Amana AMV9, ACV9 User Manual

AMV9/ACV9
®
T
WO
GAS
-S
TAGE
-
FIRED WARM AIR FURNACE
ARIABLE
INSTALLATION INSTRUCTIONS
Installer: Affix all manuals adjacent to the unit.
(T ype FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
These furnaces comply with requirements embodied in the American National S tandard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces.
S
PEED
®
C
US
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety
precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than
when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a
customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety
practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is
a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.
*NOTE: Please contact your distributor or our
website for the applicable product data book
referred to in this manual.
is a trademark of Maytag Corporation and is used under
license to Goodman Company, L.P. All rights reserved.
www.amana-hac.com
IO-253H
© 2004-2006 Goodman Company, L.P.
07/06
Table of Contents
I. Component Identification ............................................................................................................................................... 5
II. Safety .............................................................................................................................................................................. 6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................... 6
III. Product Application ...................................................................................................................................................... 6
IV . Location Requirement s & Considerations.................................................................................................................. 7
GENERAL ......................................................................................................................................................... 7
LEARANCES AND ACCESSIBILITY ........................................................................................................................... 8
C
URNACE SUSPENSION ........................................................................................................................................ 8
F
XISTING FURNACE REMOVAL .............................................................................................................................. 8
E
HERMOSTAT LOCATION ....................................................................................................................................... 9
T
V. Combustion & Ventilation Air Requirements ............................................................................................................... 9
VI. Installation Positions ...................................................................................................................................................11
VII. Horizontal Applications & Considerations ................................................................................................................11
GENERAL ........................................................................................................................................................11
RAIN TRAP AND LINES .....................................................................................................................................11
D
EVELING ........................................................................................................................................................11
L
L TERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS .....................................................................................11
A
LTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................ 12
A
RAIN PAN ..................................................................................................................................................... 12
D
REEZE PROTECTION ........................................................................................................................................ 12
F
URNACE SUSPENSION ...................................................................................................................................... 12
F
VIII. Propane Gas /High Altitude Installations............................................................................................................... 12
IX. Vent/Flue Pipe & Combustion Air Pipe ..................................................................................................................... 12
GENERAL ....................................................................................................................................................... 12
D
UAL CERTIFICATION : NON-DIRECT/DIRECT VENT ................................................................................................... 12
ATERIALS AND JOINING METHODS ..................................................................................................................... 13
M
ROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ................................................................................. 13
P
ERMINATION LOCATIONS ................................................................................................................................... 13
T
ANADIAN VENTING REQUIREMENTS..................................................................................................................... 13
C
TANDARD FURNACE CONNECTIONS ..................................................................................................................... 14
S
LTERNATE FURNACE CONNECTIONS ..................................................................................................................... 14
A
ON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................ 16
N
IRECT VENT (DUAL PIPE) PIPING ...................................................................................................................... 17
D
ENT/INT AKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES .................................................. 18
V
ONCENTRIC VENT TERMINATION ......................................................................................................................... 18
C
X. Condensate Drain Lines & Drain Trap........................................................................................................................ 18
GENERAL ....................................................................................................................................................... 18
U
PRIGHT INSTALLATIONS ..................................................................................................................................... 19
ORIZONT AL INSTALLATIONS ................................................................................................................................20
H
XI. Electrical Connections................................................................................................................................................ 21
WIRING HARNESS ............................................................................................................................................ 21
OLT LINE CONNECTIONS ............................................................................................................................ 21
115 V
OLT THERMOSTA T WIRING ............................................................................................................................ 22
24 V
INGLE-STAGE THERMOSTA T APPLICATION ............................................................................................................. 22
S
OLT DEHUMIDISTAT WIRING .......................................................................................................................... 22
24 V
OSSIL FUEL APPLICATIONS ............................................................................................................................... 23
F
OLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) ....................................... 23
115 V
OLT HUMIDIFIER ........................................................................................................................................ 23
24 V
XII. Gas Supply and Piping.............................................................................................................................................. 23
GENERAL ....................................................................................................................................................... 23
AS PIPING CONNECTIONS ................................................................................................................................24
G
ROPANE GAS TANKS AND PIPING ...................................................................................................................... 25
P
XIII. Circulating Air & Filters ............................................................................................................................................ 26
DUCTWORK - AIR FLOW ..................................................................................................................................... 26
OTTOM RETURN AIR OPENING [UPFLOW MODELS]............................................................................................... 26
B
ILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ....................................................... 27
F
PRIGHT INSTALLATIONS ..................................................................................................................................... 27
U
ORIZONT AL INSTALLATIONS ................................................................................................................................28
H
2
Table of Contents
XIV. Startup Procedure & Adjustment............................................................................................................................. 28
HEAT ANTICIP ATOR SETTING ................................................................................................................................28
RAIN TRAP PRIMING ....................................................................................................................................... 28
D
URNACE OPERATION ......................................................................................................................................... 28
F
AS SUPPLY PRESSURE MEASUREMENT.............................................................................................................. 28
G
AS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 29
G
AS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)......................................................................................... 29
G
EMPERATURE RISE ......................................................................................................................................... 30
T
IRCULATOR BLOWER SPEEDS ........................................................................................................................... 30
C
LOWER HEAT OFF DELAY TIMINGS ................................................................................................................... 32
B
XV. Normal Sequence of Operation ................................................................................................................................ 32
POWER UP ..................................................................................................................................................... 32
EATING MODE ............................................................................................................................................... 32
H
OOLING MODE .............................................................................................................................................. 32
C
AN ONLY MODE ............................................................................................................................................. 33
F
XVI. Operational Checks .................................................................................................................................................. 33
BURNER FLAME ............................................................................................................................................... 33
XVII. Safety Circuit Description ....................................................................................................................................... 33
GENERAL ....................................................................................................................................................... 33
NTEGRATED CONTROL MODULE .......................................................................................................................... 33
I
RIMARY LIMIT ................................................................................................................................................ 33
P
UXILIARY LIMIT ............................................................................................................................................... 33
A
OLLOUT LIMIT ................................................................................................................................................ 33
R
RESSURE SWITCHES ........................................................................................................................................ 33
P
LAME SENSOR ............................................................................................................................................... 33
F
XVIII. T roubleshooting...................................................................................................................................................... 33
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 33
IAGNOSTIC CHART .......................................................................................................................................... 34
D
ESETTING FROM LOCKOUT ............................................................................................................................... 34
R
XIX. Maintenance ............................................................................................................................................................. 34
ANNUAL INSPECTION .......................................................................................................................................... 34
ILTERS .......................................................................................................................................................... 34
F
URNERS ....................................................................................................................................................... 34
B
NDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 34
I
ONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)...................................................................... 35
C
LAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 35
F
LUE PASSAGES (QUALIFIED SERVICER ONLY)..................................................................................................... 35
F
XX. Internal Filter Removal ............................................................................................................................................. 35
XXI. Before Leaving an Installation ................................................................................................................................ 35
XXII. Repair & Replacement Parts .................................................................................................................................. 35
APPENDIX
Troubleshooting Chart...................................................................................................................................................... 37
Wiring Diagram ................................................................................................................................................................ 39
3
WARNING
F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A
I
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
D
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –
WHAT TO DO IF YOU SMELL GAS
D
• PHONE IN YOUR BUILDING.
PHONE.
• DEPARTMENT.
I
NSTALL ATION AND SE RVICE MUST BE PER FORM ED BY A QUALI FIED INS TALLE R,
– SERVICE AGENCY OR THE GAS SUPPLIER.
O NOT TRY TO LIGHT ANY APPLIANCE.
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
F
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
I
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
:
WARNING
HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN
S
OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
TO THE OWNER
It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the regis­tration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date. Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference. If additional information or operating instructions are required, con­tact the dealer where the purchase was made.
Homeowner Notice: If the residence is left unattended for an extended period of time
(i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances be­yond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.
TO THE INSTALLER
Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, cir­culating air temperature rise, minimum or maximum CFM, and mo­tor speed connections.
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms o r Parking Areas
Carbon monoxide producing devices (su ch as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a fu rnace or air handler is installed in an enclosed area such as a garage, utility room or parking area an d a carbon monoxide producing device is operated therein, there must be adequate, direct outsid e ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.
CO can cause serious illness including permanent brain damage or death.
-
B10259-216
TRANSPORTATION DAMAGE
All units are securely packed in shipping containers tested accord­ing to International Safe Transit Association specifications. The car­ton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately. The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:
1. Make a notation on delivery receipt of any visible damage to shipment or container.
2. Notify carrier promptly and request an inspection.
3. With concealed damage, carrier must be notified as soon as possible - preferably within five days.
4. File the claim with the following support documents within a nine month statute of limitations.
Original or certified copy of the Bill of Lading, or indemnity
bond.
Original paid freight bill or indemnity in lieu thereof.
Original or certified copy of the invoice, showing trade and
other discounts or reductions.
Copy of the inspection report issued by carrier’s
representative at the time damage is reported to carrier.
The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.
Keep this literature in a safe place for future reference.
4
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BLOWER COMPARTMENT BURNER COMPARTMENT
8
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27
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11
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BURNER COMPARTMENT BLOWER COMPARTMENT
28
27
Upflow/Horizontal
1 Two-Stage Gas Valve 2 Gas Line Entrance (Alternate) 3 Pressure Switch(es) 4 Gas Manifold 5 Combustion Air Intake Connection 6 Hot Surface Igniter 7 Rollout Limit 8 Burners 9 Flame Sensor 10 Flue Pipe Connection 11 Flue Pipe 12 Combustion Air Intake (Alternate) 13 Primary Limit 14 Gas Line Entrance 15 Flue Pipe Connection (Alternate) 16 Rubber Elbow 17 Two-Speed Induced Draft Blower 18 Electrical Connection Inlets (Alternate) 19 Coil Front Cover Pressure Tap 20 Coil Front Cover Drain Port 21 Drain Line Penetrations
25
9
7
8
6
7
4
Counterflow/Horizontal
22 Drain Trap 23 Blower Door Interlock Switch 24 Inductor (Not All Models) 25 Two-Stage Integrated Control Module
(with fuse and diagnostic LED) 26 24 Volt Thermostat Connections 27 Transformer (40 VA) 28 ECM Variable Speed Circulator Blower 29 Auxiliary Limit 30 Junction Box 31 Electrical Connection Inlets 32 Coil Front Cover 33 Combustion Air Inlet Pipe
1
5
II. SAFETYII. SAFETY
II. SAFETY
II. SAFETYII. SAFETY
Please adhere to the following warnings and cautions when in­stalling, adjusting, altering, servicing, or operating the furnace.
WARNING
O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,
T
ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A
F
WARNING
HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH
T
MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE
TATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER
S
REPRODUCTIVE HARM.
WARNING
O PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
T
DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTR ICAL COMPO NENTS FROM WA TER.
WARNING
EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE,
H
INSPECTION, MAINTENANCE AND SUPERVISION. SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SO URCE CLOSED. I N THE EVENT T HAT THE BUI LDING MAY BE EX POSED TO FREEZ ING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTI LIZED.
F THE BUILIDNG IN WHICH ANY
I
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge static electrictiy accumulated in the body before
touching the unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and ser­vicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electro­static potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is appli­cable to both installed and non-installed (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.).
If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.
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This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). This furnace can be used in the following non-industrial commer­cial applications:
Schools, Office buildings, Churches, Retail stores Nursing homes, Hotels/motels, Common or office areas
In such applications , the furnace must be installed with the follow­ing stipulations:
It must be installed per the installation instructions provided and per local and national codes.
It must be installed indoors in a building constructed on site.
It must be part of a ducted system and not used in a free air delivery application.
It must not be used as a “make-up” air unit.
It must be installed with two-pipe systems for combustion air, especially if VOC’s or other contaminants are present in the conditioned space.
All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required).
Dual certification means that the combustion air inlet pipe is op­tional and the furnace can be vented as a:
Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,
Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.
This furnace may be used as a construction site heater ONLY if the following conditions are met:
The vent system is permanently installed per these installation instructions.
A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.
Return air ducts are provided and sealed to the furnace.
A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.
Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced.
The input rate and temperature rise are set per the furnace rating plate.
100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used.
6
NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation
Air Requirements, Section 5.3.3.
The furnace heat exchanger, components, duct system,
air filters and evaporator coils are thoroughly cleaned following final construction clean up.
All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.
NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met:
Gas furnaces must be installed by a licensed plumber or gas fitter.
A T-handle gas cock must be used.
If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.
To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.
WARNING
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
P
EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.
WARNING
O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
T
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their ab­sence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:
American National Standards Institute 1430 Broadway New York, NY 10018
National Fire Protection Association 1 Batterymarch Park Quincy , MA 02269
CSA International 8501 East Pleasant Valley Cleveland, OH 44131
A copy of the CAN/CSA B149 Installation Codes can also be ob­tained from:
CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1R3
The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accor­dance with “ASHRAE Guide” or “Manual J-Load Calculations” pub­lished by the Air Conditioning Contractors of America.
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WARNING
O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL
T
INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.
Follow the instructions listed below when selecting a furnace loca­tion. Refer also to the guidelines provided in Section V, Combus-
tion and Ventilation Air Requirements.
Centrally locate the furnace with respect to the proposed or existing air distribution system.
Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.
Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.
Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to Section X, Condensate Drain Lines and Trap for further details.
Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Section V,
Combustion and Ventilation Air Requirements.
Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Section VII, Horizontal Applications and Considerations for leveling of horizontal furnaces.
Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.
A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.
Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances:
chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride
7
halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials
Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Section V, Combustion and Ventilation Air Requirements for details.
If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace.
If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.
If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.
CLEARANCES AND ACCESSIBILITY
Installations must adhere to the clearances to combustible mate­rials which this furnace has been design certified to. The mini­mum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently main­tained. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for details. NOTE: In addition to the required clearances to combus­tible materials, a minimum of 24 inches service clearance must be available in front of the unit.
TOP
TOP
SIDE SIDE SIDE
BOTTOM
BOTTOM
Upflow Counterflow Horizontal
A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Product Data Book applicable to your model* for minimum clearances to combustible surfaces. One of the ventilation open­ings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical
construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.
FURNACE SUSPENSION
If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.
PROVIDE 8" MINMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL
3/8" DIAMETER
THREADED ROD
(6 PLACES)
HOLD DOWN
NUTS
SUPPORT
NUTS
2"X2"X1/8" ANGLE IRON
(3 PLACES)
POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR
CIRCULATOR BLOWER REMVOAL
ASSURE FURNAC E IS LEVEL F ROM
END TO END AND HAS A SLIGHT
FORWARD TILT WIT H THE FRONT
OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE FURNAC E
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
REMOVAL
Suspended Furnace
EXISTING FURNACE REMOVAL
NOTE: When an existing furnace is removed from a venting system
serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Cen­tral Furnaces ANSI Z21.47b-2002, CSA-2.3b-2002 Section 1.23.1.
The following steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances con­nected to the venting system are not in operation:
a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch, as
required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficien­cies which could cause an unsafe condition;
c. In so far as practical, close all building doors and windows and all
doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting sys­tem. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;
d. Follow the lighting instructions. Place the appliance being inspected
in operation. Adjust thermostat so appliance shall operate continu­ously;
e. T est for draft hood equipped spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the flame of a match or candle;
f. After it has been determined that each appliance connected to the
venting system properly vents when tested as outlined above, re­turn doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;
g. If improper venting is observed during any of the above tests, the
common venting system must be corrected.
*NOTE: Please contact your distributor or our website for the applicable
product data book referred to in this manual.
8
Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes. If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes.
THERMOSTAT LOCATION
The thermostat should be placed approximately five feet fom the floor on a vibration-free, inside wall in an area having good air circulation. Do not install the thermostat where it may be influ­enced by any of the following:
Drafts, or dead spots behind doors, in corners, or under
cabinets.
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat, such as an
outside wall.
DRAFTS OR DEAD SPOTS
-BEHIND DOORS
-IN CORNERS
-UNDER CABINETS
Thermostat Influences
Consult the instructions packaged with the thermostat for mount­ing instructions and further precautions.
VV
. CO. CO
V
. CO
VV
. CO. CO
MBUSTIMBUSTI
MBUSTI
MBUSTIMBUSTI
OO
N & VENTILN & VENTIL
O
N & VENTIL
OO
N & VENTILN & VENTIL
AA
TITI
OO
N AIR REQUIREMENTSN AIR REQUIREMENTS
A
TI
O
N AIR REQUIREMENTS
AA
TITI
OO
N AIR REQUIREMENTSN AIR REQUIREMENTS
WARNING
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR
P
IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.
Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying com­bustion and ventilation air for gas fired and other fuel burning appli­ances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air. House depressurization can cause back drafting or improper com­bustion of gas-fired appliances, thereby exposing building occu­pants to gas combustion products that could include carbon mon­oxide. If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/
HOT
COLD
ANSI Z223.1 (Section 5.3), or CSA B149 Installation Codes (Sec­tions 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.
The following information on air for combustion and ventilation is repro­duced from the National Fuel Gas Code NFP A 54/ANSI Z223.1 Section
5.3.
5.3.1 General:
(a) The provisions of 5.3 apply to gas utilization equipment installed in
buildings and which require air for combustion, ventilation and dilu­tion of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.
(b) Equipment shall be installed in a location in which the facilities for
ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.
(c) In addition to air needed for combustion, process air shall be pro-
vided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.
(d) In addition to air needed for combustion, air shall be supplied for
ventilation, including all air required for comfort and proper working conditions for personnel.
(e) While all forms of building construction cannot be covered in detail,
air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be ob­tained by application of one of the methods covered in 5.3.3 and
5.3.4.
(f) Air requirements for the operation of exhaust fans, kitchen ventila-
tion systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.
5.3.2 Equipment Located in Unconfined Spaces:
In unconfined spaces (see definition below) in buildings, infiltration may
be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), addi­tional air may need to be provided using the methods described in 5.3.3­b or 5.3.4.
Space, Unconfined.
For purposes of this Code, a space whose volume is not less than 50
cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.
5.3.3 Equipment Located in Confined Spaces:
(a) All Air from Inside the Building: The confined space shall be pro-
vided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each open­ing shall have a minimum free area of 1 square inch per 1,000 BTU
9
per hour of the total input rating of all gas utilization equipment in
A
the confined space, but not less than 100 square inches. One open­ing shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.
NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equ ip­ment in the enclosure, but not less than 100 square inches.
Equipment Located in Confined Spaces; All Air from Inside
Building. See 5.3.3-a.
Chimney or Gas Vent
Water Heater
Furnace
(b) All Air from Outdoors: The confined space shall be provided with
two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Ventila t ion l ouv er s (each end of attic)
NOTE: The inlet and outlet air opening s must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclo sure.
Outlet Air
Water Heater
lternate
air inlet
Furnace
Inlet Air
Opening
Opening
Chimney or Gas Vent
Ventilation louvers (each end of attic)
NOTE: The inlet and outlet air openings must eac h have a free area of not less than one square inch per 4000 BTU o f the total input rating of all equipment in the enclosure.
Outlet Air
Furnace
Water Heater
Inlet air duct [ends 1 ft (300 mm) above floor]
Equipment Located in Confined Spaces; All Air from Outdoors
Through Ventilated Attic. See 5.3.3-b.
3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the
Outlet air duct
Water Heater
Furnace
Inlet air duct
*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.
Equipment Located in Confined Spaces; All Air from Outdoors.
See 5.3.3-b.
enclosure*.
4. 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 not be less than 3 inches.
Ventila t ion l ouv er s for unheated crawl space
Equipment Located in Confined Spaces; All Air from Outdoors—
Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated
Attic. See 5.3.3-b
NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equip­ment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.
Chimney or Gas Vent
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the
Opening
enclosure.
Water
Furnace
Equipment Located in Confined Spaces; All Air from Outdoors -
Single Air Opening. See 5.3.3-b.
Heater
Alternate Opening Location
10
5. When directly communicating with the outdoors, the single open­ing shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclo­sure.
5.3.4 Specially Engineered Installations:
The requirements of 5.3.3 shall not necessarily govern when special engi-
neering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.
5.3.5 Louvers and Grilles:
In calculating free area in 5.3.3, consideration shall be given to the blocking
effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
5.3.6 Special Conditions Created by Mechanical Exhausting or Fire­places:
Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces
may create conditions requiring special attention to avoid unsatisfac­tory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a.
VI. INSTVI. INST
VI. INST
VI. INSTVI. INST
ALLALL
ALL
ALLALL
AA
TITI
A
TI
AA
TITI
OO
N POSITIN POSITI
O
N POSITI
OO
N POSITIN POSITI
OO
O
OO
NSNS
NS
NSNS
This furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal up- flow furnaces, return air ductwork must be attached to the basepan. For both upright or horizontal counterflow furnaces, return duct- work must be attached to the basepan (top end of the blower com­partment). NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow require­ments and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate in­stallation positions, ductwork connections, and resulting airflow arrangements.
VII. HOVII. HO
VII. HO
VII. HOVII. HO
RIZORIZO
RIZO
RIZORIZO
NTNT
AL APPLIAL APPLI
NT
AL APPLI
NTNT
AL APPLIAL APPLI
CC
AA
TITI
OO
A
TI
AA
TITI
NS & CONS & CO
O
NS & CO
OO
NS & CONS & CO
C
CC
NSIDNSID
NSID
NSIDNSID
ERAERA
ERA
ERAERA
TITI
TI
TITI
OO
O
OO
NSNS
NS
NSNS
GENERAL
Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connec­tions, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:
FURNA CE MUST B E LEVEL
ALTERNA TE VENT/FLUE AND COMBUS TION AI R INTAKE LOCATIO NS
GAS LINE W ITH DRIP LEG (3" MINI MUM)
DRAIN PAN
FURNA CE MUST B E SUPPOR TED AT BOTH ENDS AND MIDDLE
FROM END TO END
4 3/4" MINIMUM DRAIN TRAP CLEARANCE
DRAIN LINE WITH 1/4" PER FOOT DOWNWARD SLOPE
MINIMUM
SERVICE
24"
CLEARANCE REQUIRED
FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0" - 3/4" BELOW THE BACK PA NEL
Horizontal Furnace
DRAIN TRAP AND LINES
In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A mini­mum clearance of 4 3/4 inches below the furnace must be pro­vided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Section X, Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.
LEVELING
Leveling ensures proper condensate drainage from the heat ex­changer and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel. The slight tilt allows the heat exchanger condensate, gen­erated in the recuperator coil, to flow forward to the recuperator coil front cover.
ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS
In horizontal installations provisions for alternate flue and com­bustion air piping are available for upflow furnaces with left dis­charge and counterflow furnaces with right air discharge. This con­figuration allows the flue and combustion air piping to be run verti­cally through the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connec­tions may also be used in these positions. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue and combustion air connec­tions.
11
AIR
NOTE
tified to 4500 feet
DISCHARGE
Side
Return
Duct
Connection
AIR
DISCHARGE
UPFLOW HORIZONTAL
LEFT AIR DIS CHARGE
Bottom Return
Duct
Connection
UPFLOW HORIZ ONT AL
RIGHT AIR DISCHARGE
Bottom Return
Duct
Connection
UPFLOW UPRIGHT
ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS
ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS
Side
Return
Duct
Connection
Bottom Return
Duct
Connection
AIR
DISCHARGE
Recommended Installation Positions
NOTE: Alternate “vertical” piping connections can not be used when
an upflow furnace is installed with supply air discharging to the right, or when a counterflow furnace is installed with supply air discharging to the left. In either case, use the standard flue and combustion air piping connections.
ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS
This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.
DRAIN PAN
A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).
FREEZE PROTECTION
Refer to Section VI, Horizontal Applications and Conditions - Drain Trap and Lines.
FURNACE SUSPENSION
If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. Refer to
Section IV, Location Requirements and Considerations - Furnace Suspension for further details.
VIII. PRVIII. PR
VIII. PR
VIII. PRVIII. PR
OO
PP
ANE GAANE GA
O
P
ANE GA
OO
PP
ANE GAANE GA
S /HIS /HI
S /HI
S /HIS /HI
GH ALGH AL
GH AL
GH ALGH AL
TITUDTITUD
TITUD
TITUDTITUD
E INSTE INST
E INST
E INSTE INST
ALLALL
ALL
ALLALL
AA
TITI
OO
NSNS
A
TI
O
NS
AA
TITI
OO
NSNS
WARNING
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF
P
THE CORRECT CONVERSION KITS ARE NOT INSTALLED. MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.
HE APPROPRIATE KITS
T
A
LL
High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. For installations above 7000 feet, please refer to your distributor for required kit(s).
Gas Altitude Kit
Natural None #43 3.5" w. c. 1.9" w.c . None
Propane
0-7000
LPM -03B
: In Canada, gas furnaces are only cer
Orifice
#55 10 .0" w. c . 6.0" w.c. None
M a n if ol d P ressu re P ressu re
High Stage Low Stage
Swi tch Change
.
Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installa­tions. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a quali­fied installer, or service agency.
IX. VENT/FLUE PIPE & COMBUSTION AIR PIPEIX. VENT/FLUE PIPE & COMBUSTION AIR PIPE
IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE
IX. VENT/FLUE PIPE & COMBUSTION AIR PIPEIX. VENT/FLUE PIPE & COMBUSTION AIR PIPE
GENERAL
WARNING
AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR
F
DEATH. SECTION.
AREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS
C
WARNING
PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE
U
ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED. PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.
EAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS
L
A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water con­densation requirements, PVC pipe is used as venting material. This furnace must not be connected to T ype B, BW , or L vent or vent connector , and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connec­tors” other than those shipped with this product. It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connec­tors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connec­tions possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.
DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT
This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.
12
MATERIALS AND JOINING METHODS
WARNING
O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE
T
KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.
Two- or three-inch nominal diameter PVC Schedule 40 pipe meet­ing ASTM D1785, PVC primer meeting ASTM F656, and PVC sol­vent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC. As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifi­cations may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/ 16” minimum from the plane of one opening to the centerline of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.
VOID BREATHING
A
PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES
Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions. Piping must be adequately secured and supported to prohibit sag­ging, joint separation, and/or detachment from the furnace. Hori­zontal runs of vent/flue piping must be supported every three feet and must maintain a 1/4 inch per foot downward slope, back to­wards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches. Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.
TERMINATION LOCATIONS
NOTES: Refer to Section IV, Location Requirements and
Considerations for combustion air contaminant restrictions. The following bullets and diagram describe the restrictions con-
cerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Di- rect Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping
located in this section for specific details on termination construc­tion.
All terminations (flue and/or intake) must be located at least 12 inches above ground level or the anticipated snow level.
Vent terminations (non-direct and direct vent) must terminate at least 3 feet above any forced air inlet located within 10 feet.
NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.
The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window , or gravity air inlet into any building.
The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).
The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).
A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.
The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.
Non-Direct Vent
&
Direct Vent
Vent/Flue Terminations
Non-Direct Vent
Vent/Flue Termination
No Terminations Above Walkway
Grade or H ig he st
Anticipated Snow Level
3' min.
Forced Air
Inlet
<10'
12"
12" min.
Direct Vent
Vent/Flue Termination
12" min.
4' min.
4'
min.
12"
min.
Non-Direct Vent
Vent/F lu e Ter m i nation
Vent Termination Clearances
NOTE: In Canada, the Canadian Fuel Gas Code takes precedence
over the preceding termination restrictions.
CANADIAN VENTING REQUIREMENTS
In Canada, venting must conform to the requirements of the cur­rent CAN/CSA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.
13
STANDARD FURNACE C ONNECTIONS
It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported. As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or basepan (counterflow). To use the standard connec­tions, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.
VENT/FLUE PIPE
Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (see “Standard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing. NOTE: Do not use other commercially available “no hub connectors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see Section IX, Materials and Joining Meth- ods.
NOTE: For non-direct vent installations, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage.
COMBUSTION AIR PIPE DIRECT VENT INSTALLATIONS
On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combus­tion air intake pipe to the air intake coupling using the rubber cou­pling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. NOTE: Be­cause of probable material conflicts, do not use other commer­cially available “no hub connectors”. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.
NON-DIRECT VENT INSTALLATIONS
A minimum of one 90° elbow should be installed on the combus­tion air intake “coupling” to guard against inadvertent blockage.
(DIRECT VENT ONLY)
90 PVC ELBOW
(NON-DIRECT VENT )
COMBUSTION
AIR PIPE
OR
RUBBER
COUP LING
WITH WORM
GEAR CLAMPS
VENT/FLUE
PIPE
(NON-DIRECT VENT)
90 PVC ELBOW
COMBUSTION
AIR PIPE
(DIRECT VENT ONLY)
GEAR CLAMPS
OR
RUBBER COUPLINGS WITH WORM
VENT/FLUE
PIPE
NOTE: S t andard and alternate locations can be combined (i.e., an
installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.
WARNING
DGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRE-
E
CAUTION WHEN REMOVING HOLE PLUGS.
ALTERNATE VENT/FLUE LOCATION
The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue loca­tion refer to the following steps, the “Vent/Flue Pipe Cuts” figure, and the “Alternate Vent/Flue Location” figure.
NOTE: Counterflow instructions follow the upflow instructions.
1. Remove and save the four screws securing the vent/flue coupling to the furnace top panel.
Counterflow units. Remove and save the four screws securing the vent/flue
coupling to the furnace basepan. Also remove the three screws securing the furnace’s internal vent/flue piping to the blower deck.
2. Upflow and Counterflow units. Loosen the worm gear hose clamps on the rubber elbow
and detach it from both the induced draft blower and the vent/flue pipe.
3. Upflow and Counterflow units. Remove the vent/flue pipe from the furnace.
4. Cut the vent/flue pipe 3.75 inches from the flanged end of the pipe. See Vent/Flue Pipe Cuts figure. The section of pipe attached to the coupling will reach through the side panel to the induced draft blower. Discard remaining pipe and elbows.
Counterflow units. Cut the vent/flue pipe 3.75 inches from the blower deck
coupling. See Vent/Flue Pipe Cuts figure. Save vent/flue pipe attached to blower deck coupling for use in the alternate location. Discard remaining pipe and elbows.
FLANGE
3.75"
CUT HERE
UPFLOW COUNTERFLOW
STANDARD CONNECTIONS
Standard Connections
ALTERNATE FURNACE CONNECTIONS
If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil, or to upright counterflow installations requiring additional access to a filter or electronic air cleaner, or to horizontal installations desiring vent/flue (and combustion air intake) piping run vertically from the side of the cabinet.
Vent/Flue Pipe Cuts
5. Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover).
Counterflow units. Remove plastic plug from alternate vent/flue location.
Relocate and install plug in standard vent/flue location (basepan). Plug remaining hole in blower deck with plastic plug included in the drain kit bag.
6. Upflow and Counterflow units. Insert cut section of vent/flue pipe and coupling into alternate
vent/flue location. Using a rubber coupling and worm gear hose clamps from the drain kit bag, attach the vent/flue pipe and coupling to the induced draft blower. Secure the
14
coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self drilling screws.
WARNING
HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. WHEN THE
T
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE.
7. Upflow and Counterflow units. For upright installations, externally mount the rubber elbow
to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe.
8. Upflow and Counterflow units. For horizontal installations, externally secure the field-
supplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.
3
REMOVE
PIPE
UPFLOW
1
REMOVE
4 SCREWS
REMOVE
AND RELOCATE
2
DETACH RUBBER
ELBOW FROM
ID BLOWER AND
VENT/FLUE
PIPE
COUNTERFLOW/UPRIGHT
(UPFLOW SIMILAR)
6
SECURE TO
ID BLOWER WITH
RUBBER COUPLING
AND HOSE
CLAMPS
1.
REMOVE
4 SCREWS
5
COUNTERFLOW
ID BLOWER WITH
RUBBER COUPLING
5
ADDITIONAL PLUG
FROM DRAIN KIT
7
EXTERNALLY
MOUNT
RUBBER ELBOW
6
SECURE TO
AND HOSE
CLAMPS
SECURE TO
CABINET WITH
SCREWS
3
REMOVE
PIPE
REMOVE
AND RELOCATE
DETATCH RUBBER
ELBOW FROM
ID BLOWER AND
6
1
REMOVE
3 SCREWS
5
2
VENT/FLUE
PIPE
ALTERNATE COMBUSTION AIR INTAKE LOCATION
The alternate combustion air intake location consists of a large, unobstructed hole (alternate vent connection is aligned with the Induced Draft Blower). To use the alternate combustion air intake location, refer to the following steps, and the “Alternate Combus­tion Air Intake Location” figure. NOTE: Counterflow unit instructions follow the upflow instructions.
1. Remove and save the four screws securing the combustion air intake coupling to the furnace’s top panel (upflow).
Counterflow units. Remove and save the four screws securing the combustion
air intake coupling to the basepan. Remove an additional three screws securing the furnace’s internal combustion air intake pipe to the blower deck.
2. Remove the combustion air intake coupling and gasket from the top panel.
Counterflow units. Remove the combustion air intake pipe from the furnace
and cut the pipe at the basepan coupling. Save the basepan coupling and gasket from the blower deck coupling for use in the alternate location. Discard the remaining pipe.
3. Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (top cover).
Counterflow units. Remove plastic plug from alternate combustion air intake
location. Relocate and install plug in standard air intake location (basepan). Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag.
4. Upflow and Counterflow units. With the gasket facing the cabinet side panel, and the
flange’s flat spot facing forward, secure the combustion air intake coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self -drilling screws.
CAUTION
E SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN
B
REINSTALLING COUPLING AND SCREWS.
5. Upflow and Counterflow units. For non-direct vent installations installed horizontally, a
minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. No elbow is required on the alternate combustion air intake of upright installations, however, a minimum clearance of 2 inches is required to assure proper air supply .
6. Upflow and Counterflow units. For direct vent installations, secure field-supplied
combustion air intake pipe directly to the air intake coupling. NOTE: A PVC coupling or elbow is required on counterflow
units.
UPFLOW/HORIZONTAL
(COUNTERFLOW SIMILA R)
Alternate Vent/Flue Location
15
1
REMOVE
4 SCREWS
UPFLOW
SECURE
TO CA B INET
REMOVE
4
2
2
REMOVE
AND CUT
3
REMOVE
AND
RELOCATE
UPFLOW/HORIZONTAL SHOWN
(COUNTERFL O W SI MIL A R)
1
REMOVE
3 SCREWS
3 ADDITIONAL PLUG FROM
DRAIN KIT
5
1
REMOVE
4 SCREWS
COUNTERFLOW
5
2" CLEARANCE
REQUIRED
(NON-DIRECT
VENT)
3
.
REMOVE
AND
RELOCATE
Alternate Combustion Air Intake Location
NON-DIRECT VENT (SINGLE PIPE) PIPING
Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Section IX, Vent/Flue Pipe and Combustion
Air - Standard Furnace Connections or Alternate Furnace Con­nections for specific details. Refer to the following Non-Direct Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for spe-
cific details on termination construction. Although non-direct vent installations do not require a combus­tion air intake pipe, a minimum of one 90° elbow should be at­tached to the furnace’s combustion air intake if: an upright instal­lation uses the standard intake location, or a horizontal installa­tion uses the alternate air intake location. This elbow will guard against inadvertent blockage of the air intake.
VENT/FLUE PIPE LENGTHS AND DIAMETERS
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct vent installation. In addition to the vent/flue pipe, a single 90° elbow should be secured to the combustion air intake to prevent inadvertent blockage. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.
UPFLOW
Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft)
(4)
Unit Input
Pipe
(Inch)
12345678
Number of Elbows
(1)(2)
(3)
45,000 2 7168656259565350 70,000 90,000
115,000
2 4946434037343128 3 7168656259565350 3 7168656259565350 3 4946434037343128
COUNTERFLOW
Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft)
(4)
Unit Input
70,000
90,000
Pipe
(Inch)
12345678 2 6158555249464340 3 7168656259565350 2 6158555249464340
3 7168656259565350
Number of Elbows
(1)(2)
(3)
(1 ) One 90° elbow should be secured to the combustion air intake con-
nection. (2 ) Minimum vent length is five feet and one elbow/tee. (3) Tee used in the vent/flue termination must be included when determin-
ing the number of elbows in the piping system. (4 ) 3” diameter pipe can be used in place of 2” diameter pipe.
VENT/FLUE PIPE TERMINATIONS
The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Com- bustion Air Pipe - Termination Locations for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent. Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations for details concerning loca­tion restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe while a 3 1/2” diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be in­stalled on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetra­tion should be sealed with silicone caulking material. In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.
TEE
16
12 " Min To
Roof Or
Highest Anticipated
Snow Level
Vertical Termination (Single Pipe)
90º
MEDIUM RADIUS
ELBOWS
12" MIN.
TO ROOF OR
HIGHEST ANTICIPATED SNOW LEVEL
Alternate Vertical Termination (Single Pipe)
WALL
INSIDE
ELBOW OR COUPLING
OUTSIDE
COUPLING
MIN.
FROM
WALL
12"
TEE
90°ELBOW
TURNED
DOWN
12"
TO GROUND OR
HIGHEST ANTICIPATED
SNOW LEVEL
or
Horizontal Termination (Single Pipe)
12" MIN.
VENT/FLUE TEE
or
90° ELBOW TURNED
DOWN
Horizontal Termination (Single Pipe)
Above Highest Anticipated Snow Level
DIRECT VENT (DUAL PIPE) PIPING
The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe. Installation of screens, while strongly recommended, is not required and will not affect performance of the unit. Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resis­tant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Section IX, Vent/Flue and Combustion Air Pipe - Termina- tion Locations or Concentric Vent Termination for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Section IX, Vent/Flue Pipe and
Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections.
VENT/FLUE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a direct vent (dual pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.
If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objec­tionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required.
UPFLOW
Direct Vent (Dual Pipe) Maximum Allowable Length
of Vent/Flue & Combustion Air Intake Pipe (ft)
Unit Input
(Btu)
45,000
70,000
90,000
115,000
Termination
Style
Pipe (inch)
(4)
Number of Elbows
12345678 Standard 2 71 68 65 62 59 56 53 50 Alternate 2 58 55 52 49 46 43 40 37
Standard
Alternate
2 4946434037343128 3 7168656259565350 2 3633302724211815
3 5754514845423936 Standard 3 71 68 65 62 59 56 53 50 Alternate 3 57 54 51 48 45 42 39 36 Standard 3 49 46 43 40 37 34 31 28 Alternate 3 35 32 29 26 23 20 17 14
(1)(2)(3)
COUNTERFLOW
Direct Vent (Dual Pipe) Maximum Allowable Length
of Vent/Flue & Combustion Air Intake Pipe (ft)
Unit Input
(Btu)
Termination
Style
Standard
70,000
Alternate
Standard
90,000
Alternate
(1)
Elbows and/or Tees used in the terminations must be included when determining the number of elbows in the piping system.
(2)
Number of elbows tabulated are for each (Vent/Flue & Combustion air intake) pipe.
(3)
Minimum length of each Vent/Flue & Combustion Air Intake pipe is five feet and one elbow/tee.
(4)
3” diameter pipe can be used in place of 2” diameter pipe.
(4)
Pipe (inch)
2 4946434037343128
3 7168656259565350
2 3633302724211815
3 5754514845423936
2 6158555249464340
3 7168656259565350
2 4845423936333027
3 5754514845423936
Number of Elbows
12345678
(1)(2)(3)
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS
The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
90º
MEDIUM RADIUS
ELBOWS
12" MIN.
12" MIN.
TO RO OF OR
HIGHEST ANTICIPATED SNOW LEVEL
COMBUSTION
AIR INTAKE
SCREEN
Vertical Terminations (Dual Pipe)
24" MAX. 3" MIN.
TEE
VENT/FLUE
17
Horizontal terminations should be as shown in the following fig-
V
ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe ­Termination Location for location restrictions. A 2 3/8 inch diameter
wall penetration is required for 2” diameter pipe while a 3 1/2 inch diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connec­tions, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking ma­terial.
12" MIN
3" MIN
24" MA X
3" MIN
24" MAX
Standard Horizontal Terminations (Dual Pipe)
90° MEDIUM RADIUS ELBOW
24" MAX
3" MIN
24" MAX
AIR INTAKE
Alternate Horizontal Vent Termination (Dual Pipe)
Alternate Vent Termination Above Anticipated Snow Level
(Dual Pipe)
In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES
If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clear­ances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit. If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the following figure. Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation.
ents
3" Min.
24" Max.
24" Max.
3" Min.
3" Min.
90° Medium Radius Elbows
24" Max.
12" MIN
12" MIN.
VENT/FLUE
TEE
12" MIN. ABOVE
HIGHES T AN TICI P ATE D
SNOW LEVEL
SUPPORT
STRAPS
COMBUSTION AIR INTAKE.
SCREEN
90° MEDIUM RADIUS ELBOWS
3" MIN.
24" MAX .
12" MIN. ABOVE
HIGHEST A NTIC IP AT ED
SNOW LEVEL
Standard Horizontal Terminations Above Anticipated Snow
Level (Dual Pipe)
Screen
12" Min.
Horizontal Venting Of Multiple Units
CONCENTRIC VENT TERMINATION
Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications.
X. COX. CO
NDND
ENSAENSA
X. CO
X. COX. CO
ND
NDND
TE DRAIN LINES & DRAIN TRAPTE DRAIN LINES & DRAIN TRAP
ENSA
TE DRAIN LINES & DRAIN TRAP
ENSAENSA
TE DRAIN LINES & DRAIN TRAPTE DRAIN LINES & DRAIN TRAP
GENERAL
A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropri­ate drain location. In upright installations, the furnace’s drain hoses may exit either the right or left side of the furnace. NOTE: If the alternate vent/flue outlet is utilized in an upright installation, the drain trap and drain connections must be located on the same side as the alternate vent/flue outlet. In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended be­neath the furnace. The field-supplied drain system must be in
18
accordance with all local codes and the instructions in the follow-
Y
Y
(
)
Cabinet W idth
(inches)
Models
(kBTU_Tons)
"X" Length t o Cut F r om Long
End of Hose B
17 1/2 45__30 7 inches
21 70__40 3 1/2 inches
090__50 115__50
24 1/2 None
ing sections. Follow the bullets listed below when installing the drain system.
Refer to the following sections for specific details concerning fur­nace drain trap installation and drain hose hook ups.
The drain trap supplied with the furnace must be used.
The drain line between furnace and drain location must be constructed of 3/4” PVC or CPVC.
The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain.
Do not trap the drain line in any other location than at the drain trap supplied with the furnace.
Do not route the drain line outside where it may freeze.
If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.
If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.
UPRIGHT INSTALLATIONS
In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet.
NOTE: Refer to Section X, Condensate Drain Lines and Drain T rap
- Alternate Vent/Flue Hose Connections for upright installations
using an alternate vent/flue outlet.
STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS
Upright installations using the standard vent/flue outlet require drain hoses to be connected as follows. The following quantity of hoses, tubes, and hose clamps are provided with the unit.
GREEN HOSE CLAMPS
: 3
QT
Hose and Tube Identification
1. Remove the rubber plug from the front cover drain port (right or left side, depending on the intended drain trap mounting).
2. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear side panel grommet hole.
NOTE: For left side drainage, grommets will have to be relocated to left side panel.
HOSE A QTY: 1
TUBE 1 QTY: 1
TUBE 2 QTY: 2 RED
HOSE CLAMPS
QT
HOSE B QTY: 1
:2
RIGHT SIDE
PANEL
RUBBER
ELBOW
RUBBER ELBOW
DRAIN PORT
RED HO S E CLAMP
TUBE 1
HOSE
SIDE PANEL
B
GROMMET
HOLES
TUBE(S) 2
FRONT COVER
DRAIN PORT
RED HOSE
CLAMP
HOSE
A
GREEN
HOSE
CLAMPS
3 PLACES
DRAIN TRAP
Upright “Standard” Connections - Right Side
(Upflow Shown, Counterflow Similar)
LEFT
SIDE PANEL
FRONT COVER
DRAIN PORT
RED HOSE
CLAMP
HOSE A
SIDE PANEL
DRAIN
HOLES
TUBE(S) 2
DRAIN
TRAP
HOSE B
RUBBER
ELBOW
RUBBER
ELBOW
DRAIN PORT
RED HOSE
CLAMP
TUBE 1
GREEN HOSE
CLAMPS
(3 PLACES)
Upright “Standard” Connections - Left Side
(Upflow Shown, Counterflow Similar)
3. Cut and remove 1/4 inch from the end of the drain port on the rubber elbow.
4. Insert Tube 1 into rubber elbow drain port and secure with red hose clamp. Angle tube outward toward front of furnace.
5. Right side drains Cut 17 3/4 inches from the long end of Hose B and discard.
Secure the remaining hose to Tube 1 with a green hose clamp. Route the other end of Hose B to front right side panel grommet hole.
Left side drains Cut “X” inches from the long end of Hose B and discard.
Refer to table for appropriate length to cut. Secure remaining hose to Tube 1 with a green hose clamp. Route other end of Hose B to front left side panel grommet hole.
6. Insert short end of each Tube 2 through side panel grommet holes. Secure tubes to Hose A and Hose B with green hose clamps. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.
For details concerning mounting of the drain trap, refer to Section
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS
Upright installations using the alternate vent/flue outlet will require
19
“right-side only” drain hoses to be connected as follows. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection.
1. Remove the rubber plug from the front cover right-side drain port. Save for use in step 3.
2. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear right side panel grommet hole.
3. Remove grommet from front right-side panel drain hole. Seal hole in grommet with large end of plug. Reinstall grommet and plug into side panel drain hole.
4. Cut 1/4 inch from the end of the drain port on the externally mounted rubber elbow. Discard cut portion.
5. Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp. Angle tube outward toward front of furnace.
6. Cut 17 7/8 inches from the long end of Hose B and discard.
7. Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose toward right side panel grommet holes.
8. Insert short end of one Tube 2 through rear right side panel grommet drain hole. Secure tube to Hose A with a green hose clamp.
9. Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp. Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding.
FRONT COVER
DRAIN PORT
RED HOSE
CLAMP
RUBBER ELBOW
(EXTERNALLY
MOUNTED)
HOSE A
TUBE(S) 2
RUBBER
ELBOW
DRAIN PORT
RED HOSE CLAMP
GREEN HOSE
TUBE 1
(3 PLACES)
HOSE B
SIDE PANEL
GROMMET
HOLES
DRAIN TRAP
CLAMPS
Upright “Alternate” Connections - Right Side Only
(Upflow Shown, Counterflow Similar)
For details concerning mounting of the drain trap, refer to the fol­lowing section.
UPRIGHT DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)
1. Insert drain tubes into drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap.
2. Secure drain trap to side panel at the mounting holes (dimples or crosshairs on counterflow models) located below the grommet drain holes.
3. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling.
HORIZONTAL INSTALLATIONS
RIGHT SIDE DOWN
Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port.
NOTE: On counterflow models, relocation of the front cover pressure switch hose is required.
Make connections as follows:
1. Remove the rubber plug from the coil front cover drain port.
Counterflow furnaces
Relocate the front cover pressure switch hose connection from the left side pressure tap to the right (down) side tap. The pressure switch hose must be connected to the down side to guard against blocked drain conditions. Cut hose to appropriate length to minimize sagging. Plug left (unused) pressure tap with plug removed from right side.
2. Secure Hose A to front cover drain tap with a red hose clamp. Route hose to rear right (down) side panel grommet holes.
3. Cut 1/4 inch from the end of the drain port on the rubber elbow and discard.
4. Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp. Angle tube outward toward front of furnace.
5. Cut 17 3/4 inches from the long end of Hose B and discard.
6. Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose to front right down side panel grommet holes.
7. Cut 5 1/2 inches straight length from the long end of each Tube 2.
FRONT COVER DRAIN PORT
RED HOSE
CLAMP
HOSE A
HOSE B
SIDE PANEL
GROMMET
HOLES
TUBES 2
DRAIN TRAP
GREEN
HOSE
CLAMP
(3 PLACES)
TUBE 1
FRONT
COVER
PRESSURE
TAP
RUBBER ELBOW
RED HOSE
RUBBER
ELBOW
RIGHT
SIDE
PANEL
DRAIN PORT
CLAMP
Horizontal Connections - Right Side Down
(Upflow Shown, Counterflow Similar)
8. Insert approximately one inch of each Tube 2 through the right down side panel grommet holes. Secure tubes to Hose A and Hose B using green hose clamps. Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound.
For details concerning mounting of the drain trap, refer to Section
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
LEFT SIDE DOWN
Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow.
1. Remove the rubber plug from the coil front cover left (down) side drain port.
2. Relocate the front cover pressure switch hose connection from the right side (as shipped) pressure tap to the left (down) side tap. The pressure switch hose must be connected to the down side to guard against blocked drain conditions. Cut hose to appropriate length to minimize sagging. Plug right (unused) pressure tap with plug removed from left side.
3. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear left (down) side panel grommet holes. NOTE: For left side drainage, grommets must be relocated to left side panel.
20
INDUCED
DRAFT BLOWER
DRAIN PORT
HOSE B
LEFT SI DE
PANEL
FRONT COVER
PRESSURE
TAP
FRONT COVER
DRAIN PORT
RED HOSE CLAMP
SIDE PANEL
GROMMET
HOLES
HOSE A
GREEN HOSE
CLAMPS
(3 PLACES)
TUBE(S) 2
DRAIN TRAP
Horizontal Connections - Left Side Down
(Upflow Shown, Counterflow Similar)
4. Remove the rubber cap from the side drain port on the rubber elbow.
5. Secure the short end of Hose B to rubber elbow side drain port using a green hose clamp. NOTE: For left side drainage, route hose to far left (down) side panel grommet holes. NOTE: Horizontal left side connections (when using new side port drain elbow)
does not require connecting a hose
to the induced draft blower housing.
6. Cut 5 1/2 inches straight length from the long end of each Tube 2.
7. Insert approximately one inch of each Tube 2 through left side panel grommet hole. Secure tubes to Hose A and Hose B with a green hose clamps. NOTE: Tube must reach bottom of trap. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.
For details concerning mounting of the drain trap, refer to Section
X, Condensate Drain Lines and Drain Trap - Upright Drain Trap Mounting.
HORIZONTAL DRAIN TRAP MOUNTING (LEFT OR RIGHT SIDE PANEL)
1. Position the drain trap against side panel with drain tubes inserted into trap. Note that the trap may be orientated with the outlet facing either the furnace’s top cover or base pan.
2. Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes.
3. Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding.
4. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling.
XI. ELECTRICAL CONNECTIONSXI. ELECTRICAL CONNECTIONS
XI. ELECTRICAL CONNECTIONS
XI. ELECTRICAL CONNECTIONSXI. ELECTRICAL CONNECTIONS
WARNING
O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
T
POLARIZED AND GROUNDED.
CAUTION
ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
L
IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
W
ERIFY PROPER OPERATION AFTER SERVICING.
V
WIRING HARNESS
The wiring harness is an integral part of this furnace. Field alter­ation to comply with electrical codes should not be required. Wires are color and number coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C. Any replacement wiring must be copper conductor.
115 VOLT LINE CONNECTIONS
Before proceeding with electrical connections, ensure that the sup­ply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent pro­tection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.
NOTE: Line polarity must be observed when making field connections.
Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. For direct vent applica­tions, the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non-reactive UL approved sealant to bushing. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side (right side for counterflows) electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below.
CAUTION
DGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION
E
WHEN REMOVING HOLE PLUGS.
1. Remove the burner compartment door.
2. Remove and save the two screws securing the junction box to the side panel.
3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2.
WARNING
O AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL
T
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
21
STANDARD
X
3
2
1
T W O
S
I
N
G
L E
TSTAT
OFF
3
2
1
T-Stat selection jumper in single-st age ther mostat position.
DIP switch position 3: ON
DIP switch position 3: OFF
T W O
S
I N G L E
TSTAT
ON
JUNCTION BOX
LOCATION
*
***
*
ALTERNATE
JUNCTION BO
LOCATION
*
**
*
Junction Box Relocation
WARNING
O AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE
T
MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE
ODE.
C
ATIONAL ELECTRIC
N
W2
Y
G
YLO
(Single-Stage Cooling)
B/C G R W1 W2O
Y
Y C Remote
Condensing Unit
W1
R
NEU
HOT
Two -Stage Heating with S ingle-Stage Coolin g
YLO W2
()
Y
W1
Thermostat
Two-Stage Heating
()
with
Single-Stage C ooling
Furnace Integrated
DEHUM
TWIN
Control M odule
Dehum idistat
[O ptio na l]
Thermo stat
Two-Stage Heating
with
Two- Stag e C o oling
To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box
G
R
all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check.
1. Measure resistance between the neutral (white) connection and one of the burners.
2. Resistance should measure 10 ohms or less.
This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servic­ing. Do not defeat this switch.
24 VOLT THERMOSTAT WIRING
NOTE: Wire routing must not interfere with circulator blower
operation, filter removal, or routine maintenance. As a two-stage furnace, the furnace integrated control module pro-
vides terminals for both “W1” and “W2”, and “YLO” and “Y” thermo­stat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heat­ing with Single-Stage Cooling’, and ‘Two-Stage Heating with Two­Stage Cooling’. Refer to the following figures and table for proper connections to the integrated control module. Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. Wire routing must not interfere with circula­tor blower operation, filter removal, or routine maintenance.
Thermostat
Single-Stage H eating
with
Sin gl e - S ta g e C o o ling
Furnace Integrated
DEHUM
TWIN
Control Module
Dehumidistat
[O p tio n a l]
Y
B/C G R W1 W2O YLO Y
Y C
Remote
Condensing Unit
(Single-Stage Cooling)
()
W
G
R
NEU
HOT
This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring.
SINGLE-STAGE THERMOSTAT APPLICATION
A single-stage thermostat with only one heating stage can be used to control this furnace. The application of a single-stage thermo­stat does not offer “true” thermostat-driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay pe­riod prior to stepping up can be set at either 5 or 10 minutes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module. To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection jumper on the integrated control module from the “two-stage” position to the “single-stage” position, turn power back on. Refer to the following figures.
YLO
YLO
Condensing Unit
(Two-S tage Cooling)
Y
Y
Remote
B/C G R W1 W2O
NEU
C
HOT
Two-Stage Heating with Tw o-Stage Cooling
Thermostat Diagrams
Single-Stage Heating w ith S ingle-Stage C ooling
NOTE:
To apply a single-stage heating thermostat, the therm ostat selector jumper on the integrated Control module must be set on single stage.
24 VOLT DEHUMIDISTAT WIRING
The optional usage of a dehumidistat allows the furnace’s circula­tor blower to operate at a slightly lower speed during a combined thermostat call for cooling and dehumidistat call for dehumidifica-
Delay Period: 10 minutes.
Furnace Integ ra ted
DEHUM
TWIN
Control M o du le
Dehu midistat
[Optional]
Delay Period: 5 minutes.
22
tion. This lower blower speed enhances dehumidification of the
OPTIONAL ACCESSORIES
EAC-H
12 CIRCUIT CONNECTOR
INTEGRATED
CONTROL MODULE
ELECTRONIC
AIR CLEANER
HUMIDIFIER
HUM-N
HUM-H
EAC-N
OPTIONAL ACCESSORIES
EAC-N
12 CIRCUIT CONNECTOR
INTEGRATED
CONTROL MODULE
ELECTRONIC
AIR CLEANER
HUMIDIFIER
HUM-H
HUM-N
EAC-H
conditioned air as it passes through the AC coil. For proper func­tion, a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise. To install/connect a dehumidistat:
1. Turn OFF power to furnace.
2. Secure the dehumidistat neutral wire (typically the white lead) to the screw terminal marked “DEHUM” on the furnace integrated control module.
3. Secure the dehumidistat hot wire (typically the black lead) to the screw terminal marked “R” on the furnace integrated control module.
4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumidistats.
5. Turn ON power to furnace.
To enable the dehumidify function on the integrated control mod­ule:
1. Cut the jumper wire labeled “CUT FOR DEHUM” located adjacent to the DEHUM screw terminal.
Once the jumper wire is cut, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (Dehum-Stat). The yellow LED adjacent to the DEHUM screw ter­minal will be illuminated during dehumidification.
DEHUM
0 YL0 Y B/C G R W1 W2
0YL0YB/CGRW1W2
R84
DS4 DS5
DS3
CUT FOR
DEHUM
R85
R22
TWIN
TP1
DEHUMIDIFICATION
LED (YELLOW)
TP2
DS7 R191
W14
W3
R128
R122
CR35
DEHUMIDIFICATION
JUMPER WIRE
(CUT TO ENABLE)
FOSSIL FUEL APPLICATIONS
This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump, gas furnace, or both).
A heat pump thermostat with three stages of heat is required to properly use a two-stage furnace in conjunction with a heat pump. Refer to the fossil fuel kit installation instructions for additional thermostat requirements.
Strictly follow the wiring guidelines in the fossil fuel kit installa­tion instructions. All furnace connections must be made to the furnace two-stage integrated control module and the “FUR­NACE” terminal strip on the fossil fuel control board.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER
ELECTRONIC A IR CLEANER)
AND
WARNING
O AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL
T
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
The furnace’s integrated control module is equipped with line volt­age accessory terminals for controlling power to an optional field­supplied humidifier and/or electronic air cleaner. The accessory load specifications are as follows:
Humidifier 1.0 Amp maximum at 120 VAC
Electronic Air Cleaner 1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The humidifier and electronic air cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown.
Accessories Wiring
If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box. The integrated control module humidifier terminals (HUM) are en­ergized with 115 volts whenever the induced draft blower is ener­gized. The integrated control module electronic air cleaner termi­nals (EAC) are energized with 115 volts whenever the circulator blower is energized.
24 VOLT HUMIDIFIER
A 5" long brown wire in the wire harness at the low fire pressure provides 24 VAC humidifier control. This wire is powered any time the pressure switch is closed. To connect 24 VAC HUM, connect the 24 V AC line of the humidifier to the 5” brown wire. The connec­tion can be made by either stripping the wire and using a wire nut or by using a field supplied quick connect terminal. The wiring must conform to all local and national codes. Connect the COM side of the humidifier to the B/C terminal on the furnace control board (or to the COM side of the 24 VAC transformer). Do not connect 115V humidifier to these terminals.
XII. GAS SUPPLY AND PIPINGXII. GAS SUPPLY AND PIPING
XII. GAS SUPPLY AND PIPING
XII. GAS SUPPLY AND PIPINGXII. GAS SUPPLY AND PIPING
GENERAL
The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.
CAUTION
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET
T
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
23
Inlet gas supply pressures must be maintained within the ranges
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
Length of N ominal Black Pipe Size
Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"
10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490
100 38 79 150 305 460
(P ressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
CFH =
BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)
specified below. The supply pressure must be constant and avail­able with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to pre­vent unit overfiring.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum:5.0" W.C. Maximum :10.0" W.C. Minimum:11.0" W.C. Maximum :13.0" W.C.
HIGH ALTITUDE DERATE
When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combus­tion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range. High altitude kits are purchased according to the installation alti­tude and usage of either natural or propane gas. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, propane gas, and/or Pressure Switch) kits. Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flash­back, and possible yellow tipping. In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artifi­cially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude regard­less of the BTU/ft3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and correspond­ing manufacturer’s pressure switch kits.
PROPANE GAS CONVERSION
WARNING
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF
P
THE CORRECT CONVERSION KITS ARE NOT INSTALLED. MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations. Refer to the Section VIII, Propane Gas / High Altitude Installations section for details.
GAS VALVE
This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the lighting instructions label or Section XIV, Startup Pro- cedure & Adjustment for use of this control during start up and shut
T
HE APPROPRIATE KITS
LL
A
down periods.
GAS PIPING CONNECTIONS
GENERAL
CAUTION
O AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE
T
DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED W HEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.
When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line. The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFP A 54/ANSI Z223.1.
To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size. The following stipulations apply when connecting gas piping. Re­fer to Gas Piping Connections figure for typical gas line connec­tions to the furnace.
Use black iron or steel pipe and fittings for building piping.
Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound.
Use pipe joint compound on male threads ONLY. Always
use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads.
Use ground joint unions.
Install a drip leg to trap dirt and moisture before it can enter
the gas valve. The drip leg must be a minimum of three inches long.
Install a 1/8" NPT pipe plug fitting, accessible for test gage
connection, immediately upstream of the gas supply connection to the furnace.
Always use a back-up wrench when making the connection
to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as
24
shipped from the factory . Maximum torque for the gas valve
A
A
connection is 375 in-lbs; excessive over-tightening may damage the gas valve.
CAUTION
Install a manual shutoff valve between the gas meter and
DGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION
unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.
Tighten all joints securely.
Connect the furnace to the building piping by one of the
following methods:
Rigid metallic pipe and fittings.Semi-rigid metallic tubing and metallic fittings.
Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.
Use listed gas appliance connectors in accordance with
their instructions. Connectors must be fully in the same room as the furnace.
Protect connectors and semirigid tubing against physical
and thermal damage when installed. Ensure aluminum­alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage.
MANUAL
SHUT OFF VALVE
(UPSTR EAM FRO M
GROUND JOINT
PIPE UNION)
*
*
GROUND JOINT
PIPE UNION
ALTERNATE
GAS LINE
LOCATION
**
COUNTERFLOW
MANUAL SHUT-OFF VALVE
(UPSTREAM FROM GR OUND
GROUND JOINT
PIPE UNION
GAS VALVE
MANIFOLD
JOINT PIPE UNIO N)
DRIP LEG
GROMMET IN STANDARD
GAS LINE HOLE
DRAIN TRAP
PLUG IN ALTERNATE
GAS LINE HOLE
HORIZONTAL[COUNTERFLOW]
2. DRIP LEG MAY TERMINATE WITH A 1/2" X 1/8" PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT.
ALTERNATE
BURNERS
LTERNATE GAS LINE LOCATION
PLUG IN LTERNATE GAS LINE
HOLE
GROUND JOINT
PIPE UNION
MANIFOLD
GAS VALV E
BURNERS
MANUAL
SHUT OFF VALVE
(UPSTREA M FROM
GROUND JOINT
PIPE UNION)
HEIGHT REQUIRED
BY LOCAL CO DE
GROMMET
IN STANDARD
GAS LINE HOLE
DRIP LEG
HEIGHT REQUIRED
BY LOCAL CODE
GROMMET
IN STANDARD
GAS LINE HOLE
DRIP LEG
UPFLOW
MANUAL SHUT-O F F VALVE
(UPSTREAM FRO M G ROUN D
GROUND JOINT
PIPE UNI ON
GAS VALVE
BURNERS
MANIFOLD
ALTERNATE GAS
LINE LOC ATION
HORIZONTAL [UPFLOW MODEL]
NOTES: 1. WHEN GAS LINE IS IN THE ALTERNATE
LOCATION, SWAP THE POSITION OF THE PLUG AND GROMMET
JOINT PIPE UNION)
DRIP LEG
GROMMET IN STANDAR D
GAS LINE HOLE
PLUG IN ALTERNATE
GAS LI NE HOLE
DRAIN TR AP
.
ALTERNATE
GAS LINE LOCATION
Gas Piping Connections
BURNERS
E
WHEN REMOVING HOLE PLUGS.
DIRECT/STANDARD INLET PIPING
When gas piping enters directly to the gas valve through the stan­dard inlet hole, the installer must supply straight pipe with a ground
joint union to reach the exterior of the furnace. The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.
INDIRECT/ALTERNATE INLET PIPING
When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the following fittings (starting from the gas
valve) to reach the outside of the cabinet must be supplied:
Coupling.
90 degree elbow.
2 inch close nipple.
90 degree elbow.
Straight pipe, with a ground joint union, to reach the exterior
of the furnace. The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.
GAS PIPING CHECKS
Before placing unit in operation, leak test the unit and gas connec­tions.
PLUG IN
GAS LINE
HOLE
GAS VALVE
MANIFOLD
O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEV ER USE A MATCH OR
T
OPEN FLAME TO TEST FOR LEAKS.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.
NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure.
Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pres­sures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).
PROPANE GAS TANKS AND PIPING
ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN
P
ANY LOW AREAS OR CONFINED SPACES. PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DEVICE.
WARNING
WARNING
O PREVENT PR OPERTY DAM AGE,
T
A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane
25
gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Page 4 of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. For satisfactory operation, propane gas pressure must be 11 inch w.c. at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:
1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.
2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).
3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.
Complete information regarding tank sizing for vaporization, rec­ommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Since propane gas will quickly dissolve white lead and most stan­dard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied pe­troleum gases such as Gasolac®, Stalactic®, Clyde’s® or John Crane® are satisfactory. Refer to the following illustration for typical propane gas installa­tions.
200 PSIG Maximum
5 to 15 PSIG (20 PSIG Max.)
Second Stage Regulator
Continuous
11" W.C.
Firs t Stage Regulator
Sizing Between Single or Second Stage Regulator and Appliance*
Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour.
Pipe or Nominal Pipe Si z e Tubing Tubi ng Size, O.D. Type L Sch e dule 40 Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1-1/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"
Feet
10 39 92 199 329 501 935 275 567 1,071 2,205 3,307 20 26 62 131 216 346 630 189 393 732 1,496 2,299 30 21 50 107 181 277 500 152 315 590 1,212 1,858 40 19 41 90 145 233 427 129 267 504 1,039 1,559 50 18 37 79 131 198 376 114 237 448 913 1,417 60 16 35 72 121 187 340 103 217 409 834 1,275
80 13 29 62 104 155 289 89 185 346 724 1,066 100 11 26 55 90 138 255 78 162 307 630 976 125 10 24 48 81 122 224 69 146 275 567 866 150 9 21 43 72 109 202 63 132 252 511 787 200 8 19 39 66 100 187 54 112 209 439 665 250 8 17 36 60 93 172 48 100 185 390 590
*Data in accordance with NFPA pamphlet NO. 54
Propane Gas Piping Chart II
XIII. CIRXIII. CIR
XIII. CIR
XIII. CIRXIII. CIR
CULCUL
CUL
CULCUL
AA
A
AA
TINTIN
TIN
TINTIN
G AIR & FILG AIR & FIL
G AIR & FIL
G AIR & FILG AIR & FIL
TERTER
TER
TERTER
SS
S
SS
DUCTWORK - AIR FLOW
Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D.
Install the duct system in accordance with Standards of the Na­tional Board of Fire Underwriters for the Installation of Air Condi­tioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B.
A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Flexible joints may be used for supply and return connections to reduce noise transmission. To prevent the blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed be­tween the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber.
Propane Gas Installation (Typ.)
Sizing Betwee n Fi rst and Second Stage Regul ator*
Maximum Propane Capaci ties listed are based on 2 psi g pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.
Pipe or Nominal Pipe Size Tubing Tubing Size, O.D. Type L Schedule 40
Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"
Feet
10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 2,200 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 850 1,700 2,700 4,100 1,600 3,700 50 330 770 1,500 2,400 3,700 1,500 3,400 60 300 700 1,300 2,200 3,300 1,300 3,100
80 260 610 1,200 1,900 2,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 125 200 490 900 1,400 2,300 900 2,100 150 190 430 830 1,300 2,100 830 1,900 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500
To conve rt to capaciti es at 15 psig settin gs - m ul ti pl y by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879
Propane Gas Piping Chart I
BOTTOM RETURN AIR OPENING [UPFLOW MODELS]
The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the corners of the open­ing, cut the sheet metal along the scribe lines to free the duct flanges. Using the scribe line along the duct flange as a guide, unfold the duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs. NOTE: Airflow area will be reduced by approximately 18% if duct flanges are not unfolded. This could cause performance issues and noise issues.
WARNING
DGES OF SHEET METAL MAY BE SHARP. USE GLOVES AS A PRECAUTION
E
WHEN REMOVING SHEET METAL FROM THE DUCT OPENING.
26
CUT USING TIN SNIPS
PRESS OUT BY HAND
CUT FOUR CORNERS AFTER REMOVING SHEET METAL
SCRIBE LINES OUTLINING DUCT FLANGES
Duct Flange Cut Outs
When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.
When the furnace is installed without a cooling coil, it is recom­mended that a removable access panel be provided in the outlet air duct. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream. The access panel must be made to prevent air leaks when the furnace is in operation.
When the furnace is heating, the temperature of the return air enter­ing the furnace must be between 55°F and 100°F.
UPFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600 800 1000 1200 1400 1600 2000
0453__XA 376* 384 480 576 --- --- --­0704__XA --- --- 627* 627* 672 768 --­0905__XA --- --- --- 836* 836* 836* 960
Input__Airflow
1155__XA --- --- --- 940* 940* 940* 960
COUNTERFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600 800 1000 1200 1400 1600 2000
0704__XA --- --- 320* 320* 336 384 ---
Input
0905__XA --- --- --- 427* 427* 427* 480
Airflow
*Minimum filter area dictated by heating airflow requirement.
Permanent Minimum Filter Area (sq. in)
[Based on a 600 ft/min filter face velocity]
UPFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600 800 1000 1200 1400 1600 2000
0453__XA 376* 384 480 576 --- --- --­0704__XA --- --- 564* 564* 672 768 0905__XA --- --- --- 752* 752* 768 960
Input__Airflow
1155__XA --- --- --- 940* 940* 940* 960
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK
Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without fil­ters, the warranty will be voided.
On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. NOTE: An undersized opening will cause reduced airflow.
Refer to Minimum Filter Area tables to determine filter area require­ments.
COUNTERFLOW
COOLING AIRFLOW REQUIREMENT (CFM)
600 800 1000 1200 1400 1600 2000
0704__XA --- --- 641* 641* 672 768 ---
Input
0905__XA --- --- --- 854* 854* 854* 960
Airflow
*Minimum filter area dictated by heating airflow requirement.
Disposable Minimum Filter area (sq. in)
[Based on 300 ft/min filter face velocity]
UPRIGHT INSTALLATIONS
Depending on the installation and/or customer preference, differ­ing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter.
The following figure shows possible filter locations.
27
A
FILTER
On/Off Switch
Inlet
Pressure Boss
High Fire
Coil Terminal (HI)
Low Fire
Regulator Adjust
M
a
n
o
m
e
t
e
r
M
a
n
o
m
e
t
e
r
H
o
s
e
A
High Fire Regulator
Adjust
Regulator
Vent
Common
Terminal (C)
Coaxial Coil
Terminal (M)
Outlet
Pressure Boss
Open to
Atmosphere
ACCESS
DOOR
FIL
T
ER
LTER
I
CENTRAL
RETURN
GRILLE
EXTERNAL FILTER
FILTER
SIDE RETURN
RACK KIT
(EITHER SIDE)
AIR FLOW
FILTE R
Possible Upright Upflow Possible Upright
RETURN
DUCT
FILTER SUPPORT BRACKET
(PROVIDED)
Counterflow
F
IR FLOW
CENTRAL
RETURN
GRILLE
FILTER
Filter Locations
NOTE: Internal filter retention is not provided on this furnace. If an
internal installation is desired, an internal filter retention kit is avail­able as an accessory. Please see your distributor for details.
HORIZONTAL INSTALLATIONS
Filters must be installed in either the central return register or in the return air duct work.
XIVXIV
. ST. ST
ARAR
XIV
XIVXIV
. ST
. ST. ST
TUP PRTUP PR
AR
TUP PR
ARAR
TUP PRTUP PR
OCEDURE & ADOCEDURE & AD
OCEDURE & AD
OCEDURE & ADOCEDURE & AD
JUSTJUST
JUST
JUSTJUST
MENTMENT
MENT
MENTMENT
Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct op­eration. In addition to the following start-up and adjustment items, refer to further information in Section XVI, Operational Checks.
HEAT ANTICIPATOR SETTING
The heat anticipator in the room thermostat must be correctly ad­justed to obtain the proper number of cycles per hour and to pre­vent “overshooting” of the setting. Set the heat anticipator setting to
0.7 amps. Follow the thermostat manufacturer’s instructions on how to adjust the heat anticipator setting.
DRAIN TRAP PRIMING
The drain trap must be primed prior to furnace startup. To prime, fill the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system.
position.
6. Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air.
7. If you smell gas after five minutes, immediately follow the instructions on page 4 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position.
8. Replace the burner compartment door.
9. Open the manual gas shutoff valve external to the furnace.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room temperature.
12. After the burners are lit, set the thermostat to desired temperature.
FURNACE SHUTDOWN
1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish
flame. Following a 15 second delay , the induced draft blower will be de-energized. After a 120, 150, 180 or 210-second delay period (field selectable delay OFF [90, 120, 150, 180] plus 30-second ramp down), the circulator blower de­energizes.
2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position.
3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.
GAS SUPPLY PRESSURE MEASUREMENT
CAUTION
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET
T
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
WHITE-RODGERS 36G54 GAS VALVE
The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure boss or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.
FURNACE OPERATION
Purge gas lines of air prior to startup. Be sure not purge lines into an enclosed burner compartment. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed.
FURNACE STARTUP
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. Move the furnace gas valve manual control to the OFF
White-Rodgers Model 36G54 Connected to Manometer
28
1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.
2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure boss or the gas piping drip leg.
Gas Line
Gas Shutoff Valve
Gas Line To Furnace
Open To Atmosphere
Drip Leg C ap With Fitting
Manometer Hos e
Manometer
Measuring Inlet Gas Pressure (Alt. Method) NOTE: If measuring gas pressure at the drip leg, a field supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure boss on the gas valve, then use the 36G Valve Pressure Check Kit, Goodman Part No. 0151K00000S.
3. Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line.
4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c. Minimum: 11.0" w.c. Maximum:13.0" w.c.
If supply pressure differs from table, make the necessary adjust­ments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in step
3.
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT
CAUTION
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS
T
MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE.
NLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE
O
PRESSURE REGULATOR.
Only small variations in gas pressure should be made by adjust­ing the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure.
1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.
2. Turn off all electrical power to the system.
3. Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure boss of the valve.
5. Turn ON the gas supply.
6. Turn on power and energize main (M) solenoid. Do not energize the HI solenoid.
7. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below.
8. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.
9. Energize main (M) solenoid as well as the HI terminal.
10. Remove regulator cover screw from the HI outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.
11. Turn off all electrical power and gas supply to the system.
12. Remove manometer hose from outlet pressure boss.
13. Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).
14. Turn on electrical power and gas supply to the system.
15. Turn on system power and energize valve.
16. Using a leak detection solution or soap suds, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIA TEL Y .
NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.
Manifold Gas P ressure
Gas
Natural Low Stage 1.6 - 2.2" w .c. 1.9" w .c.
High Stage 3.2 - 3.8" w.c. 3.5" w .c.
Pr opane Low Stage 5.7 - 6.3" w.c. 6.0" w.c.
High Stage 9.7 - 10.3" w.c. 10.0" w .c.
Range Nom inal
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)
The gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure.
1. Turn OFF the gas supply to all other gas-burning appliances except the furnace.
2. While the furnace is operating, time and record one complete revolution of the smallest gas meter dial.
3. Calculate the number of seconds per cubic foot (sec/ft gas being delivered to the furnace. If the dial is a one cubic foot dial, divide the number of seconds recorded in step 2 by one. If the dial is a two cubic foot dial, divide the number of seconds recorded in step 2 by two.
4. Calculate the furnace input in BTUs per hour (BTU/hr). Input equals the sum of the installation’s gas heating value and a conversion factor (hours to seconds) divided by the number of seconds per cubic foot. The measured input must not be greater than the input indicated on the unit rating plate.
EXAMPLE: Installation’s gas heating (HTG) value: 1,000 BTU/ft
(Obtained from gas supplier)
3
) of
3
29
Installation’s seconds per cubic foot: 34 sec/ ft
3
Conversion Factor (hours to seconds): 3600 sec/hr Input = (Htg. value x 3600) ÷ seconds per cubic foot Input = (1,000 BTU/ft
3
x 3600 sec/hr) ÷ 34 sec/ ft
3
Input = 106,000 BTU/hr
Minor changes to the input rate may be accomplished through manifold pressure adjustments at the gas valve. Refer to Section
XIV, Startup Procedure and Adjustment - Gas Manifold Pressure Measurement and Adjustment for details. NOTE: The final mani-
fold pressure cannot vary by more than ± 0.3” w.c. from the speci­fied setting. Consult your local gas supplier if additional input rate adjustment is required.
5. Repeat steps 2 through 4 on high stage.
6. Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances are functioning properly and that all pilot burners are operating.
TEMPERATURE RISE
Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise may result in condens­ing in or overheating of the heat exchanger. An airflow and tem­perature rise table is provided in the Product Data Book applicable to your model*. Determine and adjust temperature rise as follows:
1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.
2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.
HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
SUPPLY AIR
T
SUPPLY
RISE =
T
T
-
SUPPLY
RETURN
T
RETURN
RETURN AIR
Temperature Rise Measurement
3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Section XIV , S tartup Procedure and Adjustment -Circulator Blower Speeds for speed changing details.
CIRCULATOR BLOWER SPEEDS
WARNING
O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN
T
OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The Product Data Book applicable to your model* provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. The heating blower speed is shipped set at “B”, and the cooling blower speed is set at “D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM. Use the CFM LED (green), adjacent to the integrated control mod­ule fuse to verify airflow quantity. The green CFM LED blinks once for each 100 CFM of airflow.
1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 Tons
2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton.
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements.
3. Knowing the furnace model, locate the high stage cooling air flow charts in the Product Data Book applicable to your model*. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting.
Example: A *MV90704BXA furnace installed with a 2.5
ton air conditioning system. The air flow needed is 1000 CFM. Looking at the cooling speed chart for *MV90704BXA, find the air flow closest to 1000 CFM. A cooling airflow of 990 CFM can be attained by setting the cooling speed to “C” and the adjustment to “-” (minus).
NOTE: Continuous Fan Speed will be 56% of high stage cooling.
4. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches 1 and 2 appropriately. Select the desired “adjust” tap by positioning switches 3 and 4 appropriately. Refer to the following figure for switch positions and their corresponding taps. Turn off power to furnace for a minimum of reset and recognize new speed selection. Turn on power to furnace. Verify CFM by counting the number of times the green CFM LED blinks.
10 seconds, allowing motor to
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.
30
65
87 4321
Cooling
Speed Tap A
87
87
87
65
65
65
Cooling
Speed Tap B
Cooling
Speed Tap C
Cooling
Speed Tap D
*
Cooling Speed Taps
(
* indicates factory setting)
O
O
F
F
F
F
4321
O
O
F
N
F
4321
ONO
F F
4321
ONO
N
87
Normal
*
+ (Plus)
Adjust
- (Minus) Adjust
87
87
Adjust Taps
*
(
indicates factory setting)
87 4321
Heating
Speed
Tap A
Heating
Speed
Tap B
Heating
Speed
Tap C
Heating
Speed
Tap D
O F F
87 4321
*
O F F
87 4321
ONO
87 4321
ONO
O F F
O N
F F
N
65
65
65
65
65
65
65
4321
O
O
F
F
F
F
4321
O
O
F
N
F
4321
ONO
F F
Heating Spee d Taps
(
* indicates factory setting)
5. The multi-speed circulator blower also offers several custom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP switches 5 and 6. Refer to the following figure for switch positions and their corresponding taps. Refer to the bullet points below for a description of each ramping profile. Turn OFF power to the furnace for a minimum of 10 seconds, allowing motor to reset and recognize the new profile selection. Turn ON power to the furnace. Verify profile selection by counting the green CFM LED blinks and timing each step of the ramping profile.
Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow.
OFF
100% CFM
Cooling
Demand
100% CFM
1 min
Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. A one (1) minute OFF delay at 100% of the cooling airflow.
OFF OFF
50% CFM
1/2 min
100% CFM 100% CFM
Cooling Demand
Profile C ramps up to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile C also has a one (1) minute 100% OFF delay.
7 1/2 min
Cooling Demand
Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/ 2 minute at 50% airflow OFF delay.
50% CFMOFF OFF
1/2 min
82% CFM
7 1/2 min
Ramping
Profile
Tap A
Ramping
Profile
Tap B
Ramping
Profile
Tap C
Ramping
Profile Tap D
Cooling Demand
87 4321
*
87
87
87
Ramping Profiles
* indicates factory setting)
(
100% CFM 50% CFM
65
O
O
F
F
F
F
4321
65
O
O
F
N
F
65
4321
ONO
F F
65
4321
ONO
N
6. Select the heating speed from the heating speed chart in the Product Data Book applicable to your model* for your model. The adjust setting (already established by the cooling speed selection) determines which set of speeds are available. The selected speed must provide a temperature rise within the rise range listed with the particular model.
Example: The *MV90704BXA is set for 990 CFM on
OFF
cooling, the “ADJUST” is set to “-” (minus). The four heating speeds available are “A Minus”, “B Minus”, “C Minus”, and “D Minus”. “A Minus” has a rise of 56°F for both stages which is within the 30-60°F rise range for the *MV90704BXA. This setting will keep electrical consumption to a minimum. Set the “Heat” speed DIP switches to “A”.
7. Select the desired “heating” speed tap by positioning switches 7 and 8 appropriately . Refer to figure above. Turn off power to furnace for a minimum of 10 seconds, allowing
1 min
100% CFM100% CFM82% CFM
1 min
1/2 min
OFF
31
motor to reset and recognize new speed selection. Turn on power to furnace. Verify selected CFM by counting the green CFM LED blinks.
In general lower heating speeds will: reduce electrical consump­tion, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds avail­able allow the blower performance to be optimized for the particu­lar homeowner’s needs.
BLOWER HEAT OFF DELAY TIMINGS
The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 90, 120, 150, 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and/or homeowner preference. Refer to the following figures for switch positions and corresponding delay times.
Heat Off
Delay
90 Seconds
Heat Off
Delay
120 Seconds
Heat Off
Delay
150 Seconds
Heat Off
Delay
180 Secon ds
CE OCE O
F OPERAF OPERA
CE O
F OPERA
CE OCE O
F OPERAF OPERA
*
TITI
OO
NN
TI
O
N
TITI
OO
NN
XVXV
XV
XVXV
. NO. NO
. NO
. NO. NO
3 ON ON 1
ON
OFF
OFF
ON 1
OFF OFF
(* indicates factory setting)
Heat Off Delay Switches
RMRM
AL SEQUENAL SEQUEN
RM
AL SEQUEN
RMRM
AL SEQUENAL SEQUEN
2
3
2
1
3
2
3
2
1
Heat Off Delay
POWER UP
The normal power up sequence is as follows:
115 VAC power applied to furnace.
Integrated control module performs internal checks.
Integrated control module flashes LED one time.
Integrated control module monitors safety circuits
continuously.
Furnace awaits call from thermostat.
HEATING MODE
The normal operational sequence in heating mode is as follows:
R and W1 (or R and W1/W2) thermostat contacts close,
initiating a call for heat.
Integrated control module performs safety circuit checks.
Induced draft blower is energized on high speed for a 10-
second prepurge. Humidifier terminals are energized with induced draft blower.
Induced draft blower steps to low speed following prepurge.
Low stage pressure switch contacts are closed.
Igniter warm up begins upon step to low speed and
presence of closed low stage pressure switch contacts.
Gas valve opens at end of igniter warm up period, delivering
gas to burners and establishing flame.
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
If the thermostat call is for low heat, gas valve and induced
draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage.
Circulator blower is energized on heat speed following a
fixed thirty second blower on delay. The circulator blower requires thirty (30) seconds to ramp up to full speed. Electronic air cleaner terminals are energized with circulator blower.
Furnace is now operating on the specified stage called for
by the two-stage thermostat.
Furnace runs, integrated control module monitors safety
circuits continuously.
If the two-stage thermostat changes the call from low heat
to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.
If the two-stage thermostat changes the call from high heat
to low heat, the control will immediately switch the induced draft blower and gas valve to their low stage settings. The circulator blower will remain on high heating speed for thirty (30) seconds before switching to the low heat circulating
speed.
R and W1 (or R and W1/W2) thermostat contacts open,
completing the call for heat.
Gas valve closes, extinguishing flame.
Induced draft blower is de-energized following a fifteen
second post purge. Humidifier terminals are de-energized.
Circulator blower continues running for the selected heat
off delay period (90, 120, 150 or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.
If the last call for heat was a call for low heat, the air circulator motor will run on low heat speed for the duration of the heat off delay period (90, 120, 150 or 180 seconds).
If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds).
Circulator blower and electronic air cleaner terminals are
de-energized.
Circulator blower ramps down to OFF during the 30 seconds
following the heat off delay period.
Furnace awaits next call from thermostat.
COOLING MODE
The normal operational sequence in cooling mode is as follows:
R and YLO/G or Y/G thermostat contacts close, initiating a
call for cool.
Integrated control module performs safety circuit checks.
Outdoor fan and compressor are energized to their
appropriate speed.
32
Circulator blower is energized on the appropriate cool speed
at the level and time determined by the selected ramping profile. Electronic air cleaner terminals are energized with circulator blower.
Furnace circulator blower and outdoor cooling unit run their
appropriate speed, integrated control module monitors safety circuits continuously.
R and YLO/G or Y/G thermostat contacts open, completing
the call for cool.
Outdoor fan and compressor are de-energized.
Circulator blower continues running during a cool off delay
period. The OFF delay time and airflow level are determined by the selected ramping profile.
Electronic air cleaner terminals and circulator blower are
de-energized.
Furnace awaits next call from thermostat.
FAN ONLY MODE
The normal operational sequence in fan only mode is as follows:
R and G thermostat contacts close, initiating a call for fan.
Integrated control module performs safety circuit checks.
Circulator blower is energized on continuous fan speed
(56% of high stage cooling) following a five (5) second delay . Electronic air cleaner terminals are energized.
Circulator blower runs, integrated control module monitors
safety circuits continuously.
R and G thermostat contacts open, completing the call for
fan.
Circulator blower is de-energized. Electronic air cleaner
terminals are de-energized.
Furnace awaits next call from thermostat.
XVI. OPERAXVI. OPERA
XVI. OPERA
XVI. OPERAXVI. OPERA
BURNER FLAME
The burner flames should be inspected with the burner compart­ment door installed. A sight glass is provided for inspection pur­poses. Flames should stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat ex­changer firing tubes.
XVII. SAFETY CIRCUIT DESCRIPTIONXVII. SAFETY CIRCUIT DESCRIPTION
XVII. SAFETY CIRCUIT DESCRIPTION
XVII. SAFETY CIRCUIT DESCRIPTIONXVII. SAFETY CIRCUIT DESCRIPTION
GENERAL
A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagno-
TITI
OO
NAL CHECKNAL CHECK
TI
O
NAL CHECK
TITI
OO
NAL CHECKNAL CHECK
Check the burner flames for:
1. Good adjustment
2. Stable, so ft and bl ue
3. Not curling, floating, or lifting off.
Burner Flame
SS
S
SS
sis of abnormal function. These circuits are continuously moni­tored during furnace operation by the integrated control module.
INTEGRATED CONTROL MODULE
The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary pre­cautions and provide diagnostic information through an LED.
PRIMARY LIMIT
The primary limit control is located on the partition panel and moni­tors heat exchanger compartment temperatures. It is a normally­closed (electrically), automatic reset, temperature-activated sen­sor. The limit guards against the overheating as a result of insuffi­cient conditioned air passing over the heat exchanger.
AUXILIARY LIMIT
The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures. They are a normally-closed (electrically), manual-reset sensors. These lim­its guard against overheating as a result of insufficient conditioned air passing over the heat exchanger.
ROLLOUT LIMIT
The rollout limit controls are mounted on the burner/manifold as­sembly and monitor the burner flame. They are normally-closed (electrically), manual-reset sensors. These limits guard against burner flames not being properly drawn into the heat exchanger.
PRESSURE SWITCHES
The pressure switches are normally-open (closed during opera­tion) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat ex­changer via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient air­flow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions.
FLAME SENSOR
The flame sensor is a probe mounted to the burner/manifold as­sembly which uses the principle of flame rectification to determine the presence or absence of flame.
XVIII. TROUBLESHOOTINGXVIII. TROUBLESHOOTING
XVIII. TROUBLESHOOTING
XVIII. TROUBLESHOOTINGXVIII. TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit. An
electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and ser-
vicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electro­static potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is appli­cable to both installed and uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat
33
step 2 before touching control or wires.
4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.
Drainage system. Check for blockage and/or leakage.
Check hose connections at and internal to furnace.
Wiring. Check electrical connections for tightness and/or
corrosion. Check wires for damage.
Filters.
DIAGNOSTIC CHART
WARNING
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL
T
POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems. The red diagnostic LED blinks to assist in troubleshooting the unit. The number of blinks refers to a specific fault code.
RESETTING FROM LOCKOUT
Furnace lockout results when a furnace is unable to achieve igni­tion after three attempts. It is characterized by a non-functioning furnace and a one flash diagnostic LED code. If the furnace is in “lockout”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period.
2. Manual power interruption. Interrupt 115 volt power to the furnace for 0 - 20 seconds.
3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 0 - 20 seconds.
NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to Section XVIII, T roubleshooting - Diagnostic Chart for aid in determining the cause.
XIX. MAINTENANCEXIX. MAINTENANCE
XIX. MAINTENANCE
XIX. MAINTENANCEXIX. MAINTENANCE
WARNING
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL
T
POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE IGNITER, HANDLE WITH CARE. FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAI LURE. EVER HANDLE THE IGNITER.
OUCHING THE IGNITER ELEMENT WITH BARE
T
NLY A QUALIFIED SERVICER SHOULD
O
ANNUAL INSPECTION
The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all fur­nace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the fol­lowing items. Repair or service as necessary.
Flue pipe system. Check for blockage and/or leakage. Check
the outside termination and the connections at and internal to the furnace.
Heat exchanger. Check for corrosion and/or buildup within
the heat exchanger passageways.
Burners. Check for proper ignition, burner flame, and flame
sense.
FILTERS
CAUTION
O ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES
T
GIVEN IN THE
RODUCT DATA BOOK APPLICABLE TO YOUR MODEL*.
P
RECOMMENDED MINIMUM FILTER SIZE TABLE OR
MAINTENANCE
Improper filter maintenance is the most common cause of inad­equate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as re­quired. When replacing a filter, it must be replaced with a filter of the same type and size.
FILTER REMOVAL
Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance. To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. To remove internal filters see Internal Filter Removal section. Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.
HORIZONTAL UNIT FILTER REMOVAL
Filters in horizontal installations are located in the central return register or the ductwork near the furnace. To remove:
1. Turn OFF electrical power to furnace.
2. Remove filter(s) from the central return register or ductwork.
3. Replace filter(s) by reversing the procedure for removal.
4. Turn ON electrical power to furnace.
MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL
Follow the manufacturer’s directions for service.
BURNERS
Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). They should extend directly outward from the burners with­out curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.
INDUCED DRAFT AND CIRCULATOR BLOWERS
The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.
*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.
34
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)
Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool. Following clean­ing, the flame sense signal should be as indicated in the Specifi­cations Sheet.
FLUE PASSAGES (QUALIFIED SERVICER ONLY)
The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the pas­sageways as outlined below.
1. Turn OFF the electrical power and gas supply to the furnace.
2. Disconnect the gas line and remove the burner/ manifold assembly by removing the screws securing the assembly to the partition panel.
3. Disconnect the flue pipe system from the induced draft blower.
4. Remove the induced draft blower and, drain and pressure tap hoses from the recuperator coil front cover.
5. Remove the recuperator coil front cover to expose the coil tubes and turbulators.
6. Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly.
7. Clean the recuperator coil tubes using a long handle wire brush, such as a gun cleaning brush.
8. Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the cable. Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Repeat for each tube.
9. Clean residue from furnace using a vacuum cleaner.
10. Replace the parts removed in the previous steps in reverse order.
11 . Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.
12. Severe heat exchanger fouling is an indication of an operational problem. Perform the checks listed in Section XIV, Startup Procedure and Adjustments to reduce the chances of repeated fouling.
XX
X. INTERNAL FILX. INTERNAL FIL
X
X. INTERNAL FIL
XX
X. INTERNAL FILX. INTERNAL FIL
TER REMTER REM
TER REM
TER REMTER REM
OVOV
OV
OVOV
ALAL
AL
ALAL
Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.
BOTTOM RETURN REMOVAL
1. Turn OFF electrical power to furnace.
2. Remove blower compartment door.
3. Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan.
4. Slide filter forward and out.
5. Replace filter by reversing the procedure.
BLOWER COMPARTMENT REMOVAL
1. Turn OFF electrical power to furnace.
2. Remove blower compartment door.
3. Grasp lower portion of filter and lift up.
Front of Furnace
Blower
Grab He re And Lift
r e
t
l
i F
Front of Furnace
Blower
4. Angle filter toward the blower until filter clears bottom rail.
5. Lower filter down and pull outward.
Fron t of Furnace
Blower
Fron t of Furnace
Blower
6. Replace filter by reversing procedure.
XX
XI. BEFOXI. BEFO
X
XI. BEFO
XX
XI. BEFOXI. BEFO
RE LEARE LEA
RE LEA
RE LEARE LEA
VINVIN
G AN INSTG AN INST
VIN
G AN INST
VINVIN
G AN INSTG AN INST
ALLALL
ALL
ALLALL
AA
TITI
OO
NN
A
TI
O
N
AA
TITI
OO
NN
Cycle the furnace with the thermostat at least three times.
Verify cooling and fan only operation.
Review the Owner’s Manual with the homeowner and
discuss proper furnace operation and maintenance.
Leave literature packet near furnace.
XX
XII. REPXII. REP
X
XII. REP
XX
XII. REPXII. REP
AIR & REPLAIR & REPL
AIR & REPL
AIR & REPLAIR & REPL
ACEMENT PARACEMENT PAR
ACEMENT PAR
ACEMENT PARACEMENT PAR
TSTS
TS
TSTS
When ordering any of the listed functional parts, be sure to
provide the furnace model, manufacturing, and serial numbers with the order.
Although only functional parts are shown in the parts list, all
sheet metal parts, doors, etc. may be ordered by description.
Parts are available from your distributor.
Functional Parts List-
Gas V alve Blower Motor Gas Manifold Blower Wheel Natural Gas Orifice Blower Mounting Bracket Propane Gas Orifice Blower Cutoff Igniter Blower Housing Flame Sensor Capacitor
35
Rollout Limit Switch Heat Exchanger Primary Limit Switch Recuperator Coil Auxiliary Limit Switch Coil Front Cover Pressure Switch Integrated Control Module Induced Draft Blower Transformer Door Switch
36
TRTR
OUBLESHOUBLESH
TR
OUBLESH
TRTR
OUBLESHOUBLESH
OOOO
OO
OOOO
TINTIN
TIN
TINTIN
G CHARG CHAR
G CHAR
G CHARG CHAR
TT
T
TT
Symptoms of Abnormal
Operation
• Furnace fails to operate.
• Integrated control
module diagnostic LED provides no signal.
• Furnace fails to operate.
• Integrated control
module diagnostic LED is flashing ONE (1) flash.
Associated LED Code
NONE
ON
CONTINUOUS
ON
1
1 FLASH
Fault Description(s) Possible Causes Corrective Action Cautions and Notes
2
• No 115 volt power to furnace, or no 24 volt power to integrated control module.
• Blown fuse or circuit breaker.
• Integrated control module has an internal fault.
• Normal operation.
• Furnace lockout due to an excessive number of ignition “retries” (3 total)1 .
• Manual disconnect switch OFF, door switch open, or 24 volt wires improperly connected or loose.
• Blown fuse or circuit breaker.
• Integrated control module has an internal fault.
• Normal operation. • None.LED is steady ON.
• Failure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad igniter or igniter alignment, improper orifices, or coated/oxidized or improperly connected flame sensor.
• Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.
•Assure 115 and 24 volt power to furnace integrated control module.
•Check integrated control module fuse (3A). Replace if necessary.
•Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.
•Replace bad integrated control module.
• Locate and correct gas interruption.
• Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.
• Replace or realign igniter.
• Check flame sense signal. Sand sensor if coated and/or oxidized.
• Check flue piping for blockage, proper length, elbows, and termination.
• Verify proper induced draft blower perfor­mance.
• Turn power OFF prior to repair.
• Replace integrated control module fuse with 3A automotive fuse.
• Read precautions in “Electrostatic Discharge” section of manual.
• Normal operation.
• Turn power OFF prior to repair.
• Igniter is fragile, handle with care.
• Sand flame sensor with emery cloth.
• See “Vent/Flue Pipe” section for piping details.
• Furnace fails to operate.
• Integrated control module diagnostic LED is flashing TWO (2) flashes.
• Induced draft blower runs continuously with no further furnace operation.
• Integrated control module diagnostic LED is flashing THREE (3) flashes.
1
Integrated control module will automatically attempt to reset from lockout after one hour.
2 FLASHES
3 FLASHES
• Pressure switch
2
3
circuit is closed.
• Induced draft blower is not operating.
• Pressure switch circuit not closed.
• Induced draft blower is operating.
• Induced draft blower pressure switch contacts sticking.
• Shorts in pressure switch circuit.
• Pressure switch hose blocked, pinched or connected improperly.
• Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.
• Incorrect pressure switch setpoint or malfunctioning switch contacts.
• Loose or improperly connected wiring.
37
• Replace induced draft blower pressure switch.
• Repair short.
• Inspect pressure switch hose. Repair, if necessary,
• Inspect flue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.
• Correct pressure switch setpoint or contact motion.
• Tighten or correct wiring connection.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
TRTR
OUBLESHOUBLESH
TR
OUBLESH
TRTR
OUBLESHOUBLESH
OOOO
OO
OOOO
TINTIN
TIN
TINTIN
G CHARG CHAR
G CHAR
G CHARG CHAR
TT
T
TT
Symptoms of Abnormal
Operation
• Circulator blower runs continuously. No furnace operation.
• Integrated control module diagnostic LED is flashing FOUR (4) flashes.
• Induced draft blower and circulator blower runs continuously. No furnace operation.
• Integrated control module diagnostic LED is flashing FIVE (5) flashes.
• Normal furnace operation.
• Integrated control module diagnostic LED is flashing SEVEN (7) flashes.
Associated LED Code
4
4 FLASHES
5
5 FLASHES
7
7 FLASHES
Fault Description(s)
2
• Primary or auxiliary limit circuit is open.
• Rollout limit circuit is
open.
• Flame sensed with no call for heat.
• Flame sense microamp signal is low.
Possible Causes Corrective Action Cautions and Notes
• Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.
• Flame rollout.
• Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.
• Loose or improperly connected wiring.
• Short to ground in flame sense circuit.
• Lingering burner flame.
• Slow closing gas valve
• Flame sensor is coated/ oxidized.
• Flame sensor incorrectly positioned in burner flame.
• Lazy burner flame due to improper gas pressure or combustion air.
• Check filters and ductwork for blockage. Clean filters or remove obstruction.
• Check circulator blower speed and performance. Correct speed or replace blower if necessary.
• Check burners for proper alignment.
• Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.
• Check induced draft blower for proper performance. Replace, if necessary.
• Tighten or correct wiring connection.
• Correct short at flame sensor or in flame sensor wiring.
• Check for lingering flame
• Verify proper operation of gas valve
• Sand flame sensor is coated/oxidized.
• Inspect for proper sensor alignment.
• Check inlet air piping for blockage, proper length, elbows, and termination.
• Compare current gas pressure to rating plate info. Adjust as needed.
• Turn power OFF prior to repair.
• See Product Data Book applicable to your model* for allowable rise range and proper circulator speed.
• See “Vent/Flue
Pipe” section for piping details.
• Replace pressure
switch with proper replacement part.
• Turn power OFF
prior to repair.
• Turn power OFF
prior to repair.
• Sand flame
sensor with emery clot.
• See “Vent/Flue
Pipe” section for piping details.
• See rating plate
for proper gas pressure.
• Furnace not operating.
• Integrated control module diagnostic LED is flashing EIGHT (8) flashes.
• Furnace operating on low stage gas with high stage induced draft blower
• High stage circulator blower (temperature, of conditioned air, lower than typical).
• Integrated control module diagnostic LED is flashing NINE (9) flashes.
• Furnace fails to operate.
• Integrated control module diagnostic LED is flashing SIX (6) flashes.
8
8 FLASHES
9
9 FLASHES
C
CONTINUOUS
FLASHING
• Problem with igniter circuit.
• High stage pressure
switch circuit does not close in response to high stage induced draft blower operation.
• Polarity of 115 volt
power is reversed.
• Improperly connected igniter
• Bad igniter
• Poor unit ground
• Pressure switch hose blocked, pinched or connected improperly.
• Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.
• Incorrect pressure switch setpoint or malfunctioning switch contacts.
• Loose or improperly connected wiring.
• Polarity of 115 volt AC power to furnace or integrated control module is reversed.
• Poor unit ground.
38
• Check and correct wiring from integrated control module to igniter
• Replace bad igniter
• Check and correct unit ground wiring
• Inspect pressure switch hose. Repair, if necessary.
• Inspect flue and/or inlet air piping for blockage, proper length, elbows, and termina­tion. Check drain system. Correct as necessary.
• Correct pressure switch setpoint or contact motion.
• Tighten or correct wiring connection.
• Review wiring diagram to correct polarity.
• Verify proper ground. Correct if necessary.
• Check and correct wiring.
• Turn power OFF prior to repair.
• Replace igniter with proper silicon nitride replace­ment part.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Turn power OFF prior to repair.
WIRINWIRIN
WIRIN
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Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.
39
®
is a trademark of Maytag Corporation and is used under
license to Goodman Company, L.P. All rights reserved.
2550 North Loop West, Suite 400
Houston, TX 77092
www.amana-hac.com
© 2004-2006 Goodman Company, L.P.
40
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