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

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!

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

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

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. Remove 7/8” K.O. in casing. Attach J box bracket to casing. 3. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing. 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 diagram 7. Install cover to J--Box. Do not pinch wires between cover and bracket. If a field-supplied disconnect is provided at the furnace casing, the J box is not required provided: The disconnect is grounded to the green ground lead and the furnace casing.

Upflow This is how the inducer assembly looks in the upflow position. To install the furnace in the downflow or horizontal orientation, it will be necessary to relocate the condensate trap, the condensate trap relief tube and pressure switch tube.

Downflow - Trap Unconverted PSC Inducer Models The installation instructions will show you how the furnace looks in the unconverted and converted orientations. Each step is numbered in the drawings to aid you in the conversion. The first drawing will be in the installed unconverted orientation and the second drawing will show you how it should look in the properly converted orientation. The 140 size furnace cannot be installed in the downflow orientation.

Downflow - Trap Converted PSC Inducer Models Route tube through Switch Tube to Port On Collector Box After you remove the components in the unconverted drawing, use the numbered steps in the converted drawing to re-install the components for the required orientation. The 140 size furnace cannot be installed in the downflow orientation. To 15 ib-in

Horizontal Left - Trap Unconverted PSC Inducer Models Horizontal left is when you view the furnace from the front and the air discharges to your left

Horizontal Left - Trap Converted PSC Inducer Models Route Pressure Switch Remember to follow all the steps and install the plug you removed in the remaining open port of the collector box.

Horizontal Right - Trap Unconverted PSC Inducer Models Horizontal right is when you view the furnace from the front and the air discharges to your right

Horizontal Right - Trap Converted PSC Inducer Models Remember to follow all the steps and install the plug you removed in the remaining open port of the collector box.

Horizontal Trap Grommet An accessory rubber grommet is available to seal the condensate trap to the casing in horizontal installation. This grommet is only required when direct venting (sealed combustion) is required Required accessory for Direct Vent applications (only) Maintains a sealed vestibule

Repositioning Vent Elbow The vent elbow provides venting flexibility by rotating 360 degrees to allow the vent to exit the casing through the sides or through the blower compartment when the accessory internal vent kit is used. Do not run the vent and combustion air pipes through the blower compartment without using the accessory internal vent kit. The internal vent kit seals the blower compartment from the vestibule of the furnace. If the kit is not used, products of combustion may be drawing into the blower compartment and circulated through the airstream into the living space. Loosen the Vent Elbow Clamp. Remove the Vent Elbow. Re-install in the desired position. Torque clamp 15 lb-in.

Condensate Trap and Drain Elbow Clear trap Shown for clarity Production Trap White, Opaque front/Clear back The trap is clear in the back to allow service technicians to verify the trap is clean after flushing it out. Cleaning the trap is recommended as part of a regular maintenance program. The gasket between the trap and collector box should be replace if the trap is removed for service. The rubber drain elbow and clamp is shipped in the loose parts bag and is used to complete the condensate drain to the furnace casing.

Condensate Trap Mounting Screw Hole Expanded View Outlet Relief Port Inlets Front View Back View Mounting Screw Hole There are 2 sets of drain openings in the rear of the trap. One is for the inducer assembly and the other is for the collector box. The trap cannot be disassembled and is only shown as a reference. The relief port acts as a “vent” and is connected to the opposite corner of the collector box.

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

Right Side Drain This is the image shown in the installation instructions. Connect the field supplied CPVC pipe to the outlet of the drain elbow. If PVC drain is used, a CPVC to PVC adapter is shipped in the loose parts bag. Remember to clamp the drain pipe to the drain elbow to prevent condensate leaks.

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

Left Side Drain This is how the left side drain looks without any components in front or behind it. Note is this example, the ½” CPVC to ¾” adapter is attached to the formed end

Left Side Drain

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

Maximum Equivalent Length Table The vent and intake air pipe maximum lengths decrease as the installation altitude increases. The vent tables go up to 10,000 ft. (3048m)

Deductions Table and Example Different types of elbow have different equivalent lengths. These lengths are subtracted from the maximum allowable length of vent or combustion air pipe. The two terminations shown have 0 losses and are figured into the maximum vent lengths.

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.

Sizing The Vent Pipe Follow the example above to size the vent and combustion air pipe. This example is for a complete rigid PVC vent system.

Sizing The Vent Pipe DRAFT COPY - ICP CONFIDENTIAL Follow the example above to size the vent and combustion air pipe. This example is for a polypropylene vent system that uses a flexible section of vent material. DRAFT COPY - ICP CONFIDENTIAL

Vent Pipe Support Helps support vent pipe Notches in coupling slide over buttresses on adapter Adds to unit serviceability Provides an optional disconnect point

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

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

Vent Coupling & Adapter Coupling is notched Provides for proper orientation of coupling Notches slide over buttresses on adapter

Vent Pipe Coupling & Combustion Air Pipe Adapter Gaskets

Continuous Vent Pipe Vent pipe Vent coupling w/clamps Inserts through coupling to vent elbow Vent coupling w/clamps Slides over adapter Vent coupling adapter Attaches to furnace casing Passes through adapter Inserts into Vent Elbow 360° Vent Elbow Connects to vent pipe

Flush Mount Vent Pipe Vent pipe Vent coupling w/clamps Inserts ½ way into coupling Vent coupling w/clamps Slides over adapter Vent coupling adapter Attaches to furnace casing Vent pipe from inducer Passes through adapter 360° Vent coupling Vent pipe connects to coupling In this arrangement, the vent pipe from the inducer is a separate pipe from the rest of the vent system. The pipes are “split” in the middle of the vent coupling. The vent pipe from the inducer must be cemented or sealed to the vent pipe adapter. The advantage to this arrangement is if the furnace needs major service, the vent can be disconnected without cutting the vent pipe. The pipe from the inducer can then be removed by removing the adapter from the furnace casing.

Flush Mount Vent Pipe 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 This method is used to make a removable connection at the top plate of the furnace.

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!

Optional Flush Mount Vent Pipe 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 Insert remaining vent pipe into coupling Torque clamp on coupling 15 lb-in. Torque clamp on vent elbow 15 lb-in.

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.

Combustion Air Pipe (Non-Direct Vent) 12” 12” 12” 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

Single-Stage and Two-Stage PSC Inducer Assembly 360°Inducer outlet coupling PSC inducer motor Capacitor

Single- and Two-Stage Inducer 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

Key Features Inducer Assembly Drain outlets with gaskets Mounting tabs Inlet gasket Flue gas inlet

PSC Inducer Inlet Choke Factory Installed Inlet Choke Plate (when used)

Integrated Inducer Vent/Drain Flue gases exit through the inner opening Each type of inducer has a set of concentric outlets behind the inducer elbow. The outlet on the outside allows any condensate from the vent pipe to pass back through the inducer housing and out one of the 2 drain openings in the back of the inducer. The inner outlet is for flue gases to exit into the non-metallic vent pipe. The larger opening channels condensate from the vent through the inducer and out the drain openings in the back of the inducer.

Vent Condensate Drainage Flue 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. DRAFT COPY - ICP CONFIDENTIAL

Collector Box-Front View Inducer drain openings Inducer attachment points w/brass inserts (red circles) 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 The inducer assembly attaches to the collector box at 5 points. A brass insert is molded into the collector box to prevent stripped or broken mounting point. There are 2 sets of 3 condensate trap openings. Each orientation will use 2 opening for drainage to the trap. The remaining opening will be plugged, as will the other set of 3 openings on the opposite corner of the collector box.

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

Single Stage Pressure Switches Note the label shows where the reference tube for the switch is connected to, either “COLLECTOR BOX-LPS” or “HOUSING-HPS”. The nominal break point is shown on each switch. There are different switches for different input furnaces. Use the exact replacement switch for the model furnace you are working on. The switches shown are for reference only

Single Stage Wiring Diagram Refer to the legend HPS Inducer Housing Pressure Switch, SPST (N.O.) LPS Collector Box Pressure Switch, SPST (N.O.)

Single Stage Pressure Switches The switches are wired in parallel.

Pressure Switch Settings Single Stage Pressure Switches Input Part Number Collector Box Pressure Switch Housing Pressure Switch Max Make-IWC Nom Break-IWC 100 & 120 HK06NB030  0.45 0.30 +/- 0.05 0.45 140 HK06NB031 0.60 0.45 +/- 0.05

Heat Exchanger Assembly Front View Primary cell panel is not shown in this image. This is the primary and secondary heat exchanger assembly.

Heat Exchanger Assembly Rear View This is the rear view. Note how the flue gas flows from the inlet of the primary through the primary and secondary heat exchangers. DRAFT COPY - ICP CONFIDENTIAL

Primary Assembly Completely redesigned heat exchanger The insulated primary cell panel is a one piece design that attaches to primary cell inlet plate. The snap-disk type limit switch attaches to an opening in the primary cell panel. Completely redesigned heat exchanger Compact multi-pass design Aluminized Service replacement sold fully assembled to the Primary Cell Inlet Plate

Condensing Heat Exchanger Fin and tube type design Stainless steel tubes Aluminum fins Tubes are straight through Turbulators are “locked” in each tube

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

Manifold Assembly Features (Top plate removed for clarity) Four screws attach manifold here Manifold is the same type for all families

Burner Assembly Igniter resistance is 40 to 70 ohms @ room temperature and is stable over the life of the igniter

Burner Assembly

Single-Stage Gas Valve - Features

Blower Assemblies Improved blower rails Forward-facing mounting screws Mounting Screw Locations Improved blower rails Forward-facing mounting screws Longer main harness (not shown) Blower can be removed without harness removal Forward-facing control board

Torsion-Flex Blower Motors The torsion flex PSC motor is used in these models Mounting arms attached to motor Isolated with rubber grommets

Typical Blower Assembly (Expanded) This is the expanded view of the blower assembly. The blower wheel set screw torque is 160 in-lbs, +/- 20 in.-lbs

Motor Mounting Holes 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.

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

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 A factory accessory conversion kit is required for installations using propane gas. Along with a regulator spring change in the gas valve, all propane installations require Mixing Screws in each burner venturi and a low gas pressure switch. Instructions are included in the conversion kit.

Converting The Gas Valve The furnace is shipped with the gas valve configured for Natural Gas. In the propane conversion kit, there is a propane regulator spring. This spring allows the regulator in the valve to operate at the required pressure for propane. Note that the natural gas spring is silver and the propane spring is white. The approximate number of turns to pre-set the regulator spring are shown. Final adjustment must be made when starting the furnace.

Spoiler Screw

LGPS Installation 14 3/16” casing Or, vent passes across vestibule Install switch as shown Manifold removed Add wires to switch Install manifold A low gas pressure switch is used on the inlet pressure tap. The switch will shut down the furnace if the pressure in the propane tank falls below 7.2 in.-w.c.

Low Gas Pressure Switch Installation The switch installation is covered in the propane conversion instructions.

Low Gas Pressure Switch Installation Optional Location Additional fitting are supplied in the kit if more room is needed to install the switch.

Setup and Service

Control Board Features 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 Cool Airflow Selectable High Cool Only Non-Volatile Memory Continuous Fan Same as Heat

Single-Stage PSC Control Component Layout All thermostat and accessory connections are made at the control board of the furnace.

Optional 3-Second Cooling Off Delay CUT J2 JUMPER TO REDUCE 90 SECOND COOLING OFF-DELAY TO 3 SECONDS (NON-REVERSIBLE)

Single-Stage PSC Control Fan Speed Selection SELECT HEATING AND COOLING SPEEDS REQUIRED CONTINUOUS FAN SPEED IS HEATING SPEED STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS

Heating Off Delay Single-Stage Control 90 120 150 180 2 PIN JUMPER: 1 TO 2 90 SECONDS 2 TO 3 120 SECONDS 3 TO 4 150 SECONDS 4 TO 5 180 SECONDS

Single-Stage Control Component 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 inducer The 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.

Status Codes Code 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.

Status Codes 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.

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.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot–surface igniter HSI, and gas valve GV.

Thermostat Thermostat The wall thermostat “calls for heat,” closing the R–to–W circuit. The furnace control performs a self–check, verifies the pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM.

Thermostat Thermostat Inducer Prepurge Period– As the inducer motor IDM comes up to speed, the HUM terminal is energized at 220v, and the low pressure switch contacts LPS close to begin an 18 second prepurge period, and 24 vac is supplied for a field installed humidifier at the HUM 24 vac terminal. The high pressure switch contacts HPS are ignored until one minute after the gas valve is energized.

Thermostat Thermostat Igniter Warm–Up– At the end of the prepurge period, the Hot–Surface igniter HSI is energized for a 20–sec igniter warm–up period. Trial–for–Ignition Sequence– When the igniter warm–up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners where it is ignited by the HSI. Five sec after the GVR closes, a 2–sec flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2–sec flame proving period begins. Flame–Proving– When the burner flame is proved at the flame–proving sensor electrode FSE, the furnace control CPU begins the blower–ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two sec, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials–For–Ignition before going to Ignition–Lockout. Lockout will be reset automatically after 3–1/2 hours or by momentarily interrupting 220 vac power to the furnace, or by interrupting 24 vac power at 24VAC or COM to the furnace control CPU (not at W, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas–Heating mode and operate the inducer motor IDM until flame is no longer proved.

DRAFT COPY - ICP CONFIDENTIAL Thermostat Thermostat Blower–On Delay– If the burner flame is proven, the blower motor is energized on HEAT speed 30 sec after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC is energized and remains energized as long as the blower motor BLWM is energized. DRAFT COPY - ICP CONFIDENTIAL

DRAFT COPY - ICP CONFIDENTIAL Heat–Off Delay– When the thermostat is satisfied, the R–to–W circuit is opened, de–energizing the gas valve GV, stopping gas flow to the burners, and de–energizing the humidifier terminal HUM24 VAC. The inducer motor IDM, and HUM terminal will remain energized for an 18–sec post–purge period. The blower motor BLWM and air cleaner terminal EAC will remain energized for 108, 144, 180, or 216 sec (depending on the heat–OFF delay selection). Note board selections are shown as 90, 120, 150, 180. The furnace control CPU is factory–set for a 144–sec heat–OFF delay. DRAFT COPY - ICP CONFIDENTIAL

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

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

Priming The Condensate Trap 1. Remove upper and middle collector box drain plugs opposite of 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, 7. Remove funnel and tube from collector box and replace collector box drain plug.

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

Single-Stage Gas Valve - Features

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.

Start-up procedures (cont.) are: 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

Single-Stage PSC Control Component Layout All thermostat and accessory connections are made at the control board of the furnace.

Single-Stage PSC Control Fan Speed Selection SELECT HEATING AND COOLING SPEEDS REQUIRED CONTINUOUS FAN SPEED IS HEATING SPEED STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS

Heating Off Delay Single-Stage Control 90 120 150 180 2 PIN JUMPER: 1 TO 2 90 SECONDS 2 TO 3 120 SECONDS 3 TO 4 150 SECONDS 4 TO 5 180 SECONDS

Start-up Continued Start-up procedures (cont.) are: Check safety control operation Pressure switch operation Limit switch operation Flame sensing circuit Review installation checklist The safety controls are checked in the traditional manner, such as blocking the vent outlet to verify the pressure switch opens and shuts the furnace down. The limit is checked by slowly restricting the return air to the furnace until the limit switch opens. The flame sensor can be checked by removing the wire from the flame sensor, then setting the furnace to call for heat. After completing the installation and start up, review the installation instructions to verify the installation is complete.