Condensing Furnace
Distributor
Technical Training
1
ICP Confidential
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Model Nomenclature System
2
ICP Confidential
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Model Nomenclature System
3
ICP Confidential
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Agenda
Product Line Overview
New Features
Installation
Adjustment
Servicing
4
ICP Confidential
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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
5
ICP Confidential
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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
6
ICP Confidential
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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
7
ICP Confidential
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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
8
ICP Confidential
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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
9
ICP Confidential
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Casing
10
ICP Confidential
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Casing
11
ICP Confidential
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Casing
12
ICP Confidential
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Casing
Combustion Air Opening
Combustion Air Opening
Gas Entry
Gas Entry
Horizontal Drain
Trap Opening
Vent or Combustion Air
Opening
Vent or Combustion Air
Opening
Condensate Drain K.O.
J Box K.O.
Return Air Opening
35”
Horizontal Drain
Trap Opening
Condensate Drain K.O.
J Box K.O.
Return Air Opening
13
ICP Confidential
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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
14
ICP Confidential
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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
15
ICP Confidential
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Upflow Return Air Connections
16
ICP Confidential
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Downflow Return Air Connections
17
ICP Confidential
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Horizontal Return Air Connections
18
ICP Confidential
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Upflow Venting
19
ICP Confidential
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100,000 BTUH & 120,000 BTUH
Downflow Venting
20
ICP Confidential
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Horizontal Left Venting
21
ICP Confidential
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Horizontal Right Venting
22
ICP Confidential
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Terminations
• 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
23
ICP Confidential
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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.
24
ICP Confidential
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Indoor Air For Combustion Option
• Use a (minimum) 12-inch
piece of PVC
– Maximum of 5 feet
• Tight radius elbow
12” (min)
– Face away for better sound
control
• Secure pipe to adapter
– Pilot drill 1/8” hole
– Install sheet metal screw
– Seal with silicone
25
ICP Confidential
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Alternate Indoor Air For Combustion
Connection
12” (min)
12” (min)
26
ICP Confidential
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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
27
ICP Confidential
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Supply Air Flanges
28
ICP Confidential
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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
29
ICP Confidential
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Return Air Connections
30
ICP Confidential
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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
31
ICP Confidential
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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
Use backup wrench
on gas valve!
– (Required For Direct Vent)
• Install gas line into elbow
• Tighten gas line
32
ICP Confidential
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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
33
ICP Confidential
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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 knockouts are available
34
ICP Confidential
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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 diagram
7. Install cover to J--Box. Do not pinch wires between cover and bracket.
35
ICP Confidential
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Upflow
36
ICP Confidential
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Downflow - Trap Unconverted
PSC Inducer Models
37
ICP Confidential
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Downflow - Trap Converted
PSC Inducer Models
Route tube through
Switch Tube to Port
On Collector Box
To 15 ib-in
38
ICP Confidential
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Horizontal Left - Trap Unconverted
PSC Inducer Models
39
ICP Confidential
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Horizontal Left - Trap Converted
PSC Inducer Models
Route Pressure Switch
40
ICP Confidential
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Horizontal Right - Trap Unconverted
PSC Inducer Models
41
ICP Confidential
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Horizontal Right - Trap Converted
PSC Inducer Models
42
ICP Confidential
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Horizontal Trap Grommet
• Required accessory for Direct Vent applications (only)
• Maintains a sealed vestibule
43
ICP Confidential
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Repositioning Vent Elbow
•
•
•
•
ICP Confidential
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Loosen the Vent Elbow Clamp.
Remove the Vent Elbow.
Re-install in the desired position.
Torque clamp 15 lb-in.
44
Condensate Trap and Drain Elbow
• Clear trap
– Shown for clarity
• Production Trap
– White, Opaque front/Clear back
ICP Confidential
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45
Condensate Trap
Mounting Screw Hole
Expanded View
ICP Confidential
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Outlet Relief Port
Front View
Inlets
Back View
46
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
47
ICP Confidential
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Right Side Drain
48
ICP Confidential
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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
49
ICP Confidential
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Left Side Drain
50
ICP Confidential
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Left Side Drain
51
ICP Confidential
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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
52
ICP Confidential
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Maximum Equivalent Length Table
53
ICP Confidential
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Deductions Table and Example
54
ICP Confidential
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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.
55
ICP Confidential
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Sizing The Vent Pipe
56
ICP Confidential
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Sizing The Vent Pipe
57
ICP Confidential
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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
58
ICP Confidential
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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
59
ICP Confidential
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Comparing the Two Adapters
(Both fit 2” PVC pipe)
2”
2 3/8”
Internal pipe stop
No pipe stop
Combustion Air
Pipe Adapter
Vent Pipe
Support
60
ICP Confidential
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Vent Coupling & Adapter
• Coupling is notched
• Provides for proper
orientation of
coupling
• Notches slide over
buttresses on
adapter
61
ICP Confidential
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Vent Pipe Coupling &
Combustion Air Pipe Adapter
Gaskets
62
ICP Confidential
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Continuous Vent Pipe
Vent pipe
Inserts through coupling to
vent elbow
Vent coupling w/clamps
Slides over adapter
Vent coupling adapter
Attaches to furnace casing
Vent pipe
Passes through adapter
Inserts into Vent Elbow
360° Vent Elbow
Connects to vent pipe
ICP Confidential
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63
Flush Mount Vent Pipe
Vent pipe
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
Inserts ½ way into coupling
360° Vent coupling
Vent pipe connects to coupling
64
ICP Confidential
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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
65
ICP Confidential
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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!
66
ICP Confidential
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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.
67
ICP Confidential
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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.
68
ICP Confidential
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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.
ICP Confidential
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69
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
ICP Confidential
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70
Single-Stage and Two-Stage
PSC Inducer Assembly
360°Inducer outlet coupling
PSC inducer motor
Capacitor
71
ICP Confidential
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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
72
ICP Confidential
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Key Features Inducer Assembly
Drain outlets with gaskets
Mounting tabs
Inlet gasket
Flue gas inlet
ICP Confidential
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73
PSC Inducer Inlet Choke
Factory Installed
Inlet Choke Plate
(when used)
74
ICP Confidential
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Integrated Inducer Vent/Drain
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.
ICP Confidential
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75
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.
76
ICP Confidential
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Collector Box-Front View
Condensate trap openings for
downflow and horizontal left
Inducer drain
openings
Pressure
Switch/Relief
port
Condensate trap
gasket
Inducer attachment
points w/brass inserts
(red circles)
Condensate
trap gasket
Pressure
Switch/Relief
port
Outlet to inducer
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Condensate trap openings for
upflow and horizontal right
77
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
ICP Confidential
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Single Stage Pressure Switches
ICP Confidential
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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.)
ICP Confidential
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Single Stage Pressure Switches
ICP Confidential
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Pressure Switch Settings
Single Stage Pressure Switches
Collector Box Pressure Switch
Input
Housing Pressure Switch
Part Number
Max Make-IWC
Nom Break-IWC
Max Make-IWC
Nom Break-IWC
100
&
120
HK06NB030
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
ICP Confidential
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Heat Exchanger Assembly
Front View
83
ICP Confidential
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Heat Exchanger Assembly
Rear View
84
ICP Confidential
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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
85
ICP Confidential
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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
86
ICP Confidential
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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
87
ICP Confidential
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Manifold Assembly Features
(Top plate removed for clarity)
Four screws attach manifold here
Manifold is the same type for all families
ICP Confidential
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88
Burner Assembly
ICP Confidential
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Igniter resistance is 40 to 70 ohms @
room temperature and is stable over
the life of the igniter
89
Burner Assembly
90
ICP Confidential
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Single-Stage Gas Valve - Features
91
ICP Confidential
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Blower Assemblies
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
92
ICP Confidential
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Torsion-Flex Blower Motors
• Mounting arms attached to motor
• Isolated with rubber grommets
93
ICP Confidential
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Typical Blower Assembly (Expanded)
94
ICP Confidential
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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.
95
ICP Confidential
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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
96
ICP Confidential
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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
97
ICP Confidential
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Converting The Gas Valve
98
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Spoiler Screw
99
ICP Confidential
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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
100
ICP Confidential
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Low Gas Pressure Switch Installation
101
ICP Confidential
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Low Gas Pressure Switch Installation
Optional Location
102
ICP Confidential
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Setup and Service
103
ICP Confidential
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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
Yes
Cool Airflow
Selectable High Cool Only
Non-Volatile Memory
Yes
Continuous Fan
Same as Heat
104
ICP Confidential
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Single-Stage PSC Control
Component Layout
105
ICP Confidential
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Optional 3-Second Cooling Off Delay
CUT J2 JUMPER TO REDUCE
90 SECOND COOLING OFFDELAY TO 3 SECONDS
(NON-REVERSIBLE)
106
ICP Confidential
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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
107
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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
108
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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.
109
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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 continuityGas 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.
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110
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.
111
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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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Thermostat
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Thermostat
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Thermostat
Thermostat
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Thermostat
DRAFT
COPY
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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 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,
and flow into open field drain.
7. Remove funnel and tube from collector box
and replace collector
box 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 Control
Component Layout
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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
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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
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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
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