507961-02B Page 1 of 57Issue 2302
(P) 507961-02B
*P507961-02B*
Manufactured By
Blue Summit LLC
8201 C National Turnpike
Louisville, KY 40214
This manual must be left with the homeowner for future reference.
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to
the potential for personal injury or death.
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
CAUTION
Table of Contents
Unit Dimensions ..........................................................2
Parts Arrangement.......................................................3
Gas Furnace ................................................................4
Shipping and Packing List ...........................................4
Safety Information .......................................................4
General ........................................................................6
Installation .................................................................10
Filters .........................................................................13
Duct System ..............................................................14
Venting Practices .......................................................15
Condensate Piping ....................................................34
Gas Piping .................................................................37
Electrical ....................................................................40
Blower Performance ..................................................48
Unit Start-Up ..............................................................51
Other Unit Adjustments..............................................53
Service.......................................................................54
Repair Parts List ........................................................56
INSTALLATION INSTRUCTIONS
BG962UHV
Warm Air Gas Furnace Upow/
Horizontal Left/Right Air Discharge
Direct Vent & Non-Direct Vent
507961-02BPage 2 of 57 Issue 2302
24
(61)
20-3/4
(53)
20-3/8
(52)
15-1/2
(39)
2 (5)
3-1/4
(8)
2-5/8 (7)
6-1/2 (17)
1-5/8 (4)
14 (36)
23
(58)
28-1/2
(72)
27-3/4
(70)
19-1/2
(50)
1-7/8 (5)
24-7/8
(63)
24-3/8
(62)
1-7/8
(5)
D
SIDE VIEWFRONT VIEW
(19)
3/4
(19)
1
Bottom Return
Air Opening
A
B
9/16 (14)
C
3/4
33
(838)
16
(406)
14−3/4
(375)
2
OPTIONAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
5/8
(16)
TOP VIEW
1 NOTE - C*20 (5 Ton) size units installed in upow applications that
require air volumes of 1800 cfm (850 L/s) or greater must have one
of the following:
1. Single side return air with transition, to accommodate 20 x 25 x 1
in. (508 x 635 x 25 mm) air lter.
2. Single side return air with optional RAB Return Air Base
3. Bottom return air.
4. Return air from both sides.
5. Bottom and one side return air.
2 Optional External Side Return Air Filter kit is not for use with
optional Return Air Base.
* Consider sizing requirements for optional IAQ equipment before
cutting side return opening.
Unit Dimensions
Capacity
A B C D
in. mm in. mm in. mm in. mm
070-12 17-1/2 448 16-3/8 416 16 406 7-5/8 194
090-12
090-20
110-20
21 533 19-7/8 505 19-1/2 495 9-3/8 238
507961-02B Page 3 of 57Issue 2302
Figure 1.
CONTROL BOX
BLOWER ASSEMBLY
ACCESS
PANEL
COMBUSTION
AIR INDUCER
FLUE COLLAR
BURNER BOX
ASSEMBLY
BLOWER
DECK
PRIMARY
LIMIT
CABINET
HEAT EXCHANGER
ASSEMBLY
GAS VALVE
AND MANIFOLD
Parts Arrangement
507961-02BPage 4 of 57 Issue 2302
Gas Furnace
The BG962UHV Category IV gas furnace is shipped ready
for installation in the upow or horizontal position. The
furnace is shipped with the bottom panel in place. The
bottom panel must be removed if the unit is to be installed
in horizontal or upow applications with bottom return air.
The BG962UHV can be installed as either a Direct Vent or
a Non-Direct Vent Gas Central Furnace.
The furnace is equipped for installation in natural gas
applications. A conversion kit (ordered separately) is
required for use in propane/LP gas applications.
NOTE: In Direct Vent installations, combustion air is taken
from outdoors and ue gases are discharged outdoors.
Non-Direct Vent installations, combustion air is taken from
indoors or a ventilated attic or crawl space and ue gases
are discharged outdoors. See Figure 2 and Figure 3 for
applications involving roof termination.
Figure 2.
Figure 3.
Shipping and Packing List
1 - Assembled Gas Furnace
1 - Bag assembly containing the following:
1 - Snap bushing
1 - Snap Plug
1 - Wire tie
1 - Condensate trap
1 - Condensate trap cap
1 - Condensate trap clamp
1 - 2” Diameter debris screen
1 - 3/4” Threaded street elbow
Check equipment for shipping damage. If you nd any
damage, immediately contact the last carrier.
Please refer to specication sheets for available
accessories.
Safety Information
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
CAUTION
DANGER OF EXPLOSION!
There are circumstances in which odorant used with
LP/Propane gas can lose its scent. In case of a leak,
LP/Propane gas will settle close to the oor and may be
dicult to smell. An LP/Propane leak detector should be
installed in all LP applications.
DANGER
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
BG962UHV units are CSA International certied to ANSI
Z21.47 and CSA 2.3 standards.
507961-02B Page 5 of 57Issue 2302
Building Codes
In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas
Code is available from the American National Standards
Institute, Inc., 11 West 42nd Street, New York, NY 10036.
In Canada, installation must conform with current National
Standard of Canada CSA-B149 Natural Gas and Propane
Installation Codes, local plumbing or waste water codes
and other applicable local codes.
In order to ensure proper unit operation in non-direct vent
applications, combustion and ventilation air supply must
be provided according to the current National Fuel Gas
Code or CSA-B149 standard.
Installed Locations
This furnace is CSA International certied for installation
clearances to combustible material as listed on the unit
nameplate and in the table in Figure 12 and Figure 18.
Accessibility and service clearances must take precedence
over re protection clearances.
NOTE: For installation on combustible oors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood ooring.
For installation in a residential garage, the furnace must be
installed so that the burner(s) and the ignition source are
located no less than 18 inches (457 mm) above the oor.
The furnace must be located or protected to avoid physical
damage by vehicles. When a furnace is installed in a public
garage, hangar, or other building that has a hazardous
atmosphere, the furnace must be installed according to
recommended good practice requirements and current
National Fuel Gas Code or CSA B149 standards.
NOTE: Furnace must be adjusted to obtain a temperature
rise within the range specied on the unit nameplate.
Failure to do so may cause erratic limit operation and
premature heat exchanger failure.
This furnace must be installed so that its electrical
components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling units (Figure 4),
it shall be installed in parallel with, or on the upstream
side of, cooling units to avoid condensation in the heating
compartment. With a parallel ow arrangement, a damper
(or other means to control the ow of air) must adequately
prevent chilled air from entering the furnace. If the damper
is manually operated, it must be equipped to prevent
operation of either the heating or the cooling unit, unless it
is in the full HEAT or COOL setting.
When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National
Electric Code, ANSI/NFPA No. 70. The National Electric
Code (ANSI/NFPA No. 70) is available from the following
address:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
In Canada, all electrical wiring and grounding for the unit
must be installed according to the current regulations of
the Canadian Electrical Code Part I (CSA Standard C22.1)
and/or local codes.
Figure 4.
Heating Unit Installed Parallel to Air Handler Unit
Heating Unit Installed Upstream of Cooling Unit
NOTE: This furnace is designed for a minimum continuous
return air temperature of 60°F (16°C) or an intermittent
operation down to 55°F (13°C) dry bulb for cases where a
night setback thermostat is used. Return air temperature
must not exceed 85°F (29°C) dry bulb.
This furnace may be installed in alcoves, closets, attics,
basements, garages, and utility rooms in the upow or
horizontal position.
This furnace design has not been CSA certied for
installation in mobile homes, recreational vehicles, or
outdoors.
507961-02BPage 6 of 57 Issue 2302
Use of Furnace as a Construction Heater
Units may be used for heating of buildings or structures
under construction, if the following conditions are met to
ensure proper operation.
DO NOT USE THE UNIT FOR CONSTRUCTION HEAT
UNLESS ALL OF THE FOLLOWING CRITERIA ARE
MET:
a. Furnace must be in its nal location. The vent system
must be permanently installed per these installation
instructions.
b. Furnace must be installed as a two pipe system
and one hundred percent (100%) outdoor air must
be provided for combustion air requirements during
construction.
c. A room thermostat must control the furnace. The use
of xed jumpers that will provide continuous heating is
prohibited.
d. The input rate and temperature rise must be set per
the furnace rating plate.
e. Supply and Return air ducts must be provided and
sealed to the furnace. Return air must be terminated
outside of the space where furnace is installed.
f. Return air temperature range between 60°F (16°C)
and 80°F (27°C) must be maintained.
g. MERV 11 or greater air lters must be installed in
the system and must be regularly inspected and
maintained (e.g., regular static checks and replaced at
end of life) during construction.
h. Blower and vestibule access panels must be in place
on the furnace at all times.
i. The furnace heat exchanger, components, duct
system, and evaporator coils must be thoroughly
cleaned following nal construction clean−up.
j. Air lters must be replaced upon construction
completion.
k. All furnace operating conditions (including ignition,
input rate, temperature rise and venting) must
be veried in accordance with these installation
instructions.
EQUIPMENT MAY EXPERIENCE PREMATURE
COMPONENT FAILURE AS A RESULT OF FAILURE TO
FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS.
FAILURE TO FOLLOW THE ABOVE INSTALLATION
INSTRUCTIONS VOIDS THE MANUFACTURER’S
EQUIPMENT LIMITED WARRANTY. BLUE SUMMIT
DISCLAIMS ALL LIABILITY IN CONNECTION WITH
INSTALLER’S FAILURE TO FOLLOW THE ABOVE
INSTALLATION INSTRUCTIONS.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
In addition to the requirements outlined previously, the
following general recommendations must be considered
when installing one of these furnaces:
• Place the furnace as close to the center of the air
distribution system as possible. The furnace should
also be located close to the chimney or vent termination
point.
• When the furnace is installed in an attic or other
insulated space, keep insulation away from the
furnace.
• When the furnace is installed in non-direct vent
applications, do not block the furnace combustion air
opening with clothing, boxes, doors, etc. Air is needed
for proper combustion and safe unit operation.
• When the furnace is installed in an attic or other
insulated space, keep insulation away from the
furnace.
• When the furnace is installed in an unconditioned
space, consider provisions required to prevent freezing
of condensate drain system.
NOTE: The Commonwealth of Massachusetts stipulates
these additional requirements:
• Gas furnaces shall be installed by a licensed plumber
or tter only.
• The gas cock must be “T handle” type.
• When a furnace is installed in an attic, the passageway
to and service area surrounding the equipment shall
be oored.
These units should not be installed in areas normally
subject to freezing temperatures.
CAUTION
NOTWITHSTANDING THE FOREGOING, INSTALLER
IS RESPONSIBLE FOR CONFIRMING THAT THE USE
OF CONSTRUCTION HEAT IS CONSISTENT WITH
THE POLICIES AND CODES OF ALL REGULATING
ENTITIES. ALL SUCH POLICIES AND CODES MUST BE
ADHERED TO.
507961-02B Page 7 of 57Issue 2302
Combustion, Dilution & Ventilation Air
If this unit is installed as a Non-Direct Vent Furnace, follow
the guidelines in this section.
NOTE: In Non-Direct Vent Installations, combustion air is
taken from indoors and ue gases are discharged outdoors.
Insucient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting
and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combustion
air supply:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine base swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
WARNING
In the past, there was no problem in bringing in sucient
outdoor air for combustion. Inltration provided all the air
that was needed. In today’s homes, tight construction
practices make it necessary to bring in air from outside
for combustion. Take into account that exhaust fans,
appliance vents, chimneys, and replaces force additional
air that could be used for combustion out of the house.
Unless outside air is brought into the house for combustion,
negative pressure (outside pressure is greater than inside
pressure) will build to the point that a down draft can
occur in the furnace vent pipe or chimney. As a result,
combustion gases enter the living space creating a
potentially dangerous situation.
In the absence of local codes concerning air for combustion
and ventilation, use the guidelines and procedures in this
section to install these furnaces to ensure ecient and safe
operation. You must consider combustion air needs and
requirements for exhaust vents and gas piping. A portion
of this information has been reprinted with permission from
the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This
reprinted material is not the complete and ocial position
of ANSI on the referenced subject, which is represented
only by the standard in its entirely.
In Canada, refer to the CSA B149 Installation codes.
Do not install the furnace in a corrosive or contaminated
atmosphere. Meet all combustion and ventilation air
requirements, as well as all local codes.
CAUTION
All gas-red appliances require air for the combustion
process. If sucient combustion air is not available,
the furnace or other appliance will operate ineciently
and unsafely. Enough air must be provided to meet the
needs of all fuel-burning appliances and appliances such
as exhaust fans which force air out of the house. When
replaces, exhaust fans, or clothes dryers are used at the
same time as the furnace, much more air is required to
ensure proper combustion and to prevent a down draft.
Insucient air causes incomplete combustion which can
result in carbon monoxide.
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contaminants
may include bleaches, adhesives, detergents, solvents
and other contaminants which can corrode furnace
components.
The requirements for providing air for combustion and
ventilation depend largely on whether the furnace is
installed in an unconned or a conned space.
Unconned Space
An unconned space is an area such as a basement
or large equipment room with a volume greater than 50
cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of
the combined input rating of all appliances installed in that
space. This space also includes adjacent rooms which are
not separated by a door. Though an area may appear to
be unconned, it might be necessary to bring in outdoor air
for combustion if the structure does not provide enough air
by inltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures in the “Air
from Outside” section.
Conned Space
A conned space is an area with a volume less than 50
cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of
the combined input rating of all appliances installed in that
space. This denition includes furnace closets or small
equipment rooms.
When the furnace is installed so that supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air must be handled by
ducts which are sealed to the furnace casing and which
507961-02BPage 8 of 57 Issue 2302
terminate outside the space containing the furnace. This
is especially important when the furnace is mounted on
a platform in a conned space such as a closet or small
equipment room. Even a small leak around the base of the
unit at the platform or at the return air duct connection can
cause a potentially dangerous negative pressure condition.
Air for combustion and ventilation can be brought into the
conned space either from inside the building or from
outside.
Air from Inside
If the conned space that houses the furnace adjoins a
space categorized as unconned, air can be brought in
by providing two permanent openings between the two
spaces. Each opening must have a minimum free area of 1
square inch (645 mm²) per 1,000 Btu (.29 kW) per hour of
total input rating of all gas-red equipment in the conned
space. Each opening must be at least 100 square inches
(64516 mm²). One opening shall be within 12 inches (305
mm) of the top of the enclosure and one opening within 12
inches (305 mm) of the bottom. See Figure 5.
Figure 5. Equipment in Conned Space - All Air From
Inside
Air from Outside
If air from outside is brought in for combustion and
ventilation, the conned space shall be provided with two
permanent openings. One opening shall be within 12” (305
mm) of the top of the enclosure and one within 12” (305
mm) of the bottom. These openings must communicate
directly or by ducts with the outdoors or spaces (crawl
or attic) that freely communicate with the outdoors or
indirectly through vertical ducts. Each opening shall have
a minimum free area of 1 square inch per 4,000 Btu (645
mm² per .59 kW) per hour of the total input rating of all
equipment in the enclosure (see Figure 6 and Figure 7).
It is also permissible to bring air for combustion from a
ventilated attic (Figure 9) or ventilated crawl space (Figure
10).
Figure 6. Equipment in Conned Space - All Air from
Outside
(Inlet Air from Crawl Space and Outlet Air to
Ventilated Attic)
When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1
square inch (645 mm²) per 2,000 Btu (.56 kW) per hour of
the total input rating of all equipment in the enclosure. See
Figure 8.
Figure 7. Equipment in Conned Space - All Air from
Outside
(All Air through Ventilated Attic)
If this unit is being installed in an application with
combustion air coming in from a space serviced by an
exhaust fan, power exhaust fan, or other device which
may create a negative pressure in the space, take care
when sizing the inlet air opening. The inlet air opening
must be sized to accommodate the maximum volume
of exhaust air as well as the maximum volume of
combustion air required for all gas appliances serviced
by this space.
WARNING
507961-02B Page 9 of 57Issue 2302
Figure 8. Equipment in Conned Space - All Air from
Outside
Figure 9. Equipment in Conned Space
(Inlet Air from Ventilated Attic and Outlet Air to
Outside)
Ventilation Louvers
Inlet Air
(Minimum 12 in.
(305mm) above
Attic Floor)
Roof Terminated
Exhaust Pipe
Furnace
*Intake Debris
Screen
(Provided)
* See Maximum Vent Lengths table
NOTE-The inlet and outlet air openings shall each have a
free area of at least one square inch per 4,000 Btu (645mm
2
per 1.17kW) per hour of the total input rating of all equipment
in the enclosure.
When ducts are used, they shall be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular
air ducts shall be no less than 3 inches (75 mm). In
calculating free area, the blocking eect of louvers, grilles,
or screens must be considered. If the design and free area
of protective covering is not known for calculating the size
opening required, it may be assumed that wood louvers
will have 20 to 25 percent free area and metal louvers and
grilles will have 60 to 75 percent free area. Louvers and
grilles must be xed in the open position or interlocked
with the equipment so that they are opened automatically
during equipment operation.
Figure 10. Equipment in Conned Space
(Inlet Air from Ventilated Crawlspace and Outlet Air to
Outside)
Roof Terminated
Exhaust Pipe
Furnace
Ventilation
Louvers
(Crawl Space)
*Intake Debris Screen Provided
Inlet Air
Minimum
12 in. (305mm)
above Crawl
Space Floor
Coupling or
3 in. to 2 in.
Transition
(Field Provided)
* See Maximum Vent Lengths table
NOTE-The inlet and outlet air openings shall each have a
free area of at least one square inch per 4,000 Btu (645mm
2
per 1.17kW) per hour of the total input rating of all equipment
in the enclosure.
Shipping Bolt Removal
Units with 1/2 hp blower motor are equipped with three
exible legs and one rigid leg. The rigid leg is equipped
with a shipping bolt and a at white plastic washer (rather
than the rubber mounting grommet used with a exible
mounting leg). See Figure 11. The bolt and washer must
be removed before the furnace is placed into operation.
After the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
Figure 11.
Units with 1/2 HP
Blower Motor
507961-02BPage 10 of 57 Issue 2302
Installation
Setting Equipment
Do not connect the return air ducts to the back of the
furnace. Doing so will adversely aect the operation of
the safety control devices, which could result in personal
injury or death.
WARNING
Blower access panel must be securely in place when
blower and burners are operating. Gas fumes, which
could contain carbon monoxide, can be drawn into
living space resulting in personal injury or death.
WARNING
Upow Applications
The gas furnaces can be installed as shipped in the upow
position. Refer to Figure 12 for clearances. Select a location
that allows for the required clearances that are listed on
the unit nameplate. Also consider gas supply connections,
electrical supply, vent connection, condensate trap and
drain connections, and installation and service clearances
[24 inches (610 mm) at unit front]. The unit must be level
from side to side. Tilt the unit slightly (maximum 1/2 in.
from level) from back to front to aid in the draining of the
heat exchanger. See Figure 13.
Allow for clearances to combustible materials as indicated
on the unit nameplate.
Figure 12. Installation Clearances
Top
Right SideLeft Side
Bottom (floor)
Top/Plenum 1 in. (25 mm)
*Front 0
Back 0
Sides 0†
Vent 0
Floor 0‡
* Front clearance in alcove installation must be 24 in. (610
mm). Maintain a minimum of 24 in. (610 mm) for front service
access.
† Allow proper clearances to accommodate condensate trap
and vent pipe installation.
‡ For installations on a combustible oor, do not install
the furnace directly on carpeting, tile or other combustible
materials other than wood ooring.
Figure 13. Setting Equipment
Tilt the unit slightly (Max. 1/2”) from back to front to aid in the draining of the heat exchanger.
Unit must be level side-to-side in all applications.
507961-02B Page 11 of 57Issue 2302
Improper installation of the furnace can result in
personal injury or death. Combustion and ue products
must never be allowed to enter the return air system or
air in the living space. Use sheet metal screws and joint
tape to seal return air system to furnace.
In platform installations with furnace return, the furnace
should be sealed airtight to the return air plenum. A door
must never be used as a portion of the return air duct
system. The base must provide a stable support and an
airtight seal to the furnace. Allow absolutely no sagging,
cracks, gaps, etc.
For no reason should return and supply air duct systems
ever be connected to or from other heating devices
such as a replace or stove, etc. Fire, explosion, carbon
monoxide poisoning, personal injury and/or property
damage could result.
WARNING
Return Air Guidelines
Return air can be brought in through the bottom or either
side of the furnace installed in an upow application. If the
furnace is installed on a platform with bottom return, make
an airtight seal between the bottom of the furnace and the
platform to ensure that the furnace operates properly and
safely. The furnace is equipped with a removable bottom
panel to facilitate installation.
Markings are provided on both sides of the furnace cabinet
for installations that require side return air. Cut the furnace
cabinet at the maximum dimensions shown on Page 2.
Furnace applications which include side return air and a
condensate trap installed on the same side of the cabinet
(trap can be installed remotely within 5 ft.) require either a
return air base or eld-fabricated transition to accommodate
an optional IAQ accessory taller than 14.5”. See Figure 14.
Figure 14. Optional Return Air Base
(Upow Applications Only)
FRONT VIEW
1
Unit side return air
Opening
SIDE VIEW
3−1/4
(83)
1
23 (584)
Overall
(Maximum)
(584)
23
3/4
(19)
1
22−7/16
(570)
Overall
(Maximum)
SIDE RETURN
AIR OPENINGS
(Either Side)
5−5/8
(143)
1
Minimum
11 (279)
2
Maximum
14 (356)
(683)
26−7/8
7−1/4
(184)
FURNACE
FRONT
AIR FLOW
IF BASE
IS USED
WITHOUT
IAQ CABINET,
A SINGLE
RETURN AIR
PLENUM
MUST
COVER BOTH
UNIT AND
RETURN
AIR BASE
OPENINGS
INDOOR AIR
QUALITY
CABINET
(PCO, Filter
Cabinet, etc.)
AIR BASE
OPTIONAL
RETURN
CONDENSATE
TRAP
17−1/2 (446) B Width (68W62)
21 (533) C Width (68W63)
24−1/2 (622) D Width (68W64)
NOTE: Optional side return air lter kits are not for use with return air base.
1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in. (584 x 279 mm).
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the eld. There are cutting guides stenciled on the cabinet for the side return air opening.
The size of the opening must not extend beyond the markings on the furnace cabinet.
2 To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
507961-02BPage 12 of 57 Issue 2302
Figure 15. Side Return Air
(with transition and lter)
Removing the Bottom Panel
Remove the two screws that secure the bottom cap to the
furnace. Pivot the bottom cap down to release the bottom
panel. Once the bottom panel has been removed, reinstall
the bottom cap. See Figure 16.
Figure 16. Removing the Bottom Panel
Horizontal Applications
Do not install the furnace on its front or its back. See
Figure 17.
WARNING
Figure 17.
This furnace can be installed in horizontal applications with
either right or left hand air discharge.
Refer to Figure 18 for clearances in horizontal applications.
Figure 18. Horizontal Application
Installation Clearances
Top
Bottom (floor)**
Air
Flow
Air
Flow
Right-Hand Discharge
Left-Hand Discharge
Bottom (floor)**
Top
Right EndLeft End
Air
Flow
Air
Flow
Right EndLeft End
Top 0
*Front 0
Back 0
Ends 0
Vent 0
Floor 0‡
* Front clearance in alcove installation must be 24 in. (610
mm). Maintain a minimum of 24 in. (610 mm) for front service
access.
** An 8” service clearance must be maintained below the unit
to provide for servicing of the condensate trap unless the trap
is mounted remotely.
‡ For installations on a combustible oor, do not install
the furnace directly on carpeting, tile or other combustible
materials other than wood ooring.
507961-02B Page 13 of 57Issue 2302
Suspended Installation of Horizontal Unit
This furnace may be installed in either an attic or a crawl
space. Either suspend the furnace from roof rafters or oor
joists, as shown in Figure 19, or install the furnace on a
platform, as shown in Figure 20. A horizontal suspension
kit (51W10) may be ordered from your distributor or use
equivalent.
NOTE: Heavy-gauge sheet metal straps may be used to
suspend the unit from roof rafters or ceiling joists. When
straps are used to suspend the unit in this way, support
must be provided for both the ends. The straps must not
interfere with the plenum or exhaust piping installation.
Cooling coils and supply and return air plenums must be
supported separately.
Figure 19. Typical Horizontal Application
NOTE: When the furnace is installed on a platform or with
the horizontal suspension kit in a crawl space, it must be
elevated enough to avoid water damage, accommodate
drain trap and to allow the evaporator coil to drain.
Platform Installation of Horizontal Unit
1. Select location for unit, keeping in mind service and
other necessary clearances. See Figure 18.
2. Construct a raised wooden frame and cover frame
with a plywood sheet. If unit is installed above nished
space, fabricate an auxiliary drain pan to be installed
under unit. Set unit in drain pan as shown in Figure
20. Leave 8 inches for service clearance below unit for
condensate trap.
3. Provide a service platform in front of unit. When
installing the unit in a crawl space, a proper support
platform may be created using cement blocks.
4. Route auxiliary drain line so that water draining from
this outlet will be easily noticed by the homeowner.
5. If necessary, run the condensate line into a condensate
pump to meet drain line slope requirements. The
pump must be rated for use with condensing furnaces.
Protect the condensate discharge line from the pump
to the outside to avoid freezing.
6. Continue with exhaust, condensate and intake piping
installation according to instructions.
Figure 20.
Return Air - Horizontal Applications
Return air may be brought in only through the end of a
furnace installed in the horizontal position. The furnace
is equipped with a removable bottom panel to facilitate
installation. See Figure 16.
Filters
This unit is not equipped with a lter or rack. A eld provided
lter is required for the unit to operate properly. Table 1 lists
recommended lter sizes.
A lter must be in place whenever the unit is operating.
Furnace Cabinet
Width
Filter Size
Side Return Bottom Return
17-1/2”
16 x 25 x 1
16 x 25 x 1
21” 20 x 25 x 1
Table 1.
507961-02BPage 14 of 57 Issue 2302
Duct System
Use industry approved standards to size and install the
supply and return air duct system. This will result in a quiet
and low-static system that has uniform air distribution.
NOTE: This furnace is not certied for operation in heating
mode (indoor blower operating at selected heating speed)
with an external static pressure which exceeds 0.8 inches
w.c. Operation at these conditions may result in improper
limit operation.
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable
access panel should be installed in the supply air duct. The
access panel should be large enough to permit inspection
(by reected light) of the heat exchanger for leaks after the
furnace is installed. The furnace access panel must always
be in place when the furnace is operating and it must not
allow leaks into the supply air duct system.
Return Air Plenum
NOTE: Return air must not be drawn from a room where
this furnace, or any other gas fueled appliance (i.e., water
heater), or carbon monoxide producing device (i.e., wood
replace) is installed.
When return air is drawn from a room, a negative pressure
is created in the room. If a gas appliance is operating in
a room with negative pressure, the ue products can be
pulled back down the vent pipe and into the room. This
reverse ow of the ue gas may result in incomplete
combustion and the formation of carbon monoxide gas.
This raw gas or toxic fumes might then be distributed
throughout the house by the furnace duct system.
Return air can be brought in through the bottom or either
side of the furnace. If a furnace with bottom return air is
installed on a platform, make an airtight seal between the
bottom of the furnace and the platform to ensure that the
unit operates properly and safely. Use berglass sealing
strips, caulking, or equivalent sealing method between the
plenum and the furnace cabinet to ensure a tight seal. If
a lter is installed, size the return air duct to t the lter
frame.
Pipe & Fittings Specications
All pipe, ttings, primer and solvent cement must conform
with American National Standard Institute and the American
Society for Testing and Materials (ANSI/ASTM) standards.
The solvent shall be free owing and contain no lumps,
undissolved particles or any foreign matter that adversely
aects the joint strength or chemical resistance of the
cement. The cement shall show no gelation, stratication,
or separation that cannot be removed by stirring. Refer to
Table 2 for approved piping and tting materials.
Solvent cements for plastic pipe are ammable liquids
and should be kept away from all sources of ignition.
Do not use excessive amounts of solvent cement when
making joints. Good ventilation should be maintained to
reduce re hazard and to minimize breathing of solvent
vapors. Avoid contact of cement with skin and eyes.
CAUTION
Table 2.
Piping and Fittings Specications
Schedule 40 PVC (Pipe)
D1785
Schedule 40 PVC (Fittings)
D2466
Schedule 40 CPVC (Pipe)
F441
Schedule 40 CPVC (Fittings)
F438
SDR-21 PVC or SDR-26 PVC (Pipe)
D2241
SDR-21 CPVC or SDR-26 CPVC (Pipe)
F442
Schedule 40 ABS (Pipe)
D1527
Schedule 40 ABS (Fittings)
D2468
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
D2661
PVC-DWV (Drain Waste & Vent)
Pipe & Fittings)
D2665
PRIMER & SOLVENT CEMENT
ASTM
SPECIFICATION
PVC & CPVC Primer
F656
PVC Solvent Cement
D2564
CPVC Solvent Cement
F493
ABS Solvent Cement
D2235
PVC/CPVC/ABS All Purpose Cement For
Fittings & Pipe of the same material
D2564, D2235,
F493
ABS to PVC or CPVC Transition Solvent
Cement
D3138
CANADA PIPE & FITTING & SOLVENT
CEMENT
MARKING
PVC & CPVC Pipe and Fittings
ULCS636
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
POLYPROPYLENE VENTING SYSTEM
ULC-S636
PolyPro® by Duravent
InnoFlue® by Centrotherm
ULC-S636
ECCO Polypropylene Vent
TM
ULC-S636
507961-02B Page 15 of 57Issue 2302
BG962UHV exhaust and intake connections are made
of PVC. Use PVC primer and solvent cement when
using PVC vent pipe. When using ABS vent pipe, use
transitional solvent cement to make connections to the
PVC tting in the unit.
IMPORTANT
Use PVC primer and solvent cement or ABS solvent
cement meeting ASTM specications, refer to Table 2.
As an alternate, use all purpose cement, to bond ABS,
PVC, or CPVC pipe when using ttings and pipe made of
the same materials. Use transition solvent cement when
bonding ABS to either PVC or CPVC.
Low temperature solvent cement is recommended during
cooler weather. Metal or plastic strapping may be used for
vent pipe hangers. Uniformly apply a liberal coat of PVC
primer for PVC or use a clean dry cloth for ABS to clean
inside socket surface of tting and male end of pipe to
depth of tting socket.
Canadian Applications Only
Pipe, ttings, primer and solvent cement used to vent
(exhaust) this appliance must be certied to ULC S636 and
supplied by a single manufacturer as part of an approved
vent (exhaust) system. When bonding the vent system to
the furnace, use ULC S636 approved One-Step Transition
Cement to bond the pipe to the ue collar, or to bond
the 90° elbow or reducing 90° elbow to the ue collar. In
addition, the rst three feet of vent pipe from the furnace
ue collar must be accessible for inspection.
Joint Cementing Procedure
All cementing of joints should be done according to the
specications outlined in ASTM D 2855.
DANGER OF EXPLOSION!
Fumes from PVC glue may ignite during system check.
Allow fumes to dissipate for at least 5 minutes before
placing unit into operation.
DANGER
1. Measure and cut vent pipe to desired length.
2. Debur and chamfer end of pipe, removing any ridges
or rough edges. If end is not chamfered, edge of pipe
may remove cement from tting socket and result in a
leaking joint.
3. Clean and dry surfaces to be joined.
4. Test t joint and mark depth of tting on outside of pipe.
5. Uniformly apply a liberal coat of PVC primer for PVC
or use a clean dry cloth for ABS to clean inside socket
surface of tting and male end of pipe to depth of tting
socket.
NOTE: Time is critical at this stage. Do not allow
primer to dry before applying cement.
6. Promptly apply solvent cement to end of pipe and
inside socket surface of tting. Cement should be
applied lightly but uniformly to inside of socket. Take
care to keep excess cement out of socket. Apply
second coat to end of pipe.
7. Immediately after applying last coat of cement to pipe,
and while both inside socket surface and end of pipe
are wet with cement, forcefully insert end of pipe into
socket until it bottoms out. Turn PVC pipe 1/4 turn
during assembly (but not after pipe is fully inserted) to
distribute cement evenly. Do not turn ABS or cellular
core pipe.
NOTE: Assembly should be completed within 20
seconds after last application of cement. Hammer
blows should not be used when inserting pipe.
8. After assembly, wipe excess cement from pipe at end
of tting socket. A properly made joint will show a bead
around its entire perimeter. Any gaps may indicate
an improper defective assembly due to insucient
solvent.
9. Handle joints carefully until completely set.
Venting Practices
Piping Suspension Guidelines
NOTE: Isolate piping at the point where it exits the outside wall or
roof in order to prevent transmission of vibration to the structure.
Wall Thickness Guidelines
Figure 21.
507961-02BPage 16 of 57 Issue 2302
Exhaust Piping
1. In areas where piping penetrates joist or interior walls,
hole must be large enough to allow clearance on all
sides of pipe through center of hole using a hanger.
2. When furnace is installed in a residence where unit
is shut down for an extended period of time, such
as a vacation home, make provisions for draining
condensate collection from trap and lines.
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from
a venting system commonly run with separate gas
appliances, the venting system is likely to be too large to
properly vent the remaining attached appliances.
Conduct the following test while each appliance is operating
and the other appliances (which are not operating) remain
connected to the common venting system. If the venting
system has been installed improperly, you must correct the
system as indicated in the general venting requirements
section.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
WARNING
Capacity
VENT PIPE
DIA.
(in.)
STANDARD CONCENTRIC
Outdoor Exhaust
Accelerator
(Dia. X
Length)
Outdoor
Exhaust
Accelerator
(Dia. X
Length)
Flush
Mount
Kit
1-1/2”
Concentric
Kit
2”
Concentric
Kit
3”
Concentric
Kit
1-1/2” X 12” 2” X 12” 51W11 *
71M80
or
+44W92++
69M29
or
+44W92++
60L46
or 44W93+
070
1
1-1/2 YES YES
2 YES YES YES
2-1/2 YES YES YES
3 YES YES YES
090
2 YES YES YES YES
2-1/2 YES YES YES YES
3 YES YES YES YES
110
2 YES YES YES YES
2-1/2 YES YES YES YES
3 YES YES YES YES
1
2 inch to 1-1/2 inch reducer required, must be eld provided.
* Requires eld-provided and installed 1-1/2” exhaust accelerator.
** Kit 51W11 is provided with a 1-1/2” accelerator, which must be used for all 45,000 and 70,000 furnace installations. When using
1-/2 in. piping, the pipe must be transitioned to 2 in. pipe when used with the Flush Mount Kit.
† Termination kits 44W92, 44W93, 30G28 and 81J20 approved for use in Canadian installations to meet CSAB149.
†† The 44W92 concentric kit is provided with a 1-1/2” accelerator, which must be installed on the exhaust outlet when this kit is used
with the 45,000 and 70,000 furnaces. When using 1-1/2 in. piping, the pipe must be transitioned to 2 in. pipe when used with the
Concentric Kit.
Table 3. Outdoor Termination Kits
1. Seal any unused openings in the common venting system.
2. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage,
corrosion, or other deciencies which could cause an unsafe condition.
3. Close all building doors and windows and all doors between the space in which the appliances remaining connected to
the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not
connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so
507961-02B Page 17 of 57Issue 2302
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close replace dampers.
4. Follow the lighting instructions. Turn on the appliance
that is being inspected. Adjust the thermostat so that
the appliance operates continuously.
5. After the main burner has operated for 5 minutes, test
for leaks of ue gases at the draft hood relief opening.
Use the ame of a match or candle.
6. After determining that each appliance connected to
the common venting system is venting properly, (step
3) return all doors, widows, exhaust fans, replace
dampers, and any other gas burning appliances to
their previous mode of operation.
7. If a venting problem is found during any of the
preceding tests, the common venting system must be
modied to correct the problem.
8. Resize the common venting system to the minimum
vent pipe size determined by using the appropriate
tables in Appendix G. (These are in the current
standards of the National Fuel Gas Code ANSI
Z223.1.)
Figure 22.
If this gas furnace replaces a furnace which was commonly vented
with another gas appliance, the size of the existing vent pipe for
that gas appliance must be checked. Without the heat of the original
furnace ue products, the existing vent pipe is probably oversized
for the single water heater or other appliance. The vent should be
checked for proper draw with the remaining appliance.
Exhaust Piping
Route piping to outside of structure. Continue with
installation following instructions given in piping termination
section.
Do Not discharge exhaust into an existing stack or
stack that also serves another gas appliance. If vertical
discharge through an existing unused stack is required,
insert PVC pipe inside the stack until the end is even
with the top or outlet end of the metal stack.
CAUTION
The exhaust vent pipe operates under positive pressure
and must be completely sealed to prevent leakage of
combustion products into the living space.
CAUTION
Vent Piping Guidelines
This gas furnace can be installed as either Non-Direct Vent
or a Direct Vent gas central furnace.
NOTE: In Non-Direct Vent installations, combustion air is
taken from indoors and ue gases are discharged outdoors.
Intake and exhaust pipe sizing - Size pipe according to
Table 4 and Table 5A through Table 5C. Table 4 lists the
minimum vent pipe lengths permitted. Table 5A through
Table 5C lists the maximum pipe lengths permitted.
Regardless of the diameter of pipe used, the standard roof
and wall terminations described in section Exhaust Piping
Terminations should be used. Exhaust vent termination
pipe is sized to optimize the velocity of the exhaust gas as
it exits the termination. Refer to Table 7.
In some applications which permit the use of several
dierent sizes of vent pipe, a combination vent pipe may
be used. Contact Blue Summit for assistance in sizing vent
pipe in these applications.
NOTE: The exhaust collar on all models is sized to
accommodate 2” Schedule 40 vent pipe. When vent
pipe which is larger than 2” must be used in an upow
application, a transition must be applied at the exhaust
collar in order to properly step to the larger diameter vent
pipe. Contact Blue Summit for more information concerning
sizing of vent systems which include multiple pipe sizes.
507961-02BPage 18 of 57 Issue 2302
NOTE: All horizontal runs of exhaust pipe must slope back toward
unit. A minimum of 1/4” (6 mm) drop for each 12” (305 mm) of
horizontal run is mandatory for drainage.
NOTE: Exhaust pipe MUST be glued to furnace exhaust ttings.
NOTE: Exhaust piping should be checked carefully to make sure
there are no sages or low spots.
Figure 23. Exhaust Pipe
Horizontal Application
Do not use screens or perforated metal in exhaust or
intake terminations. Doing so will cause freeze-ups and
may block the terminations.
IMPORTANT
Table 4. Minimum Vent Pipe Lengths
Capacity Min. Vent Length*
070, 090, 110
15 ft. or
5 ft. plus 2 elbows or
10 ft. plus 1 elbow
*Any approved termination may be added to the minimum
length listed.
Use the following steps to correctly size vent pipe diameter.
070, 090,
110 btuh
Standard or
Concentric?
See Table 3
Intake or
Exhaust?
1-1/2”, 2”,
2-1/2”
or 3”
Furnace capacity?
1
Which termination?
2
Which needs most
elbows?
3
How many?
4
Desired pipe size?
5
What is the altitude?
6
Use Table 5 to find
max pipe length.
7
Figure 24.
507961-02B Page 19 of 57Issue 2302
Maximum Allowable Intake or Exhaust Vent Length in Feet
Standard Termination at Elevation 0 - 4,500 ft
Number of 90°
Elbows Used
1-1/2" Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
61 39 19 110 88 53 132 113 113
2 15 56 34 14 105 83 48 127 108 108
3 10 51 29 9 100 78 43 122 103 103
4
n/a
46 24
n/a
95 73 38 117 98 98
5 41 19 90 68 33 112 93 93
6 36 14 85 63 28 107 88 88
7 31 9 80 58 23 102 83 83
8 26
n/a
75 53 18 97 78 78
9 21 70 48 13 92 73 73
10 16 65 43 8 87 68 68
Standard Termination Elevation 4,501 - 10,000 ft
Number of 90°
Elbows Used
1-1/2" Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
61 39
n/a
110 88 53 132 113 113
2 15 56 34 105 83 48 127 108 108
3 10 51 29 100 78 43 122 103 103
4
n/a
46 24 95 73 38 117 98 98
5 41 19 90 68 33 112 93 93
6 36 14 85 63 28 107 88 88
7 31 9 80 58 23 102 83 83
8 26
n/a
75 53 18 97 78 78
9 21 70 48 13 92 73 73
10 16 65 43 8 87 68 68
*Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and
Exhaust must be same pipe size.
Table 5A.
507961-02BPage 20 of 57 Issue 2302
Maximum Allowable Intake or Exhaust Vent Length in Feet
Concentric Termination at Elevation 0 - 4,500 ft
Number of 90°
Elbows Used
1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
53 37 17 100 84 49 116 109 109
2 15 48 32 12 95 79 44 111 104 104
3 10 43 27 7 90 74 39 106 99 99
4
n/a
38 22
n/a
85 69 34 101 94 94
5 33 17 80 64 29 96 89 89
6 28 12 75 59 24 91 84 84
7 23 7 70 54 19 86 79 79
8 18
n/a
65 49 14 81 74 74
9 13 60 44 9 76 69 69
10 8 55 39 n/a 71 64 64
Concentric Termination Elevation 4,501 - 10,000 ft
Number of 90°
Elbows Used
1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
53 37
n/a
100 84 49 116 109 109
2 15 48 32 95 79 44 111 104 104
3 10 43 27 90 74 39 106 99 99
4
n/a
38 22 85 69 34 101 94 94
5 33 17 80 64 29 96 89 89
6 28 12 75 59 24 91 84 84
7 23 7 70 54 19 86 79 79
8 18
n/a
65 49 14 81 74 74
9 13 60 44 9 76 69 69
10 8 55 39 n/a 71 64 64
*Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and
Exhaust must be same pipe size.
Table 5B.
507961-02B Page 21 of 57Issue 2302
Maximum Allowable Exhaust Vent Lengths with Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl
Space for Intake Air in Feet
Standard Termination at Elevation 0 - 4500 ft
Number of 90°
Elbows Used
1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
51 29 9 95 73 38 112 93 93
2 15 46 24 4 90 68 33 107 88 88
3 10 41 19
n/a
85 63 28 102 83 83
4
n/a
36 14 80 58 23 97 78 78
5 31 9 75 53 18 92 73 73
6 26 4 70 48 13 87 68 68
7 21
n/a
65 43 8 82 63 63
8 16 60 38 3 77 58 58
9 11 55 33
n/a
72 53 53
10 6 50 28 67 48 48
Standard Termination Elevation 4,501 - 10,000 ft
Number of 90°
Elbows Used
1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe
Capacity Capacity Capacity Capacity
70 90 110 70 90 110 70 90 110 70 90 110
1 20
n/a n/a
51 29
n/a
95 73 38 112 93 93
2 15 46 24 90 68 33 107 88 88
3 10 41 19 85 63 28 102 83 83
4
n/a
36 14 80 58 23 97 78 78
5 31 9 75 53 18 92 73 73
6 26 4 70 48 13 87 68 68
7 21
n/a
65 43 8 82 63 63
8 16 60 38 3 77 58 58
9 11 55 33
n/a
72 53 53
10 6 50 28 67 48 48
* Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and
Exhaust must be same pipe size.
* Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length
calculation.
Table 5C.
507961-02BPage 22 of 57 Issue 2302
TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR
NON-DIRECT VENT APPLICATIONS
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
NOTE: Exhaust pipe and intake pipe must be the same diameter.
2”
2”
2”
2”
or
or
TRANSITION
3”
*2”
2”
EXHAUST
Pipe size determined in Table 5
DO NOT transition
from smaller to larger
pipe in horizontal runs
of exhaust pipe.
070 Only
TRANSITION
1-1/2”
2”
6”
MINIMUM
Figure 25. Typical Exhaust Pipe Connections in Upow Direct or Non-Direct Vent Applications
TYPICAL EXHAUST PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT
APPLICATIONS (RIGHT-HAND DISCHARGE SHOWN)
SIDE VIEW
45°
MAX
45°
MAX
2”
2”
2”
2”
or
2”
12” max.
EXHAUST
TRANSITION
3”
*2”
*2”
EXHAUST
TRANSITION
1-1/2”
2”
2”
EXHAUST
or
NOTE: 1-1/2” Vent
Pipe Diameter Allowed
Only on 070 Units
.
DO NOT transition
from larger to smaller
pipe in horizontal runs
of exhaust pipe.
EXHAUST
DO NOT transition
from smaller to larger
pipe in horizontal runs
of exhaust pipe.
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
NOTE: Exhaust pipe and intake pipe must be the same diameter.
Figure 26. Typical Exhaust Pipe Connections in Horizontal Direct or Non-Direct Vent Applications
(Right Hand Discharge Shown)
507961-02B Page 23 of 57Issue 2302
TYPICAL INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR
NON-DIRECT VENT APPLICATIONS
2”
2”
2”
2”
or
AIR
INTAKE
2”
TRANSITION
3”
*2”
Pipe size determined in Table 5
or
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
NOTE: Exhaust pipe and intake pipe must be the same diameter.
Figure 27. Typical Air Intake Pipe Connections in Upow Direct Vent Applications
TYPICAL INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT
APPLICATION (RIGHT-HAND DISCHARGE SHOWN)
2”
2”
2”
2”
or
2”
AIR
INTAKE
TRANSITION
3”
*2”
*2”
* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.
NOTE: Exhaust pipe and intake pipe must be the same diameter.
Figure 28. Typical Air Intake Pipe Connections in Horizontal Direct Vent Applications
(Right Hand Discharge Shown)
Intake Piping
(Figure 27 through Figure 30)
This gas furnace may be installed in either direct vent
or non-direct vent applications. In non-direct vent
applications, when intake air will be drawn into the furnace
from the surrounding space, the indoor air quality must be
considered and guidelines listed in Combustion, Dilution
and Ventilation Air section must be followed
Follow the next two steps when installing the unit in Direct
Vent applications, where combustion air is taken from
outdoors and ue gases are discharged outdoors. The
provided air intake screen must not be used in direct vent
applications (outdoors).
1. Use transition solvent cement or a sheet metal screw
to secure the intake pipe to the inlet air connector.
2. Route piping to outside of structure. Continue with
installation following instructions given in general
guide lines for piping terminations and in intake and
exhaust piping terminations for direct vent sections.
Refer to Table 5A through Table 5C for pipe sizes.
507961-02BPage 24 of 57 Issue 2302
Figure 29. Typical Air Intake Pipe Connections
Upow Non-Direct Vent Applications
Intake
Debris
Screen
(Provided)
NOTE: Debris screen and elbow may be rotated, so that screen
may be positioned to face forward or to either side.
Figure 30. Typical Air Intake Pipe Connections
Horizontal Non-Direct Vent Applications
(Horizontal Right-Hand Air Discharge Application
Shown)
Intake
Debris
Screen
(Provided)
OR
PVC Pipe
Coupling
NOTE: Debris screen may be positioned straight out (preferred) or
with an elbow rotated to face down.
Follow the next steps when installing the unit in Non–Direct
Vent applications where combustion air is taken from
indoors and ue gases are discharged outdoors.
1. Use eld-provided materials and the factory-provided
air intake screen to route the intake piping as shown in
Figure 29 or Figure 30. Maintain a minimum clearance
of 3” (76 mm) around the air intake opening. The air
intake opening (with the protective screen) should
always be directed forward or to either side in the
upow position, and either straight out or downward in
the horizontal position.
The air intake piping must not terminate too close to
the ooring or a platform. Ensure that the intake air
inlet will not be obstructed by loose insulation or other
items that may clog the debris screen.
2. If intake air is drawn from a ventilated attic (Figure
31) or ventilated crawlspace (Figure 32) the exhaust
vent length must not exceed those listed in Table 5C.
If 3” diameter pipe is used, reduce to 2” diameter pipe
at the termination point to accommodate the debris
screen.
3. Use a sheet metal screw to secure the intake pipe to
the connector, if desired.
If this unit is being installed in an application with
combustion air coming in from a space serviced by an
exhaust fan, power exhaust fan, or other device which
may create a negative pressure in the space, take care
when sizing the inlet air opening. The inlet air opening
must be sized to accommodate the maximum volume
of exhaust air as well as the maximum volume of
combustion air required for all gas appliances serviced
by this space.
CAUTION
Figure 31. Equipment in Conned Space
(Inlet Air from Ventilated Attic and Outlet Air to
Outside)
Ventilation Louvers
Inlet Air
(Minimum 12 in.
(305mm) above
Attic Floor)
Roof Terminated
Exhaust Pipe
Furnace
*Intake Debris
Screen
(Provided)
* See Maximum Vent Lengths table
NOTE-The inlet and outlet air openings shall each have a
free area of at least one square inch per 4,000 Btu (645mm
2
per 1.17kW) per hour of the total input rating of all equipment
in the enclosure.
507961-02B Page 25 of 57Issue 2302
Figure 32. Equipment in Conned Space
(Inlet Air from Ventilated Crawlspace and Outlet Air to
Outside)
Roof Terminated
Exhaust Pipe
Furnace
Ventilation
Louvers
(Crawl Space)
*Intake Debris Screen Provided
Inlet Air
Minimum
12 in. (305mm)
above Crawl
Space Floor
Coupling or
3 in. to 2 in.
Transition
(Field Provided)
* See Maximum Vent Lengths table
NOTE-The inlet and outlet air openings shall each have a
free area of at least one square inch per 4,000 Btu (645mm
2
per 1.17kW) per hour of the total input rating of all equipment
in the enclosure.
General Guidelines for Vent Terminations
In Non–Direct Vent applications, combustion air is taken
from indoors and the ue gases are discharged to the
outdoors. This furnace is then classied as a non–direct
vent, Category IV gas furnace.
In Direct Vent applications, combustion air is taken from
outdoors and the ue gases are discharged to the outdoors.
The furnace is then classied as a direct vent, Category IV
gas furnace.
In both Non–Direct Vent and Direct Vent applications, the
vent termination is limited by local building codes. In the
absence of local codes, refer to the current National Fuel
Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current
CSA-B149 Natural Gas and Propane Installation Codes in
Canada for details.
In Direct Vent applications, the vent termination is limited
by local building codes. In the absence of local codes,
refer to the current National Fuel Gas Code ANSI Z223-1/
NFPA 54 in U.S.A., and current CSA-B149 Natural Gas
and Propane Installation Codes in Canada for details.
Position termination according to location given in Figure
34 and Figure 35. In addition, position termination so it
is free from any obstructions and 12” above the average
snow accumulation.
At vent termination, care must be taken to maintain
protective coatings over building materials (prolonged
exposure to exhaust condensate can destroy protective
coatings). It is recommended that the exhaust outlet not be
located within 6 feet (1.8 m) of a condensing unit because
the condensate can damage the painted coating.
NOTE: See Table 6 for maximum allowed exhaust pipe
length without insulation in unconditioned space during
winter design temperature below 32° F (0° C). If required,
exhaust pipe should be insulated with 1/2” (13 mm),
Armaex or equivalent when run through an unconditional
area. In extremely cold climate areas with temperature
below 20° F (6.7° C) it is recommended that, 3/4” (19 mm)
Armaex or equivalent be used. Insulation on outside
runs of exhaust pipe should be painted or wrapped to
protect insulation from deterioration in accordance with
the insulation manufacturers recommendation. Exhaust
pipe insulation may not be necessary in some specic
applications.
NOTE: During extremely cold temperatures, below
approximately 20° F (6.7° C), units with long runs of vent
pipe through unconditioned space, even when insulated,
may form ice in the exhaust termination that prevents the
unit from operating properly. Longer run times of at least 5
minutes will alleviate most icing problems. Also, a heating
cable may be installed on exhaust piping and termination
to prevent freeze-ups. Heating cable installation kits are
available see unit specication sheets for part numbers.
Do not use screens or perforated metal in exhaust
terminations. Doing so will cause freeze-ups and may
block the terminations.
IMPORTANT
For Canadian Installations Only:
In accordance to CSA International B149 installation
codes, the minimum allowed distance between the
combustion air intake inlet and the exhaust outlet of
other appliances shall not be less than 12 inches (305
mm).
IMPORTANT
507961-02BPage 26 of 57 Issue 2302
Maximum Allowable Exhaust Vent Pipe Length
3
(in ft.) without Insulation in Unconditioned Space for Winter Design
Temperatures
Winter Design Temperatures1 ºF (ºC)
Vent Pipe
Diameter
Unit Input Size
070 090 110
32 to 21
(0 to -6)
PVC
2
PP PVC
2
PP PVC
2
PP
1-1/2 in. 25 N/A N/A N/A N/A N/A
2 in. 33 30 46 42 30 30
2-1/2 in. 26 N/A 37 N/A 36 N/A
3 in. 21 21 30 30 29 29
20 to 1
(-7 to -17)
1-1/2 in. 20 N/A N/A N/A N/A N/A
2 in. 19 17 28 25 27 24
2-1/2 in. 14 N/A 21 N/A 20 N/A
3 in. 9 9 16 16 14 14
0 to -20
(-18 to -29)
1-1/2 in. 13 N/A N/A N/A N/A N/A
2 in. 12 10 19 16 18 15
2-1/2 in. 7 N/A 13 N/A 12 N/A
3 in. N/A N/A 8 8 7 7
1
Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.
2
Poly-Propylene vent pipe (PP) by Duravent and Centrotherm
3
Vent length in table is equivalent length. Each elbow is equivalent to 5ft of straight pipe and should be included when measuring
total length.
NOTE - Concentric terminations are the equivalent of 5’ and should be considered when measuring pipe length.
NOTE- Maximum uninsulated vent lengths listed may include the termination (vent pipe exterior to the structure) and cannot exceed 5
linear feet or the maximum allowable intake or exhaust vent length listed in Table 5A through Table 5C or Table 6.
NOTE - If insulation is required an unconditioned space, it must be located on the pipe closed to the furnace. See Figure 33.
Table 6.
Conditioned
Space
Unconditioned
Space
Exhaust
Pipe
Intake
Pipe
Conditioned
Space
Pipe Insulation
Figure 33. Insulating Exhaust Pipe in an Unconditioned Space
507961-02B Page 27 of 57Issue 2302
VENT TERMINATION CLEARANCES
FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA
K
D
E
L
B
C
F
G
A
B
J
A
M
I
H
INSIDE CORNER
DETAIL
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL
IS NOT PERMITTED
Fixed
Closed
Operable
B
Fixed
Closed
Operable
B
B
A =
B =
C =
D =
E =
F =
G =
H =
I =
J =
K =
L =
M =
US Installations
1
Canadian Installations
2
Clearance above grade, veranda,
porch, deck or balcony
Clearance to window or
door that may be opened
4 feet (1.2 m) below or to side of opening;
1 foot (30cm) above opening
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
Clearance to permanently
closed window
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 feet (610 mm)
from the center line of the terminal
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
tended above meter / regulator assembly
Clearance to service regulator
vent outlet
Clearance to non-mechanical air
pliance
ply inlet
Clearance above paved sidewalk or
paved driveway located on public property
Clearance under veranda, porch, deck or balcony
* 12”
* Equal to or greater than soffit depth.
*
* 3 feet (.9m)
* 12”
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
3 feet (.9m)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
3 feet (.9m) above if within 10 feet
(3m) horizontally
6 feet (1.8m)
7 feet (2.1m)†
12 inches (305mm)‡
1
2
†
‡
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
7 feet (2.1m)†
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
* No minimum to outside corner * No minimum to outside corner
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
*12 inches (305mm)‡
**
Permitted only if veranda, porch, deck or balcony is fully open on a minimum of
two sides beneath the floor. Avoiding this location is recommended if possible.
*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA
B149.1, clearance will be in accordance with local installation
codes and the requirements of the gas supplier and these
installation instructions.”
NOTE - This figure is intended to illustrate clearance
requirements and does not serve as a substitute for locally
adopted installation codes.
A vent shall not terminate directly above a sidewalk or paved driveway that is
located between two single family dwellings and serves both dwellings.
In accordance with the current CSA B149.1, Natural Gas and Propane Installation
Code
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code
12 inches (305mm) or 12 inches (305mm)
above average snow accumulation.
12 inches (305mm) or 12 inches (305mm)
above average snow accumulation.
Figure 34. Vent Termination Clearances for Non-Direct Vent Installations in the USA and Canada
507961-02BPage 28 of 57 Issue 2302
VENT TERMINATION CLEARANCES
FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA
K
D
E
L
B
C
F
G
A
B
J
A
M
I
H
INSIDE CORNER
DETAIL
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL
IS NOT PERMITTED
Fixed
Closed
Operable
B
Fixed
Closed
Operable
B
B
A =
B =
C =
D =
E =
F =
G =
H =
I =
J =
K =
L =
M =
US Installations
1
Canadian Installations
2
12 inches (305mm) or 12 inches (305mm)
above average snow accumulation.
12 inches (305mm) or 12 inches (305mm)
above average snow accumulation.
Clearance above grade, veranda,
porch, deck or balcony
Clearance to window or
door that may be opened
6 inches (152mm) for appliances <10,000
pliances > 10,000 Btuh (3kw) and <50,000
pliances > 50,000 Btuh (15kw)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
Clearance to permanently
closed window
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 feet (610mm)
from the center line of the terminal
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
tended above meter / regulator assembly
Clearance to service regulator
vent outlet
Clearance to non-mechanical air
pliance
ply inlet
Clearance above paved sidewalk or
paved driveway located on public property
Clearance under veranda, porch, deck or balcony
* 12”
*
*
* 7 feet (2.1m)
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
3 feet (.9m)
6 inches (152mm) for appliances <10,000
pliances > 10,000 Btuh (3kw) and <50,000
pliances > 50,000 Btuh (15kw)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
3 feet (.9m) above if within 10 feet
(3m) horizontally
6 feet (1.8m)
7 feet (2.1m)†
12 inches (305mm)‡
* 12”
* Equal to or greater than soffit depth* Equal to or greater than soffit depth
* Equal to or greater than soffit depth * Equal to or greater than soffit depth
* No minimum to outside corner
* No minimum to outside corner
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
3 feet (.9m)
*
*12 inches (305mm)‡
Btuh (3kw), 9 inches (228mm) for ap-
Btuh (15kw), 12 inches (305mm) for ap-
Clearance to each side of center line ex-
Btuh (3kw), 9 inches (228mm) for ap-
Btuh (15kw), 12 inches (305mm) for ap-
supply inlet to building or the com-
bustion air inlet to any other ap-
Clearance to mechanical air sup-
1
2
†
‡
Permitted only if veranda, porch, deck or balcony is fully open on a minimum of
two sides beneath the floor. Avoiding this location is recommended if possible.
*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA
B149.1, clearance will be in accordance with local installation
codes and the requirements of the gas supplier and these
installation instructions.”
NOTE - This figure is intended to illustrate clearance
requirements and does not serve as a substitute for locally
adopted installation codes.
A vent shall not terminate directly above a sidewalk or paved driveway that is
located between two single family dwellings and serves both dwellings.
In accordance with the current CSA B149.1, Natural Gas and Propane Installation
Code
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code
Figure 35. Vent Termination Clearances for Direct Vent Installations in the USA and Canada
507961-02B Page 29 of 57Issue 2302
Details of Intake and Exhaust Piping
Terminations for Direct Vent Installations
NOTE: In Direct Vent installations, combustion air is taken
from outdoors and ue gases are discharged to outdoors.
NOTE: Flue gas may be slightly acidic and may adversely
aect some building materials. If any vent termination is
used and the ue gasses may impinge on the building
material, a corrosion resistant shield (minimum 24 inches
square) should be used to protect the wall surface. If the
optional tee is used, the protective shield is recommended.
The shield should be constructed using wood, plastic,
sheet metal or other suitable material. All seams, joints,
cracks, etc. in the aected area should be sealed using an
appropriate sealant. See Figure 44.
Intake and exhaust pipes may be routed either horizontally
through an outside wall or vertically through the roof. In
attic or closet installations, vertical termination through the
roof is preferred. Figure 36 through Figure 43 show typical
terminations.
1. Intake and exhaust terminations are not required to be
in the same pressure zone. You may exit the intake on
one side of the structure and the exhaust on another
side (Figure 37). You may exit the exhaust out the roof
and the intake out the side of the structure (Figure 38).
2. Intake and exhaust pipes should be placed as close
together as possible at termination end (refer to
illustrations). Minimum separation is 3” (76 mm)
on roof terminations and 6” (152 mm) on sidewall
terminations.
3. On roof terminations, the intake piping should terminate
straight down using two 90° elbows (see Figure 36).
4. Exhaust piping must terminate straight out or up as
shown. A reducer may be required on the exhaust
piping at the point where it exits the structure to
improve the velocity of exhaust away from the intake
piping. See Table 7.
Figure 36. Direct Vent Roof Termination Kit
UNCONDITIONED
ATTIC SPACE
SIZE PER EXHAUST PIPE
TERMINATION SIZE
REDUCTION TABLE
3” (76MM) MIN.
12” (305MM) ABOVE
AVERAGE SNOW
ACCUMULATION
3” (76MM) OR
2” (51MM) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
8” (203MM) MIN
Inches (MM)
1/2” (13MM) FOAM
INSULATION IN
UNCONDITIONED
SPACE
Figure 37. Exiting Exhaust and Intake Vent
(no common pressure zone)
Exhaust
Pipe
Furnace
Inlet Air
Minimum 12 in.
(305MM) above
grade or snow
accumulation
Figure 38. Exiting Exhaust and Intake Vent
(no common pressure zone)
Roof T
erminated
Exhaust Pipe
Furnace
Inlet Air
Minimum 12 in.
(305MM) above
grade or snow
accumulation
Capacity Exhaust Pipe Size
Termination Pipe
Size
070
2” (51mm),
2-1/2” (64mm),
3” (76mm)
1-1/2” (38mm)
090
2” (51mm)
110
* Units with the ush mount termination must use the 1-1/2”
accelerator supplied with the kit
Table 7. Exhaust Pipe Termination Size Reduction
NOTE: Care must be taken to avoid recirculation of
exhaust back into intake pipe.
5. On eld supplied terminations for sidewall exit, exhaust
piping may extend a maximum of 12 inches (305 mm)
for 2” PVC and 20 inches (508 mm) for 3” (76 mm)
PVC beyond the outside wall. Intake piping should be
as short as possible. See Figure 44.
6. On eld supplied terminations, a minimum distance
between the end of the exhaust pipe and the end of
the intake pipe without a termination elbow is 8” and a
minimum distance of 6” with a termination elbow. See
Figure 44.
507961-02BPage 30 of 57 Issue 2302
7. If intake and exhaust piping must be run up a side
wall to position above snow accumulation or other
obstructions, piping must be supported every 24”
(610 mm) as shown in Figure 44. Exhaust and
intake piping that is run up a wall is considered to
be in an unconditioned space, so piping should be
sized according to Table 6. The intake piping may be
equipped with a 90° elbow turndown. Using turndown
will add 5 feet (1.5 m) to the equivalent length of the
pipe.
8. A multiple furnace installation may use a group of up to
four terminations assembled together horizontally, as
shown in Figure 42.
Figure 39. Direct Vent Concentric Rooftop
Termination
71M80, 69M29 or 60L46 (US)
41W92 or 41W93 (Canada)
Minimum
Above Average
Snow
Accumulation
SHEET METAL STRAP
(Clamp and sheet metal strap
must be field installed to support
the weight of the termination kit.)
FLASHING
(Not Furnished)
CLAMP
FIELD-PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT DIFFERENT VENT
PIPE SIZE TO TERMINATION
1 1/2” (38mm) accelerator
provided on 71M80 & 44W92
kits for -045 and -070 models
12” (305mm)
INTAKE
AIR
EXHAUST
VENT
Figure 40. Flush-Mount Side Wall Termination
51W11
1-1/2” ACCELERATOR
(all -45, -070 and -090 units)
FURNACE
EXHAUST
PIPE
FURNACE
INTAKE
PIPE
4''
GLUE EXHAUST
END FLUSH INTO
TERMINATION
FLAT
SIDE
2” EXTENSION FOR 2” PVC
PIPE1” EXTENSION FOR 3”
PVC PIPE
Figure 41. Direct Vent Concentric Wall Termination
71M80, 69M29 OR 60L46 (US)
41W92 or 41W93 (Canada)
12” (305mm) Min.
above grade or
average snow
accumulation.
INTAKE
AIR
INTAKE
AIR
INTAKE
AIR
OUTSIDE
WALL
GRADE
CLAMP
(Not Furnished)
FIELD-PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT DIFFERENT VENT
PIPE SIZE TO TERMINATION
EXHAUST
VENT
1-1/2” (38mm) accelerator
provided on 71M80 & 44W92
kits for -045 and -070 models
EXHAUST
VENT
Figure 42. Optional Vent Termination for Multiple Unit
Installation of Direct Vent Wall Termination
EXHAUST
VENT
INTAKE
AIR
5-1/2”
(140mm)
Front View
12”
(305mm)
5”
(127mm)
18” MAX.
(457mm)
EXHAUST VENT
INTAKE
AIR
Inches (mm)
Side View
12” (305mm) Min.
above grade or
cumulation.
optional intake elbow
Figure 43. Direct Vent Application Using Existing
Chimney
STRAIGHT-CUT OR
ANGLE-CUT IN DIRECTION
OF ROOF SLOPE *
EXHAUST VENT
1/2” (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
ALTERNATE
INTAKE PIPE
INTAKE PIPE
INSULATION (optional)
EXTERIOR
PORTION OF
CHIMNEY
INSULATE
TO FORM
SEAL
SHEET
METAL TOP
PLATE
8” - 12”
(203mm - 305mm)
* SIZE TERMINATION
PIPE PER EXHAUST
PIPE TERMINATION
SIZE REDUCTION
TABLE
3” - 8”
(76mm -
203mm)
3” - 8”
(76mm -
203mm)
Minimum 12” (305mm)
above chimney top
plate or average snow
accumulation
NOTE: Do not discharge exhaust gases directly into any chimney
or vent stack. If vertical discharge through an existing unused
chimney or stack is required, insert piping inside chimney until
the pipe open end is above top of chimney and terminates as
illustrated. In any exterior portion of chimney, the exhaust vent
must be insulated.
507961-02B Page 31 of 57Issue 2302
* Use wall support every 24” (610 mm). Use two
wall supports if extension is greater than
24” (610 mm) but less than 48” (1219 mm).
NOTE − One wall support must be within 6” (152 mm)
from top of each pipe (intake and exhaust) to prevent
movement in any direction.
NOTE − FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO ADAPT
LARGER VENT PIPE SIZE
TO TERMINATION
STRAIGHT
APPPLICATION
EXTENDED
APPLICATION
D
B
D
B
A
2” (51mm)
Vent Pipe
3” (76mm)
Vent Pipe
A− Minimum clearance
above grade or average
snow accumulation
B− Maximum horizontal
separation between
intake and exhaust
D− Maximum exhaust
pipe length
E− Maximum wall support
distance from top of each
pipe (intake/exhaust)
12” (305 mm)
12” (305 mm)
12” (305 mm)
6” (152 mm)6” (152 mm)
6” (152 mm)6” (152 mm)
8” (203 mm)8” (203 mm)
20” (508 mm)
6” (152 mm)6” (152 mm)
A
Intake
Elbow
* WALL
SUPPORT
B
A
D
E
B
D
E
A
ALTERNATE TERMINATIONS (TEE & FORTY−FIVE DEGREE ELBOWS ONLY)
C2 -Minimum from end of
exhaust to inlet of intake
C1 -Minimum from end of
exhaust to inlet of intake
FIELD FABRICATED WALL TERMINATION
C1
C2
C1
C2
Front View of
Intake and Exhaust
Intake
Exhaust
C
B
1
2
D
A
C
3
Intake
Elbow
Exhaust
B
A
D
2” (51MM)
Vent Pipe
3” (76MM)
Vent Pipe
A− Clearance above
grade or average snow
accumulation
B− Horizontal
separation between
intake and exhaust
C− Minimum from
end of exhaust to
inlet of intake
D− Exhaust pipe length
E− Wall support distance
from top of each pipe
(intake/exhaust)
12” (305 mm) Min. 12” (305 mm) Min.
6” (152 mm) Min.
24” (610 mm) Max.
9” (227 mm) Min.
12” (305 mm) Min.
16” (405 mm) Max.
6” (152 mm) Max.
6” (152 mm) Min.
24” (610 mm) Max.
9” (227 mm) Min.
12” (305 mm) Min.
20” (508 mm) Max.
6” (152 mm) Max.
D
C
12”
1
2
E
B
A
1
The exhaust termination tee should be connected to the 2” or 3” PVC flue pipe as shown in the illustration.
Do not use an accelerator in applications that include an exhaust termination tee.
The accelerator is not required.
2
As required. Flue gas may be acidic and may adversely affect some building materials. If a side wall vent
termination is used and flue gases will impinge on the building materials, a corrosion-resistant shield
(24 inches square) should be used to protect the wall surface. If optional tee is used, the protective shield
is recommended. The shield should be constructed using wood, sheet metal or other suitable material.
All seams, joints, cracks, etc. in affected area, should be sealed using an appropriate sealant.
3
Exhaust pipe 45° elbow can be rotated to the side away from the combustion air inlet to direct exhaust
away from adjacent property. The exhaust must never be directed toward the combustion air inlet.
D
C
12”
1
2
E
B
A
Figure 44.
507961-02BPage 32 of 57 Issue 2302
Details of Exhaust Piping Terminations for Non-
Direct Vent Applications
Exhaust pipes may be routed either horizontally through
an outside wall or vertically through the roof. In attic or
closet installations, vertical termination through the roof
is preferred. Figure 45 through Figure 48 show typical
terminations.
1. Exhaust piping must terminate straight out or up as
shown. The termination pipe must be sized as listed
in Table 7. The specied pipe size ensures proper
velocity required to move the exhaust gases away
from the building.
2. On eld supplied terminations for side wall exit,
exhaust piping may extend a maximum of 12 inches
(305 mm) for 2” PVC and 20” (508 mm) for 3” (76 mm)
PVC beyond the outside wall. See Figure 44.
3. If exhaust piping must be run up a sidewall to position
above snow accumulation or other obstructions, piping
must be supported every 24” (610 mm) as shown in
Figure 47. When exhaust piping must be run up an
outside wall, any reduction in exhaust pipe size must
be done after the nal elbow.
Figure 45. Non-Direct Vent Roof Termination Kit
UNCONDITIONED
ATTIC SPACE
3” (76MM) OR
2” (51MM) PVC
PROVIDE SUPPORT
FOR EXHAUST LINES
12” (305MM)
ABOVE AVE.
SNOW
ACCUMULATION
SIZE PER EXHAUST PIPE
TERMINATION SIZE
REDUCTION TABLE
Figure 46. Non-Direct Vent Field Supplied Wall
Termination
SIZE TERMINATION
PER EXHAUST PIPE
TERMINATION SIZE
REDUCTION TABLE
FIELD-PROVIDED
REDUCER MAY BE
REQUIRED TO
ADAPT DIFFERENT
VENT PIPE SIZE TO
TERMINATION
SIZE TERMINATION
PER EXHAUST PIPE
TERMINATION SIZE
REDUCTION TABLE
* Use wall support every 24” (610 mm). Use two supports of extension is greater than 24”
(610 mm) but less than 48” (1219 mm).
FIELD-PROVIDED
REDUCER MAY BE
REQUIRED TO
ADAPT DIFFERENT
VENT PIPE SIZE TO
TERMINATION
Figure 47. Non-Direct Vent Field Supplied Wall
Termination Extended
Figure 48. Non-Direct Vent Application Using Existing
Chimney
STRAIGHT-CUT OR
ANGLE-CUT IN DIRECTION
OF ROOF SLOPE *
EXHAUST VENT
1/2” (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
INTAKE PIPE
INSULATION (optional)
EXTERIOR
PORTION OF
CHIMNEY
INSULATE
TO FORM
SEAL
SHEET
METAL TOP
PLATE
* SIZE TERMINATION PIPE PER EXHAUST
PIPE TERMINATION SIZE REDUCTION TABLE
Minimum 12” (305mm)
above chimney top
plate or average snow
accumulation
NOTE: Do not discharge exhaust gases directly into any chimney or
vent stack. If vertical discharge through an existing unused chimney
or stack is required, insert piping inside chimney until the pipe open
end is above top of chimney and terminate as illustrated. In any
exterior portion of chimney, the exhaust vent must be insulated.
Exhaust through Crawl Space Vent Option
507961-02B Page 33 of 57Issue 2302
All 33” condensing gas furnaces (92%+) are now approved
to be vented down through a crawl space. Ensure a vent
pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as
directed through the oor joists and into the crawl space.
See the following gures.
Consult the vent tables for vent lengths and approved
materials.
2” or 3”
Sanitary Tee
1/2” PVC
Drain Stub
Drain Trap
Assembly
Rubber Boot (51W18)
Drain Plug (15Z70)
Clamp
(51W18 Only)
From
Furnace
To Vent
Termination
Drain Trap
(assembled)
Figure 49. Kit 51W18 (USA) / 15Z70 (Canada) Parts
Identication and Assembly
Exhaust from
Furnace
To Te rmination
Exhaust from
Furnace
To Te rmination
* Kit 51W18 is shown.
Figure 50. Crawl Space Vent Pipe Drain Trap
Assembled Incorrectly
KIT 51W18 (USA)
Basement Floor
To Termination
1/2” PVC to
Code-Approved
Drain
24” max.
Downflow Furnace
Exhaust
KIT 15Z70 (Canada)
* Kit 51W18 is shown.
NOTE: Upow furnaces exhaust from the left side. All dimensions shown are typical for upow or downow furnaces.
NOTE: All horizontal runs of exhaust pipe must slope back toward the kit a minimum of 1/4” (6mm) for each 12” (305mm) to ensure drainage.
Figure 51. Upow or Downow Furnace with Exhaust through Crawl Space
507961-02BPage 34 of 57 Issue 2302
Condensate Piping
This unit is designed for either right or left side exit of
condensate piping in upow applications. In horizontal
applications, the condensate trap must extend below the
unit. An 8” service clearance is required for the condensate
trap. Refer to Figure 52 and Figure 54 for condensate trap
locations. Figure 58 shows trap assembly using 1/2” PVC
or 3/4” PVC.
Plug
(same on
left side)
Trap
(same on
right side)
1-1/2 in.
Figure 52. Condensate Trap and Plug Locations
(Unit shown in upow position)
NOTE: In upow applications where side return air lter is installed
on same side as the condensate trap, lter rack MUST be installed
beyond condensate trap or trap must be relocated to avoid
interference.
NOTE: If necessary the condensate trap may be installed
up to 5’ away from the furnace. Use PVC pipe to connect
trap to furnace condensate outlet. Piping from furnace
must slope down a minimum of 1/4” per ft. toward trap.
1. Determine which side condensate piping will exit the
unit, location of trap, eld-provided ttings and length
of PVC pipe required to reach available drain.
2. Use a large at head screw driver or a 1/2” drive
socket extension and remove plug (Figure 52) from
the cold end header box at the appropriate location
on the side of the unit. Install provided 3/4 NPT street
elbow tting into cold end header box. Use Teon tape
or appropriate pipe dope.
3. Install the cap over the clean out opening at the base
of the trap. Secure with clamp. See Figure 58.
4. Install drain trap using appropriate PVC ttings, glue
all joints. Glue the provided drain trap as shown in
Figure 58. Route the condensate line to an open drain.
Condensate line must maintain a 1/4” downward slope
from the furnace to the drain.
Do not use copper tubing or existing copper condensate
lines for drain line.
CAUTION
5. Figure 54 and Figure 55 show the furnace and
evaporator coil using a separate drain. If necessary
the condensate line from the furnace and evaporator
coil can drain together. See Figure 56 and Figure 57.
Upow furnace (Figure 53) - In upow furnace
applications the eld provided vent must be a minimum
1” to a maximum 2” length above the condensate drain
outlet connection. Any length above 2” may result in a
ooded heat exchanger if the combined primary drain
line were to become restricted.
Horizontal furnace (Figure 54) - In horizontal furnace
applications the eld provided vent must be minimum
4” to a maximum 5” length above the condensate drain
outlet connection. Any length above 5” may result in a
ooded heat exchanger if the combined primary drain
line were to become restricted.
NOTE: In horizontal applications it is recommended to
install a secondary drain pan underneath the unit and
trap assembly.
NOTE: Vinyl tubing may be used for condensate drain.
Tubing must be 1-1/4” o.d. X 1” i.d. and should be
attached to the drain on the trap using a hose clamp.
6. If unit will be started immediately upon completion of
installation, prime trap per procedure outlined in Unit
Start-Up section.
Condensate line must slope downward away from the
trap to drain. If drain level is above condensate trap,
condensate pump must be used. Condensate drain line
should be routed within the conditioned space to avoid
freezing of condensate and blockage of drain line. If
this is not possible, a heat cable kit may be used on the
condensate trap and line. Heating cable kit is available in
various lengths; 6 ft. (1.8 m) - kit no. 26K68; 24 ft. (7.3 m) -
kit no. 26K69; and 50 ft. (15.2 m) - kit no. 26K70.
Figure 53. Condensate Trap Locations
(Unit shown in upow position with remote trap)
*Piping from furnace must slope down a minimum of 1/4” per
ft. toward trap.
507961-02B Page 35 of 57Issue 2302
(Unit shown in horizontal left-hand discharge position)
Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap
5’ max.
PVC Pipe Only
Evaporator
Coil
Drain Pan
Condensate
DrainConnection
Field Provided Vent
(4” min. to 5” max. above
condensate drain connection)
(Trap at coil is optional)
4”min
5”max
Figure 54. Furnace with Evaporator Coil Using a Separate Drain
Condensate
Drain
Connection
Field Provided Vent
(1” min. 2” max. above
condensate connection)
Evaporator drain
line required
(Trap at coil is optional)
Figure 55. Furnace with Evaporator Coil Using a
Separate Drain
(1” min.to2” Max.above
condensate drain connection)
Condensate
Drain Connection
Evaporator drain
line required
(Trap at coil is optional)
Field-Provided Vent
Figure 56. Furnace with Evaporator Coil Using a
Common Drain
(Unit shown in horizontal left−hand discharge position)
Condensate Drain
Connection
(4” min.to5” Max. above
condensate drain connection)
5’ max.
PVC Pipe Only
Evaporator
Coil
Drain Pan
Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap
(Trap at coil is optional)
4”min
5”max
Field-Provided Vent
Figure 57. Furnace with Evaporator Coil Using a Common Drain
507961-02BPage 36 of 57 Issue 2302
Figure 58. Trap / Drain Assembly Using 1/2” PVC or 3/4” PVC
507961-02B Page 37 of 57Issue 2302
When combining the furnace and evaporator coil
drains together, the A/C condensate drain outlet must
be vented to relieve pressure in order for the furnace
pressure switch to operate properly.
IMPORTANT
Figure 59. Condensate Trap with Optional Overow
Switch
Gas Piping
If a exible gas connector is required or allowed by
the authority that has jurisdiction, black iron pipe shall
be installed at the gas valve and extend outside the
furnace cabinet. The exible connector can then be
added between the black iron pipe and the gas supply
line.
CAUTION
Do not exceed 600 in.-lbs. (50 ft.-lbs.) torque when
attaching the gas piping to the gas valve.
WARNING
1. Gas piping may be routed into the unit through either
the left or right hand side. Supply piping enters into the
gas valve from the side of the valve as shown in Figure
61 and Figure 62.
A low inlet pressure switch in LP/propane applications
is recommended.
IMPORTANT
2. When connecting gas supply, factors such as length
of run, number of ttings and furnace rating must be
considered to avoid excessive pressure drop. Table 8
lists recommended pipe sizes for typical applications.
NOTE: Use two wrenches when connecting gas piping
to avoid transferring to the manifold.
3. Gas piping must not run in or through air ducts,
clothes chutes, chimneys or gas vents, dumb waiters
or elevator shafts. Center gas line through piping hole.
Gas line should not touch side of unit. See Figure 61
and Figure 62.
4. Piping should be sloped 1/4 “ per 15 feet (6 mm per 5.6
m) upward toward the gas meter from the furnace. The
piping must be supported at proper intervals, every 8
to 10 feet (2.44 to 3.05 m), using suitable hangers or
straps. Install a drip leg in vertical pipe runs to serve as
a trap for sediment or condensate.
5. A 1/8” N.P.T. plugged tap or pressure post is located
on the gas valve to facilitate test gauge connection.
See Figure 60.
6. In some localities, codes may require installation of a
manual main shut-o valve and union (furnished by
installer) external to the unit. Union must be of the
ground joint type.
Compounds used on threaded joints of gas piping must
be resistant to the actions of liquied petroleum gases.
IMPORTANT
Leak Check
After gas piping is completed, carefully check all eld-
installed piping connections for gas leaks. Use a
commercially available leak detecting solution specically
manufactured for leak detection. Never use an open ame
to test for gas leaks.
The furnace must be isolated from the gas supply
system by closing the individual manual shut-o valve
during any gas supply system at pressures greater than
or equal to 1/2 psig (3.48 kPa, 14 inches w.c.). This
furnace and its components are designed, manufactured
and independently certied to comply with all applicable
ANSI/CSA standards. A leak check of the furnace and its
components is not required.
507961-02BPage 38 of 57 Issue 2302
Figure 60.
When testing pressure of gas lines, gas valve must be
disconnected and isolated. See Figure 60. Gas valves
can be damaged if subjected to pressures greater than
1/2 psig (3.48 kPa).
IMPORTANT
NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
FIELD
PROVIDED
AND INSTALLED
GROUND
JOINT
UNION
DRIP LEG
MANUAL
MAIN SHUT-OFF
VALVE
Upflow Application
Right Side Piping
(Alternate)
Gas Valve
In LP/Propane applications, a 4” BIP nipple must be
installed to allow clearance for the low inlet pressure switch.
GROUND
JOINT
UNION
Upflow Application
Left Side Piping
(Standard)
DRIP LEG
MANUAL
MAIN SHUT-OFF
VALVE
AUTOMATIC
GAS VALVE
(with manual
shut-off valve)
Gas Valve
Figure 61. Upow Applications
Possible Gas Piping Congurations
Figure 62. Horizontal Applications
Possible Gas Piping Congurations
NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
FIELD
PROVIDED
AND INSTALLED
GROUND
JOINT
UNION
DRIP LEG
MANUAL
MAIN SHUT-OFF
VALVE
Horizontal Application
Right-Side Air Discharge
Gas Valve
GROUND
JOINT
UNION
DRIP LEG
MANUAL
MAIN SHUT-OFF
VALVE
GROUND
JOINT
UNION
DRIP LEG
MANUAL
MAIN SHUT-OFF
VALVE
Horizontal Application
Left-Side Air Discharge
Gas Valve
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could
result in serious injury, death, or property damage.
Never use an open ame to test for gas leaks. Check
all connections using a commercially available soap
solution made specically for leak detection. Some
soaps used for leak detection are corrosive to certain
metals. Carefully rinse piping thoroughly after leak test
has been completed.
IMPORTANT
507961-02B Page 39 of 57Issue 2302
Gas Pipe Capacity - FT³/HR (kL/HR)
Table 8.
Nominal
Iron Pipe
Size -
inches
(mm)
Internal
Diameter
- inches
(mm)
Length of Pipe - feet (m)
10
(3.048)
20
(6.096)
30
(9.144)
40
(12.192)
50
(15.240)
60
(18.288)
70
(21.336)
80
(24.384)
90
(27.432)
100
(30.480)
1/2
(12.7)
.622
(17.799)
175
(4.96)
120
(3.40)
97
(2.75)
82
(2.32)
73
(2.07)
66
(1.87)
61
(1.73)
57
(1.61)
53
(1.50)
50
(1.42)
3/4
(19.05)
.824
(20.930)
360
(10.19)
250
(7.08)
200
(5.66)
170
(4.81)
151
(4.28)
138
(3.91)
125
(3.54)
118
(3.34)
110
(3.11)
103
(2.92)
1
(25.4)
1.049
(26.645)
680
(19.25)
465
(13.17)
375
(10.62)
320
(9.06)
285
(8.07)
260
(7.36)
240
(6.80)
220
(6.23)
205
(5.80)
195
(5.52)
1-1/4
(31.75)
1.380
(35.052)
1400
(39.64)
950
(26.90)
770
(21.80)
660
(18.69)
580
(16.42)
530
(15.01)
490
(13.87)
460
(13.03)
430
(12.18)
400
(11.33)
1-1/2
(38.1)
1.610
(40.894)
2100
(59.46)
460
(41.34)
1180
(33.41)
990
(28.03)
900
(25.48)
810
(22.94)
750
(21.24)
690
(19.54)
650
(18.41)
620
(17.56)
2
(50.8)
2.067
(52.502)
3950
(111.85)
2750
(77.87)
2200
(62.30)
1900
(53.80)
1680
(47.57)
1520
(43.04)
1400
(39.64)
1300
(36.81)
1220
(34.55)
1150
(32.56)
2-1/2
(63.5)
2.469
(67.713)
6300
(178.39)
4350
(123.17)
3520
(99.67)
3000
(84.95)
2650
(75.04)
2400
(67.96)
2250
(63.71)
2050
(58.05)
1950
(55.22)
1850
(52.38)
3
(76.2)
3.068
(77.927)
11000
(311.48)
7700
(218.03)
6250
(176.98)
5300
(150.07)
4750
(134.50)
4300
(121.76)
3900
(110.43)
3700
(104.77)
3450
(97.69)
3250
(92.03)
4
(101.6)
4.026
(102.260)
23000
(651.27)
15800
(447.39)
12800
(362.44)
10900
(308.64)
9700
(274.67)
9700
(274.67)
8100
(229.36)
7500
(212.37)
7200
(203.88)
6700
(189.72)
NOTE: Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specic gravity gas.
507961-02BPage 40 of 57 Issue 2302
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
Electrostatic discharge can aect electronic components.
Take precautions during furnace installation and service
to protect the furnace’s electronic controls. Precautions
will help to avoid control exposure to electrostatic
discharge by putting the furnace, the control and the
technician at the same electrostatic potential. Neutralize
electrostatic charge by touching hand and all tools on
an unpainted unit surface, such as the gas valve or
blower deck, before performing any service procedure.
CAUTION
Figure 63. Interior Make-Up Box Installation
Figure 64. Interior Make-Up Box Installation
The unit is equipped with a eld makeup box. The makeup
box may be moved to the right side of the furnace to
facilitate installation. Seal unused openings on left side
with plugs removed from right side. Secure the excess wire
to the existing harness to protect it from damage.
Refer to Figure 73 for eld wiring and Figure 74 for
schematic wiring diagram and troubleshooting.
1. The power supply wiring must meet Class I restrictions.
Protected by either a fuse or circuit breaker, select
circuit protection and wire size according to unit
nameplate.
NOTE: Unit nameplate states maximum current draw.
Maximum over current protection allowed is shown in
Table 10.
2. Holes are on both sides of the furnace cabinet to
facilitate wiring.
3. Install a separate (properly sized) disconnect switch
near the furnace so that power can be turned o for
servicing.
Table 9.
Capacity
Maximum Over-Current
Protection (Amps)
070*B12, 090*C12 15
090*C20, 110*C20 20
4. Before connecting the thermostat, check to make sure
the wires will be long enough for servicing at a later
date. Make sure that thermostat wire is long enough to
facilitate future removal of blower for service.
5. Complete the wiring connections to the equipment.
Use the provided unit wiring diagram and the eld
wiring diagram shown in Figure 73. Use 18 gauge
wire or larger that is suitable for Class II rating for
thermostat connections.
6. Electrically ground the unit according to local codes or,
in the absence of local codes, according to the current
National Electric Code (ANSI/NFPA No. 70). A green
ground wire is provided in the eld make-up box.
NOTE: This furnace contains electronic components
that are polarity sensitive. Make sure that the furnace
is wired correctly and is properly grounded.
7. One line voltage “ACC” 1/4” spade terminal is provided
on the furnace integrated control. Any electronic air
cleaner or other accessory rated up to one amp can
be connected to this terminal with the neutral leg of the
circuit being connected to one of the provided neutral
terminals. This terminal is energized when the indoor
blower is operating.
8. One line voltage “HUM” 1/4” spade terminal is provided
on the furnace integrated control. Any humidier rated
up to one amp can be connected to this terminal
with the neutral leg of the circuit being connected to
one of the provided neutral terminals. This terminal
is energized in the heating mode whenever the
combustion air inducer is operating.
507961-02B Page 41 of 57Issue 2302
9. Install the room thermostat according to the instructions
provided with the thermostat. If the furnace is being
matched with a heat pump, refer to the instruction
packaged with the dual fuel thermostat.
Indoor Blower Speeds
1. When the thermostat is set to “FAN ON,” the indoor
blower will run continuously at approximately 38%
of the second stage cooling speed when there is no
cooling or heating demand. See Table 13 for allowable
continuous circulation speeds.
2. When this unit is running in the heating mode, the
indoor blower will run on the heating speed designated
by the positions of DIP switches 1 (A,B,C,D) of the
HEAT jumper plug. When the heat demand is satised,
the indoor blower will continue to run at the low stage
heat cfm for the duration of the user-selected heat
blower o delay. The user can select one of the four
preset heat blower o delays (60/90/120/180 sec) by
repositioning the movable shunt on the 5-pin header
on the ignition control.
Figure 65. Heat Blower O Delay Moveable Shunt
60
180
120
90
Heat Blower OFF
Delay Moveable
Shunt
P4
3. When there is a cooling demand, the indoor blower will
run on the cooling speed designated by the positions
of DIP switches (A, B, C, D) of the COOL jumper plug.
Generator Use - Voltage Requirements
The following requirements must be kept in mind when
specifying a generator for use with this equipment:
• The furnace requires 120 volts ± 10% (Range: 108
volts to 132 volts).
• The furnace operates at 60 Hz ± 5% (Range: 57 Hz
to 63 Hz).
• The furnace integrated control requires both polarity
and proper ground. Both polarity and proper grounding
should be checked before attempting to operate the
furnace on either permanent or temporary power.
• Generator should have a wave form distortion of less
than 5% THD (Total Harmonic Distortion).
Electrical Wiring
Risk of electrical shock. Disconnect electrical power
at the circuit breaker or service panel before making
electrical connections. Failure to disconnect power
supplies can result in property damage, personal injury,
or death.
WARNING
The furnace must be grounded and wired in accordance
with local codes or, in the absence of local codes, with the
National Electrical Code ANSI/NFPA No. 70 (latest edition)
and/or CSA C22.1 Electrical Code (latest edition) if an
external electrical source is utilized.
In all instances, other than wiring for the thermostat,
the wiring to be done and any replacement of wire shall
conform with the temperature limitation for Type T wire
–63°F (35°C) rise.
Connect a suciently sized wire with ground to the
furnace’s line voltage connections and ground wire. Refer
to the furnace rating plate for electrical characteristics
to be used in sizing eld supply wiring and overcurrent
protection.
The line voltage supply should be routed through a readily
accessible disconnect located within sight of the furnace. A
junction box on the furnace side panel is provided for line
voltage connections. Refer to the furnace wiring diagram
for specic connection information.
Proper polarity of the supply connections (“HOT” and
“NEUTRAL”) must be observed to ensure that safety
controls provide the protection intended.
A connection to the unit’s ground wire and actual earth
ground (typically a ground stake or buried steel pipe) must
be maintained for proper operation.
Thermostat
Install a room thermostat according to the instructions
furnished with it. Select a location on an inside wall that
is not subject to drafts, direct sunshine, or other heat
sources. The initial heat anticipator setting should be equal
to the total current draw of the control circuit. Low voltage
thermostat connections are to be made to the integrated
ignition/blower control board as indicated on the wiring
diagram.
NOTE: The automatic heat staging option allows a single
stage thermostat to be used with two stage furnace
models (BG962UHV). To activate this option, move the
jumper pin (see Figure 66) to desired setting (5 minutes
or 10 minutes). The furnace will start on 1st stage heat
and stay at 1st stage heat for the duration of the selected
time before switching to 2nd stage heat. W1 on the control
board must be connected to W1 on the thermostat.
507961-02BPage 42 of 57 Issue 2302
Figure 66. Automatic Heat Staging Jumper
Humidier
Terminals are provided on the integrated ignition/blower
control board for connection to a 120-volt humidier. The
“HUM” terminal is energized whenever the thermostat
calls for heat. See the furnace wiring diagram for specic
connection information.
Electronic Air Cleaner
Terminals are provided on the integrated ignition/blower
control board for connection of a 120-volt electronic air
cleaner. The “EAC” terminal is energized whenever the
thermostat calls for heat, cooling, or continuous blower. See
furnace wiring diagram for specic connection information.
Variable Speed Features
This furnace is equipped with a variable speed circulation
air blower motor that will deliver a constant airow within a
wide range of external static pressures. Other features of
this variable speed motor include:
Soft Start
The variable speed motor will slowly ramp up to normal
operating speed. This minimizes noise and increases
comfort by eliminating the initial blasts of air encountered
with standard motors.
Soft Stop
At the end of a cooling or heating cycle, the variable speed
motor will slowly ramp down after a short blower “o” delay.
If continuous blower operation has been selected, the
variable speed motor will slowly ramp down until it reaches
the airow for that mode.
Passive and Active Dehumidication
Passive Dehumidication
For situations where humidity control is a problem, a
dehumidication feature has been built into the variable
speed motor. At the start of each cooling cycle, the variable
speed motor will run at 82% of the rated airow for 7.5
minutes. After 7.5 minutes has elapsed, the motor will
increase to 100% of the rated airow.
Active Dehumidication
To achieve additional dehumidication, clip the jumper
wire located below the DEHUM terminal on the integrated
ignition/blower control board and connect a humidity
control that opens on humidity rise to the DEHUM and
R terminals. The DEHUM terminal on the control board
must be connected to the normally closed contact of the
humidity control so that the board senses an open circuit
on high humidity. In this setup, the variable speed motor
will operate at a 30% reduction in the normal cooling airow
rate when there is a call for dehumidication.
Both the passive and active dehumidication methods
described above can be utilized on the same furnace.
Circulating Airow Adjustments
Cooling Mode
The units are factory set for the highest airow for each
model. Adjustments can be made to the cooling airow
by repositioning the jumper plug marked COOL – A, B, C,
D (see Figure 67). To determine what CFM the motor is
delivering at any time, count the number of times the amber
LED on the control board ashes. Each ash signies 100
CFM; count the ashes and multiply by 100 to determine
the actual CFM delivered (for example: 10 ashes x 100 =
1000 CFM).
Heating Mode
These units are factory set to run at the middle of the
heating rise range as shown on the unit rating plate. If
higher or lower rise is desired, reposition the jumper plug
marked HEAT - A, B, C, C (see Figure 66). See Table 12
for allowable heating speeds. To determine what CFM the
motor is delivering at any time, count the number of times
the amber LED on the control board ashes. Each ash
signies 100 CFM; count the ashes and multiply by 100
to determine the actual CFM delivered (for example: 10
ashes x 100= 1000 CFM).
Adjust Tap
Airow amounts may be increased or decreased by 10%
by moving the ADJUST jumper plug (see Figure 67) from
the NORM position to the (+) or (-) position. Changes to the
ADJUST tap will aect both cooling and heating airows.
The TEST position on the ADJUST tap is not used.
Continuous Blower Operation
The comfort level of the living space can be enhanced
when using this feature by allowing continuous circulation
of air between calls for cooling or heating. The circulation
of air occurs at half the full cooling airow rate.
To engage the continuous blower operation, place the
fan switch on the thermostat into the ON position. A call
for fan from the thermostat closes R to G on the ignition
control board. The control waits for a 1 second thermostat
debounce delay before responding to the call for fan by
ramping the circulating blower up to 38% of the cooling
speed. When the call for continuous fan is satised, the
control immediately ramps down the circulating blower.
507961-02B Page 43 of 57Issue 2302
Figure 67. ADJUST, HEAT, and COOL Taps on
Integrated Ignition/Blower Control Board
Sequence of Operation
Heating
On a call for heat from the room thermostat, the control
board performs a 1 second self check. Upon conrmation
that the pressure switch contacts are in an open position,
the control energizes the combustion blower on high
speed. The control then checks for adequate combustion
air by making sure the low-re pressure switch contacts
are closed.
The igniter energizes and is allowed to warm up for 20
seconds before the gas valve energizes on 1st stage
and burners ignite. 45 seconds after the control conrms
ignition has occurred, the control drops the combustion
blower to low speed.
The circulating blower operates at full 1st stage heat
speed until either the heat call is satised or the thermostat
initiates a call for 2nd stage heat. On a call for 2nd stage
heat, the control energizes the circulating air blower on full
CFM 2nd stage heat.
If the automatic heat staging option is being used the
furnace does not switch to 2nd stage heat in response
to a call from the thermostat but instead operates at 1st
stage heat for the duration of the selected time before
automatically switching to 2nd stage heat.
When the call for heat is satised, the gas valve and
combustion air blower shut down. The control board shuts
o the gas valve and runs the combustion blower for an
additional 15 seconds. The circulating air blower continues
to run for selected blower o delay time (60/90/120/180
sec) before ramping down and shutting o.
In the event the unit loses ignition, the control will attempt
to recycle up to ve times before it goes into a 1 hour
lockout. Lockout may be manually reset by removing
power from the control for more than 1 second or removing
the thermostat call for heat for more than 3 seconds.
If during a heating cycle the limit control senses an
abnormally high temperature and opens, the control board
de-energizes the gas valve and the combustion blower
while the circulating blower runs at 1st stage heat speed.
The circulating blower remains energized until the limits
are closed.
Fan On
When the thermostat is set for continuous fan operation
and there is no demand for heating or cooling, a call for fan
closes the R to G circuit and the circulating blower motor
runs at 38% of the selected cooling CFM until switched o.
When the call for fan is turned o, the control de-energizes
the circulating blower.
Cooling
The unit is set up at the factory for single stage cooling. For
two stage cooling operation, clip the jumper wire located
between the Y to Y2 terminals on the integrated ignition/
blower control board.
If the active dehumidication feature is enabled, the
circulating blower runs at 70% of the selected cooling
speed as long as there is a call for dehumidication.
The system must not be in either the passive or active
dehumidication mode when charging a cooling system.
WARNING
Single Stage Cooling
A call for cooling from the thermostat closes the R to Y
circuit on the integrated ignition/blower control board. The
control waits for a 1-second delay before energizing the
circulating blower to 82% of the selected cooling CFM
(passive dehumidication mode). After 7.5 minutes, the
circulating blower automatically ramps up to 100% of
the selected cooling airow. When the call for cooling is
satised, the circulating blower ramps down to continuous
fan cfm (38% of high stage cooling) for 45 seconds before
completely shutting down the blower.
Two Stage Cooling
A call for 1st stage cooling from the thermostat closes the
R to Y circuit on the control board. The control waits for a
1-second delay before energizing the circulating blower.
The blower motor runs at 57% of the selected air ow
for the rst 7.5 minutes of the 2nd stage cooling demand
(passive dehumidication mode). After 7.5 minutes, the
blower motor runs at 70% of the selected cooling air ow
until 1st stage cooling demand is satised.
A call for 2nd stage cooling from the thermostat closes
the R to Y2 circuit on the control board. The blower motor
ramps up to 100% of the selected cooling air ow. When
the demand for cooling is met, the blower ramps down
to Y1 until satised, then ramps down to continuous fan
cfm (38% of high stage cooling) for 45 seconds before
completely shutting down the blower.
507961-02BPage 44 of 57 Issue 2302
Heat Pump
For heat pump operation, clip the jumper wire located below the O terminal on the integrated ignition/blower control board.
In heat pump mode, a call for heat will result in the circulating air blower operating at the selected cooling airow after a brief
ramp-up period.
W1 - Heat Demand Present
w1 - Heat Demand Satisfied
W2 - High Heat Demand Present
w2 - High Heat Demand Satisfied
OFF
w1 w2
***min
100%*
W1/W2
100%**
W1
CALL
*Percentage of Low Fire CFM
** Percentage of High Fire CFM
*** User-Selected Heat Blower OFF Delay
100%*
w1
100%*
***min
Figure 68. Indoor Blower Operation - 1st Stage-2nd Stage (W1/W2) Heat Call
W2 - High Heat Demand Present
w2 - High Heat Demand Satisfied
OFF
w2
***min
100%*
W2
CALL
*Percentage of Low Fire CFM
** Percentage of High Fire CFM
*** User-Selected Heat Blower OFF Delay
Figure 69. Indoor Blower Operation - High Heat (W2)
Call
G - Fan Switch ON
g - Fan Switch OFF
OFF
gG
CALL
38%*
*Percentage of High Stage Cooling CFM
Figure 70. Indoor Blower Operation - Call for Fan
Y - Heat Demand Present
y - Heat Demand Satisfied
OFF
y
45
sec
38%
100%*
Y
CALL
7.5 minutes
82%*
*Percentage of High Stage Cooling CFM
Figure 71. Indoor Blower Operation - Single Stage
Cooling
Figure 72. Indoor Blower Operation - Two Stage
Cooling
OFF
Y1 y2
45 sec
38%*
Y1/Y2
100%*
Y1
CALL
*Percentage of High Stage Cooling
57%*
y1
70%*
70%*
y1
Y1 - 1st Stage Cool Demand Present
y1 - 1st Stage Cool Demand Satisfied
Y2 - 2nd Stage Cooling Demand Present
y2 - 2nd Stage Cooling Demand Satisfied
7.5
min.
45 sec
38%*
507961-02B Page 45 of 57Issue 2302
Control Diagnostics
Troubleshooting
Make the following visual checks before troubleshooting:
1. Check to see that the power to the furnace and the
integrated ignition/blower control board is ON.
2. The manual shuto valves in the gas line to the furnace
must be open.
3. Make sure all wiring connections are secure.
4. Review the Sequence of Operation.
Start the system by setting thermostat above room
temperature. Observe system response. Then use the
information provided in this section to check the system
operation.
The furnace has a built-in, self-diagnostic capability. If a
system problem occurs, a fault code is shown by a red LED
on the control board. The control continuously monitors its
own operation and the operation of the system. If a failure
occurs, the LED will indicate the failure code. The ash
codes are presented in Table 10.
Fault Code History Button
The control stores the last ve fault codes in memory. A
push-button switch is located on the control. When the
push-button switch is pressed and released, the control
ashes the stored fault codes. The most recent fault code
is ashed rst; the oldest fault code is ashed last. To clear
the fault code history, press and hold the push-button
switch in for more than 5 seconds before releasing.
High Heat State LED
On BG962UHV models, a green LED is provided on the
control board to indicate high heat state (see Table 11).
CFM LED
On BG962UHV models equipped with a variable speed
motor, an amber LED is provided on the control board to
display CFM. To determine what CFM the motor is delivering
at any time, count the number of times the amber LED
ashes. Each ash signies 100 CFM; count the ashes
and multiply by 100 to determine the actual CFM delivered
(for example: 10 ashes x 100 = 1000 CFM).
Table 10. Failure Codes - Red LED
LED Status Fault Description
LED O
No power to control or control hardware
fault detected
LED On Normal operation
1 Flash Flame present with gas valve o
2 Flashes Pressure switch closed with inducer o
3 Flashes
Pressure switch open with inducer
energized
4 Flashes
Primary Limit, Secondary Limit, or Roll-
Out switch open
5 Flashes Not used
6 Flashes Pressure switch cycle lockout
7 Flashes Lockout due to no ignition
8 Flashes Lockout due to too many ame dropouts
9 Flashes Incorrect polarity and phasing
Table 11. High Heat State - Green LED
LED Status Description
LED O No demand for high heat
LED On High heat demand, operating normally
LED Flashing
High heat demand, high pressure switch
not closed
507961-02BPage 46 of 57 Issue 2302
Figure 73. Typical Field Wiring Diagram
NOTE-
IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT
MUST BE REPLACED WITH WIRE OF LIKE SIZE,
HEATING UNITS-GAS
WARNING-
ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY
OR DEATH.UNIT MUST BE GROUNDED IN ACCORDANCE
WITH NATIONAL AND LOCAL CODES.
Supersedes
RATING, INSULATION THICKNESS, AND TERMINATION
GAS FIRED TWO STAGE
FURNACE
WIRING SCHEMATIC
LINE VOLTAGE FIELD INSTALLED
CLASS II VOLTAGE FIELD WIRING
W1
W2
YR
G
THERMOSTAT CONDENSER
W1
W2
Y
R
G
C
LPS1
HPS1
TH
FP
TR
MVH
IGNITION
CONTROL
ROLLOUT
SWITCH
(IF USED)
ROLLOUT
SWITCH
PRESSURE
SWITCH
(LOW)
1ST STAGE
2ND STAGE
GAS VALVE
24V
120V
MOTOR
AIR CLEANER
HUMIDIFIER
TRANSFORMER
CIRCULATION
BLOWER
EAC
HUM
IND LOW
IND HIGH
IGN
INDUCED DRAFT
BLOWER
HOT SURFACE
IGNITER
INTERLOCK
SWITCH
LOW VOLTAGE - FACTORY
LINE VOLTAGE - FACTORY
120/1
/60
HLI
HLO
MVL
FLAME
SENSOR
CHOKE
(IF USED)
MOTOR
MOTOR
L1 HOT
NEUTRAL
PRESSURE
SWITCH
(HIGH)
LIMIT
507961-02B Page 47 of 57Issue 2302
Figure 74. Typical Wiring Diagram
W1
W2
YR
G
CONDENSER
1
2
3
45
5 PIN
CONNECTOR
THERMOSTAT
W1
W2
R
G
YC Y2
0
DEHUM
LINE
CIRC
EAC
XFMR
HUM
LO HEAT
HI HEAT
PARK 2
PARK 1
COOL
EAC
CONT
XFMR
LINE
HUM
3 AMP
C
1
2
3
4
5
6
9
8
7
10
11
12
YELLOW
BLUE
PURPLE
BROWN
ORANGE
YELLOW
1
1
2
2
2 PIN
CONNECTOR
INPUT CHOKE
(IF USED)
H1 C
M
FLAME
SENSOR
WHT/PINK
HOT
NEUTRAL
IGNITION
1
2
3
4
5
4
4
2
2
3
3
INDUCED
DRAFT
BLOWER
5 PIN
CONNECTOR
WHITE
RED
BLACK
WHITE
RED
BLACK
S1
P1
HOT SURFACE
IGNITOR
WHITE
BLACK
GRN
RED
WHITE
WHITE
WHITE
BLACK
BLACK
WHITE
BLUE
GAS VALVE
PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE
VOLTAGE SUPPLY. IGNITION CONTROL WILL LOCK OUT IF
POLARITY IS REVERSED
CONNECTION DIAGRAM
1
CIRCULATION
BLOWER
CONTROL
1
1
GRN/YLW
BLACK
HOT
NEUTRAL
GROUND
GRN/YLW
120/1
/60
1
INTERLOCK
SWITCH
WHITE
BLACK
BLACK
LIMIT
ROLLOUT
PRESSURE
SWITCH (HIGH)
PRESSURE
SWITCH (LOW)
ROLLOUT
PINK
BROWN
PINK
PUR
BROWN
BLUE
NOTES:
1. PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO DISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLD BUTTON
IN FOR MORE THAN 5 SECONDS
2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING
MATERIAL HAVING A TEMP. RATING OF AT LEAST 90°c.
3. DO NOT CONNECT C (COMMON) CONNECTION BETWEEN INDOOR UNIT AND THERMOSTAT EXCEPT WHEN REQUIRED BY THE
INDOOR THERMOSTAT. REFER TO THE THERMOSTAT INSTALLATION INSTRUCTIONS.
507961-02BPage 48 of 57 Issue 2302
Blower Performance
BG962UH070BV12
Temp. Rise Speed Adjustment
Heating CFM @ 0 - 0.8” w.c.
Setting D Setting C Setting B Setting A
High Fire
50-80
+ 965 1130 1255 1400
Normal 880 990 1140 1295
- 810 890 1030 1170
Low Fire
25-55
+ 940 1070 1195 1345
Normal 830 965 1100 1235
- 755 840 975 1130
Cooling Stage Cooling CFM @ 0 - 0.8” w.c.
2nd Stage
+ 860 1060 1215 1365
Normal 810 960 1130 1265
- 705 840 1005 1140
1st Stage
+ 600 740 840 970
Normal 555 665 770 855
- 500 600 680 790
BG962UH090CV12
Temp. Rise Speed Adjustment
Heating CFM @ 0 - 0.8” w.c.
Setting D Setting C Setting B Setting A
High Fire
60-90
+ 1060 1135 1240 1430
Normal 960 1040 1120 1310
- 830 935 980 1175
Low Fire
35-65
+ 960 1040 1120 1310
Normal 875 945 995 1195
- 790 840 920 1080
Cooling Stage Cooling CFM @ 0 - 0.8” w.c.
2nd Stage
+ 875 1040 1210 1360
Normal 800 945 1100 1245
- 720 840 970 1115
1st Stage
+ 625 710 830 950
Normal 565 670 760 860
- 520 610 685 785
507961-02B Page 49 of 57Issue 2302
BG962UH090CV20
Temp. Rise Speed Adjustment
Heating CFM @ 0 - 0.8” w.c.
Setting D Setting C Setting B Setting A
High Fire
40-70
+ 1450 1565 1725 1865
Normal 1310 1450 1585 1690
- 1155 1305 1450 1545
Low Fire
30-60
+ 1120 1265 1420 1520
Normal 965 1120 1285 1395
- 865 950 1120 1235
Cooling Stage Cooling CFM @ 0 - 0.8” w.c.
2nd Stage
+ 1385 1595 1820 2020
Normal 1225 1465 1645 1885
- 1065 1320 1505 1675
1st Stage
+ 935 1055 1275 1465
Normal 835 980 1120 1335
- 740 870 1010 1150
BG962UH110CV20
Temp. Rise Speed Adjustment
Heating CFM @ 0 - 0.8” w.c.
Setting D Setting C Setting B Setting A
High Fire
45-75
+ 1560 1760 1905 2080
Normal 1415 1610 1740 1930
- 1285 1485 1560 1745
Low Fire
35-65
+ 1155 1325 1420 1565
Normal 1055 1200 1310 1480
- 935 1075 1170 1315
Cooling Stage Cooling CFM @ 0 - 0.8” w.c.
2nd Stage
+ 1310 1560 1745 1955
Normal 1220 1405 1570 1795
- 1075 1270 1430 1635
1st Stage
+ 935 1065 1245 1405
Normal 865 970 1145 1280
- 790 890 1025 1165
507961-02BPage 50 of 57 Issue 2302
Allowable Heating Speeds
Model Number Speed Adjust Setting "D" Setting "C" Setting "B" Setting "A"
BG962UH070BV12
+10% Allowed Allowed Allowed Not Allowed
Norm Allowed Allowed Factory Setting Not Allowed
-10% Allowed Allowed Allowed Not Allowed
BG962UH090CV12
+10% Allowed Allowed Allowed Allowed
Norm Allowed Allowed Factory Setting Allowed
-10% Allowed Allowed Allowed Allowed
BG962UH090CV20
+10% Allowed Allowed Allowed Allowed
Norm Allowed Allowed Factory Setting Allowed
-10% Allowed Allowed Allowed Allowed
BG962UH110CV20
+10% Allowed Allowed Allowed Allowed
Norm Allowed Allowed Factory Setting Allowed
-10% Allowed Allowed Allowed Allowed
Table 12.
Allowable Circulation Speeds
Model Number 38% of Second Stage Cooling
All Models Factory Setting
Table 13.
507961-02B Page 51 of 57Issue 2302
Unit Start-Up
FOR YOUR SAFETY READ BEFORE OPERATING
Do not use this furnace if any part has been underwater.
A ood-damaged furnace is extremely dangerous.
Attempts to use the furnace can result in re or explosion.
Immediately call a qualied service technician to inspect
the furnace and to replace all gas controls, control
system parts, and electrical parts that have been wet or
to replace the furnace, if deemed necessary.
WARNING
Danger of explosion. Can cause injury or
product or property damage. Should the
gas supply fail to shut o or if overheating
occurs, shut o the gas valve to the
furnace before shutting o the electrical
blower deck, before performing any
service procedure.
WARNING
Before attempting to perform any service or
maintenance, turn the electrical power to unit OFF at
disconnect switch.
CAUTION
BEFORE LIGHTING the unit, smell all around the furnace
area for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the oor.
The gas valve on the unit is equipped with a gas control
switch (lever). Use only your hand to move switch. Never
use tools. If the switch will not move by hand, do not try to
repair it. Force or attempted repair may result in a re or
explosion.
Placing the Furnace into Operation
This furnace is equipped with an automatic hot surface
ignition system. Do not attempt to manually light burners
on this furnace. Each time the thermostat calls for heat, the
burners will automatically light. The ignitor does not get hot
when there is no call for heat on these units.
Gas Valve Operation
1. STOP! Read the safety information at the beginning
of this section.
Figure 75.
2. Set the thermostat to the lowest setting.
3. Turn OFF all electrical power to the unit.
4. This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5. Remove the upper access panel.
6. Move gas valve switch to OFF. See Figure 75.
7. Wait ve minutes to clear out any gas. If you then
smell gas, STOP! Immediately call your gas supplier
from a neighbor’s phone. Follow the gas supplier’s
instructions. If you do not smell gas go to next step.
8. Move gas valve switch to ON. See Figure 75.
9. Replace the upper access panel.
10. Turn on all electrical power to the unit.
11. Set the thermostat to desired setting.
NOTE: When unit is initially started, steps 1 through
11 may need to be repeated to purge air from gas line.
12. If the appliance will not operate, follow the instructions
“Turning O Gas to Unit” and call your service
technician or gas supplier.
Capacity Gas
Manifold Pressure in w.g.
Supply Line
Pressure in
w.g.
0 - 10000 ft.
0 - 4500 ft. 4501 - 5500 ft. 5501 - 6500ft. 6501 - 7500ft. 7501-10000ft.
Low
Fire
High
Fire
Low
Fire
High
Fire
Low
Fire
High
Fire
Low
Fire
High
Fire
Low
Fire
High
Fire
Min. Max.
All
Natural 1.7 3.5 1.6 3.3 1.5 3.2 1.5 3.1 1.7 3.5 4.5 13.0
Lp/
Propane
4.5 10.0 4.2 9.4 4.0 9.1 3.9 8.9 4.5 10.0 11.0 13.0
Table 14. Manifold and Supply Line Pressure 0 - 10,000 ft.
507961-02BPage 52 of 57 Issue 2302
Turning O Gas to Unit
1. Set the thermostat to the lowest setting.
2. Turn o all electrical power to the unit if service is to
be performed.
3. Remove the upper access panel.
4. Move gas valve switch to OFF.
5. Replace the upper access panel.
Failure to Operate
If the unit fails to operate, check the following:
1. Is the thermostat calling for heat?
2. Are access panels securely in place?
3. Is the main disconnect switch closed?
4. Is there a blown fuse or tripped breaker?
5. Is the lter dirty or plugged? Dirty or plugged lters will
cause the limit control to shut the unit o.
6. Is gas turned on at the meter?
7. Is the manual main shut–o valve open?
8. Is the internal manual shut–o valve open?
9. Is the unit ignition system in lockout? If the unit locks
out again, inspect the unit for blockages.
Heating Sequence of Operation
1. When thermostat calls for heat, combustion air inducer
starts.
2. Combustion air pressure switch proves blower
operation. Switch is factory set and requires no
adjustment.
3. After a 15 second pre-purge, the hot surface ignitor
energizes.
4. After a 20 second ignitor warm-up period, the gas
valve solenoid opens.
5. Gas is ignited, ame sensor proves the ame, and the
combustion process continues.
6. If ame is not detected after rst ignition trial, the
ignition control will repeat steps 3 and 4 four more
times before locking out the gas valve. The ignition
control will then automatically repeat steps 1 through
6 after 60 minutes. To interrupt the 60 minute period,
move thermostat from “Heat” to “OFF” then back to
“Heat”. Heating sequence then restarts at step 1.
Gas Pressure Adjustment
Gas Flow (Approximate)
Capacity
Seconds for One Revolution
Natural LP
1 cu ft
Dial
2 cu ft
Dial
1 cu ft
Dial
2 cu ft
Dial
-70 55 110 136 272
-90 41 82 102 204
-110 33 66 82 164
Natural - 1000 btu/cu ft LP - 2500 btu/cu ft
Table 15. Gas Meter Clocking Chart
Furnace should operate at least 5 minutes before checking
gas ow. Determine time in seconds for two revolutions of
gas through the meter. (Two revolutions assures a more
accurate time.) Divide by two and compare to time in Table
15. If manifold pressure matches Table 14 and rate is
incorrect, check gas orices for proper size and restriction.
Remove temporary gas meter if installed.
NOTE: To obtain accurate reading, shut o all other gas
appliances connected to meter.
Supply Pressure Measurement
An inlet pressure post on the inlet side of the gas valve
provides access to the supply pressure. See Figure 75.
Back out the 3/32 Hex screw one turn, connect a piece
of 5/16” tubing and connect to a manometer to measure
supply pressure.
NOTE: Shut unit o and remove manometer as soon as
an accurate reading has been obtained. Take care to re-
tighten the 3/32 Hex screw.
Capacity
Natural to LP/
Propane
High Altitude Natural
Burner Orice Kit
High Altitude LP/
Propane Burner
Orice Kit
High Altitude Pressure Switch
0 - 7500 ft
(0 - 2286m)
7501 - 10000 ft
(2286 - 3048m)
7501 - 10000 ft
(2286 - 3048m)
4501 - 7500 ft
(1371 - 2286m)
7501 - 10000 ft
(2286 - 3048m)
070
11K48 *51W01 11K47
14A54 14A53
090 14A57 14A54
110 14A46 14A51
*Conversion requires installation of a gas valve manifold spring which is provided with the gas conversion kit.
Pressure switch is factory set. No adjustment necessary. All models use the factory-installed pressure switch from 0-4500 feet (0-1371 m).
Table 16. Conversion Kit Fan Pressure Switch Requirements at Varying Altitudes
507961-02B Page 53 of 57Issue 2302
For proper furnace operation the minimum gas supply
pressure is 4.5” w.c and the maximum gas supply pressure
is 10.5” w.c for natural gas. The minimum gas supply
pressure is 10” w.c. and the maximum gas supply pressure
is 13” w.c. for LP/propane gas.
Manifold Pressure Measurement
1. A manifold pressure post located on the gas valve
provides access to the manifold pressure. See Figure
75. Back out the 3/32 Hex screw one turn, connect a
piece of 5/16” tubing and connect to a manometer to
measure supply pressure.
2. Start unit and allow 5 minutes for unit to reach steady
state.
3. While waiting for the unit to stabilize, observe the
ame. Flame should be stable and should not lift from
burner. Natural gas should burn blue.
4. After allowing unit to stabilize for 5 minutes, record
manifold pressure and compare to value given in
Table 14.
NOTE: Shut unit o and remove manometer as soon as
an accurate reading has been obtained. Take care to re-
tighten the 3/32 Hex screw.
Proper Combustion
Furnace should operate minimum 15 minutes with correct
manifold pressure and gas ow rate before checking
combustion. Take combustion sample beyond the ue
outlet and compare to the tables below. The maximum
carbon monoxide reading should not exceed 100 ppm.
High Altitude Information
NOTE: In Canada, certication for installations at
elevations over 4500 feet (1371 m) is the jurisdiction of
local authorities.
Units may be installed at altitudes up to 4,500 ft. above
sea level without manifold adjustment. Units installed
at altitude of 4,501 - 10,000 feet (1371 to 3048 m) may
require a pressure switch change, which can be ordered
separately. Table 16 lists conversion kit and pressure
switch requirements at varying altitudes.
The combustion air pressure switch is factory-set and
requires no adjustment.
Other Unit Adjustments
Primary Limit
The primary limit is located on the heating compartment
vestibule panel. This limit is factory set and requires no
adjustment.
Flame Rollout Switches (Two)
These manually reset switches are located on the front of
the burner box.
Pressure Switches
The pressure switches are located in the heating
compartment on the cold end header box. These switches
check for proper combustion air inducer operation before
allowing ignition trial. The switches are factory set and
must not be adjusted.
Temperature Rise
After the furnace has been started and supply and return
air temperatures have been allowed to stabilize, check
the temperature rise. If necessary, adjust the blower
speed to maintain the temperature rise within the range
shown on the unit nameplate. See Table 12 for allowable
heating speeds. Increase the blower speed to decrease
the temperature. Decrease the blower speed to increase
the temperature rise. Failure to adjust the temperature rise
may cause erratic limit operation.
Fan Control
The fan ON time of 30 seconds is not adjustable. The fan
OFF delay (amount of time that the blower operates after
the heat demand has been satised) is 120 seconds and
is not adjustable.
Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to
the amp draw listed on the wiring diagram that is attached
to the unit.
Electrical
1. Check all wiring for loose connections.
2. Check for the correct voltage at the furnace (furnace
operating).
3. Check amp–draw on the blower motor.
Motor Nameplate__________Actual__________
Electronic Ignition
The integrated control has an added feature of an internal
Watchguard control. The feature serves as an automatic
reset device for integrated control lockout caused by
ignition failure. This type of lockout is usually due to low
gas line pressure. After one hour of continuous thermostat
demand for heat, the Watchguard will break and remake
thermostat demand to the furnace and automatically reset
the integrated control to begin the ignition sequence.
Exhaust and Air Intake Pipe
1. Check exhaust and air intake connections for tightness
and to make sure there is no blockage.
2. Is pressure switch closed? Obstructed exhaust pipe
will cause unit to shut o at pressure switch. Check
termination for blockages.
3. Obstructed pipe or termination may cause rollout
switches to open. Reset manual ame rollout switches
on burner box assembly if necessary.
507961-02BPage 54 of 57 Issue 2302
Service
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD.
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death or property
damage.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace.
When servicing controls, label all wires prior to
disconnecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
WARNING
At the beginning of each heating season, system should
be checked as follows by a qualied service technician:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are pre-lubricated for extended bearing
life. No further lubrication is needed.
The blower access panel must be securely in place
when the blower and burners are operating. Gas fumes,
which could contain carbon monoxide, can be drawn
into living space resulting in personal injury or death.
WARNING
Filters
All air lters are installed external to the unit. Filters should
be inspected monthly. Clean or replace the lters when
necessary to ensure proper furnace operation. Table 1
lists recommended lter sizes. A lter must be in place
whenever the unit is operating.
Exhaust and Air Intake Pipes
Check the exhaust and air intake pipes and all connections
for tightness and to make sure there is no blockage.
NOTE: After any heavy snow, ice or frozen fog event the
furnace vent pipes may become restricted. Always check
the vent system and remove any snow or ice that may be
obstructing the plastic intake or exhaust pipes.
Electrical
1. Check all wiring for loose connections.
2. Check for the correct voltage at the furnace (furnace
operating).
3. Check amp-draw on the blower motor.
Motor Nameplate__________Actual__________
Winterizing and Condensate Trap Care
1. Turn o power to the furnace.
2. Have a shallow pan ready to empty condensate water.
3. Remove the clean out cap from the condensate trap
and empty water. Inspect the trap then reinstall the
clean out cap.
Cleaning Heat Exchanger
If cleaning the heat exchanger becomes necessary,
follow the below procedures and refer to Figure 1 when
disassembling unit. Use papers or protective covering in
front of furnace while removing heat exchanger assembly.
1. Turn o electrical and gas supplies to the furnace.
2. Remove the burner access panel.
3. Mark all gas valve wires and disconnect them from
valve.
4. Remove gas supply line connected to gas valve.
5. Remove sensor wire from ame sensor. Disconnect
2–pin plug from the ignitor.
6. Disconnect wires from ame rollout switches.
7. Remove four burner assembly screws at the vestibule
panel and remove gas valve /manifold and burner box
as a single unit.
8. If necessary, clean burners at this time. Follow
procedures outlined in Burner Cleaning section.
9. Remove the clean-out cap on trap and drain. Replace
cap.
10. Disconnect condensate drain line from the condensate
trap. Remove condensate trap (it may be necessary to
cut drain pipe). Remove the 1/2” NPT tting from the
cold end header box. Disconnect drain tubes from cold
end header collector box.
11. Disconnect condensate drain tubes from ue collar.
Remove screws that secures ue collar in place.
Remove ue collar. It may be necessary to cut the
exiting exhaust pipe for removal of the tting.
12. Loosen two clamps from exible no-hub exhaust collar.
13. Disconnect the 2–pin plug from the combustion air
inducer. Remove screws which secure combustion
air inducer to collector box. Remove combustion air
inducer assembly. Remove ground wire.
14. Mark and disconnect all combustion air pressure
tubing from cold end header collector box.
15. Mark and remove wires from pressure switch. Remove
pressure switch. Keep tubing attached to pressure
switch.
16. Remove electrical junction box from the side of the
furnace.
17. Remove blower access panel.
507961-02B Page 55 of 57Issue 2302
18. Mark and disconnect any remaining wiring to heating
compartment components. Disengage strain relief
bushing and pull wiring and bushing through the hole
in the blower deck.
19. Remove the primary limit from the vestibule panel.
20. Remove top cap screws to allow top cap to be
tilted upward to allow clearance for removing heat
exchanger.
21. Remove two screws from the front cabinet ange at
the blower deck. Spread cabinet sides slightly to allow
clearance for removal of heat exchanger.
22. Remove screws along vestibule sides and bottom
which secure vestibule panel and heat exchanger
assembly to cabinet. Remove two screws from blower
rails which secure bottom heat exchanger ange.
Remove heat exchanger from furnace cabinet.
23. Back wash heat exchanger with soapy water solution
or steam. If steam is used it must be below 275°F
(135°C).
24. Thoroughly rinse and drain the heat exchanger. Soap
solutions can be corrosive. Take care to rinse entire
assembly.
25. Reinstall heat exchanger into cabinet making sure
that the rear bae of the heat exchanger assembly
is nested under the support located at the rear of the
cabinet. Remove the indoor blower to view this area
through the blower opening.
26. Re–secure the supporting screws along the vestibule
sides.
27. Reinstall blower assembly and reinstall two screws
through rails.
28. Reinstall cabinet screws on front ange at blower
deck.
29. Reinstall screws securing top cap.
30. Reinstall the primary limit on the vestibule panel.
31. Route heating component wiring through hole in
blower deck and reinsert strain relief bushing.
32. Reinstall pressure switch and reconnect pressure
switch wiring.
33. Carefully connect combustion air pressure switch
hosing from pressure switch to proper stubs on cold
end header collector box.
34. Reinstall 1/2” NPT (if removed) in the cold end header
box. Reconnect drain tubing to collector box.
35. Reinstall condensate trap pipe. Reconnect condensate
drain line to the condensate trap.
36. Reinstall electrical junction box.
37. Reinstall the combustion air inducer and exible no
hub connector. Reconnect the 2 pin plug to the wire
harness.
38. Reconnect drain tubes between ue collar and cold
end header box.
39. Secure burner assembly to vestibule panel using four
existing screws. Burners are self aligning to center of
clam shells.
40. Reconnect gas supply line to gas valve.
41. Reconnect ame rollout switch wires.
42. Reconnect sensor wire and reconnect 2 pin plug from
ignitor.
43. Reconnect wires to gas valve.
44. Replace the blower compartment access panel.
45. Refer to instruction on verifying gas and electrical
connections when reestablishing supplies.
46. Follow lighting instructions to light and operate furnace
for 5 minutes to ensure that heat exchanger is clean
and dry and that furnace is operating properly.
47. Replace heating compartment access panel.
Cleaning the Burner Assembly
1. Turn o gas and electrical power to the furnace.
Remove heating compartment access panel.
2. Disconnect the gas supply line from the gas valve.
3. Disconnect and label wires from gas valve.
4. Disconnect ignitor wiring at 2 circuit plug.
5. Disconnect and label wires from rollout switch.
6. Disconnect and label ame sensor wire.
7. Disconnect and label ground wire from burner/manifold
assembly.
8. Remove four screws that secures burner/manifold
assembly to vestibule. Remove the assembly and
make note not to allow ignitor plate to dislodge from
the assembly.
9. Gently clean the face of the burners using the soft
brush attachment on a vacuum cleaner. Visually
inspect the inside of the burners and crossovers for
any blockage caused by foreign matter. Remove any
blockage
10. Reinstall the burner/manifold assembly using the
existing four screws. Burners are self aligning to
center of clam shells.
11. Reconnect ground wire.
12. Reconnect ame sensor wire.
13. Reconnect rollout switch wires.
14. Reconnect ignitor wires.
15. Reconnect gas valve wires.
16. Reconnect gas supply line to gas valve.
17. Refer to instructions on verifying gas and electrical
connections when re-establishing supplies.
18. Follow instructions to place furnace in operation. Run
furnace 5 minutes to ensure burners are clean and
operating correctly.
19. Replace heating compartment access panel.
507961-02BPage 56 of 57 Issue 2302
Planned Service
A service technician should check the following items
during an annual inspection. Power to the unit must be
shut o for safety.
Fresh air grilles and louvers (on the unit and in the
room where the furnace is installed) - Must be open and
unobstructed to provide combustion air.
Burners - Must be inspected for rust, dirt, or signs of water.
Vent pipe - Must be inspected for signs of water, cracked,
damaged or sagging pipe, or disconnected joints.
Unit appearance - Must be inspected for rust, dirt, signs of
water, burnt or damaged wires, or components.
Blower access door - Must be properly in place and
provide a seal between the return air and the room where
the furnace is installed.
Return air duct - Must be properly attached and provide
an air seal to the unit.
Operating performance - Unit must be observed during
operation to monitor proper performance of the unit and
the vent system.
Combustion gases - Flue products should be analyzed
and compared to the unit specications.
Problems detected during the inspection may make it
necessary to temporarily shut down the furnace until the
items can be repaired or replaced.
Instruct the homeowners to pay attention to their
furnace. Situations can arise between annual furnace
inspections that may result in unsafe operation. For
instance, items innocently stored next to the furnace may
obstruct the combustion air supply. This could cause
incomplete combustion and the production of carbon
monoxide gas.
Repair Parts List
The following repair parts are available through Blue
Summit dealers. When ordering parts, include the complete
furnace model number listed on the CSA nameplate. All
service must be performed by a licensed professional
installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
• Upper Access Panel
• Blower Access Panel
• Top Cap
Control Panel Parts
• Transformer
• Integrated Control Board
• Door Interlock Switch
Blower Parts
• Blower Wheel
• Motor
• Motor Mounting Frame
• Motor Choke
• Blower Housing Cuto Plate
Heating Parts
• Flame Sensor
• Heat Exchanger Assembly
• Gas Manifold
• Combustion Air Inducer
• Gas Valve
• Main Burner Cluster
• Main Burner Orices
• Pressure Switches
• Ignitor
• Primary Limit Control
• Flame Rollout Switches
507961-02B Page 57 of 57Issue 2302
Requirements for Commonwealth of Massachusetts
Modications to NFPA-54, Chapter 10
Revise NFPA-54 section 10.8.3 to add the following
requirements:
For all side wall, horizontally vented, gas-fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7)
feet above the nished grade in the area of the venting,
including but not limited to decks and porches, the following
requirements shall be satised:
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side
wall, horizontally vented, gas-fueled equipment, the
installing plumber or gas tter shall observe that a
hard-wired carbon monoxide detector with an alarm
and battery backup is installed on the oor level where
the gas equipment is to be installed. In addition, the
installing plumber or gas tter shall observe that a
battery-operated or hard-wired carbon monoxide
detector with an alarm is installed on each additional
level of the dwelling, building or structure served by the
side wall, horizontally vented, gas-fueled equipment.
It shall be the responsibility of the property owner to
secure the services of qualied licensed professionals
for the installation of hard-wired carbon monoxide
detectors.
a. In the event that the side wall, horizontally
vented, gas-fueled equipment is installed in a
crawl space or an attic, the hard-wired carbon
monoxide detector with alarm and battery backup
may be installed on the next adjacent oor level.
b. In the event that the requirements of this subdivision
cannot be met at the time of completion of
installation, the owner shall have a period of thirty
(30) days to comply with the above requirements;
provided, however, that during said thirty (30)
day period, a battery-operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in
accordance with the above provisions shall comply
with NFPA 720 and be ANSI/UL 2034 listed and IAS
certied.
3. SIGNAGE. A metal or plastic identication plate shall
be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented, gas-fueled heating appliance or
equipment. The sign shall read, in print size no less
than one-half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
4. INSPECTION. The state or local gas inspector of the
side wall, horizontally vented, gas-fueled equipment
shall not approve the installation unless, upon
inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt
from 24 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment
Not Required to Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
2. Product Approved side wall, horizontally vented, gas-
fueled equipment installed in a room or structure
separate from the dwelling, building or structure used
in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT
VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall,
horizontally vented, gas-fueled equipment provides a
venting system design or venting system components
with the equipment, the instructions provided by the
manufacturer for installation of the equipment and the
venting system shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components: and
2. A complete parts list for the venting system design or
venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT
VENTING SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved sidewall,
horizontally vented, gas-fueled equipment does not
provide the parts for venting the ue gases, but identies
“special venting systems,” the following requirements shall
be satised by the manufacturer:
1. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
2. The “special venting systems” shall be Product
Approved by the Board, and the instructions for that
system shall include a parts list and detailed installation
instructions.
A copy of all installation instructions for all Product
Approved side wall, horizontally vented, gas-fueled
equipment, all venting instructions, all parts lists
for venting instructions, and/or all venting design
instructions shall remain with the appliance or
equipment at the completion of the installation.
