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Carrier 120 Series User Manual

Carrier 120 Series
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1
59MN7A
Modulating 4---Way Multipoise
Condensing Gas Furnace
Series 120
Installation, Start---up, Operating and
Se rvice and Mainte nance Ins t ructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS 3.........................
INTRODUCTION 4...................................
CODES AND STANDARDS 4...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 5...
ACCESSORIES 5.....................................
LOCATION 5........................................
AIR FOR COMBUSTION AND VENTILATION 10.........
CONDENSATE TRAP 12...............................
Upflow 12........................................
Downflow 12.....................................
Horizontal 12......................................
CONDENSATE DRAIN 16.............................
INSTALLATION 19...................................
Upflow 19........................................
Downflow 20.....................................
Horizontal 20......................................
Filter Arrangement 21...............................
AIR DUCTS 29.......................................
Ductwork Acoustical Treatment 29.....................
GAS PIPING 33......................................
ELECTRICAL CONNECTIONS 34.......................
115-- V Wiring 34...................................
J--Box Installation 35................................
24--V Wiring 35....................................
Accessories 36.....................................
Alternate Power Supplies 36..........................
VENTING 41........................................
Special Venting Requirements for Installations in Canada 41.
Materials 42.......................................
Venting Systems 42.................................
Locating Vent Termination 43.........................
Size the Vent and Combustion Air Pipes 44...............
Combustion Air and Vent Piping Insulation Guidelines 45...
Configure the Furnace 45............................
Installing the Vent Termination 47......................
Venting System Length Calculations 51.................
START--UP, ADJUSTMENT, AND SAFETY CHECK 63......
Select Setup Switch Positions 63........................
Prime Condensate Trap 64.............................
Purge Gas Lines 64...................................
Adjustments 64......................................
Check Safety Controls 68..............................
Checklist 68........................................
SERVICE AND MAINTENANCE PROCEDURES 78........
Cleaning Heat Exchangers 83...........................
SEQUENCE OF OPERATION 90........................
PARTS REPLACEMENT GUIDE 95......................
TABLE
Loose Parts Bag Contents 7..............................
Minimum Clearances to Combustible Materials 7.............
Minimum Free Area Required 11.........................
Minimum S pace Volumes 11.............................
Filter Size Information 23...............................
Opening Dimensions 25................................
Air Delivery CFM 30...................................
Maximum Capacity of Pipe 34...........................
Electrical Data 36......................................
Vent Termination Kit for Direct Vent (2--Pipe) Systems 43......
Combustion--Air Vent Pipe, Fitting & Cement Material.. 48.....
Maximum Allowable Exposed Vent Lengths Insulation 49......
Maximum Equivalent Vent Length 50......................
Deductions from Maximum Equivalent Vent Length 50........
Altitude Derate Multiplier for U.S.A. 73....................
Blower Off Delay Setup Switch 73........................
Gas Rate 73..........................................
Orifice Size and Manifold Pressure 76.....................
CERTIFIED
Use of the AHRI Certified
TM
Mark indicates a
manufacturers participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-- 2012E, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the complete
and official position of the NFPA or ANSI on the referenced
subject, which is represented only by the standard in its entirety.

Table of Contents

Other manuals for Carrier 120 Series

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Carrier 120 Series Specifications

General IconGeneral
StagesSingle-Stage
Ignition TypeHot Surface Ignition
Heat Exchanger MaterialAluminized Steel
Fuel TypeGas
Efficiency80% AFUE
Heating Capacity40, 000 to 130, 000 BTU/h
Blower Motor TypePSC
Vent TypeNatural Draft

Summary

Required Notice for Massachusetts Installations

SAFETY CONSIDERATIONS

WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Details hazards like carbon monoxide poisoning, explosion, fire, and electrical shock.

WARNING FIRE HAZARD

Warns about fire hazards from combustible materials and vapors.

CAUTION FURNACE RELIABILITY HAZARD

Discusses potential damage to unit components from improper installation or service.

CAUTION CUT HAZARD

Warns about sharp edges and burrs on sheet metal parts during handling.

INTRODUCTION

CODES AND STANDARDS

Safety

Lists safety standards like NFGC, NFPA 54, ANSI Z223.1, and CSA standards.

General Installation

Details codes for general installation practices in the US and Canada.

Combustion and Ventilation Air

Refers to codes for air for combustion and ventilation requirements.

Duct Systems

Lists standards for duct system design and installation.

Acoustical Lining and Fibrous Glass Duct

Refers to standards for acoustical lining and fibrous glass ducts.

Gas Piping and Gas Pipe Pressure Testing

Outlines codes for gas piping installation and pressure testing.

Electrical Connections

Refers to electrical codes such as NEC and CSA.

Condensate Drain Connection

Lists standards for condensate drain connections.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE

CAUTION FURNACE RELIABILITY HAZARD

Warns of potential component damage from electrostatic discharge.

ACCESSORIES

LOCATION

CAUTION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Warns about hazards from improper use or installation, leading to component failure.

General

WARNING FIRE, INJURY OR DEATH HAZARD

Hazards when installing in a residential garage or hazardous atmosphere building.

WARNING CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD

Hazards from corrosive or contaminated air affecting heat exchangers.

WARNING FIRE HAZARD

Warning against installing the furnace on its back or hanging it incorrectly.

Location Relative to Cooling Equipment

AIR FOR COMBUSTION AND VENTILATION

Introduction

Explains direct vent and ventilated combustion air options.

Direct Vent (2-pipe) Applications

Notes no special provisions for combustion air in direct vent systems.

Ventilated Combustion Air Applications

Details requirements for ventilated combustion air systems.

CAUTION FURNACE CORROSION HAZARD

Warns about corrosive air affecting heat exchangers.

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about negative pressure conditions and the need for make-up air.

Outdoor Combustion Air Method

CONDENSATE TRAP

Condensate Trap-Upflow Orientation

Notes no relocation needed for upflow orientation.

Condensate Trap-Downflow Orientation

Details relocation requirements for downflow orientation.

Condensate Trap-Horizontal Orientation

Explains repositioning for horizontal orientation.

CONDENSATE DRAIN CONNECTION

CAUTION FROZEN AND BURST WATER PIPE HAZARD

Warns about freezing risks and necessary protection measures.

CAUTION PROPERTY DAMAGE HAZARD

Warns about property damage from burst pipes due to condensate.

Upflow/Downflow Orientation

Describes condensate trap location and drain routing for upflow/downflow.

INSTALLATION

Upflow Installation

Details installation requirements for upflow configuration.

Bottom Return Air Inlet

Instructions for removing the bottom closure panel for return air.

Side Return Air Inlet

Notes panel requirement for side return air, and configuration limitations.

Filter Arrangement

WARNING FIRE, CARBON MONOXIDE AND POISONING HAZARD

Warns about operating furnace without a filter or with access doors removed.

Downflow Installation

Supply Air Connections

Details approved accessories for downflow supply air connections.

Return Air Connections

Instructions on connecting return air ducts, prohibiting back connection.

Bottom Return Air Inlet

Steps to remove the bottom closure panel for return air.

Horizontal Installation

WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Hazards from improper furnace orientation or return air duct connection.

CAUTION MINOR PROPERTY HAZARD

Requirement for drain pan in attic or over finished ceiling applications.

Platform Furnace Support

Guidelines for constructing a platform to support the furnace.

Suspended Furnace Support

Instructions for supporting the furnace using threaded rod and angle iron.

Roll-Out Protection

Requirement for sheet metal for flame roll-out protection.

Supply Air Connections

Details connection of supply air ducts to furnace or coil casing.

Return Air Connections

Bottom Return Air Inlet

Steps to remove the bottom closure panel for return air.

Side Return Air Inlet

Notes panel requirement for side return air, and configuration limitations.

Filter Arrangement

WARNING FIRE, CARBON MONOXIDE AND POISONING HAZARD

Warns about operating furnace without a filter or with access doors removed.

Filter and Return Duct Sizing

AIR DUCTS

General Requirements

Discusses duct design, sizing, and sealing according to standards.

Return Duct Sizing

Refers to filter selection and duct sizing for proper return airflow.

Ductwork Acoustical Treatment

Details requirements for internal acoustical lining or fibrous ductwork.

GAS PIPING

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

WARNING FIRE OR EXPLOSION HAZARD

Emphasizes using new, listed flexible connectors and proper black iron pipe installation.

WARNING FIRE OR EXPLOSION HAZARD

Warns about keeping gas valve inlet capped and installing a sediment trap.

WARNING FIRE OR EXPLOSION HAZARD

Stresses adhering to codes and using a separate gas supply line.

NOTICE In the State of Massachusetts:

Details Massachusetts-specific requirements for gas piping connections.

CAUTION FURNACE DAMAGE HAZARD

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

Gas Pipe Grommet

ELECTRICAL CONNECTIONS

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Emphasizes the need for proper grounding and avoiding electrical faults.

WARNING ELECTRICAL SHOCK HAZARD

Warns about bypassing the blower door switch, which controls power.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Highlights the importance of uninterrupted ground connection for safety.

CAUTION FURNACE MAY NOT OPERATE HAZARD

Caution regarding intermittent operation if furnace control is not properly grounded.

115-V Wiring

WARNING FIRE HAZARD

Warns against using aluminum wire and stresses using copper wire.

J-Box Installation

WARNING FIRE OR ELECTRICAL SHOCK HAZARD

Hazards related to manual disconnect switch installation and damage to components.

Electrical Box on Furnace Casing Side

Instructions for mounting an external electrical box to the furnace casing.

Power Cord Installation in Furnace J-Box

Steps for installing a power cord into the furnace J-Box.

BX Cable Installation in Furnace J-Box

Steps for installing BX cable into the furnace J-Box.

24-V Wiring

Instructions for making field 24-V connections at the terminal strip.

Thermostats

Accessories (See Fig. 32 and 34.)

Lists accessories like Electronic Air Cleaner and Humidifier.

Alternate Power Supplies

VENTING

Special Venting Requirements for Installations in Canada

Details Canadian venting code requirements and material specifications.

WARNING CARBON MONOXIDE POISONING HAZARD

General

Venting Systems

WARNING CARBON MONOXIDE POISONING HAZARD

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATION

Direct Vent / 2-Pipe System

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Ventilated Combustion Air Systems

NOTICE OPTIONAL VENTING BELOW THE FURNACE

WARNING CARBON MONOXIDE POISONING HAZARD

Locating the Vent Termination

General

Mentions Alberta/Saskatchewan requirements and local codes.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Size the Vent and Combustion Air Pipes

General

Discusses pipe sizing based on National codes and manufacturer data.

WARNING CARBON MONOXIDE POISONING HAZARD

Reiterates CO hazard and safe venting practices.

Ventilated Combustion Air

Explains vent termination and combustion air pipe routing for this system.

Termination Requirements for the Provinces of Alberta and Saskatchewan

Details minimum unobstructed distances for vent terminations in these provinces.

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Optional Combustion Air Inlet Moisture Trap

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

Combustion Air and Vent Piping Insulation Guidelines

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about routing pipes through the furnace and sealing the blower compartment.

Install the Vent and Combustion Air Pipes

WARNING CARBON MONOXIDE POISONING HAZARD

Warns against using cement for polypropylene venting systems.

WARNING CARBON MONOXIDE POISONING HAZARD

Reinforces not using cement for polypropylene systems and proper coupling use.

NOTICE FOR POLYPROPYLENE VENTING SYSTEMS

Emphasizes using same-manufacturer venting materials.

Installing the Vent Termination

Roof Terminations

Requirements for roof flashing and termination kits.

Concentric Vent

Instructions for installing concentric vent terminations and clearances.

Two-Pipe (Direct Vent) and Single-Pipe (Ventilated Combustion Air) Terminations

Instructions for installing two-pipe and single-pipe vent terminals.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Sidewall Terminations

Concentric Vent Termination

Instructions for installing concentric vent terminations on sidewalls.

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

Combustion Air and Vent Piping Insulation Guidelines

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about routing pipes through the furnace and sealing the blower compartment.

AIR DUCTS

General Requirements

Discusses duct design, sizing, and sealing according to standards.

Return Duct Sizing

Refers to filter selection and duct sizing for proper return airflow.

Ductwork Acoustical Treatment

Details requirements for internal acoustical lining or fibrous ductwork.

GAS PIPING

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

WARNING FIRE OR EXPLOSION HAZARD

Emphasizes using new, listed flexible connectors and proper black iron pipe installation.

WARNING FIRE OR EXPLOSION HAZARD

Warns about keeping gas valve inlet capped and installing a sediment trap.

WARNING FIRE OR EXPLOSION HAZARD

Stresses adhering to codes and using a separate gas supply line.

NOTICE In the State of Massachusetts:

Details Massachusetts-specific requirements for gas piping connections.

CAUTION FURNACE DAMAGE HAZARD

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

Gas Pipe Grommet

ELECTRICAL CONNECTIONS

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Emphasizes the need for proper grounding and avoiding electrical faults.

WARNING ELECTRICAL SHOCK HAZARD

Warns about bypassing the blower door switch, which controls power.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Highlights the importance of uninterrupted ground connection for safety.

CAUTION FURNACE MAY NOT OPERATE HAZARD

Caution regarding intermittent operation if furnace control is not properly grounded.

115-V Wiring

WARNING FIRE HAZARD

Warns against using aluminum wire and stresses using copper wire.

J-Box Installation

WARNING FIRE OR ELECTRICAL SHOCK HAZARD

Hazards related to manual disconnect switch installation and damage to components.

Electrical Box on Furnace Casing Side

Instructions for mounting an external electrical box to the furnace casing.

Power Cord Installation in Furnace J-Box

Steps for installing a power cord into the furnace J-Box.

BX Cable Installation in Furnace J-Box

Steps for installing BX cable into the furnace J-Box.

24-V Wiring

Instructions for making field 24-V connections at the terminal strip.

Thermostats

Accessories (See Fig. 32 and 34.)

Lists accessories like Electronic Air Cleaner and Humidifier.

Alternate Power Supplies

VENTING

Special Venting Requirements for Installations in Canada

Details Canadian venting code requirements and material specifications.

WARNING CARBON MONOXIDE POISONING HAZARD

General

Venting Systems

WARNING CARBON MONOXIDE POISONING HAZARD

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATION

Direct Vent / 2-Pipe System

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Ventilated Combustion Air Systems

NOTICE OPTIONAL VENTING BELOW THE FURNACE

WARNING CARBON MONOXIDE POISONING HAZARD

Locating the Vent Termination

General

Mentions Alberta/Saskatchewan requirements and local codes.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Size the Vent and Combustion Air Pipes

General

Discusses pipe sizing based on National codes and manufacturer data.

WARNING CARBON MONOXIDE POISONING HAZARD

Reiterates CO hazard and safe venting practices.

Ventilated Combustion Air

Explains vent termination and combustion air pipe routing for this system.

Termination Requirements for the Provinces of Alberta and Saskatchewan

Details minimum unobstructed distances for vent terminations in these provinces.

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Optional Combustion Air Inlet Moisture Trap

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

Combustion Air and Vent Piping Insulation Guidelines

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about routing pipes through the furnace and sealing the blower compartment.

Install the Vent and Combustion Air Pipes

WARNING CARBON MONOXIDE POISONING HAZARD

Warns against using cement for polypropylene venting systems.

WARNING CARBON MONOXIDE POISONING HAZARD

Reinforces not using cement for polypropylene systems and proper coupling use.

NOTICE FOR POLYPROPYLENE VENTING SYSTEMS

Emphasizes using same-manufacturer venting materials.

Installing the Vent Termination

Roof Terminations

Requirements for roof flashing and termination kits.

Concentric Vent

Instructions for installing concentric vent terminations and clearances.

Two-Pipe (Direct Vent) and Single-Pipe (Ventilated Combustion Air) Terminations

Instructions for installing two-pipe and single-pipe vent terminals.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Sidewall Terminations

Concentric Vent Termination

Instructions for installing concentric vent terminations on sidewalls.

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

Combustion Air and Vent Piping Insulation Guidelines

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about routing pipes through the furnace and sealing the blower compartment.

AIR DUCTS

General Requirements

Discusses duct design, sizing, and sealing according to standards.

Return Duct Sizing

Refers to filter selection and duct sizing for proper return airflow.

Ductwork Acoustical Treatment

Details requirements for internal acoustical lining or fibrous ductwork.

GAS PIPING

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

WARNING FIRE OR EXPLOSION HAZARD

Emphasizes using new, listed flexible connectors and proper black iron pipe installation.

WARNING FIRE OR EXPLOSION HAZARD

Warns about keeping gas valve inlet capped and installing a sediment trap.

WARNING FIRE OR EXPLOSION HAZARD

Stresses adhering to codes and using a separate gas supply line.

NOTICE In the State of Massachusetts:

Details Massachusetts-specific requirements for gas piping connections.

CAUTION FURNACE DAMAGE HAZARD

WARNING FIRE OR EXPLOSION HAZARD

Warns about gas purging, leak testing, and using proper pipe length.

Gas Pipe Grommet

ELECTRICAL CONNECTIONS

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Emphasizes the need for proper grounding and avoiding electrical faults.

WARNING ELECTRICAL SHOCK HAZARD

Warns about bypassing the blower door switch, which controls power.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Highlights the importance of uninterrupted ground connection for safety.

CAUTION FURNACE MAY NOT OPERATE HAZARD

Caution regarding intermittent operation if furnace control is not properly grounded.

115-V Wiring

WARNING FIRE HAZARD

Warns against using aluminum wire and stresses using copper wire.

J-Box Installation

WARNING FIRE OR ELECTRICAL SHOCK HAZARD

Hazards related to manual disconnect switch installation and damage to components.

Electrical Box on Furnace Casing Side

Instructions for mounting an external electrical box to the furnace casing.

Power Cord Installation in Furnace J-Box

Steps for installing a power cord into the furnace J-Box.

BX Cable Installation in Furnace J-Box

Steps for installing BX cable into the furnace J-Box.

24-V Wiring

Instructions for making field 24-V connections at the terminal strip.

Thermostats

Accessories (See Fig. 32 and 34.)

Lists accessories like Electronic Air Cleaner and Humidifier.

Alternate Power Supplies

VENTING

Special Venting Requirements for Installations in Canada

Details Canadian venting code requirements and material specifications.

WARNING CARBON MONOXIDE POISONING HAZARD

General

Venting Systems

WARNING CARBON MONOXIDE POISONING HAZARD

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATION

Direct Vent / 2-Pipe System

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Ventilated Combustion Air Systems

NOTICE OPTIONAL VENTING BELOW THE FURNACE

WARNING CARBON MONOXIDE POISONING HAZARD

Locating the Vent Termination

General

Mentions Alberta/Saskatchewan requirements and local codes.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Size the Vent and Combustion Air Pipes

General

Discusses pipe sizing based on National codes and manufacturer data.

WARNING CARBON MONOXIDE POISONING HAZARD

Reiterates CO hazard and safe venting practices.

Ventilated Combustion Air

Explains vent termination and combustion air pipe routing for this system.

Termination Requirements for the Provinces of Alberta and Saskatchewan

Details minimum unobstructed distances for vent terminations in these provinces.

NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Optional Combustion Air Inlet Moisture Trap

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

Combustion Air and Vent Piping Insulation Guidelines

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about routing pipes through the furnace and sealing the blower compartment.

Install the Vent and Combustion Air Pipes

WARNING CARBON MONOXIDE POISONING HAZARD

Warns against using cement for polypropylene venting systems.

WARNING CARBON MONOXIDE POISONING HAZARD

Reinforces not using cement for polypropylene systems and proper coupling use.

NOTICE FOR POLYPROPYLENE VENTING SYSTEMS

Emphasizes using same-manufacturer venting materials.

Installing the Vent Termination

Roof Terminations

Requirements for roof flashing and termination kits.

Concentric Vent

Instructions for installing concentric vent terminations and clearances.

Two-Pipe (Direct Vent) and Single-Pipe (Ventilated Combustion Air) Terminations

Instructions for installing two-pipe and single-pipe vent terminals.

NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Recommends support for sidewall or rooftop vent terminations.

Sidewall Terminations

Concentric Vent Termination

Instructions for installing concentric vent terminations on sidewalls.

Venting System Length Calculations

Example 1

Step-by-step calculation for TEVL using PVC/ABS vent piping.

Example 2

Calculation for TEVL using polypropylene vent piping, including corrections.

START-UP, ADJUSTMENT, AND SAFETY CHECK

NOTICE Important Installation and Start-up Procedures

Notes on initial procedures like checking manifold pressure and temperature rise.

General

General checks for power supply, thermostat wiring, gas pressure, and blower door.

CAUTION UNIT OPERATION HAZARD

Warns about intermittent operation or dissatisfaction due to improper setup.

Setup Switches

Explains the purpose and location of setup switches for configuration.

Setup Switches (SW1)

Details the function of SW1 switches for application requirements.

Air Conditioning (A/C) Setup Switches (SW2)

Explains SW2 switches for matching furnace airflow to cooling requirements.

Continuous Fan (CF) Setup Switches (SW3)

Details SW3 switches for selecting continuous fan or low-cooling airflow.

Additional Setup Switches (SW4)

Explains SW4 switches for intermediate heat and airflow adjustments.

Prime Condensate Trap with Water

WARNING CARBON MONOXIDE POISONING HAZARD

Warns about CO poisoning if the trap is not primed or used correctly.

CAUTION UNIT OPERATION HAZARD

Caution regarding intermittent operation if condensate trap is not primed.

Purge Gas Lines

WARNING FIRE OR EXPLOSION HAZARD

Warns about purging gas lines and testing for leaks.

Adjustments

CAUTION FURNACE DAMAGE HAZARD

Warns against forcing gas valve adjusting screw, which can damage it.

WARNING FIRE HAZARD

Warns against forcing gas valve adjusting screw, impacting manifold pressure.

CAUTION FURNACE DAMAGE HAZARD

Caution against redrilling orifices, which can cause noise and flame issues.

Check Inlet Gas Pressure

NOTICE

Notes on orifice size verification and checking inlet gas pressure.

Adjust Manifold Pressure - Maximum Heat

NOTICE

Notes on manifold pressure adjustment and altitude derating.

SERVICE AND MAINTENANCE PROCEDURES

WARNING FIRE, INJURY OR DEATH HAZARD

Emphasizes that only trained personnel should perform maintenance.

CAUTION ENVIRONMENTAL HAZARD

Instructions for proper disposal of components and materials.

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Stresses locking out power and tagging switches before servicing.

CAUTION ELECTRICAL OPERATION HAZARD

Warns about improper furnace operation due to wiring errors.

Electrical Controls and Wiring

WARNING ELECTRICAL SHOCK HAZARD

Warns about multiple electrical supplies and the need to lock out power.

Troubleshooting

Suggests using the Troubleshooting Guide for isolating operation problems.

Retrieving Stored Fault Codes

Instructions on how to retrieve stored fault codes from the control.

Component Self-Test

WARNING ELECTRICAL SHOCK HAZARD

Warns about electrical shock from exposed components when closing the blower door switch.

Care and Maintenance

WARNING FIRE OR EXPLOSION HAZARD

Lists materials to avoid storing near the furnace due to fire/explosion risk.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Stresses locking out power before performing maintenance or service.

WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD

Warns against operating without a filter or with access doors removed.

CAUTION CUT HAZARD

Warns about sharp edges on sheet metal parts.

Cleaning and/or Replacing Air Filter

WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD

Warns against operating without a filter or with access doors removed.

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Stresses locking out power before performing maintenance or service.

Blower Motor and Wheel Maintenance

Cleaning Burners and Flame Sensor

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Stresses locking out power before performing maintenance or service.

Servicing Hot Surface Igniter

Flushing Collector Box and Drainage System

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Stresses locking out power before performing maintenance or service.

Cleaning Condensate Drain and Trap

Checking Heat Pad Operation (If Applicable)

Cleaning Heat Exchangers

Primary Heat Exchangers

Procedure for cleaning the primary heat exchangers.

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Stresses locking out power before performing maintenance or service.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Stresses locking out power before performing maintenance or service.

Secondary Heat Exchangers

Wiring Diagrams

WINTERIZATION

CAUTION UNIT AND PROPERTY DAMAGE HAZARD

Warns about freeze protection measures for furnaces in unconditioned spaces.

CAUTION UNIT COMPONENT DAMAGE HAZARD

Warns against using ethylene glycol, which can damage plastic components.

Troubleshooting Guide

SEQUENCE OF OPERATION

CAUTION UNIT OPERATION HAZARD

Warns about intermittent operation if furnace control is not grounded.

Communicating Control and Modulating Heating (Adaptive Mode)

Explains operation with a communicating wall control.

Single-Stage Thermostat and Modulating Heating (Adaptive Mode)

Details operation with a single-stage thermostat in adaptive mode.

1. Inducer Prepurge Period

Describes the inducer prepurge period and RPM evaluation.

2. Igniter Warm-Up

Details the igniter warm-up period and its function.

3. Trial-For-Ignition Sequence

Explains the trial-for-ignition sequence and flame proving.

4. Flame-Proving

Describes the flame proving process and furnace control actions.

Two-Stage Thermostat and Modulating Heating (Adaptive Mode)

Two-Stage Thermostat and Two-Stage Minimum/Maximum Heating

Operation with a two-stage thermostat for minimum/maximum heating.

1. Switching from Maximum- to Minimum-Heat

Describes transition from maximum to minimum heat.

Cooling Mode

1. Single-Speed Cooling

Operation with a single-speed thermostat for cooling.

2. Single-Stage Thermostat and Two-Speed Cooling (Adaptive Mode)

Operation with a single-stage thermostat for two-speed cooling.

3. Two Stage Thermostat and Two-Speed Cooling

Operation with a two-stage thermostat for two-speed cooling.

4. Dehumidification Mode

Explains the dehumidification mode operation.

Super Dehumidify Mode

a. Low cooling – When the R to G-and-Y1 circuit

Low cooling operation with dehumidify demand.

b. High cooling – When the R to G-and Y/Y2 circuit

High cooling operation with dehumidify demand.

c. Cooling off-delay

Cooling off-delay adjustment for dehumidify demand.

1. Low cooling – When the R to Y1 circuit

Low cooling operation in super-dehumidify mode.

2. High cooling – When the R to Y/Y2 circuit

High cooling operation in super-dehumidify mode.

3. Cooling off-delay

Cooling off-delay adjustment in super-dehumidify mode.

Continuous Blower Mode

Continuous Blower Speed Selection from Thermostat

How to select continuous blower speeds using the thermostat.

Heat Pump

Component Self Test

Refers to instructions on page 79 for component self-test.

Two-Stage Thermostat and Two-Stage Intermediate/Maximum Heating

Cooling Mode

1. Single-Speed Cooling

Operation with a single-speed thermostat for cooling.

2. Single-Stage Thermostat and Two-Speed Cooling (Adaptive Mode)

Operation with a single-stage thermostat for two-speed cooling.

3. Two Stage Thermostat and Two-Speed Cooling

Operation with a two-stage thermostat for two-speed cooling.

4. Dehumidification Mode

Explains the dehumidification mode operation.

PARTS REPLACEMENT INFORMATION GUIDE

Casing Group

Lists replacement parts for the furnace casing.

Electrical Group

Lists replacement parts for the electrical system.

Blower Group

Lists replacement parts for the blower assembly.

Filter Group

Lists replacement parts for the filter system.

Gas Control Group

Lists replacement parts for the gas control system.

Heat Exchanger Group

Lists replacement parts for heat exchangers and related components.

Inducer Group

Lists replacement parts for the inducer assembly.

Model Nomenclature

Explains the model nomenclature and specifications.

WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

General warning about using only factory-authorized parts for modifications.

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