FOR YOUR SAFETY!

IF THE INFORMATION IN THESE INSTRUCTIONSIS NOT FOLLOWED EXACTLY, A FIRE OR EXPLO-SION MAY RESULT, CAUSING PROPERTY DAM-AGE, PERSONAL INJURY OR DEATH.

USER’S INFORMATION MANUALFOR MODULATING CONDENSING GAS FURNACES

92-20802-71-09SUPERSEDES 92-20802-71-08

Recognize this symbol as an indication of Important Safety Information!!

— Do not store or use gasoline or other flammablevapors and liquids, or other combustible materialsin the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch; do not useany phone in your building.

• Immediately call your gas supplier from a neigh-bor’s phone. Follow the gas supplier’s instruc-tions.

• If you cannot reach your gas supplier, call thefire department.

• Do not rely on smell alone to detect leaks. Dueto various factors, you may not be able to smellfuel gases.

• U.L. recognized fuel gas and CO detectors arerecommended in all applications, and theirinstallation should be in accordance with themanufacturer’s recommendations and/or locallaws, rules, regulations, or customs.

— Installation and service must be performed bya qualified installer, service agency or the gassupplier.

WARNING!

PROPOSITION 65: THIS PRODUCT CONTAINSCHEMICALS KNOWN TO THE STATE OF CALI-FORNIA TO CAUSE CANCER, BIRTH DEFECTSOR OTHER REPRODUCTIVE HARM.

WARNING!

NOTE TO INSTALLER: REVIEW THISMANUAL WITH THE USER AND LEAVEIT WITH THE EQUIPMENT.

DO NOT DESTROY. PLEASE READCAREFULLY AND KEEP IN A SAFEPLACE FOR FUTURE REFERENCE.

2

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCH ASWATER HEATERS OR BOILERS -ALL JOINTS, SEAMS, AND OPEN-INGS IN THE EQUIPMENT ANDDUCT MUST ALSO BE SEALED TOPREVENT DEPRESSURIZATION OFTHE SPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDING CAR-BON MONOXIDE INTO THE LIVINGSPACE.

IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE CSAINTERNATIONAL (CSA) CERTIFICA-TION OR THESE INSTRUCTIONS,CAN RESULT IN UNSATISFACTORYOPERATION AND/OR DANGEROUSCONDI-TIONS AND ARE NOT COV-ERED BY THE UNIT WARRANTY.

IN COMPLIANCE WITH RECOG-NIZED CODES, IT IS RECOMMEND-ED THAT AN AUXILIARY DRAINPAN BE INSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSTHAT ARE LOCATED IN ANY AREAOF A STRUCTURE WHERE DAM-AGE TO THE BUILDING OR BUILD-ING CONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OFTHE COIL DRAIN PAN OR A STOP-PAGE IN THE PRIMARY CONDEN-SATE DRAIN PIPING. SEE ACCES-SORIES SECTION OF THESEINSTRUCTIONS FOR AUXILIARYHORIZONTAL OVERFLOW PANINFORMATION (MODEL RXBM).

GENERAL INFORMATION

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM AND DRAWPOLLUTANTS SUCH AS DIRT, DUST,FUMES AND ODORS INTO THEHOME CAUSING PROPERTY DAM-AGE. FUMES AND ODORS FROMTOXIC, VOLATILE OR FLAMMABLECHEMICALS, AS WELL AS AUTO-MOBILE EXHAUST AND CARBONMONOXIDE (CO), CAN BE DRAWNINTO THE LIVING SPACE THROUGHLEAKING DUCTS AND UNBAL-ANCED DUCT SYSTEMS CAUSINGPERSONAL INJURY OR DEATH (SEEFIGURE 1).

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUST BESEALED TO LIMIT THE MIGRA-TION OF TOXIC FUMES ANDODORS INCLUDING CARBONMONOXIDE FROM MIGRATINGINTO THE LIVING SPACE.

WARNING!

NOTICE!

NOTICE!

3

FIGURE 1MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

CARBON MONOXIDE (CO) IS A COLORLESS, ODORLESS, POISONOUSGAS THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.CARBON MONOXIDE CAN BE PRODUCED BY ANY FUEL-BURNINGDEVICE, INCLUDING BUT NOT LIMITED TO:• MOTOR VEHICLES• GENERATORS AND OTHER GASOLINE POWERED TOOLS ANDENGINES

• GAS AND FUEL-OIL APPLIANCES• CHARCOAL OR GAS GRILLS• WOOD OR GAS FIREPLACES AND STOVES• OUTDOOR CAMPING EQUIPMENTCARBON MONOXIDE FROM ANY ONE OF THESE DEVICES CAN BE INAD-VERTENTLY DRAWN INTO AND DISTRIBUTED THROUGH THE LIVINGSPACE BY THE NORMAL OPERATION OF THE CENTRAL HEATING / AIRCONDITIONING SYSTEM (SEE FIGURE 1).APPLIANCES AND FUEL BURNING DEVICES MUST BE INSTALLED, OPER-ATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER’SINSTRUCTIONS.GASOLINE-POWERED TOOLS AND MOTOR VEHICLES MUST NOT BEOPERATED IN ENCLOSED SPACES, SUCH AS BASEMENTS, CRAWL-SPACES, OR GARAGES, EVEN WITH DOORS AND WINDOWS OR VENTSOPEN, AS EXHAUST FUMES INCLUDING CARBON MONOXIDE CAN BUILDUP AND SEEP INTO THE LIVING SPACE THROUGH CRACKS AND OPEN-INGS IN THE STRUCTURE. TOXIC FUMES, INCLUDING CARBON MONOX-IDE, CAN ALSO BE DRAWN INTO THE LIVING SPACE THROUGH OPEN-INGS AND SEAMS IN THE CENTRAL HEATING AND AIR CONDITIONINGEQUIPMENT AND / OR DUCTWORK.FOR THESE REASONS, THE U.S. CONSUMER PRODUCT SAFETYCOMMISSION (CPSC) RECOMMENDS THAT EVERY HOME HAVE ATLEAST ONE CARBON MONOXIDE ALARM INSTALLED IN THE HALLWAYNEAR THE BEDROOMS IN EACH SEPARATE SLEEPING AREA OF THEHOME. CARBON MONOXIDE ALARMS SHOULD BE CERTIFIED TO THEREQUIREMENTS OF THE MOST RECENT UL, IAS OR CSA STANDARD,AND SHOULD BE INSTALLED, OPERATED AND MAINTAINED IN ACCOR-DANCE WITH THE ALARM MANUFACTURER’S INSTRUCTIONS.

WARNING!

Proper balance and sealing of the ductsystem improves the efficiency of theheating and air conditioning system andimproves the indoor air quality of thehome by reducing the amount of air-borne pollutants that enter homes fromspaces where the ductwork and / orequipment is located. The manufacturerand the U.S. Environmental ProtectionAgency’s Energy Star Program recom-mend that central duct systems bechecked by a qualified contractor forproper balance and sealing.

RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damaged car-tons should be opened immediately. Ifdamage is found, it should be noted onthe delivery papers, and a damage claimfiled with the last carrier.• After unit has been delivered to jobsite, remove carton taking care not todamage unit.

• Check the unit rating plate for unitsize, electric heat, coil, voltage,phase, etc. to be sure equipmentmatches what is required for the jobspecification.

• Read the entire instructions beforestarting the installation.

• Some building codes require extracabinet insulation and gasketing whenunit is installed in attic applications.

• If installed in an unconditioned space,apply caulking around the powerwires, control wires, refrigerant tubingand condensate line where they enterthe cabinet. Seal the power wires onthe inside where they exit conduitopening. Caulking is required to pre-vent air leakage into and condensatefrom forming inside the unit, controlbox, and on electrical controls.

• Install the unit in such a way as toallow necessary access to thecoil/filter rack and blower/control com-partment.

• Install the unit in a level position toensure proper condensate drainage.Make sure unit is level in both direc-tions within 1/8”.

• Install the unit in accordance with anylocal code which may apply and thenational codes. Latest editions areavailable from: “National FireProtection Association, Inc.,Batterymarch Park, Quincy, MA02269.” These publications are:

• ANSI/NFPA No. 70-(Latest Edition)National Electrical Code.

• NFPA90A Installation of AirConditioning and Ventilating Systems.

• NFPA90B Installation of warm airheating and air conditioning systems.

• The equipment has been evaluated inaccordance with the Code of FederalRegulations, Chapter XX, Part 3280.

IMPORTANT INFORMATIONABOUT EFFICIENCY ANDINDOOR AIR QUALITYCentral cooling and heating equipmentis only as efficient as the duct system

that carries the cooled or heated air. Tomaintain efficiency, comfort and goodindoor air quality, it is important to havethe proper balance between the airbeing supplied to each room and the airreturning to the cooling and heatingequipment.

4

INTRODUCTION TO YOUR FURNACEThank you for the purchase of your new modulating gas fur-nace! This furnace is designed to be the ultimate in heatingcomfort and is the only true modulating gas furnace availableon the market today.

The modulating gas furnace provides a superior level ofcomfort due to the interaction of seven basic components:

• Variable Output Thermostat - Whereas conventional ther-mostats only send an On/Off signal to the furnace, the ther-mostat for the modulating furnace system is speciallydesigned to indicate the exact heating requirements of theconditioned space. This is accomplished by a logic controlroutine that accurately senses the space load, minimizesrecovery times, reduces temperature swings and optimizessystem efficiency and performance.

• Modulating Gas Valve - The gas valve has the convention-al redundant solenoid valves for inherent safety, but also hasa third operator for capacity control. This operator is actually

a servo valve which varies the input rate of the furnace pro-portionally to the signal from the controller. The modulatingfurnace can operate anywhere from 40% to 100% of thenameplate input of the furnace.

• Furnace Controller - The furnace controller provides all ofthe ignition and safety functions of the typical IFC as well asinterpreting the signals from the thermostat. The furnacecontroller will optimize furnace performance by monitoring allthermostat and temperature inputs and insuring the stableoperation of the inducer, gas valve and indoor blower motor.

• ECM Variable Speed Blower - The airflow through the ductwork is varied to meet the load demand. Airflow as low as300 CFM is achieved by the response of a brushless perma-nent magnet variable speed blower motor.

• Two Speed Draft Inducer - To insure clean combustionand peak efficiency, the induced draft motor speed is adjust-ed based on the gas valve setting to provide the properamount of combustion air to the burners.

FIGURE 3DOWNFLOW FURNACE

FIGURE 2UPFLOW FURNACE

I678

ITEMNO. PART NAME

1 CONDENSATE TRAP2 DOOR SWITCH3 JUNCTION BOX4 TRANSFORMER5 LOW PRESSURE SWITCH6 HIGH PRESSURE SWITCH7 EXHAUST TRANSITION8 CONNECTOR9 MAIN LIMIT10 EXHAUST AIR PIPE11 VENT CAP PLUG12 FLAME SENSOR13 OVERTEMPERATURE SWITCH

ITEMNO. PART NAME

14 TOP PLATE15 BURNER16 IGNITER17 COMBUSTION AIR INLET18 GAS VALVE19 CAPACITOR20 INDUCED DRAFT BLOWER21 POWER FACTOR CHOKE22 IGNITION CONTROL23 INTEGRATEDFURNACECONTROL24 BLOWER MOTOR25 R/A SENSOR26 BLOWER HOUSING

ITEMNO. PART NAME

1 GAS VALVE2 CAPACITOR3 LOW PRESSURE SWITCH4 HIGH PRESSURE SWITCH5 BLOWER HOUSING6 POWER FACTOR CHOKE7 BLOWER MOTOR8 DOOR SWITCH9 JUNCTION BOX10 COMBUSTION AIR INLET11 HALC12 TOP PLATE13 RETURN AIR SENSOR

ITEMNO. PART NAME

14 VENT CAP PLUG15 EXHAUST AIR PIPE16 INTEGRATEDFURNACECONTROL17 TRANSFORMER18 IGNITION CONTROL19 INDUCED DRAFT BLOWER20 CONNECTOR21 EXHAUST TRANSITION22 MAIN LIMIT23 CONDENSATE TRAP24 IGNITER25 OVERTEMPERATURE SWITCH26 BURNER27 FLAME SENSOR

5

� FIGURE 4HORIZONTAL FURNACE (-)GJD

27 FACTORY-INSTALLED STREETELBOW

6

SAFETY PRECAUTIONSSIGNAL WORDSThere are some safety precautionswhich must be understood and fol-lowed by all users of equipment suchas your furnace, where flames, gas,electricity and rotating parts are pre-sent. To alert you to the above poten-tial hazards, we use the signal words“WARNING” and “CAUTION” through-out this manual and safety labelsattached to the furnace.

Read carefully and pay special atten-tion to all warnings and cautions in thismanual. They are defined anddesigned as follows to help you recog-nize and avoid the potential hazards ofoperating this furnace:

Indicates a potentially hazardoussituation which, if not avoided,could result in property damage,serious injury or death.

INSTALLATION INFORMATION

Date Installed

Dealer Name

Address

City

State Zip

Telephone No.

FURNACE

Model No.

Serial No.

AC SYSTEM

Model No.

Serial No.

INDOOR COIL

Model No.

Serial No.

fied installer, service agency or thegas supplier immediately if you haveproblems turning the knob.

• Should overheating occur, or the gasvalve fail to shut off the gas supply,turn off the manual gas valve to thefurnace before turning off the electri-cal supply.

• Soot buildup indicates a serious com-bustion problem that requires immedi-ate correction. Turn the gas supply“OFF” until the furnace is repaired.Contact a qualified installer, serviceagency or the gas supplier immedi-ately to inspect the furnace.

• Do not place, store or use gasoline orother flammable vapors and liquidson, against, or around the furnacejacket.

• Do not store combustible materialsnear the furnace. The furnace musthave adequate clearances from allcombustible materials such as cloth-ing, paper, cardboard, wood or clean-ing materials to prevent them fromigniting.

• Keep any furnace installed in an atticor other insulated space free andclear of insulating material. Examinethe furnace area when installing thefurnace or adding insulation. Somematerials may be combustible.

• Any additions, changes or conver-sions required in order for the furnaceto satisfactorily meet the applicationneeds should be made by a qualifiedinstaller, service agency or the gassupplier, using factory specified or

POSSIBILITY OF FIRE OREXPLOSION

• Do not test for gas leaks with a matchor flame.

• Do not use this furnace with any othergas than the one listed on the ratingplate.

• Follow the furnace lighting instruc-tions carefully to be sure all gasfumes are cleared before lighting thefurnace.

• Check carefully for gas before lightinga furnace. Do not rely on smell aloneto detect gas. Use a UL recognizedfuel gas detector and a soap andwater solution on the pipes to checkfor gas leaks.

• A damaged gas control knob cancause gas to leak. Do not hit or dam-age the knob. Do not force the knobwith tools. Use only your hand to turnit to “ON” or “OFF”. Call the a quali-

THIS FURNACE OPERATES BYBURNING GAS INSIDE YOURHOME. THIS CREATES THE POS-SIBILITY OF FIRE OR AN EXPLO-SION WHICH CAN RESULT INPROPERTY DAMAGE, PERSONALINJURY OR DEATH. YOU MUSTREAD AND FOLLOW ALL OFTHESE SAFETY PRECAUTIONSTO HELP ENSURE SAFE OPERA-TION OF YOUR FURNACE.

WARNING!

Indicates a potentially hazardoussituation which, if not avoided,could result in property damage,or minor or moderate injury.

CAUTION!

• Return and Supply Air Sensors - These two thermisterassemblies, a factory installed return air sensor and a fieldinstalled air probe, communicate the furnace temperaturerise to the integrated furnace control. The integrated furnacecontrol uses this information to calculate field conditions dur-ing calibration to insure optimal efficiency and comfort duringnormal operation.

This furnace has been designed to give you many years ofefficient, dependable home comfort. With regular mainte-

nance, this furnace will operate superbly year after year.Please take the time to fill out the information below andread this manual to familiarize yourself with operation, main-tenance schedule, and safety operation.

IMPORTANT: READ THESE INSTRUCTIONS THOR-OUGHLY BEFORE ATTEMPTING TO OPERATE THISFURNACE.

WARNING!

7

approved parts. Read your Warranty.Contact the WARRANTOR for con-version information. This furnace wasequipped at the factory for use onNATURAL GAS ONLY. Conversionto LP GAS requires a special kit sup-plied by the WARRANTOR.

DANGER FROMASPHYXIATION

• Do not operate this furnace withoutprovisions for an adequate combus-tion air supply.

• Do not allow snow, ice, or any otherdebris to accumulate in or around theexhaust and intake terminations ofthis furnace. These are extendedthrough the roof or horizontallythrough the sidewall of the structure.See Figures 5 & 6. Blockage of theintake and exhaust can result in inad-

equate combustion air as well asinadequate unit performance or nui-sance tripping.

• Prevent flue gases from escaping intoyour residence. Deterioration of theventing system, or soot build-up cancause leaks into the system. Have aqualified installer, service agency or thegas supplier replace damaged parts orrepair obstructions in a deterioratedvent system immediately.

• Do not use this furnace if any part hasbeen under water. A flood-damagedfurnace is extremely dangerous.Attempts to use the furnace can resultin fire or explosion. A qualified serviceagency should be contacted to inspectthe furnace and to replace all gas con-trols, control system parts, electricalparts that have been wet or the furnace,if deemed necessary.

• To prevent carbon monoxide poisoning,all blower doors and compartment cov-ers must be replaced after the furnaceis serviced. Do not operate the unitwithout all panels and doors securely inplace.

SYSTEM OPERATIONINFORMATION• Keep the air filters clean. Your heatingsystem will operate more efficiently andprovide better heating, more economi-cally.

• Arrange your furniture and drapes sothat the supply air registers and returnair grilles are unobstructed.

• Close doors and windows. This willreduce the heating load on your sys-tem.

• Avoid excessive use of exhaust fans.

• Do not permit the heat generated bytelevision, lamps, or radios to influencethe thermostat operation.

• If you desire to operate your systemwith constant air circulation, consultyour thermostat manual or please askadvice from a qualified installer, serviceagency or the gas supplier.

IMPORTANT: FOR COMPLETEOPERATION AND SET UP OF YOURTHERMOSTAT REFER TO THE MAN-UAL INCLUDED IN THE LITERATUREPACKET SHIPPEDWITH THIS FUR-NACE.

STARTING YOURFURNACELIGHTING INSTRUCTIONS

This appliance is equipped with a directspark ignition device. This device lightsthe main burners each time the roomthermostat calls for heat. DO NOT try tolight the burner by hand. See lightinginstructions on the furnace.

1. Remove the burner access door.

2. Set the thermostat to the lowest set-ting.

3. Turn the gas control knob counter-clockwise to the “ON” position.

4. Replace the burner access door.

5. Turn on the electrical power.

6. Set the room thermostat to a pointabove the room temperature to lightthe main burners. After the burners arelit, set the room thermostat to a desiredtemperature.

7. If the appliance will not operate, followthe instructions “To Turn Off Gas ToThe Appliance” and call your servicetechnician or gas supplier.

BE SURE THAT THE MANUAL GASCONTROL HAS BEEN IN THE “OFF”POSITION FOR AT LEAST FIVEMINUTES. DO NOT ATTEMPT TOMANUALLY LIGHT THE MAINBURNERS. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE AFIRE OR AN EXPLOSION RESULT-ING IN PROPERTY DAMAGE, PER-SONAL INJURY OR DEATH.

WARNING!

THIS FURNACE OPERATES BYBURNING GAS INSIDE YOURHOME. IMPROPER OR INCOM-PLETE BURNING OF THIS GASCAN RESULT IN THE FORMATIONOF CARBON MONOXIDE. IFINTRODUCED INTO THE LIVINGSPACE, THIS CAN CAUSE DIZZI-NESS, NAUSEA, OR DEATH BYASPHYXIATION. YOU MUSTREAD AND OBSERVE THE SAFE-TY RULES BELOW TO PREVENTOXYGEN DEPLETION ORUNBURNED GAS OR COMBUS-TION FROM ESCAPING INTO THELIVING SPACE OF YOUR RESI-DENCE.

WARNING!

FIGURE 5STANDARD VERTICALDIRECT VENTING

FIGURE 6STANDARD HORIZONTALDIRECT VENTING

I407

I407

8

After the warm-up period, the furnacewill respond to the thermostat demandby adjusting the gas valve pressure andblower heating speeds to the “W” signalvalues. “W” only = 40% gas valve pres-sure and blower heating speed. “W2” =65% gas valve pressure and blowerheating speed for first five minutes and100% thereafter. Also, if the call for heatends, the furnace terminates at the pre-sent rate.

� SINGLE-STAGE FUNCTION:(“W” signal only)After the warm-up period, the furnacewill respond to the thermostat demandby altering the gas valve pressure andblower speed as follows:Phase 1: 0 to 5 minutes = 40% of fur-nace capacity (gas valve output andblower speed)Phase 2: 5 to 12 minutes = 65% of fur-nace capacity (gas valve output andblower speed)Phase 3: After 12 minutes = 100% offurnace capacity (gas valve output andblower speed)NOTE: If the call for heat ends duringany phase, the furnace will terminateimmediately at the firing rate of thatphase.

Heating Cycle Termination(“W” signal only, refer to dip switch setSW2 on IFC)When the 24 volt signal is removed fromW1, the heating cycle will end and thefurnace will shut down and return to theproper off cycle operation.

When the controller senses 24 volts onW, the following sequence occurs:• High and low pressure switches arechecked to insure contacts are open.

• Inducer is powered on high speed for athirty (30) second prepurge.

• Pressure switches are monitored asthe inducer creates the vacuum toclose the contacts.

• The servo valve on the gas valve isenergized with ~180 milliamps current.(No flow yet.)

• The controller sends 120 volts to theignition control, which sparks acrossthe electrodes.

• The main solenoids on the gas valveare energized allowing gas to flow tothe burners.

• When flame is proven, the ignition con-trol is de-energized - 8 second maxi-mum trial time.

• The gas valve maintains 100% ratethrough the warm-up period - 20 sec-onds.

Heating Cycle ResponseThe heating cycle is always initiated by a24 volt signal on W1. When the controllersenses 24 volts on W1, the followingsequence occurs:

MODULATING FUNCTION:(“W” and “V” signal inputs, refer to dipswitch set SW2 on IFC)After the warm-up period, the furnace willrespond to the thermostat demand byadjusting the gas valve pressure andblower speed anywhere between 40% to100% heating capacity.� TWO-STAGE FUNCTION:(Two-stage function only applies whenboth switches of SW2 are in the “ON”position and a two-stage thermostat isinstalled.)

TO TURN OFF GAS TO THEAPPLIANCE

IMPORTANT: SHUT OFF THE MANUALGAS VALVE LOCATED IN THE GASSUPPLY PIPING OUTSIDE THE FUR-NACE CASING.

1. Set the thermostat to the lowest set-ting.

2. Turn off all electric power to the appli-ance on which service is to be per-formed.

3. Remove the burner access door.

4. Turn the gas control knob to the “OFF”position.

5. Replace the burner access door.

SEQUENCE OF OPERATIONHeating Cycle InitiationThe heating cycle is always initiated by a24 volt signal on W of the thermostat.

IMPORTANT: IT IS RECOMMENDEDTHAT AN ANNUAL INSPECTION OFYOUR FURNACE BE MADE BY AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIER.DURING THE ANNUAL INSPECTION,IT IS RECOMMENDED THAT 120VACPOWER BE TURNED OFF, THENBACK TO THE ON POSITION.REAPPLYING120VAC INITIATES ACALIBRATION CYCLE TO ENSUREOPTIMUM SYSTEM OPERATION.

MAINTENANCE

THIS FURNACE CONTAINS MOV-ING/ROTATING COMPONENTSAND USES HOUSEHOLD ELEC-TRICAL CURRENT. FOLLOW THESAFETY RULES BELOW TOAVOID CUTS, BURNS OR ELEC-TRICAL SHOCK WHICH CANRESULT IN SEVERE PERSONALINJURY OR DEATH.

WARNING!

POSSIBILITY OF BURNSOR ELECTRICAL INJURY• Do not perform any service or mainte-nance on the furnace while it is oper-ating. Read and follow the serviceinstructions provided with this furnacebefore beginning any service or main-tenance work.

• Do not open the blower compartment,disassemble, or remove any compo-nents while the furnace is operating.This may expose sharp edges orpoints which could cause cuts, hotsurfaces which could cause burns,and electrical circuits which couldcause shocks.

• Instruct children on the safety haz-ards associated with furnaces. Keepchildren away from the furnace at alltimes.

DO NOT OPERATE YOUR SYS-TEM FOR EXTENDED PERIODSWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED INTHE AIR MAY TEMPORARILYLODGE IN THE AIR DUCT RUNSAT THE SUPPLY REGISTERS.ANY RECIRCULATED DUST WILLBE HEATED AND CHARRED BYCONTACT WITH THE FURNACEHEAT EXCHANGER. THISRESIDUE WILL SOIL CEILINGS,WALLS, DRAPES, CARPETS ANDOTHER HOUSEHOLD ARTICLES.

CAUTION!

SHOULD OVERHEATING OCCUROR THE GAS SUPPLY FAIL TOSHUT OFF, SHUT OFF THE MANU-AL GAS VALVE TO THE APPLI-ANCE BEFORE SHUTTING OFFTHE ELECTRICAL SUPPLY. FAIL-URE TO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE, PERSON-AL INJURY OR DEATH.

WARNING!

9

CHECK THE VENT PIPE SECTIONSFOR DETERIORATION AND CHECKJOINT FITTINGS FOR THEIRINTEGRITY. IF IT HAS BECOMEDISCONNECTED TOXIC FUMESCAN ENTER THE HOME ANDCAUSE CARBON MONOXIDE POI-SONING OR DEATH. DO NOTOPERATE THIS FURNACE. APPRO-PRIATE SERVICE MUST BEAPPLIED.

FILTER MAINTENANCEHave your qualified installer, serviceagency or the gas supplier instruct youon how to access your filters for regu-lar maintenance.

• Keep air filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air dry thor-oughly and reinstall.

• After filters are cleaned and returnedto the furnace, be sure doors areproperly reinstalled. If you are nottotally sure of this procedure, consultqualified installer, service agency orthe gas supplier.

REMOVING FILTERSFILTER IN BOTTOM OR SIDELOCATION1. Remove the blower compartmentaccess door.

2. Disengage the filter retaining rod andpull filter out.

3. Clean filter and reinstall.

4. Replace the blower compartmentaccess door.

LUBRICATIONThe blower motor and induced draftmotor are permanently lubricated by themanufacturer and do not require furtherattention.

IMPORTANT: DO NOT ATTEMPT TOLUBRICATE THE BEARINGS ON THE

BLOWER MOTOR OR THE INDUCEDDRAFT BLOWER MOTOR. ADDITIONOF LUBRICANTS CAN REDUCE THEMOTOR LIFE AND VOID THE WAR-RANTY.

The blower compartment and motorshould be inspected and cleaned peri-odically by your qualified installer, ser-vice agency or the gas supplier to pre-vent the possibility of overheating dueto an accumulation of dust and dirt onthe windings or on the motor exterior.And, as suggested elsewhere in theseinstructions, keep the air filters cleanbecause dirty filters can restrict airflowand the motor depends on sufficient airflowing across and through it to keep itfrom overheating.

COMBUSTION AIR ANDVENT SYSTEM1. It is recommended that an annualinspection of your furnace’s combus-tion air and vent system be done bya qualified installer, service agencyor the gas supplier.

2. Turn OFF the electrical supply to thefurnace and remove the accessdoors.

3. Inspect the gas burners for dirt, rustor scale and clean as necessary.

4. Inspect the flue connection area andvent pipe. Be sure that the vent con-nector is in place and slopes upwardand is physically sound, withoutholes or excessive corrosion.

5. Be sure that the return air duct con-nections are physically sound, aresealed to the furnace casing and ter-minate outside the space containingthe furnace.

FIGURE 7UPFLOW SIDE FILTER LOCATION

I332

FIGURE 8UPFLOW BOTTOM FILTER INSTALLATION

ADS-5422-01

WARNING!

IF DIRT, RUST, SOOT OR SCALEACCUMULATIONS ARE PRESENT,DO NOT OPERATE THE FURNACE.INSPECT THE HEAT EXCHANGERFOR LEAKS. LEAKS CAN CAUSETOXIC FUMES TO ENTER THEHOME AND CAUSE CARBONMONOXIDE POISONING OR DEATH.

WARNING!

10

FIGURE 9DOWNFLOW FILTER INSTALLATION

A087001.S01

6. Be sure the physical support of thefurnace is sound, without sags, cracks,etc. around the base so as to providea seal between the support and thebase.

7. Look for the obvious signs of deterio-ration of the furnace.

8. If the furnace is free of the above con-ditions, replace the access doors andrestore electrical power to the fur-nace.

9. Start the furnace and observe its oper-ation. Watch the burner flames to seeif they are bright blue. If a suspectedmalfunction is observed, or the burnerflames are not bright blue, call forappropriate service.

CONDENSATEThis furnace is equipped with a pressureswitch which will shut off the main burn-ers if the condensate drain line becomesblocked.

Be sure this condensate drain line doesnot become blocked or plugged. Visualinspection of the condensate flow caneasily be made while the furnace is inoperation. Use a flashlight to illuminatethe discharge end placed in the seweropening. See Figures 11, 12 & 13.

Clean and flush the condensate tube tomake sure condensate flows freely whilethe furnace is in operation.

IMPORTANT: IT IS RECOMMENDEDTHAT AT THE BEGINNING OF THEHEATING SEASON, THE CONDEN-SATE TRAP BE INSPECTED BY AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIER FORDEBRIS OR BLOCKAGE. A BLOCKEDCONDENSATE TRAP CAN CAUSEWATER TO BACK UP INTO THE PRI-MARY HEAT EXCHANGER AND LEADTO NUISANCE TRIPPING OF THEOVER TEMPERATURE SWITCHES ORPRESSURE SWITCHES.

IMPORTANT: IT IS RECOMMENDEDTHAT AT THE BEGINNING OF THEHEATING SEASON THE CONDENSATENEUTRALIZER, IF USED, BEREPLACED BY A QUALIFIEDINSTALLER, SERVICE AGENCY ORTHE GAS SUPPLIER.

MARKINGSIt is recommended that an annualinspection and cleaning of all furnacemarkings be made to assure legibility.Attach a replacement marking, which canbe obtained through the distributor, if anyare found to be illegible or missing.

FIGURE 10HORIZONTAL -- FILTER INSTALLATION((-)GJD MODELS)

A087101.S01

AIRFLOW

AIRFLOW

AIRFLOW

11

FIGURE 12DOWNFLOW CONNECTION

A0850-01

REFER TO INSTALLATIONMANUAL

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

FIGURE 11UPFLOW CONDENSATE DRAIN

AO51601

REFER TOINSTALLATIONMANUAL.

12 CM 0710

FIGURE 13HORIZONTAL CONDENSATE DRAIN