Amana Gas Furnance 'D(H, Gas Furnance 'HS8, Gas Furnance GME8, Gas Furnance 'M(H, Gas Furnance S)8 User Manual

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INSTALLATION INSTRUCTIONS FOR *M(H,S)8 / *D(H,S)8 / *HS8 / GME8 GAS FURNACE

(CATEGORY I )

Installer: Affix all manuals adjacent to the unit.

These furnaces comply with requirements em-

 

 

 

 

bodied in the American National Standard / Na-

 

®

 

tional Standard of Canada ANSI Z21.47·CSA-

 

 

 

 

2.3 Gas Fired Central Furnaces.

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 listed below for the applicable Specification Sheet referred to in this manual.

WARNING

GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME

RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE

WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO

INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

5151 San Felipe Suite 500 • Houston, TX 77056

IO-417A

www.goodmanmfg.com • www.amana-hac.com

11/2011

© 2011 Goodman Manufacturing Company, L.P.

Table of Contents

 

ADDITIONAL SAFETY CONSIDERATIONS ......................................................................................................

6

SHIPPING INSPECTION ...........................................................................................................................

6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .....................................................................................

6

TO THE INSTALLER ..............................................................................................................................

6

IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY.................................................................

6

PRODUCT APPLICATION ...............................................................................................................................

7

LOCATION REQUIREMENTS AND CONSIDERATIONS ................................................................................................

8

CLEARANCES AND ACCESSIBILITY ............................................................................................................

9

INSTALLATION POSITIONS ......................................................................................................................

9

HORIZONTAL INSTALLATION ....................................................................................................................

9

FURNACE SUSPENSION ..........................................................................................................................

9

EXISTING FURNACE REMOVAL ..............................................................................................................

10

THERMOSTAT LOCATION ......................................................................................................................

10

COMBUSTION AND VENTILATION AIR REQUIREMENTS ..........................................................................................

10

CATEGORY I VENTING (VERTICAL VENTING) .....................................................................................................

11

EXTERIOR MASONRY CHIMNEYS (CATEGORY I FURNACES ONLY) .........................................................................

12

CHECKLIST SUMMARY ........................................................................................................................

12

CHECK 1 - PROPER CHIMNEY TERMINATION. .............................................................................................

13

CHECK 2 -ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL ......................................

13

CHECK 3 - CHIMNEY CROWN CONDITION.................................................................................................

14

CHECK 4 - DEBRIS IN CLEANOUT ..........................................................................................................

14

CHECK 5 - LINER CONDITION................................................................................................................

14

CHECK 6 - DILUTION AIR. ...................................................................................................................

14

CHECK 7 - COMPLETE THE INSTALLATION. ...............................................................................................

15

FIX 1 - LINER TERMINATION .................................................................................................................

15

FIX 2 -CHANGE VENTING ARRANGEMENTS ...............................................................................................

15

FIX 3 - REBUILD THE CROWN ...............................................................................................................

15

FIX 4 - RELINING ..............................................................................................................................

15

ELECTRICAL CONNECTIONS ........................................................................................................................

16

WIRING HARNESS ..............................................................................................................................

16

115 VOLT LINE CONNECTIONS .............................................................................................................

16

FOSSIL FUEL APPLICATIONS ................................................................................................................

16

JUNCTION BOX RELOCATION ................................................................................................................

17

24 VOLT THERMOSTAT WIRING ............................................................................................................

17

GME8 FURNACE WITH 2-STAGE CONDENSER FIELD WIRING .......................................................................

17

SETTING THE HEAT ANTICIPATOR ...........................................................................................................

18

115 VOLT LINE CONNECTION OF ACCESSORIES ........................................................................................

18

(ELECTRONIC AIR CLEANER) ................................................................................................................

18

24 VAC HUMIDIFIER ..........................................................................................................................

19

GAS SUPPLY AND PIPING ...........................................................................................................................

19

HIGH ALTITUDE DERATE ......................................................................................................................

19

PROPANE GAS CONVERSION ................................................................................................................

19

GAS PIPING CONNECTIONS ..................................................................................................................

20

UPFLOW INSTALLATIONS .....................................................................................................................

20

COUNTERFLOW INSTALLATIONS ..............................................................................................................

21

GAS PIPING CHECKS .........................................................................................................................

21

PROPANE GAS TANKS AND PIPING .........................................................................................................

21

2

Table of Contents

 

CIRCULATING AIR AND FILTERS ....................................................................................................................

22

DUCTWORK - AIR FLOW ......................................................................................................................

22

CHECKING DUCT STATIC .....................................................................................................................

22

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ............................................

23

UPRIGHT INSTALLATIONS .....................................................................................................................

23

CIRCULATION AIR FILTERS ...................................................................................................................

23

HORIZONTAL INSTALLATIONS ................................................................................................................

23

SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL) ................................................................................

23

POWER UP ......................................................................................................................................

23

HEATING MODE .................................................................................................................................

24

(MODE DIP SWITCH IS SET TO “1 STG” POSITION) ..................................................................................

24

(MODE DIP SWITCH IS SET TO “2 STG” POSITION) .................................................................................

24

COOLING MODE ................................................................................................................................

24

FAN ONLY MODE ..............................................................................................................................

25

START-UP PROCEDURE AND ADJUSTMENT .......................................................................................................

25

FURNACE OPERATION ..........................................................................................................................

25

FURNACE START-UP ...........................................................................................................................

25

FURNACE SHUTDOWN .........................................................................................................................

25

GAS SUPPLY PRESSURE MEASUREMENT ..................................................................................................

25

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .......................................................................

28

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................

29

TEMPERATURE RISE ...........................................................................................................................

29

CIRCULATOR BLOWER SPEED ADJUSTMENT .............................................................................................

30

CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ......................................................................................

30

SETTING FURNACE OPERATING MODE (*DH8, *ME8, AND *MH8 MODELS ONLY) ............................................

30

OPERATIONAL CHECKS ..............................................................................................................................

31

BURNER FLAME ................................................................................................................................

31

AUXILIARY LIMIT CONTROL .................................................................................................................

31

SAFETY CIRCUIT DESCRIPTION ....................................................................................................................

31

GENERAL .........................................................................................................................................

31

INTEGRATED CONTROL MODULE .............................................................................................................

31

PRIMARY LIMIT ................................................................................................................................

31

AUXILIARY LIMIT ...............................................................................................................................

31

ROLLOUT LIMITS ..............................................................................................................................

32

PRESSURE SWITCHES .........................................................................................................................

32

FLAME SENSOR ................................................................................................................................

32

TROUBLESHOOTING ...................................................................................................................................

32

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ...................................................................................

32

DIAGNOSTIC CHART...........................................................................................................................

32

FAULT RECALL ................................................................................................................................

32

RESETTING FROM LOCKOUT ................................................................................................................

32

3

Table of Contents

 

MAINTENANCE .........................................................................................................................................

32

ANNUAL INSPECTION ...........................................................................................................................

33

FILTERS ..........................................................................................................................................

33

FILTER MAINTENANCE .........................................................................................................................

33

FILTER REMOVAL ..............................................................................................................................

33

INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS .................................................................................

33

FLAME SENSOR (QUALIFIED SERVICER ONLY) ..........................................................................................

33

IGNITER (QUALIFIED SERVICER ONLY) .....................................................................................................

33

BURNERS .........................................................................................................................................

33

CLEANING (QUALIFIED SERVICER ONLY) ........................................................................................................

34

BEFORE LEAVING AN INSTALLATION ...............................................................................................................

34

REPAIR AND REPLACEMENT PARTS ..............................................................................................................

34

COMPONENT IDENTIFICATION .................................................................................................................

35 - 36

APPENDIX.........................................................................................................................................

37

TROUBLESHOOTING CHART ..................................................................................................................

37

BLOWER PERFORMANCE DATA .............................................................................................................

40

*M(H/S)8 .................................................................................................................................

40

*(D/H)S8 .................................................................................................................................

41

GME8 .....................................................................................................................................

42

*(M, D, H)S8 WIRING DIAGRAM ..................................................................................................

43

GME8 WIRING DIAGRAM ............................................................................................................

44

*(M,D)H* WIRING DIAGRAM......................................................................................................................

45

4

SAFETY PRECAUTIONS

Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,

REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.

WARNING

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

DO 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:

DO NOT TRY TO LIGHT ANY APPLIANCE.

DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.

IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBORS PHONE. FOLLOW THE GAS SUPPLIERS INSTRUCTIONS.

IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING

HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE,

ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILDING IN WHICH ANY 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 SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.

WARNING

CARBON MONOXIDE POISONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such 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 furnace or air handler is installed in an enclosed area such

as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside 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

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,

REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,

REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER.

5

SAFETY PRECAUTIONS

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING

CATEGORY III VENTING.

PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS OUTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.

ADDITIONAL SAFETY CONSIDERATIONS

This furnace is approved for Category I Venting only.

Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

SHIPPINGINSPECTION

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.

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 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 expos-

ing 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 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 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.

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, and venting. These furnaces are designed for Category I venting only.

WARNING

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT

WARRANTY

Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty certificate carefully to determine what is and is not covered and keep the warranty certificate in a safe place. If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service (877-254-4729) to obtain a copy.

IMPORTANT: To receive the Lifetime Heat Exchanger Limited Warranty (good for as long as you own your home) and the 10year Parts Limited Warranty, online registration must be completed within 60 days of installation. Online registration is not required in California or Quebec. Complete warranty details available from your local dealer or, for Goodman® brand products, visit www.goodmanmfg.com, and for Amana® brand products, visit www.amana-hac.com.

6

PRODUCT APPLICATION

To register your Goodman® brand unit, go to www.goodmanmfg.com and click “Warranty Registration”. Complete the registration as prompted.

To register your Amana® brand unit, go to www.amana-hac.com and click “Warranty Registration”. Complete the registration as prompted.

Product limited warranty certificates for models currently in production can be viewed at www.goodmanmfg.com or www.amanahac.com. If your model is not currently in production or does not appear on the website, please contact your installing contractor or contact customer service (877-254-4729) to obtain a copy of your warranty certificate.

Each product overview page contains a Product Warranty link; by clicking on it you will be able to view the limited warranty coverage for that specific product. To view warranty registration information, click on the Product Warranty text on the left navigation panel on the home page of each website. The Online Product Registration pages are located in this same section.

PRODUCT APPLICATION

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.

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under 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:

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. Neither is it 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,Officebuildings,Churches,Retailstores,

Nursinghomes,Hotels/motels,Commonorofficeareas

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.

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.

WARNING

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, 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

It must be part of a ducted system and not used in a CAN/CSA B149 Installation Codes, local plumbing or waste

free air delivery application.

It must not be used as a “make-up” air unit.

All other warranty exclusions and restrictions apply.

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.

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

7

LOCATION REQUIREMENTS AND CONSIDERATIONS

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.

In the USA, this furnace MUST be installed in accordance with the latest edition of the ANSI Z223.1 booklet entitled “National Fuel Gas Code” (NFPA 54), and the requirements or codes of the local utility or other authority having jurisdiction. In Canada, this furnace must be installed in accordance with the current CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing or waste water codes and other applicable codes. Additional helpful publications available from the NFPA are, NFPA 90A - Installation ofAir Conditioning and Ventilating System and NFPA 90B - Warm Air Heating and Air Conditioning System.

All venting shall be in accordance with PART 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable local building and/or air conditioning codes. These publications are available from:

National Fire Protection Association, Inc.

1 Batterymarch Park, Quincy, MA 02269

NOTE: Furnaces with NOx screens meet the California NOx emission standards and California seasonal efficiency standards. ANNUAL inspections of the furnace and its vent system is strongly recommended.

LOCATION REQUIREMENTS AND CONSIDERATIONS

Your unit model type determines which installation procedures must be used. For *MH8, *MS8, and GHS8 models, you must follow instructions for Horizontal Left, Horizontal Right or Upflow installations only. These furnaces are not approved for Downflow installations.

Downflow models GD(H,S) ARE NOT APPROVED FOR HORIZONTAL OR UPFLOW INSTALLATIONS. For these models, use only the instructions for downflow installation only.

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,

PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT.

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V, Combustion 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.

If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is available. Consult your local distributor for more details.

Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

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.

The furnace must be level. If the furnace is to be set on a floor that may become wet or damp at times, the furnace should be supported above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace.

Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

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 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

If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil 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.

8

LOCATION REQUIREMENTS AND CONSIDERATIONS

Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.

For counterflow installations, the air conditioning coil must be downstream from the heat exchanger of the furnace.

Counterflow installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicon rubber caulking compound or cement grout.

Counterflow installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory subbase (see Specification Sheet applicable to your model for details). A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Follow the instructions with the subbase for proper installations. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.

Vent Pipe Clearance to Combustibles- 6" using Single Wall Connector or 1" using B-1 vent.

Top - 1"

Back - 0"

Side

Clearance - 1"

Front Clearance - 3"

Adequate combustion/ventilation air must be supplied to the closet.

Furnace must be completely sealed to floor or base. Combustion/ ventilation air supply pipes must terminate 12" from top of closet and 12" from floor of closet. DO NOT remove solid base plate for side return.

Return air ducts must be completely sealed to the furnace and terminate outside the enclosure surfaces.

CLEARANCES AND ACCESSIBILITY

Unobstructed front clearance of 24" for servicing is recommended.

 

VEN T

SIDES

FRON T

BAC K

TOP

B1-VENT

SINGLE

(PLENUM )

 

 

 

1"

 

6"

1"

3"

0"

1"

 

 

 

 

 

 

 

Top clearance for horizontal configuration - 1"

INSTALLATION POSITIONS

An upflow 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 vertically installed upflow furnaces, return air ductwork may be attached to the side panel(s) and/ or basepan. For horizontally installed upflow furnaces, return air ductwork must be attached to the basepan. For counterflow furnaces, return ductwork must be attached to the top end of the blower compartment.

NOTE: Ductwork must never be attached to the back of the furnace.

HORIZONTALINSTALLATION

Line contact to framing is permitted when installed in the horizontal configuration. Line contact is defined as the portion of the cabinet that is formed by the intersection of the top and side. ACCESSIBILITY CLEARANCE, WHERE GREATER, SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PROTECTION CLEARANCE. A gas-fired furnace for installation in a residential garage must be installed so that the ignition source and burners are located not less than eighteen inches (18") above the floor and is protected or located to prevent physical damage by vehicles. A gas furnace must not be installed directly on carpeting, tile, or other combustible materials other than wood flooring.

FURNACESUSPENSION

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x3/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

Suspended Furnace

9

COMBUSTION & VENTILATION CATEGORY I VENTING AIR REQUIREMENTS

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 Z21.47-Latest Edition, CSA-2.3-Latest Edition 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 CAN/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.Test for draft hood equipped appliance 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.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA54/ANSI Z223.1 and/or CAN/ 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 CAN/CSA B149 Installation Codes.

THERMOSTAT LOCATION

In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. 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.

HOT

COLD

Thermostat Influences

Consult the instructions packaged with the thermostat for mounting instructions and further precautions.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,

SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO 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

10

EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY

Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed combustion) furnace.

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.

CATEGORY I VENTING (VERTICAL VENTING)

WARNING

TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING CATEGORY III VENTING.

Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.” NOTE: Single stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing, in some instances, common venting with natural draft appliances (i.e. water heaters). All installations must be vented in accordance with National Fuel Gas Code NFPA54/ANSI Z223.1 - latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

NOTE: Masonry vent kit (MVK-01 and MVK-02) is to only be used on interior masonry chimneys or qualifying exterior masonry chimney applications identified in the MVK kit installation instructions. To ensure safe and reliable operation, use only the kit listed for your model.

NOTE: The vertical height of the Category I venting system must be at least as great as the horizontal length of the venting system.

WARNING

TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURERS INDUCED DRAFT APPLIANCES IS NOT ALLOWED.

The minimum vent diameter for the Category I venting system is as shown:

MODEL

MINIMUM VENT

UPFLOW

COUNTERFLOW

 

40

4 Inch

4 Inch

60

4 Inch

4 Inch

80

4 Inch

4 Inch

100

5 Inch

5 Inch

120

5 Inch

N/A

140

5 Inch

N/A

Under some conditions, larger vents than those shown above may be required or allowed. 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.

Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated 90 degrees with the (0270F01119) chimney transition bottom kit for Category I venting. For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet.

THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCKWISE INDUCED DRAFT BLOWER ROTATION.

Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

Venting - Furnace Installed in Horizontal Position

THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORIZONTALLY VENTED THROUGH AN EXTERIOR SIDE WALL.

The following describes an optional venting procedure when the furnace is installed in the horizontal left discharge position.

To rotate the induced draft blower clockwise, you will need to purchase one (0270F01119) chimney transition bottom kit.

1.Disconnect electrical power from the furnace.

2.Disconnect the induced draft blower power leads, flue pipe, and pressure switch tubing.

3.Remove the round cutout from the right side of the wrapper.

4.Remove and save the four screws that fasten the induced draft blower to the flue collector box.

5.Remove and save the three screws that hold the chimney assembly to the induced draft blower.

6.Remove and save the four screws that fasten the chimney top to the chimney bottom.

7.Remove the chimney transition bottom from the transition bottom kit.

8.Install the chimney top with the four screws retained from step 6 onto the new chimney transition bottom from the transition bottom kit.

9.Remove the induced draft blower and install the new chimney assembly to it using the three screws retained from step 5.

10.Rotate the induced draft blower 90 degrees to the right, feed the flue pipe through the round cutout from the outside of the wrapper, and fit onto the chimney top assembly. Secure the pipe to the chimney top from the front, top, and bottom using (3) screws and rotating the induced

11

EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY

draft blower to properly orient the assembly. NOTE: If the pipe section is less than 18”, then attach it directly to the chimney top on 3 sides and feed it through the round cutout from the inside of the wrapper.

11.Reattach the induced draft blower using the (4) screws retained from step 3. Ensure the gasket located between the induced draft blower and collector box is rotated accordingly.

12.Reconnect the induced draft blower power leads. NOTE: If the wires are not long enough, pull extra wire from the wire bundle in the blower compartment.

13.Reconnect the remaining flue pipe, and the pressure switch tubing. Ensure that all wires and the pressure switch tubing is at least one inch from the flue pipe, or any other hot surface.

14.Restore power to furnace.

NOTE: In a horizontal installation the air conditioning coil must be adequately supported by proper brackets and supports. Inadequate coil support can result in furnace cabinet distortion and air leakage.

Counterflow units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” as viewed for a counterflow installation.)

Vent the furnace in accordance with the National Fuel Gas Code NFPA54/ANSI Z223.1-latest edition. In Canada, vent the furnace in accordance with the national standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and amendments.

WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY.

EXTERIORMASONRYCHIMNEYS (CATEGORYIFURNACESONLY)

An exterior masonry chimney is defined as a “Masonry” chimney exposed to the outdoors on one or more sides below the roof line.” The ability to use a clay lined masonry chimney depends on a parameter not associated with interior chimneys. This variable is the geographic location of the installation. Researchers have discovered that the winter design temperatures have a direct impact on the suitability of this type of venting. In most situations, the existing masonry chimneys will require a properly sized metallic liner.

WARNING

POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN A SINGLE FAN ASSISTED CATEGORY I APPLIANCE (80% AFUE

FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR. DO NOT CONNECT AN 80% FURNACE TO A MASONRY CHIMNEY UNLESS THE FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE B

METAL VENT. ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES. IF AN

80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS,

EXTERIOR CHIMNEYS, OR ANY COMBINATION OF THESE CONDITIONS. THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR TYPE B METAL VENT.

 

Wash

 

 

 

Roof Line

 

Clay Tile Size: 8" x 8" x12"

 

(Each x 24" Length)

 

 

Attic Floor

 

1/2" to 1" Air Space

 

Second Floor

Throat

 

 

Damper

 

 

 

 

First Floor

 

 

Water Heater

Breech

F.A.F. Vent

Vent Connector

 

Connector

 

 

 

 

 

 

 

 

 

 

 

 

 

Fan Assisted

 

Natural Draft

Clean Out

 

 

 

Forced Air

 

Water Heater

 

 

 

 

Furnace

 

 

 

 

 

 

 

 

 

 

Basement Floor

Typical Multiple Flue Clay Tile Chimney

CHECKLIST SUMMARY

This checklist serves as a summary of the items to be checked before venting an 80+ furnace into a masonry chimney. In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system.

This checklist is only a summary. For detailed information on each of the procedures mentioned, see the paragraph referenced with each item.

This inspection is based upon a draft topical report, “Masonry Chimney Inspection and Relining”, issued by the Gas Research Institute. While not yet finalized, we believe this report represents the best information on this subject which is currently available.

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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY

Proper Chimney

Termination?

(Check 1)

Chimney channel free of solid and liquid fuel appliances? (Check 2)

Crown in good condition (Check 3)

Cleanout free of debris?

(Check 4)

Liner in good condition? (Check 5)

Dilution air available? (Check 6)

Complete the installation. (Check 7)

Change venting arrangements (Fix 2)

Rebuild crown (Fix 3) and/or Reline (Fix 4)

Reline (Fix 4)

Reline (Fix 4)

Reline (Fix 4)

CHECK 1 -PROPER CHIMNEY TERMINATION.

A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it passes through the roof. It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet. In addition, the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet. The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar.

If the chimney does not meet these termination requirements, but all other requirements in the checklist can be met, it may be possible for a mason to extend the chimney. If this will not be practical, see Fix 1.

 

10' or Less

2' Min.

2' Min.

3' Min.

Wall or

Parapet

Chimney

10' or Less

2' Min.

3' Min.

Chimney

Termination 10 Feet Or Less From Ridge, Wall or Parapet

More than 10’

3’ Min.

 

NOTE: No Height

 

above parapet

Wall or

required when distance

from walls or parapet is

Parapet

more than 10 feet.

 

 

 

 

 

 

 

 

 

More than 10’

 

 

 

 

 

 

 

 

 

 

 

 

 

Ridge

 

 

 

10’

 

 

 

 

 

2” Min.

Chimney

Chimney

Height above any roof surface within 10 feet horizontally.

3’ Min.

Termination More Than 10 Feet From Ridge, Wall or Parapet

CHECK 2-ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL

Solid fuel appliances include fireplaces, wood stoves, coal furnaces, and incinerators.

13

EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY

Liquid fuel appliances include oil furnaces, oil-fired boilers and oil-fired water heaters.

Appliances which burn propane (sometimes referred to as LP (liquefied petroleum)) gas are considered gas-fired appliances.

CHECK 3-CHIMNEY CROWN CONDITION.

Damage from condensate usually shows up first in the crown. If any of the following trouble signs are present, the condition of the crown is not satisfactory:

a)Crown leaning

b)Bricks missing

c)Mortar missing

d)Tile liner cracked

e)No tile liner

f)Salt staining at mortar joints. (White stains, and mortar becomes sandy and/or erodes.)

For problems a, b, or c, see Fix 3. If problems d, e, or f are present, see Fix 4. IMPORTANT: It may be necessary to follow both Fix 3 and Fix 4.

CHECK 4-DEBRIS IN CLEANOUT

A cleanout (dropleg) must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blocked by debris. If no cleanout is present, the chimney must be relined (Fix 4). Remove the cleanout cover, and examine the cleanout for debris. If significant amounts of any of the following are found:

Fuel oil residue

Bricks

Mortar or sand

Pieces of the tile liner

Rusted pieces of the metallic liner - reline the chimney (Fix 4).

CHECK 5-LINER CONDITION.

If a metal liner is present, it must be checked. It cannot be assumed that all existing metal liners are correctly installed and in good condition.

Remove the lowest existing vent connector, and examine the inside of the elbow or tee at the base of the liner. Asmall amount of soot may be considered acceptable, provided the installer vacuums it away. If rusted pieces of the liner have collected here, the metal liner must be removed and replaced (Fix 4).

Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping does not sound like metal hitting metal, the liner must be removed and replaced (Fix 4).

Remember that all appliances must be vented inside the liner. Venting one appliance inside the liner and another appliance outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner. B vent must be supported so as to not come into direct contact with the chimney walls or tile liner. If it is not, it can probably be rehung so as to be acceptable. A thimble or fire stop may be helpful here.

Flexible liners should be hung straight or nearly straight. If it is spiraled in the chimney and in good condition, it should be rehung. To do this, break the top seal; pull up and cut off the excess liner length, and refit the top seal. Use caution when doing this, as the cut edges of flexible liners may be sharp.

The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4). Finally, confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA tables and rules.

If a metal liner is not present, a clay tile liner must be present, or the chimney must be lined (Fix 4).

Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner. If any of the following problems are present:

Tile sections misaligned

Tile sections missing

Gaps between tile sections

Signs of condensate drainage at the cleanout or vent connectors

Mortar protruding from between tile sections

Use of sewer pipe or drainage pipe rather than an approved fire clay tile reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to do this from the cleanout. The liner must be at least as large as the minimum size established by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments. If the liner is too small or too large, then the chimney must be relined (Fix 4).

CHECK 6 - DILUTION AIR.

If gas-fired appliances are to be vented into a clay tile liner, a source of dilution air is required.

Dilution air cannot be obtained through:

Induced draft appliances

Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance’s vent connector does not include a vent damper. If dilution air will not be available, the chimney must be relined (Fix 4).

14

EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY

CHECK 7 - COMPLETE THE INSTALLATION.

FIX 3 - REBUILD THE CROWN

If Checks 1 through 6 have been satisfactory, and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments, then the clay tile liner can probably be used as a vent for the gas appliances. However, the installer must keep in mind the following factors which may render the tile liner unsuitable for use as a vent:

Extremely cold weather

Long vent connectors

Masonry chimneys with no air gap between the liner and the bricks. (In practice, this can be difficult to detect.)

Exterior chimneys (The tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments assume interior chimneys.)

If, in the judgment of the local gas utility, installer, and/or local codes; one or more of the above factors is likely to present a problem, the chimney must be relined (Fix 4).

FIX 1 - LINER TERMINATION

Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use. The liner and cap/roof assembly must then terminate above the roof in accordance with the manufacturer’s instructions.

In some cases, a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney.

For further information on relining, see Fix 4.

FIX 2-CHANGE VENTING ARRANGEMENTS

If the masonry chimney has more than one channel, it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance(s) into another channel(s). Do not vent an 80+ Furnace inside of a metal liner with other appliances vented outside the liner.

Alternatively, the homeowner may agree to discontinue use of the fireplace (solid fuel appliance). If so, the tile liner must be cleaned to remove creosote buildup. The fireplace opening must then be permanently sealed.

If oil-fired appliance(s) are being replaced by gas-fired appliance(s), the tile liner must first be cleaned to remove the fuel oil residue.

If none of the above options is practical, the furnace may need to be vented vertically with a B Vent.

Under some conditions, a 90%+ furnace could be installed rather than an 80% furnace. The 90%+ furnace can be vented horizontally or vertically through PVC pipe.

If the chimney crown is damaged, a qualified mason must repair it in accordance with nationally recognized building codes or standards. One such standard which may be referenced is the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances, ANSI/NFPA 211.

FIX 4 - RELINING

Relining options include B vent and flexible liners.

If the chimney has diagonal offsets, B vent probably cannot be used.

If B vent is to be used, it must be supported adequately. Supports (such as fire stops or thimbles) must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls. Direct contact would result in higher heat loss, with an increased possibility of poor venting system performance.

It is not acceptable to vent one appliance inside the B vent and other appliances outside. The excess space between the B vent and the chimney walls must be covered at the top of the chimney by a weatherproof, corrosion resistant flashing.

The B vent should then be topped with a listed vent cap. The listed vent cap will, when installed per the manufacturer’s instructions, prevent problems due to rain, birds, or wind effects.

A B-vent installed as described in this section is considered to be an enclosed vent system, and the sizing tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/ CSA B149.2 - latest editions and amendments may be used.

If a flexible liner is to be used, it must be made of the proper materials:

For most residential applications, an aluminum liner should be acceptable.

If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine, a liner of AL 29-4C stainless steel should be used. Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine bleaches, paint strippers, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds.

Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel appliances. They are not suitable for use with gas-fired appliances. Flexible liners specifically intended and tested for gas applications are listed in the UL “Gas and Oil Equipment Directory”. (UL Standard 1777).

15

ELECTRICAL CONNECTIONS

For sizing of flexible liners, see Note 22 and the tables in the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

To install the liner, read and follow the liner manufacturer’s instructions and your local codes. Excess liner length should be pulled out of the chimney and cut off. Use caution when doing this, as the cut edges of flexible liners may be sharp. Do not spiral excess liner inside of the chimney. Support the liner as recommended by the liner manufacturer.

Some manufacturers of flexible liners offer an insulation sleeve designed to be added to the liner before it is installed in the chimney. (Poured insulation, either vermiculite or other materials, is no longer recommended.) Insulation will need to be added to the flexible liner if:

It is required by the liner manufacturer’s instructions.

The previous liner was properly sized and installed, and suffered from condensation damage.

It is required by your local building codes.

Even if none of those three conditions exist which require additional liner insulation, the installer may wish to consider it if:

The local climate is very cold.

The chimney is very tall.

The vent connectors used are very long or have a large number of elbows.

Local experience indicates that flexible liners installed without insulation are likely to have condensation problems.

Insulation must be selected and installed in accordance with the liner manufacturer’s instructions.

Finally, cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.

ELECTRICAL CONNECTIONS

WARNING

HIGH VOLTAGE !

TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED.

WARNING

HIGH VOLTAGE !

TO AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

WARNING

HIGH VOLTAGE !

TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR

DEATH, THE FURNACE MUST BE ELECTRICALLY

GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN

THEIR ABSENCE, WITH THE LATEST EDITION OF THE

NATIONAL ELECTRIC CODE.

WIRINGHARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color 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 a copper conductor.

115VOLT 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 NEC 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.

Line voltage wiring must enter into the junction box provided with the furnace.

NOTE: Line polarity must be observed when making field connections.

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).

16

ELECTRICAL CONNECTIONS

A heat pump thermostat with two stages of heat is required to properly use a 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 integrated control module and the FURNACE terminal strip on the fossil fuel control board.

JUNCTION BOX RELOCATION

WARNING

EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS.

Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,

DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT.

1.Remove both doors from the furnace.

2.Remove and save the screws holding the junction box to the right side of the furnace.

3.Models that have the junction box located in the burner compartment will need to move the junction box directly over.

4.Attach the junction box to the left side of the furnace, using the screws removed in step 2.

5.Check the location of the wiring. Confirm that it will not be damaged by heat from the burners or by the rotation of the fan. Also confirm that wiring location will not interfere with filter removal or other maintenance.

After the junction box is in the desired location, use washers to connect field-supplied conduit to the junction box in accordance with NEC and local codes. Connect hot, neutral, and ground wires as shown in the furnace wiring diagram. The wires and ground screw are located in the furnace junction box.

NOTE: In downflow applications the power leads should be routed through the supplied wire tabs when rotating junction box to the left side.

Low voltage wires may be connected to the terminal strip.

IMPORTANT NOTE: To avoid possible equipment malfunction, route the low voltage wires to avoid interference with filter removal or other maintenance.

WARNING

HIGH VOLTAGE !

TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR

DEATH, THE FURNACE MUST BE ELECTRICALLY

GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN

THEIR ABSENCE, WITH THE LATEST EDITION OF THE

NATIONAL ELECTRIC CODE.

To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box 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.

24VOLT THERMOSTAT WIRING

NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. The following figure shows connections for a “heat only” system and “heat/cool system”.

Heating

Room

Thermostat

W

Furnace

Control

Heating/Cooling

Room Thermostat

W

 

 

Remote

Condensing

Furnace

Unit

Control

 

Typical Field Wiring (24 VAC Control Circuit)

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.

A single-stage thermostat with only one heating stage can be used to control this furnace.

GME8FURNACE WITH 2-STAGE CONDENSER FIELD WIRING

The GME8 model furnaces may be used with a 2-stage outdoor air conditioner. A two stage cooling/single stage gas heat thermostat is required, in addition to a field supplied relay. The relay must have a 24VAC coil and contacts rated for up to 1 horse power at 125VAC.

17

GAS SUPPLY AND PIPING

1.Install the field supplied relay on the control mounting panel near the furnace ignition control. The relay should be installed such that the motor leads will reach the relay contact terminals.

2.Connect the “Y2” (high stage cool) thermostat terminal to one coil terminal of the field supplied relay. Connect the other field supplied relay coil terminal to the “C” terminal on the furnace ignition control. Typical 18AWG thermostat wire may be used.

3.Connect the common terminal of the field supplied relay to the “LINE-H” terminal on the furnace ignition control. Use wiring having copper conductors only and a temperature rating of at least 105°C.

4.Using the GME8 airflow tables in this manual, determine the motor speed tap needed to deliver the required high stage cooling airflow. Connect the selected motor speed tap to the normally open terminal on the field supplied relay. Use wiring having copper conductors only and a temperature rating of at least 105°C.

5.See the wiring schematic below.

Record the reading.

Divide this reading by 10.

Set the heat anticipator on the thermostat to match this reading.

Example: If the reading on the ammeter is “4”, divide this by 10. The anticipator setting will be .4 amps.

115VOLT LINE CONNECTION OF ACCESSORIES

(ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE !

TO AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE SERVICING OR CHANGING ANY ELECTRICAL

WIRING.

The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field-supplied electronic air cleaner.

The accessory load specifications are as follows:

 

 

ECO-TECH

 

 

 

 

MOTOR

 

 

 

T3

 

 

T5

 

 

 

T4

T2

 

 

Furnace

Heat-Lo

Heat-Hi

Cool

Line-H

Supplied

 

 

 

 

 

Field

Control

 

 

 

 

Relay

 

Y

 

 

 

 

 

 

 

 

 

Y1

 

 

Y2

Heating/Cooling

 

 

 

 

 

Room Thermostat

 

Y1

 

 

Y2

 

Remote Condensing Unit

Field Wiring for GME8 Furnace with 2-Stage Condenser

SETTING THE HEAT ANTICIPATOR

The following method should be used in measuring the amp draw of the control circuit to assure proper adjustment of the thermostat heat anticipator

Electronic Air Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories. Follow the 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 electronic air cleaner hot terminal is identified as EAC-H and the neutral terminal is identified as NEUTRAL. All field wiring must conform to applicable codes. Connections should be made as shown in the following illustration.

Control Module

 

 

 

Hot 120 VAC

 

 

 

Neutral 120 VAC

 

 

 

 

 

 

 

 

 

 

EAC-H

 

 

 

 

Line

Transformer

 

 

 

 

 

EAC

Transformer

Line

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Optional

Air Cleaner

 

Accessories

 

Wrap the “R” leg around a clip-on ammeter 10 times.

Energize the furnace in the heat mode.

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 electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

18

GAS SUPPLY AND PIPING

24VAC HUMIDIFIER

The yellow wire connected to the I.D. Blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control. Remove the yellow wire and connect the supplied brown jumper wire to the pressure switch terminal. Reconnect the yellow wire to the “piggyback” terminal on the brown jumper and then connect the 24 VAC line of the humidifier to the stripped end of the brown wire. Using a wire nut or a field-supplied quick connect terminal can make this connection. 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.

GAS SUPPLY AND PIPING

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

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

Inlet gas supply pressures must be maintained within the ranges specified in the following table. 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

Minimum: 5.0" w.c.

Maximum:10.0" w.c.

Propane Gas

Minimum: 11.0" w.c.

Maximum:13.0" w.c.

NOTE: Adjusting the minimum supply pressure below the limits in the above table could lead to unreliable ignition. Gas input to the burners must not exceed the rated input shown on the rating plate. Overfiring of the furnace can result in premature heat exchanger failure. Gas pressures in excess of 13 inches water column can also cause permanent damage to the gas valve.

At all altitudes, the manifold pressure must be within 0.3 inches w.c. of that listed in the Specification Sheet applicable to your model for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the furnace nameplate. Should this appliance be converted to LP, refer to the instructions included in the factory authorized LP conversion kit.

HIGH ALTITUDE DERATE

IMPORTANT NOTE: The furnace will naturally derate itself with altitude. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure. This can cause poor combustion and equipment failure.

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).

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.

PROPANE GAS CONVERSION

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION. ALL 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 “Propane Gas and/or High Altitude Installations” section for details.

Models using Single Stage Gas Valves

Altitude

Gas

Kit

Orifice

Manifold

Pressure

Pressure

Switch

 

 

 

 

 

 

 

 

 

 

 

Natural

None

#45

3.5" w.c.

 

0-7000

 

 

 

 

None

 

 

 

 

 

Propane

LPT-03

#55

10.0" w.c.

 

 

 

 

 

 

 

NOTE: In Canada, gas furnaces are certified to 4500 feet. NOTE: GMS81405DN** models utilize #43 orifices in Natural gas applications.

Models using 2-Stage Gas Valves

 

 

 

 

Manifold Pressure

Pressure

Gas

Altitude

Kit

Orifice

 

 

Switch

High

Low

 

 

 

 

Change

 

 

 

 

Stage

Stage

 

 

 

 

 

Natural

 

None

#45

3.5" w.c.

1.9" w.c.

None

Propane

0-7000

LPM-06

#55

10.0" w.c.

6.0" w.c.

None

 

 

 

 

 

 

 

NOTE: In Canada, gas furnaces are only certified to 4500 feet. NOTE: GMH81405DN** models utilize #43 orifices in Natural gas applications.

19

GAS SUPPLY AND PIPING

Contact your 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.

GAS PIPING CONNECTIONS

WARNING

TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.

When sizing a trunk line, be sure to include all appliances which will operate simultaneously.

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, NFPA 54/ANSI Z223.1.

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of

 

Nominal 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

(Pressure 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)

 

 

 

 

 

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.

Use black iron or steel pipe and fittings for the building piping.

Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.

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.

Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory.

Install a manual shutoff valve between the gas meter and 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.

Use listed gas appliance connectors in accordance

with their instructions. Connectors must be fully in the same room as the furnace.

Protect connectors and semi-rigid tubing against

physical and thermal damage when installed. Ensure aluminum-alloy 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.

Location of Manual Valve

(Installed Ahead of

Ground Joint Pipe Union)

Height Required

By Local Code

Ground Joint Pipe Union

To Be Installed Ahead of

Gas Valve

``

Drip Leg

Reducing Coupling 1/2” x 1/8” with 1/8” Pipe Plug to Measure Line Gas Pressure

General Furnace Layout

UPFLOW INSTALLATIONS

When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting from the gas valve):

90 degree elbows (2).

Close nipple.

Straight pipe to reach the exterior of the furnace .

20

GAS SUPPLY AND PIPING

A ground joint union, drip leg, and manual shutoff valve must also be supplied by the installer. In some cases, the installer may also need to supply a transition piece from 1/2" to another pipe size.

When the gas piping enters through the left side of the furnace, the installer must supply the following fittings (starting from the gas valve):

Straight pipe to reach the exterior of the furnace.

A ground joint union, drip leg, and manual shutoff valve must also be supplied by the installer. In some cases, the installer may also need to supply a transition piece from 1/2 inch to another pipe size.

COUNTERFLOW INSTALLATIONS

When the gas piping enters through the left side of the furnace, the installer must supply a straight pipe to reach the exterior of the furnace.

A ground joint union, drip leg and manual shutoff valve must also be supplied by the installer. In most cases, the installer may also need to supply a transition piece from ½” to another pipe size. When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting at the gas valve):

90 Degree Elbow

Close Nipple

90 Degree Elbow

Straight Pipe to Reach Exterior of Furnace.

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas connections.

WARNING

TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR 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).

This unit must be isolated from the gas supply system by closing its manual shutoff valve before pressure testing of gas supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).

PROPANE GAS TANKS AND PIPING

WARNING

IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES.

PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE.

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 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 3 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 10 inch WC 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 and piping.

21

CIRCULATING AIR AND FILTERS

First Stage

5 to 15 PSIG

 

(20 PSIG Max.)

 

Regulator

Continuous

 

 

11" W.C.

A duct system must be installed 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.

200 PSIG

Second Stage

Maximum

Regulator

Propane Gas Installation (Typ.)

PROPANE GAS PIPING CHARTS

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.

Pipe or

 

Tubing Size, O.D. Type L

 

Nominal Pipe Size

Tubing

 

 

 

 

 

 

 

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

310

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

Sizing Between Second Stage and Appliance Regulator*

Maxim um Propane Capacities listed are based on 2 ps ig pres sure drop at 10 psig s etting. Capacities in 1,000 BTU/hour.

Pipe or

 

Tubing Size, O.D. Type L

 

 

Nominal Pipe Size

 

Tubing

 

 

 

Schedule 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

CIRCULATING AIR AND FILTERS

DUCTWORK -AIR FLOW

WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY.

Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D.

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. For installations requiring more than 1800 CFM, use a bottom return or two sided return. Supply and return connections to the furnace may be made with flexible joints 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. Furnace is shipped with the top flanges in the flat position. Before installing a coil or ducts, the flanges must be bent 90°. A room, closet, or alcove must not be used as a return air chamber.

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.

NOTE: In a horizontal installation the air conditioning coil must be adequately supported by proper brackets and supports. Inadequate coil support can result in furnace cabinet distortion and air leakage.

When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space containing the furnace.

CHECKING DUCT STATIC

Refer to your furnace rating plate for the maximum ESP (external duct static) rating.

Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between the fur-

22

START-UP PROCEDURE AND ADJUSTMENT

nace and the cooling coil. This reading is usually taken by removing the “A” shaped block off plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. Take a duct static reading at the test hole. Tape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower.

Too much external static pressure will result in insufficient air that can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure.

To determine total external duct static pressure, proceed as follows;

1.With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure)

2.Measure the static pressure of the supply duct. (Positive Pressure)

3.The difference between the two numbers is .4” w.c.

Example:

static reading from return duct = -.1" w.c. static reading from supply duct = .3" w.c.

total external static pressure on this system = .4" w.c.

NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

If the total external static pressure exceeds the maximum listed on the furnace rating plate, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.

Checking Static Pressure

(80% Furnace Shown, 90% Similar)

FILTERS -READ THIS SECTION BEFORE INSTALLING THE

RETURNAIR 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.

NOTE: An undersized opening will cause reduced airflow. The bottom return is set up as a knock out.

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), or the ductwork above a downflow furnace. As an alternative, a media air filter or electronic air cleaner can be used as the primary filter.

CIRCULATION AIR FILTERS

One of the most common causes of a problem in a forced air heating system is a blocked or dirty filter. Circulating air filters must be inspected monthly for dirt accumulation and replaced if necessary. Failure to maintain clean filters can cause premature heat exchanger failure.

A new home may require more frequent replacement until all construction dust and dirt is removed. Circulating air filters are to be installed in the return air duct external to the furnace cabinet.

MINIMUM FILTER SIZES for DISPOSABLE FILTERS

FURNACE INPUT

FILTER SIZE

40M

320 in2

60M

483 in2

80M

640 in2

100M

800 in2

120M

738 in2

140M

738 in2

DISPOSABLE NOMINAL 300 F.M. FACE VELOCITY

HORIZONTAL INSTALLATIONS

Filters must be installed in either the central return register or in the return air duct work.

SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL)

Refer to Timing Charts for sequencing.

NOTE: Dip switch positions referenced in this section applies to *(M,D)H8 models only.

POWER UP

115 VAC power applied to furnace.

Integrated ignition control performs internal checks.

Integrated ignition LED will light.

23

START-UP PROCEDURE AND ADJUSTMENT

Integrated ignition control monitors safety circuits continuously.

Furnace awaits call from thermostat.

HEATINGMODE

(MODE DIP SWITCH IS SET TO “1 STG” POSITION)

The normal operational sequence in heating mode is as follows:

R and W thermostat contacts close, initiating a call for heat.

Integrated control module performs safety circuit checks.

Induced draft blower is energized for 15 second pre-purge period causing pressure switch contacts to close.

Igniter warm up begins after 15 second prepurge expires.

Low and high-stage gas valves open 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.

Circulator blower is energized on high heat speed following a fixed thirty second blower on delay. Electronic air cleaner terminals are energized with circulator blower.

Furnace operates; integrated control module monitors safety circuits continuously.

R and W 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.

The circulator blower remains on high speed for the selected heat off delay period.

Furnace awaits the next call from thermostat.

(MODE DIP SWITCH IS SET TO “2 STG” POSITION)

The normal operational sequence in sequence is as follows:

R and W thermostat contacts close, initiating a call for heat.

Integrated control module performs safety circuit checks.

Induced draft blower is energized for 15 second prepurge period causing pressure switch contacts to close.

Igniter warm up begins after 15 second prepurge expires.

Low and high-stage gas valves open at end of igniter warm up period, delivering gas to burners and establishing flame.

High-stage gas valve closes after five seconds; low-stage gas valve remains open.

Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.

Circulator blower is energized on low heat speed following a fixed thirty second blower on delay. Electronic air cleaner terminals are energized with circulator blower.

Furnace is now operating in low-stage heating mode.

Furnace operates; integrated control module monitors safety circuits continuously.

If low-stage delay period expires, control will shift operation from low-stage heating mode operation to highstage heating mode operation. Control will energize circulator blower high heat speed and high stage gas valve.

Furnace is now operating in high-stage heating mode.

R and W thermostat contacts open, completing the call for heat.

Induced draft blower is de-energized following a fifteen second post purge.

Circulator blower is de-energized following a heat off delay period (selectable 100 or 150 seconds; factory set at 150 seconds).

If the furnace is operating in the low-stage heating mode when thermostat contacts open, circulator remains at low heat speed for the selected delay off period.

If the furnace is operating in high-stage heating mode when the thermostat contacts open, the circulator blower remains at high heat speed for the selected heat off delay period.

Furnace awaits the next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

R and Y thermostat contacts close, initiating a call for cool.

Integrated control module performs safety circuit checks.

Outdoor fan and compressor are energized.

Circulator blower is energized on cool speed following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower.

Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously.

R and Y thermostat contacts open, completing the call for cool.

Outdoor fan and compressor are de-energized.

Circulator blower is de-energized following a fixed forty five second cool off delay period. Electronic air cleaner terminals are de-energized.

Furnace awaits the next call from thermostat.

24

START-UP PROCEDURE AND ADJUSTMENT

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 low heat speed. 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 the next call from thermostat.

START-UP PROCEDURE AND ADJUSTMENT

Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. An interlock switch prevents furnace operation if the blower door is not in place. Keep the blower access door in place except for inspection and maintenance.

This furnace is also equipped with a self-diagnosing electronic control module. In the event a furnace component is not operating properly, the control module LED will flash on and off in a factory-programmed sequence, depending on the problem encountered. This light can be viewed through the observation window in the blower access door. Refer to the Troubleshooting Chart for further explanation of the lighting codes.

Follow the start-up and adjustment items, refer to further information in Section XIII, Operational Checks (see table of contents, pages 2-3 for page number)..

FURNACEOPERATION

Purge gas lines of air prior to start-up. Do 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.

NOTE: An interlock switch prevents furnace operation if the blower door is not in place. Keep the blower access doors in place except for inspection and maintenance.

FURNACE START-UP

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.White-Rodgers Model 36G22 or 36G54: Push the switch to the OFF position.

Honeywell VR8215 or VR9205: Slide the switch to the OFF position.

6.Wait five minutes to clear out any gas. Then smell for gas, including near the floor.

7.If gas can be smelled following the five minute waiting period in Step 6, immediately follow the instructions on Page 3 of this manual. If you do not smell gas after five minutes:

White-Rodgers Model 36G22 or 36G54: Push the switch to the ON position.

Honeywell VR8215 or VR9205: Slide the switch to the ON position.

8.Replace the door on the front of the furnace.

9.Open the manual gas valve external to the furnace.

10.Turn on the electrical power supply to the furnace.

11.Set the room thermostat to the desired temperature.

NOTE: There is an approximate 30 second delay between thermostat energizing and burner firing.

FURNACESHUTDOWN

1.Set the thermostat to lowest setting.

2.Turn off the electrical power supply to the furnace.

3.Set the room thermostat to the lowest possible setting.

4.Remove the burner compartment door.

5.White-Rodgers Model 36G54: Push switch to the OFF position.

Honeywell VR8215 or VR9205: Slide the switch to the OFF position.

6.Close manual gas shutoff valve external to the furnace.

7.Replace the door on the unit.

GASSUPPLYPRESSUREMEASUREMENT

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

25

START-UP PROCEDURE AND ADJUSTMENT

WARNING

HIGH VOLTAGE !

DISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY

BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

MODELS USING SINGLE STAGE GAS VALVES

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 tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the unit OFF. To measure inlet pressure, use the following procedure.

Gas Valve

 

On/Off

 

Selector

Inlet Pressure

Switch

Tap

 

OUTLET

INLET

Pressure Regulator

Outlet Pressure

Adjustment

Tap

(Under Cap Screw)

 

White-Rodgers Model 36G22

 

Pressure Regulator

Inlet

(under cap screw)

Outlet

Pressure

Pressure

Tap

Tap

 

Gas Valve On/Off

Selector Switch

Honeywell Model VR8215 (Single-Stage)

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.Inlet pressure tap connections:

a.Honeywell VR8215 Valve:

Remove the inlet pressure boss plug. Install an 1/8” NPT hose barb fitting into the outlet pressure tap.

b.White-Rodgers 36G22 valve:

Back inlet pressure test screw (inlet pressure boss) out one turn (counterclockwise, not more than one turn).

4.

Attach a hose and manometer to the outlet pressure

 

barb fitting (Honeywell valve) or inlet pressure boss (White-

 

Rodgers valve).

5.

Turn ON the gas supply.

6.

Turn On power and close thermostat “R” and “W” contacts

 

to provide a call for heat.

7.

Using a leak detection solution or soap suds, check for

 

leaks at outlet pressure boss plug (Honeywell valve) or

 

screw (White-Rodgers valve). Bubbles forming indicate

 

a leak. SHUT OFF GAS AND REPAIR ALL LEAKS

 

IMMEDIATELY!

8.

Measure the gas supply pressure with burners firing.

 

Adjust supply pressure using the Inlet Gas Supply

 

Pressure table shown below. If supply pressure reading

 

differs from the table, make necessary adjustments to

 

pressure regulator, gas piping size, etc., and/or consult

 

with local gas utility.

 

 

 

 

 

Inlet Gas Supply Pressure

 

 

 

 

Natural Gas

Minimum:5.0" W.C. Maximum :10.0" W.C.

 

Propane Gas

Minimum:11.0" W.C. Maximum :13.0" W.C.

9.

Turn OFF all electrical power and gas supply to the

 

system.

 

10. Remove the manometer hose from the hose barb fitting or inlet pressure boss.

11. Replace inlet pressure tap: a. Honeywell VR8215 valve:

Remove the 1/8” NPT hose barb fitting from the inlet pressure tap. Replace the inlet pressure boss plug and seal with a high quality thread sealer.

b. White-Rodgers 36G22 valve:

Turn inlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).

12. Retest for leaks. If bubbles form, shut down gas and repair leaks immediately.

13. Turn ON electrical power and gas supply to the system. 14. Turn valve switch ON.

MODELS USING TWO STAGE GAS VALVES

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.

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.

26

START-UP PROCEDURE AND ADJUSTMENT

INLET

OUTLET

Gas Valve On/Off

Selector Switch

White-Rodgers Model 36G54 (Two-Stage)

Open to Atmosphere

Manometer

Hose

Outlet

High Fire Regulator

Adjust

Pressure Boss

Regulator

 

Vent

 

 

Low Fire

 

 

Regulator

Inlet

 

Adjust

 

 

Pressure

 

Boss

High Fire Coil

Coaxial Coil

Manometer

Terminal (HI)

Terminal (M)

 

 

On/Off Switch

Common

 

 

Terminal(C)

White-Rodgers Model 36G54 Connected to Manometer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

High Fire

Regulator

 

 

 

 

Regulator

 

 

 

 

Adjust

Vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Valve On/Off

Low Fire

Selector Switch

Regulator

 

Adjust

Honeywell Model VR9205 (Two-Stage)

Open to

Manometer

Atmosphere

Hose

i

Manometer

Common

Terminal(C)

High Fire Coil

Terminal (HI)

Low Fire Coil

Terminal (LO)

Inlet Pressure Tap

1/8 NPT

Outlet Pressure Tap

1/8 NPT

Honeywell Model VR9205 Connected to Manometer

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. See Honeywell VR9205 gas valve figure or White-Rodgers 36G54 gas valve figure for location of inlet pressure boss.

NOTE: If measuring gas pressure at the drip leg or Honeywell VR9205 gas valve, a field-supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure boss on the White-Rodgers 36G54 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

Minimum: 5.0" w.c.

Maximum:10.0" w.c.

Propane Gas

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.

27

START-UP PROCEDURE AND ADJUSTMENT

Gas Line

Gas

Shutoff

Valve

Gas Line

To Furnace

Drip Leg Cap

With Fitting

Manometer Hose

Measuring Inlet Gas Pressure (Alt. Method)

GASMANIFOLD PRESSUREMEASUREMENT AND ADJUSTMENT

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.

WARNING

HIGH VOLTAGE !

DISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY

BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

MODELS USING SINGLE STAGE GAS VALVES

This valve is shipped from the factory with the regulator preset (see control label).

Consult the appliance rating plate to ensure burner manifold pressure is as specified. If another outlet pressure is required, follow these steps.

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.Outlet pressure tap connections:

a.Honeywell VR8215 valve:

Remove the outlet pressure boss plug. Install an 1/8” NPT hose barb fitting into the outlet pressure tap.

b.White-Rodgers 36G22 valve:

Back outlet pressure test screw (outlet pressure boss) out one turn (counterclockwise, not more than one turn).

4.Attach a hose and manometer to the outlet pressure barb fitting (Honeywell valve) or outlet pressure boss (White-Rodgers valve).

5.Turn ON the gas supply.

6.Turn ON power and close thermostat “R” and “W” contacts to provide a call for heat.

7.Using a leak detection solution or soap suds, check for leaks at outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

8.Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below.

Manifold Gas Pressure

Natural Gas

3.5" w.c.

Propane Gas

10.0" w.c.

9.Remove regulator cover screw from the outlet pressure regulator and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

10.Turn OFF all electrical power and gas supply to the system.

11.Remove the manometer hose from the hose barb fitting or outlet pressure boss.

12.Replace outlet pressure tap:

a.Honeywell VR8215 valve:

Remove the 1/8” NPT hose barb fitting from the outlet pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread sealer.

b.White-Rodgers 36G22 valve: Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).

13.Turn ON electrical power and gas supply to the system.

14.Close thermostat contacts to provide a call for heat.

15.Retest for leaks. If bubbles form, SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

MODELS USING TWO STAGE GAS VALVES

CAUTION

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE 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.

28

START-UP PROCEDURE AND ADJUSTMENT

3.Outlet pressure tap connections:

a.Honeywell VR9205 valve: Remove the outlet pressure boss plug. Install an 1/8" NPT hose barb fitting into the outlet pressure tap.

b.White-Rodgers 36G54 valve: 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 barb fitting (Honeywell valve) or outlet pressure boss (White-Rodgers valve).

5.Turn ON the gas supply.

6.Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat.

7.Measure the 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. Replace regulator cover screw.

9.Close thermostat “R” and “W2” contacts to provide a call for high stage heat.

10.Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

11.Turn off all electrical power and gas supply to the system.

12.Remove the manometer hose from the hose barb fitting or outlet pressure boss.

13.Replace outlet pressure tap:

a.Honeywell VR9205 valve: Remove the 1/8" NPT hose barb fitting from the outlet pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread sealer.

b.White-Rodgers 36G54 valve: 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.Close thermostat contacts “R” and “W1/W2” to energize the valve.

Using a leak detection solution or soap suds, check for leaks at outlet pressure boss plug (Honeywell valve) or screw (WhiteRodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

 

Manifold Gas Pressure

 

 

Gas

Range

Nom inal

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.

Propane

Low Stage

5.7 - 6.3"

w .c.

6.0" w .c.

 

High Stage

9.7 - 10.3" w .c.

10.0" w .c.

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/ ft3) of 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 installation’s gas heating value multiplied by 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/ft3 (Obtained from gas supplier)

Installation’s seconds per cubic foot: 34 sec/ ft3 Conversion Factor (hours to seconds): 3600 sec/hr Input = (Htg. value x 3600) ÷ seconds per cubic foot Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3 Input = 106,000 BTU/hr

This measured input must not be greater than the input indicated on the unit rating plate.

5.Turn ON gas and relight appliances turned off in step 1. Ensure all the appliances are functioning properly and that all pilot burners are operating.

TEMPERATURERISE

Air temperature rise is the temperature difference between supply and return air. The proper amount of temperature rise is usually obtained when the unit is operated at the rated input with the “as shipped” blower speed. If the correct amount of temperature rise is not obtained, it may be necessary to change the blower speed.

An incorrect temperature rise can cause condensing in or overheating of the heat exchanger. Determine and adjust the temperature rise as follows. The temperature rise must be within the range specified on the rating plate or Specification Sheet applicable to your model. (Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.)

29

START-UP PROCEDURE AND ADJUSTMENT

SUPPLY

AIR

RETURN

AIR

Temperature Rise Measurement

3.Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module. (Terminals are identified as LO HEAT, HI HEAT and COOL (hot)) for *(M,D)H8 models and HEAT and COOL for *(M,H,D)S8 models). If a heating speed and the cooling speed are the same, a jumper wire must be used between the heat and cool terminals.

4.Connect all unused blower motor leads to the “PARK” terminals on the integrated control module. Any leads not connected to the “PARK” terminals must be taped.

5.Turn ON power to furnace.

6.Verify proper temperature rise as outlined in Temperature Rise section.

CIRCULATOR BLOWER FAN TIMING ADJUSTMENT

1.Operate furnace with burners firing approximately 15 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.

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 the following section for speed changing details.

CIRCULATOR BLOWER SPEEDADJUSTMENT

WARNING

TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,

TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.

This furnace is equipped with a PSC circulator blower motor. This blower provides ease in adjusting blower speeds. Refer to the Blower Performance Data in the back of the manual for proper selection of heating and cooling speeds. The cooling blower speed is shipped set on HIGH. High heat ships on MEDIUM and low heat is shipped on MEDIUM-LO. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and the correct cooling CFM.

To adjust the circulator blower speed, proceed as follows:

1.Turn OFF power to the furnace.

2.Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Specification Sheet applicable to your model. (Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.)

NOTE: Items in this section refer to the air circulator blower fan in the *(M,D)H8 models, NOT to the induced draft blower. The induced draft blower timing sequence is not adjustable. The circulator blower fan timing is adjustable only on models with optional “heating fan OFF delay” adjustment pins or switches. It is NOT adjustable in any other circumstances.

As shipped, the circulator blower fan will remain on for 150 seconds after the gas valve closes. When a call for cooling occurs, the circulator fan comes on and remains on for 45 seconds after the call for cooling ends. During normal heating operation, the circulator fan will come on approximately 34 seconds after the gas valve opens.

150

1

 

 

100

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FFO

 

NO

 

FOF

SECOND

 

 

SECOND

 

 

DELAY

 

 

DELAY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Switch viewed in an upflow installation.

Adjustment Switch

SETTING FURNACE OPERATING MODE (*DH8,*ME8,AND

*MH8MODELS ONLY)

This furnace is designed to operate with either a single gas input rate or with two discrete gas input rates. The Mode DIP switch is used to select the single gas input rate or two discrete input rates.

Setting the Mode switch to “1 STG” forces the furnace to operate at the furnace’s highest input rate only. Operation is as described under Sequence of Operation (Integrated Ignition Control) – Mode DIP Switch is set to “1 STG” position.

30

START-UP PROCEDURE AND ADJUSTMENT

Setting the Mode switch to “2 STG” allows the furnace to operate at the furnace’s highest input AND at an input rate that is 75% of the highest input rate. For this mode of operation, the furnace operates at the low input rate for a pre-determined time period then steps to the high input rate. Operation is as described under Sequence of Operation (Integrated Ignition Control) – Mode DIP Switch is set to “2 STG” position.

The time period is determined by the 2nd Stg Dly DIP switch. Setting the 2nd Stg Dly DIP switch to 5 minutes fixes the delay period at 5 minutes. Setting the 2nd Stg Dly DIP switch to Auto enables an algorithm that calculates a delay period based on the heating cycle time and the total cycle time. The delay period can range from 1 minute to 12 minutes.

 

 

OFF ON

M

2 STG

 

 

 

 

 

1 STG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2ND STG DLY

5 MIN

 

 

 

 

 

AUTO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPERATIONAL CHECKS

WARNING

TO AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP.

AUXILIARY LIMIT CONTROL

Auto reset limits are located on or near the blower. To access this auxiliary limit, disconnect the electrical power and remove the blower door. The auxiliary limit control is designed to prevent furnace operation in case of main blower failure on horizontal installations. It may also open if the power supply is interrupted while the furnace is firing. The auxiliary limit control is suitable for both horizontal right and horizontal left installations. Regardless of airflow direction, it does not need to be relocated.

WARNING

TO AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP.

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 diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated control module.

INTEGRATEDCONTROLMODULE

BURNER FLAME

The burner flames should be inspected with the burner compartment door installed. Flames should be 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.

Check the burner flames for:

1.Good adjustment

2.Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

The integrated control module is an electronic device which controls all furnace operations. Responding to the thermostat, the module initiates and controls normal furnace operation, and monitors and addresses all safety circuits. If a potential safety concern is detected, the module 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 an automatic reset, temperature sensor. The limit guards against the overheating resulting from insufficient air passing over the heat exchanger.

AUXILIARY LIMIT

The auxiliary limit control is located either on or near the circulator blower and monitors heat exchanger compartment temperatures. The control is an automatic reset, temperature sensor. It guards against overheating resulting from insufficient air passing over the heat exchanger.

31

OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION

ROLLOUT LIMITS

DIAGNOSTIC CHART

The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are manualreset, temperature sensors. This limit guards against burner flames not being properly drawn into the heat exchanger.

PRESSURESWITCHES

The pressure switches are normally-open, negative air pres- sure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger.

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.

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 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 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 furnace away from 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.

Refer to the troubleshooting chart in the Appendix 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 refer to a specific code.

NOTE: To clear all alarm codes, depress the push button for 6 seconds.

FAULT RECALL

The ignition control is equipped with a momentary push button switch that can be used to display on the diagnostic LED the last five faults detected by the control. The control must be in Standby Mode (no thermostat inputs) to use the feature. Depress the pushbutton switch for approximately 2 seconds. Release the switch when the LED is turned off. The diagnostic LED will then display the flash codes associated with the last five detected faults. The order of display is the most recent fault to the least recent fault.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts. It is characterized by a non-func- tioning furnace and a one flash diagnostic LED code from the red LED. 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 1 - 20 seconds.

3.Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat for 1 - 20 seconds then reset to previous setting.

NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Diagnostic Chart for aid in determining the cause.

MAINTENANCE

WARNING

TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE IGNITER, HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER.

32

TROUBLESHOOTING & MAINTENANCE

ANNUALINSPECTION

FILTER REMOVAL

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.

Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage.

Filters.

FILTERS

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,

DISCONNECT ELECTRICAL POWER BEFORE REMOVING FILTERS. NEVER OPERATE FURNACE WITHOUT A FILTER INSTALLED BECAUSE DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAGE AND POSSIBLE FIRE.

A return air filter is not supplied with this furnace; however, there must be a means of filtering all of the return air. The installer will supply filter(s) at the time of installation.

FILTERMAINTENANCE

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.

WARNING

HIGH VOLTAGE!

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT

ELECTRICAL POWER TO THE FURNACE BEFORE

REMOVING THE FILTER OR PERFORMING ANY OTHER

MAINTENANCE.

Become familiar with filter location and procedures for removal, cleaning and replacing them. If help is needed, contact the installer of the furnace or a qualified servicer.

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 or instruction provided by the media or electronic air cleaner manufacturer 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. For further details, see your distributor.

INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS

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.

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 1 to 6 microamps at 115 volts.

IGNITER (QUALIFIEDSERVICER ONLY)

If the igniter and the surrounding air are at about 70°F and the igniter wires are not connected to any other electrical components, the resistance of the igniter should not exceed 75 ohms. If it does, the igniter should be replaced.

BURNERS

WARNING

TO PREVENT PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP.

Periodically during the heating season, make a visual check of the burner flames. Turn the furnace on at the thermostat. Wait a few minutes, since any dislodged dust will alter the normal flame appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.

33

TROUBLESHOOTING & MAINTENANCE

CLEANING (QUALIFIED SERVICER ONLY)

1.Shut off electric power and gas supply to the furnace.

2.Disconnect the rollout limit wires, flame sensor wire, and disconnect the igniter plug.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

3. Remove four (4) screws securing the burner box top.

CAUTION

THE IGNITER IS FRAGILE AND CAN BE EASILY DAMAGED. USE EXTREME CAUTION WHEN REMOVING THE BURNER BOX TOP.

4.Remove the screws securing the burners to the burner bracket. Remove the burners.

5.Use bottle brush to clean burner insert and inside of burner.

6.Replace burner (opposite of removal). Ensure burners are fully seated on burner bracket and are properly aligned. Replace burner box top. Reconnect wiring.

7.Turn on electric power and gas supply to the furnace.

8.Check furnace for proper operation. Refer to “Operational Checks” section to verify burner flame characteristics.

BEFORE LEAVING AN INSTALLATION

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.

REPAIR AND REPLACEMENT PARTS

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 Valve

Blower/Collector Box Gasket

Natural Gas Orifice

Primary Limit Switch

Propane Gas Orifice

Rollout Limit Switch

Burner

Auxiliary Limit Switch

Hot Surface Igniter

Heat Exchanger

Flame Sensor

Door Switch

Gas Manifold

Transformer

Ignition Control

Blower Wheel

Blower Mounting Bracket

Blower Housing

Pressure Switch

Blower Cutoff

Pressure Switch Hose

Blower Motor

Induced Draft Blower

Motor Mount Bracket

Collector Box

Capacitor

34

COMPONENT IDENTIFICATION

1 Tubular Heat Exchanger

2 Pressure Switch

3 Flue Pipe Connection

4 Induced Draft Blower

(Chimney Transition Top Shipped Loose)

 

5 Gas Line

Entrance

6 Gas Valve

7 Rollout Limit

8 Junction Box

9 Wiring Harness

Grommet

Gas Manifold

Gas Line Entrance

 

Inshot Burner

(Alternate)

 

Transformer

Circulator Blower

Blower Door

Interlock Switch

Integrated Control Module

1

Tubular Heat Exchanger

9

Wiring Harness Grommet

2

Pressure Switch

10

Gas Manifold

3

Flue Pipe Connection

11

Inshot Burner

4

Induced Draft Blower

12

Transformer

5

Gas Line Entrance

13

Integrated Control Module

6

Gas Valve

14

Blower Door Interlock Switch

7

Rollout Limit

15

Circulator Blower

8

Junction Box

16

Gas Line Entrance (Alternate)

35

COMPONENT IDENTIFICATION

Inshot Burner

1 Tubular Heat Exchanger

7 Rollout Limit

Gas Manifold

 

4 Induced Draft Blower

 

 

 

Gas Line Entrance

6

Gas Valve

 

 

 

 

(Alternate)

 

 

 

8 Junction Box

 

 

 

9 Wiring Harness

 

 

 

Grommet

5

Gas Line

 

2 Pressure Switch

 

Entrance

3 Flue Pipe Connection

 

 

(Chimney Transition Top Shipped Loose)

Transformer

Integrated Control Module

 

 

 

Circulator Blower

 

Blower Door

 

 

Interlock Switch

 

1

Tubular Heat Exchanger

9

Wiring Harness Grommet

2

Pressure Switch

10

Gas Manifold

3

Flue Pipe Connection

11

Inshot Burner

4

Induced Draft Blower

12

Transformer

5

Gas Line Entrance

13

Integrated Control Module

6

Gas Valve

14

Blower Door Interlock Switch

7

Rollout Limit

15

Circulator Blower

8

Junction Box

16

Gas Line Entrance (Alternate)

36

TROUBLESHOOTING CHART

 

Symptoms of

Associated

Fault

Possible

Corrective

Cautions

 

Abnormal Operation

LED Code2

Description(s)

Causes

 

Action

& Notes

 

• Furnace fails to operate.

 

NONE

• No 115 volt power to

• Manual disconnect switch

• Assure 115 and 24 volt

• Turn power OFF

 

• Integrated control module

 

 

 

furnace, or no 24

OFF, door switch open, or

power to furnace

prior to repair.

 

 

 

 

volt power to

24 volt wires improperly

integrated control

 

 

diagnostic LED provides

 

 

 

integrated control

connected or loose.

module.

 

 

 

no signal.

 

 

 

module.

• Blown fuse or circuit

• Check integrated control

• Replace integrated

 

 

 

 

 

 

control module

 

 

 

 

 

• Blown fuse or circuit

breaker.

module fuse (3A).

 

 

 

 

 

fuse with 3A

 

 

 

 

 

breaker.

 

Replace if necessary.

 

 

 

 

 

 

automotive fuse.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Check for possible

• Turn power OFF

 

 

 

 

 

 

 

shorts in 115 and 24 volt

prior to repair.

 

 

 

 

 

 

 

circuits.

Repair as

 

 

 

 

 

 

 

 

necessary.

 

 

• Furnace fails to operate.

 

 

 

• Integrated control

• Integrated control module

• Replace bad integrated

• Read precautions

 

 

 

 

 

module has an

has an internal fault.

in “Electrostatic

 

 

 

 

 

control module.

 

 

 

 

 

internal fault.

 

Discharge” section

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of manual.

 

 

 

 

 

 

 

 

 

 

• Furnace fails to operate.

 

 

 

• Furnace lockout due

• Failure to establish flame.

• Locate and correct

• Turn power OFF

 

• Integrated control module

1

 

to an excessive

Cause may be no gas to

gas interruption.

prior to repair.

 

 

 

 

number of ignition

burners, bad igniter or

• Replace or realign

 

 

diagnostic LED is

 

 

 

attempts. (3 total)1

igniter alignment, improper

igniter.

 

• Igniter is fragile,

 

flashing ONE (1) flash.

 

1 FLASH

• Auxiliary Limit Open

orifices, or coated/

• Check flame sense

handle with care.

 

 

 

 

 

oxidized or improperly

• Clean flame sensor

 

 

 

 

 

 

signal. Sand sensor

 

 

 

 

 

 

connected flame sensor.

 

 

 

 

 

 

if coated and/or

with steel wool.

 

 

 

 

 

 

 

 

 

 

 

 

 

• Loss of flame after

oxidized.

• See “Combustion

 

 

 

 

 

 

establishment. Cause may

• Check flue piping for

 

 

 

 

 

 

and Ventilation Air

 

 

 

 

 

 

be interrupted gas supply,

blockage, proper

 

 

 

 

 

 

Requirements” and

 

 

 

 

 

 

lazy burner flames

length, elbows, and

 

 

 

 

 

 

“Category I Venting

 

 

 

 

 

 

(improper gas pressure or

termination.

 

 

 

 

 

 

(Vertical Venting)”

 

 

 

 

 

 

restriction in flue or

 

 

 

 

 

 

 

 

• Verify proper

section for details.

 

 

 

 

 

 

improper induced draft

 

 

 

 

 

 

induced draft blower

 

 

 

 

 

 

 

blower performance.

• See Product Data

 

 

 

 

 

 

performance.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Bulletin for

 

 

 

 

 

 

• Insufficient conditioned air

• Check circulator

 

 

 

 

 

 

allowable rise

 

 

 

 

 

 

over the heat exchanger.

blower speed and

 

 

 

 

 

 

range and proper

 

 

 

 

 

 

Blocked filters, restrictive

performance.

 

 

 

 

 

 

circulator speed.

 

 

 

 

 

 

ductwork, improper

Correct speed or

 

 

 

 

 

 

 

 

 

 

 

 

 

circulator blower speed,

replace blower if

 

 

 

 

 

 

 

or failed circulator blower.

necessary.

 

 

 

 

 

 

 

 

 

 

 

• Furnace fails to operate.

 

 

 

• Pressure switch

• Induced draft blower

• Replace induced

• Turn power OFF

 

• Integrated control module

2

 

circuit is closed.

pressure switch contacts

draft blower

prior to repair.

 

 

 

 

 

sticking.

pressure switch.

• Replace pressure

 

diagnostic LED is

 

 

 

• Induced draft blower

 

 

 

 

flashing TWO (2)

2 FLASHES

is not operating.

• Shorts in pressure switch

• Repair short.

switch with proper

 

replacement part.

 

flashes.

 

circuit.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Induced draft blower

 

 

 

• Pressure switch

• Pressure switch hose

• Inspect

pressure switch

• Turn power OFF

 

runs continuously with

 

3

 

circuit not closed.

blocked, pinched or

hose. Repair, if neces-

prior to repair.

 

no further furnace

 

 

• Induced draft blower

connected improperly.

sary,

 

• See “Combustion

 

operation.

 

 

 

• Blocked flue or weak

• Inspect flue for blockage,

and Ventilation Air

 

• Integrated control module 3 FLASHES

is operating.

proper length, elbows,

Requirements” and

 

• If installed, manual

induced draft blower.

and termination.

“Category I Venting

 

diagnostic LED is

 

 

 

• Incorrect pressure switch

 

 

(Vertical Venting)”

 

flashing THREE (3)

 

 

 

reset limit switch is

• Correct pressure switch

section for details.

 

flashes.

 

 

 

open on Masonry

setpoint or malfunctioning

setpoint or contact

• Replace pressure

 

 

 

 

 

Vent Kit (MVK).

switch contacts.

motion.

 

 

 

 

 

 

 

switch with proper

 

 

 

 

 

 

 

• Tighten or correct wiring

 

 

 

 

 

 

• Loose or improperly

replacement part.

 

 

 

 

 

 

connected wiring.

connection.

• Replace masonry

 

 

 

 

 

 

• Inspect

masonry

 

 

 

 

 

 

• Blockage in flue or

vent kit limit switch

 

 

 

 

 

 

chimney and flue; remove

with correct

 

 

 

 

 

 

chimney.

blockage.

replacement part.

1Integrated control module will automatically attempt to reset from lockout after one hour.

2LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

37

TROUBLESHOOTING CHART

 

Symptoms of

Associated

Fault

Possible Causes

Corrective Action

Cautions

 

Abnormal Operation

LED Code2

Description(s)

& Notes

 

 

 

 

 

 

 

 

 

 

• Circulator blower runs

 

 

 

• Primary limit

• Insufficient conditioned air

• Check primary limit.

• Turn power OFF

 

continuously. No furnace

 

4

circuit is open.

over the heat exchanger.

Replace if necessary.

prior to repair.

 

operation.

 

 

 

 

Blocked filters, restrictive

• Check filters and

• Replace primary

 

• Integrated control module

 

 

 

 

ductwork, improper

ductwork for blockage.

 

4 FLASHES

 

circulator blower speed, or

Clean filters or remove

switch with proper

 

diagnostic LED is flashing

 

replacement part.

 

 

 

 

 

failed circulator blower.

obstruction.

 

FOUR (4) flashes.

 

 

 

 

• Faulty primary limit switch.

• Check circulator blower

• Replace blower

 

 

 

 

 

 

 

 

 

 

 

 

 

speed and performance.

with correct

 

 

 

 

 

 

 

Correct speed or replace

replacement part.

 

 

 

 

 

 

• Loose or improperly

blower if necessary.

 

 

 

 

 

 

 

 

• Tighten or correct wiring

 

 

 

 

 

 

 

 

connected wiring.

connection.

 

 

 

• Induced draft blower and

 

 

 

• Flame sensed

• Short to ground in flame

• Correct short at flame

• Turn power OFF

 

circulator blower runs

 

5

 

with no call for

sense circuit.

sensor or in flame

prior to repair.

 

continuously. No furnace

 

 

 

heat.

 

sensor wiring.

 

 

 

operation.

 

 

 

 

 

 

 

5 FLASHES

 

 

 

 

 

 

• Integrated control module

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

diagnostic LED is flashing

 

 

 

 

 

 

 

 

 

FIVE (5) flashes.

 

 

 

 

 

 

 

 

 

• Furnace fails to operate.

 

 

 

• Rollout limit open.

• Flame rollout.

• Check burners for proper

• See “Vent/Flue Pipe”

 

• Integrated control module

 

6

 

• Integrated control

 

alignment.

section for piping

 

 

 

 

• Check flue and air inlet

details.

 

 

 

 

 

 

diagnostic LED is flashing

 

 

 

module fuse is

• Misaligned burners,

piping for blockage,

• Replace induced

 

SIX (6) flashes.

6 FLASHES

blown.

blocked flue and/or air

proper length, elbows,

draft

blower with

 

 

 

inlet pipe, or failed

and termination. Correct

proper replacement

 

• No furnace operation.

 

 

 

 

 

 

 

 

 

induced draft blower.

as necessary.

part.

 

 

 

 

 

 

 

• Loose or improperly

• Check rollout limit. Replace

• Replace integrated

 

 

 

 

 

 

if necessary.

 

 

 

 

 

 

connected wiring.

• Check induced draft

control module fuse

 

 

 

 

 

 

 

with 3A automotive

 

 

 

 

 

 

 

blower for proper

 

 

 

 

 

 

 

fuse.

 

 

 

 

 

 

• Short in 24 volt AC

performance. Replace, if

 

 

 

 

 

 

necessary.

• Read precautions in

 

 

 

 

 

 

control circuits or safety

• Tighten or correct wiring

“Electrostatic

 

 

 

 

 

 

circuits.

Discharge” section

 

 

 

 

 

 

connection.

 

 

 

 

 

 

 

of manual.

 

 

 

 

 

 

 

• Repair short in 24 volt AC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

control/safety circuit(s).

• Replace rollout limit

 

 

 

 

 

 

• Faulty rollout limit.

• Replace integrated control

 

 

 

 

 

 

module fuse (3A).

with

correct

 

 

 

 

 

 

 

replacement part.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Normal furnace

 

 

 

• Flame sense

• Flame sensor is coated/

• Sand flame sensor.

• Turn power OFF

 

operation.

 

7

microamp signal is

oxidized.

 

prior to repair.

 

• Integrated control module

 

 

 

low.

• Flame sensor incorrectly

• Inspect for proper sensor

• Clean flame sensor

 

 

 

 

 

with steel wool.

 

 

 

 

 

positioned in burner

alignment.

 

diagnostic LED is

7 FLASHES

 

• See “Vent/Flue

 

 

flame.

 

 

flashing SEVEN (7)

 

 

 

 

 

 

 

• Lazy burner flame due to

• Compare current gas

Pipe” section for

 

flashes.

 

 

 

 

 

 

 

 

 

pressure to rating plate

piping details.

 

 

 

 

 

improper gas pressure or

 

 

 

 

 

 

info. Adjust as needed.

• See rating plate for

 

 

 

 

 

 

combustion air.

 

 

 

 

 

 

 

 

proper gas

 

 

 

 

 

 

 

 

pressure.

 

 

 

 

 

 

 

 

 

 

2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

38

TROUBLESHOOTING CHART

 

Symptoms of

Associated

Fault

Possible Causes

Corrective Action

Cautions

 

 

Abnormal Operation

LED Code2

Description(s)

& Notes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Furnace not operating.

 

 

 

 

• Problem with

• Improperly connected

• Check and correct wiring

• Turn power OFF

 

 

 

 

 

 

 

 

 

 

 

igniter circuit.

igniter.

from integrated control

prior to repair.

 

• Integrated control module

 

 

 

 

 

 

 

 

 

 

 

 

module to igniter.

 

 

 

 

 

 

 

 

 

 

 

 

diagnostic LED is

 

 

 

 

 

• Bad igniter.

• Replace bad igniter.

• Replace igniter

 

flashing EIGHT (8)

 

 

 

 

 

 

8 FLASHES

 

 

 

with proper

 

flashes.

 

 

 

 

 

 

 

 

 

 

 

replacement part.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Poor unit ground.

• Check and correct unit

• Read precautions

 

 

 

 

 

 

 

• Poor burner ground.

ground wiring.

in “Electrostatic

 

 

 

 

 

 

 

 

 

Discharge”

 

 

 

 

 

 

 

• Faulty integrated control

• Replace bad integrated

section of manual.

 

 

 

 

 

 

 

module.

control module.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Induced draft blower runs

 

 

 

 

• Polarity of 115

• Polarity of 115 volt AC

• Review wiring diagram to

• Turn power OFF

 

continuously. No furnace

 

C

 

or 24 volt

power to furnace or

correct polarity.

prior to repair.

 

operation.

 

 

 

 

power is

integrated control module

• Verify proper ground.

 

 

 

 

 

 

 

is reversed.

 

 

 

• Integrated control module

 

 

 

 

reversed.

 

Correct if necessary.

 

 

 

CONTINUOUS

 

• Red and blue wires to

• Reverse red and blue

 

 

 

diagnostic LED is flashing

 

 

 

 

continuously.

FLASHING

 

transformer are reversed.

wires connected to

 

 

 

 

 

 

 

 

• Poor unit ground.

transformer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• LED is steady on

STEADY

• Normal operation.

 

 

 

 

2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

39

BLOWER PERFORMANCE DATA

*M(H/S)8

(CFM & Temperature Rise vs. External Static Pressure)

 

Model

Motor

Tons AC

 

 

EXTERNAL STATIC PRESSURE (Inches Water Column)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

at 0.5"

0.1

0.2

0.3

0.4

 

0.5

 

0.6

0.7

0.8

Heating Speed

Speed

 

 

As Shipped

 

ESP

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

CFM

CFM

 

 

 

HIGH

3.0

1521

----

1466

----

1414

----

1373

 

----

1298

 

----

1243

1164

1075

*M(H/S)80403A***

MED

2.5

1160

26

1160

26

1132

26

1121

 

26

1082

 

27

1042

997

925

(MEDIUM)

MED-LO

2.0

961

31

955

31

948

31

932

 

32

913

 

33

882

821

803

 

 

 

LOW

1.5

781

38

785

38

781

38

773

 

38

761

 

32

745

716

668

 

 

 

HIGH

3.0

1422

31

1352

33

1307

34

1197

 

37

1157

 

38

1092

1075

983

*M(H/S)80603A***

MED

2.5

1098

40

1081

41

1051

42

1039

 

43

1021

 

44

983

924

868

(MEDIUM)

MED-LO

2.0

919

48

913

49

892

50

847

 

----

829

 

----

818

792

728

 

 

 

LOW

1.5

758

----

741

----

741

----

733

 

----

699

 

----

677

649

626

 

 

 

HIGH

4.0

2134

21

2100

21

2042

22

1975

 

23

1883

 

24

1786

1700

1601

*M(H/S)80604B***

MED

3.5

1668

27

1663

27

1656

27

1645

 

27

1616

 

28

1549

1492

1391

(MEDIUM)

MED-LO

3.0

1419

31

1426

31

1426

31

1432

 

31

1419

 

31

1378

1328

1261

 

 

 

LOW

2.5

1134

39

1145

39

1166

38

1171

 

38

1160

 

38

1144

1111

1071

 

 

 

HIGH

3.0

1607

37

1572

38

1547

39

1498

 

40

1448

 

41

1390

1302

1222

*M(H/S)80803B***

MED

2.5

1159

51

1156

51

1145

52

1127

 

53

1108

 

53

1075

1033

957

(MEDIUM)

MED-LO

2.0

938

63

916

65

916

65

900

 

----

889

 

----

865

829

785

 

 

 

LOW

1.5

785

----

766

----

743

----

730

 

----

709

 

----

683

666

604

 

 

 

HIGH

4.0

2051

----

1983

----

1895

----

1812

 

----

1725

 

----

1627

1530

1439

*M(H/S)80804B***

MED

3.5

1736

----

1708

35

1652

36

1611

 

37

1540

 

38

1475

1394

1307

(MEDIUM)

MED-LO

3.0

1693

35

1668

36

1459

41

1429

 

41

1389

 

43

1339

1274

1204

 

 

 

LOW

2.5

1200

49

1185

50

1180

50

1173

 

51

1158

 

51

1125

1125

1080

 

 

 

HIGH

5.0

2290

----

2229

----

2155

----

2047

 

----

1960

 

----

1837

1712

1584

*M(H/S)80805C***

MED

4.0

1852

----

1820

----

1777

----

1719

 

---

1641

 

36

1567

1469

1382

(MEDIUM)

MED-LO

3.5

1615

37

1592

37

1556

38

1516

 

39

1470

 

40

1405

1346

1235

 

 

 

LOW

3.0

1290

46

1285

46

1265

47

1235

 

48

1214

 

49

1174

1044

904

 

 

 

HIGH

5.0

2323

----

2225

----

2120

35

2040

 

36

1974

 

38

1801

1688

1577

*M(H/S)81005C***

MED

4.0

1858

40

1847

40

1799

41

1744

 

42

1674

 

44

1577

1493

1399

(MEDIUM)

MED-LO

3.5

1596

46

1587

47

1571

47

1552

 

48

1493

 

50

1397

1326

1217

 

 

 

LOW

3.0

1291

57

1272

58

1261

59

1257

 

59

1205

 

61

1168

1118

1060

 

 

 

HIGH

5.0

2469

----

2389

----

2300

----

2223

 

40

2131

 

42

2027

1902

1786

*M(H/S)81205D***

MED

4.0

1575

56

1558

57

1545

58

1513

 

59

1500

 

59

1419

1354

1271

(MEDIUM)

MED-LO

3.5

1402

63

1380

64

1343

66

1319

 

67

1296

 

69

1245

1183

1106

 

 

 

LOW

3.0

1200

----

1186

----

1161

----

1127

 

----

1082

 

----

1042

995

926

 

 

 

HIGH

5.0

2469

42

2389

43

2300

45

2223

 

47

2131

 

49

2027

1902

1786

*M(H/S)81405D***

MED

4.0

1575

66

1558

67

1545

67

1513

 

69

1500

 

69

1419

1354

1271

(MEDIUM)

MED-LO

3.5

1402

----

1380

----

1343

----

1319

 

----

1296

 

----

1245

1183

1106

 

 

 

LOW

3.0

1200

----

1186

----

1161

----

1127

 

----

1082

 

----

1042

995

926

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40

BLOWER PERFORMANCE DATA

*(D/H)S8

(CFM & Temperature Rise vs. External Static Pressure)

 

Model

Motor

Tons AC

 

 

 

EXTERNAL STATIC PRESSURE (Inches Water Column)

 

 

 

 

 

at 0.5"

0.1

 

 

0.2

 

0.3

 

0.4

0.5

 

0.6

 

0.7

0.8

Heating Speed

Speed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

As Shipped

 

ESP

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

CFM

CFM

 

 

 

HIGH

3.0

1353

 

----

 

1290

 

----

1246

 

----

1199

25

1149

 

26

1116

 

1116

1099

GDS80403A***

MED

2.5

1183

 

25

 

1113

 

27

1098

 

27

1052

28

1039

 

29

1006

 

1012

969

 

(MEDIUM)

MED-LO

2.0

980

 

30

 

946

 

31

920

 

32

900

33

896

 

33

885

 

855

804

 

 

 

LOW

1.5

778

 

38

 

762

 

39

738

 

40

746

40

738

 

40

717

 

696

678

 

 

 

HIGH

3.0

1290

 

34

 

1236

 

36

1194

 

37

1166

38

1176

 

38

1166

 

1108

1029

GDS80603A***

MED

2.5

1139

 

39

 

1090

 

41

1035

 

43

1063

42

1063

 

42

1020

 

962

895

 

(MEDIUM)

MED-LO

2.0

962

 

46

 

927

 

48

925

 

48

941

47

909

 

49

877

 

834

779

 

 

 

LOW

1.5

787

 

56

 

776

 

57

763

 

58

744

60

723

 

----

690

 

641

581

 

 

 

HIGH

4.0

2128

 

----

 

2063

 

----

2001

 

----

1927

----

1824

 

----

1726

 

1628

1529

GDS80804B***

MED

3.5

1840

 

----

 

1788

 

----

1745

 

----

1689

35

1625

 

36

1550

 

1470

1364

 

(MEDIUM)

MED-LO

3.0

1602

 

37

 

1558

 

38

1543

 

38

1493

40

1455

 

41

1402

 

1328

1239

 

 

 

LOW

2.5

1277

 

46

 

1252

 

47

1244

 

48

1229

48

1214

 

49

1179

 

1141

1079

 

 

 

HIGH

5.0

2405

 

----

 

2361

 

----

2250

 

----

2161

-----

2037

 

36

1937

 

1808

1689

GDS81005C***

MED

4.0

1880

 

39

 

1838

 

40

1794

 

41

1734

43

1677

 

44

1568

 

1510

1401

 

(MEDIUM)

MED-LO

3.5

1659

 

45

 

1630

 

45

1587

 

47

1537

48

1492

 

50

1445

 

1368

1287

 

 

 

LOW

3.0

1472

 

50

 

1454

 

51

1404

 

53

1366

54

1326

 

56

1300

 

1228

1139

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(CFM & Temperature Rise vs. External Static Pressure)

 

Model

Motor

Tons AC

 

 

 

 

 

EXTERNAL STATIC PRESSURE (Inches Water Column)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

at 0.5"

0.1

 

0.2

 

0.3

 

0.4

 

0.5

 

0.6

0.7

0.8

Heating Speed

Speed

 

 

 

 

 

 

As Shipped

 

ESP

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

 

 

 

HIGH

3.0

1739

 

----

1656

 

----

1601

 

----

1551

 

----

1513

 

20

1460

22.8

1413

23.6

1353

24.6

GHS80403A***

MED

2.5

1422

 

21

1399

 

21

1378

 

22

1350

 

22

1305

 

23

1275

26.1

1220

27.3

1178

28.3

 

(MEDIUM)

MED-LO

2.0

1207

 

25

1213

 

24

1197

 

25

1169

 

25

1158

 

26

1131

29.5

1103

30.2

1068

31.2

 

 

 

LOW

1.5

991

 

30

980

 

30

958

 

31

950

 

31

937

 

32

924

36.1

910

36.6

874

38.1

 

 

 

HIGH

4.0

2097

 

21

2068

 

21

2012

 

22

1939

 

23

1869

 

24

1795

28.9

1718

30.2

1631

31.8

GHS80604B***

MED

3.5

1596

 

28

1566

 

28

1534

 

29

1492

 

30

1445

 

31

1401

37

1354

38.3

1288

40.3

 

(MEDIUM)

MED-LO

3.0

1380

 

32

1356

 

33

1328

 

33

1303

 

34

1274

 

35

1239

41.8

1192

43.5

1127

46

 

 

 

LOW

3.0

1239

 

36

1191

 

37

1165

 

37

1133

 

39

1104

 

40

1082

47.9

1040

49.9

996

52.1

 

 

 

HIGH

5.0

2382

 

----

2315

 

----

2234

 

----

2158

 

----

2078

 

----

1971

33.8

1866

35.7

1762

37.8

GHS80805C***

MED

4.0

1622

 

37

1603

 

37

1583

 

37

1556

 

38

1516

 

39

1482

45

1422

46.9

1359

49.1

 

(MEDIUM)

MED-LO

3.5

1436

 

41

1391

 

43

1387

 

41

1356

 

44

1325

 

45

1279

52.1

1239

53.8

1180

56.5

 

 

 

LOW

3.0

1240

 

48

1214

 

49

1191

 

50

1157

 

51

1120

 

53

1083

61.6

1052

63.4

1025

65

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

41

BLOWER PERFORMANCE DATA

GME8

(CFM & Temperature Rise vs. External Static Pressure)

 

Model

 

 

 

Tons AC

 

 

 

EXTERNAL STATIC PRESSURE (Inches Water Column)

 

 

 

 

 

Motor Speed

at 0.5"

0.1

 

 

0.2

 

0.3

 

0.4

 

0.5

 

0.6

 

0.7

0.8

Heating Speed

 

 

 

 

 

 

 

As Shipped

 

 

ESP

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

RISE

CFM

CFM

CFM

 

 

 

T1

- YELLOW

1.5

875

 

----

 

793

 

----

736

 

----

674

 

----

592

 

----

556

 

509

460

 

 

 

T2

- RED

2.0

1032

 

43

 

965

 

46

914

 

49

861

 

----

810

 

----

756

 

712

659

GME80603B***

T3 - ORANGE

2.5

1217

 

37

 

1153

 

39

1098

 

40

1051

 

42

1009

 

44

964

 

918

877

 

 

 

T4

- BLUE

3.0

1365

 

33

 

1313

 

34

1268

 

35

1221

 

36

1172

 

38

1129

 

1086

1054

 

 

 

T5

- BLACK

3.5

1549

 

29

 

1505

 

30

1460

 

30

1420

 

31

1378

 

32

1350

 

1305

1268

 

 

 

T1

- YELLOW

2.5

1268

 

47

 

1198

 

49

1151

 

51

1092

 

54

1041

 

57

988

 

932

883

 

 

 

T2

- RED

3.0

1362

 

44

 

1305

 

45

1261

 

47

1212

 

49

1170

 

51

1121

 

1074

1021

GME80805C***

T3 - ORANGE

3.5

1576

 

38

 

1519

 

39

1473

 

40

1426

 

42

1398

 

42

1341

 

1290

1252

 

 

 

T4

- BLUE

4.0

1755

 

----

 

1711

 

35

1657

 

36

1627

 

36

1579

 

38

1548

 

1502

1463

 

 

 

T5

- BLACK

5.0

2183

 

----

 

2128

 

----

2094

 

----

2060

 

----

2014

 

----

1992

 

1944

1847

 

 

 

T1

- YELLOW

3.0

1466

 

51

 

1415

 

52

1357

 

55

1306

 

57

1248

 

59

1202

 

1144

1088

 

 

 

T2

- RED

3.5

1642

 

45

 

1596

 

46

1552

 

48

1499

 

49

1449

 

51

1388

 

1352

1306

GME81005C***

T3 - ORANGE

4.0

1750

 

42

 

1750

 

42

1707

 

43

1667

 

44

1610

 

46

1574

 

1531

1486

 

 

 

T4

- BLUE

4.0

1870

 

40

 

1805

 

41

1782

 

42

1737

 

43

1701

 

44

1656

 

1606

1571

 

 

 

T5

- BLACK

5.0

2297

 

----

 

2297

 

----

2224

 

----

2106

 

35

2014

 

37

1896

 

1813

1669

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Notes:

CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two return filters, this chart assumes both filters are installed.

All furnaces ship as high-speed cooling and medium-speed heating. Installer must adjust blower cooling and heating speed as needed.

For most jobs, about 375 - 400 CFM per ton when cooling is desirable.

INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.

This chart is for information only. For satisfactory operation, external static pressure should not exceed value shown on the rating plate.

The above chart is for U.S. furnaces installed at 0-2000 feet. At higher altitudes, a properly derated unit will have approximately the same

 

temperature rise at a particular CFM, while ESP at the CFM will be lower.

Factory Motor Speed Setting: T1 = 1st Stage Ht, T2 = 2nd Stage Ht, T5 = Cooling.

Temperature rise data is based on 2nd-stage heat. First-stage heat is 75% of rise indicated above.

42

*(M, D, H)S8 WIRING DIAGRAM

UNIT.

MAY

 

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO

CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

 

 

 

 

 

BOX

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

43

GME8 WIRING DIAGRAM

UNIT.

MAY

 

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO

CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

 

 

 

 

 

WARNING:DISCONNECTPOWERBEFORE

SERVICING.WIRINGTOUNITMUSTBE

PROPERLYPOLARIZEDANDGROUNDED.

24VAC HUMIDIFIER

 

 

 

C

G R

W

Y

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

G

L

 

 

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

AUTO

5MIN

N

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

1STG

2STG

MODE

 

 

 

 

 

 

 

150SEC

100SEC

HT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

 

 

 

 

 

10

11

12

 

 

 

 

 

FF

DLY

 

 

 

 

WH

 

 

 

 

 

 

 

7

8

9

 

 

 

 

BL

 

 

 

 

 

 

 

 

 

 

 

 

 

4

5

6

FUSE

BR

 

 

 

DIAGNOSTIC LED

 

 

1

2

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SEENOTE6

 

 

 

 

 

 

 

 

 

 

 

 

INTEGRATED

 

 

 

 

 

 

 

 

 

 

 

 

CONTROLMODULE

 

 

 

-HEATHI

 

 

 

 

 

 

 

 

FS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

RD

RD

 

 

 

BL

 

 

 

 

 

 

 

 

 

PU

 

 

RD

 

 

 

 

COOL

 

 

 

 

NEUTRALLINE

 

 

 

 

 

 

 

 

YL

YL

 

2

 

OR

 

 

 

H-HEATLO H-

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

WH

 

XFMR-H LINE-H EAC-H

 

 

 

 

 

 

 

 

PU

 

 

 

 

 

 

 

 

 

PARK

 

 

 

 

 

 

 

 

 

BK

 

 

 

 

 

 

BK

 

24V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

XFMR

 

 

 

 

 

 

 

 

 

 

 

WH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BK

 

 

 

 

 

 

 

 

 

 

 

 

GR

 

 

 

 

 

 

 

 

 

 

 

WH

BK

 

 

 

DOORSWITCH

 

 

 

 

 

 

 

 

 

 

SWITCHLOCATEDINBLOWER

 

 

 

 

 

 

 

 

 

 

COMPARTMENTONSOMEMODELS

 

 

 

 

 

 

RD

 

 

RD

 

 

 

 

 

 

 

WH

WH

 

 

PRIMARYLIMIT

 

 

 

 

 

 

 

 

 

 

 

RD

 

 

 

 

 

 

 

 

 

 

 

 

YL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WH

 

 

 

 

PM

C

HI

 

 

 

 

 

 

 

 

 

 

HOT

 

1

3

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SURFACE

2STAGE

 

 

 

 

 

 

 

 

 

 

 

IGNITER

 

 

 

 

 

 

 

 

 

 

 

GASVALVE

 

 

 

 

 

 

 

 

 

 

 

 

(HONEYWELL)

 

 

 

 

 

 

 

 

 

 

 

 

PU

 

 

 

 

 

 

 

 

 

 

 

 

PU

 

 

 

PU

 

 

 

 

 

 

 

 

 

 

 

 

ROLLOUTLIMITS

 

 

 

 

 

 

 

 

 

 

 

(SINGLECONTROLONSOMEMODELS)

 

 

 

 

 

 

 

 

 

HUMIDIFIER

 

INTEGRATED

 

 

 

 

 

 

 

CONTROLMODULE

 

 

 

 

XFMR(6)

GND

 

 

 

 

 

 

 

 

 

 

 

 

 

GND(8)

 

C2

 

 

 

 

 

MVC(9)

 

GAS

 

 

 

 

MVH(12)

 

HI

VALVE

 

 

 

 

 

 

 

 

 

 

 

MVL(2)

 

M1

 

 

C

 

 

 

IDBLOWER

 

 

 

 

 

 

 

 

 

 

 

AUXILIARY

 

PRESSURE

 

CONNECTIONSTHERMOSTAT24V

 

 

 

LIMITCONTROLS

 

SWITCH

 

G

 

PS(10)

 

C

NO

 

Y

TO

PSO(4)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MICRO

HLI(7)

 

 

 

 

 

W

 

HLO(1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AUTORESET

 

 

R

 

 

 

 

PRIMARY

 

 

 

RO2(11)

 

 

LIMIT

 

 

 

 

 

 

AUXILIARY

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

LIMITS

 

 

 

RO1(5)

 

 

 

 

 

 

 

 

MANUALRESETROLLOUT

 

 

 

 

 

LIMITCONTROL(S)

 

 

 

 

XFMR(3)

(SINGLECONTROLONSOMEMODELS)

 

 

 

 

24VAC

 

 

 

 

 

 

 

 

 

BR

 

 

 

 

 

40VA

 

 

 

 

 

 

TRANSFORMER

 

 

 

XFMR-H

 

115VAC

 

XFMR-N

 

 

 

 

 

FLAMESENSOR

 

 

 

 

FP

HOTSURFACE

 

 

 

 

 

 

 

 

 

 

 

 

 

IGNITER

 

 

 

 

 

IGN

 

 

IGN-N

 

(N)WH

(HI)BK HI)(MEDBL OR(MED) LOW)(MEDRD (LOW)YL

INTEGRATED

BR WH BL

BLOWER

CIRCULATOR

MODULECONTROL

IND

H

L

E O

 

 

A

 

 

T-

 

 

H

COOL-H

I

-H

 

H

 

 

T

A

E

 

 

 

H

 

 

 

ID

BLWR IND-N

CIRCULATOR

BLWR CIR-N

MODULECONTROLINTEGRATED

 

 

 

 

ELECTRONIC

 

15PINPLUG

 

 

EAC-H

AIRCLEANER

EAC-N

ONSOMEMODELS

 

 

 

 

 

BLOWERCOMPARTMENT

LINE-H

 

 

LINE-N

BURNERCOMPARTMENT

 

JUNCTIONBOX

 

 

 

 

 

 

24VAC

 

DOOR

 

 

 

 

HUMIDIFIER

SWITCH

 

 

 

NO

C

 

 

 

 

 

OR

 

 

WARNING:

 

 

 

 

 

DISCONNECTPOWER

 

 

YL PRESSURE

YL

 

DISCONNECT

BEFORESERVICING.

 

 

 

SWITCH

 

WIRINGTOUNIT

 

 

 

 

 

 

MUSTBE

 

 

 

 

 

 

PROPERLY

 

 

 

 

WH

 

POLARIZED

 

 

 

BK

 

ANDGROUNDED.

L

GND

N

 

 

 

 

 

 

OVERCURRENTPROTECTIONDEVICE

BK

 

 

 

 

 

 

 

 

 

JUNCTION

 

 

 

W

 

 

BOX

 

 

 

H

 

 

 

 

 

 

 

 

 

LINE-N

 

 

 

 

 

 

GND

 

 

 

 

 

 

LINEH

 

 

 

INDUCEDDRAFT

 

 

 

 

 

BLOWER

 

TO115VAC/1/60HZ

 

 

 

 

 

 

 

 

 

FLAME

 

 

POWERSUPPLYWITH

 

 

 

 

 

OVERCURRENTPROTECTION

 

 

 

SENSOR

 

 

 

 

 

 

 

DEVICE

 

 

 

 

 

 

 

 

 

0

STEADYON=NORMALOPERATION

 

OFF =CONTROLFAILURE

1

1FLASH =

SYSTEMLOCKOUT(RETRIES/RECYCLESEXCEEDED)

2

2FLASHES=PRESSURESWITCHSTUCKCLOSED

3

3FLASHES=PRESSURESWITCHSTUCKOPEN

4

4FLASHES=OPENHIGHLIMIT

5

5FLASHES=FLAMESENSEWITHOUTGASVALVE

6

6FLASHES= OPENROLLOUTOROPENFUSE

7

7FLASHES=LOWFLAMESIGNAL

8

8FLASHES=CHECKIGNITERORIMPROPERGROUND

C

RAPIDFLASHES=REVERSED115VACPOLARITY/VERIFYGND

LOWVOLTAGE(24V)

EQUIPMENTGND

LOWVOLTAGEFIELD

FIELDGND

 

HIVOLTAGE(115V)

FIELDSPLICE

HIVOLTAGEFIELD

SWITCH(TEMP.)

JUNCTION

IGNITER

TERMINAL

 

INTERNALTO

SWITCH(PRESS.)

 

INTEGRATEDCONTROL

OVERCURRENT

PLUGCONNECTION

PROT.DEVICE

 

 

 

NOTES:

 

COLORCODES:

PKPINK

1.SETHEATANTICIPATORONROOMTHERMOSTATAT0.7AMPS.

 

2.MANUFACTURER'SSPECIFIEDREPLACEMENTPARTSMUSTBEUSEDWHENSERVICING.

 

YL YELLOW

BRBROWN

 

3.IFANYOFTHEORIGINALWIREASSUPPLIEDWITHTHEFURNACEMUSTBEREPLACED,ITMUSTBEREPLACEDWITH

OR ORANGE

WH WHITE

WIRINGMATERIALHAVINGATEMPERATURERATINGOFATLEAST105°C.USECOPPER

CONDUCTORSONLY.

PUPURPLE

BLBLUE

4.BLOWERSPEEDSSHOULDBEADJUSTEDBYINSTALLERTOMATCHTHEINSTALLATIONREQUIREMENTSSOASTO

PROVIDETHECORRECTHEATINGTEMPERATURERISEANDTHECORRECTCOOLINGCFM.(SEESPECSHEETFORAIR

GRGREEN

GYGRAY

FLOWCHART)

 

BKBLACK

RD RED

5.UNITMUSTBEPERMANENTLYGROUNDEDANDCONFORMTON.E.C.ANDLOCALCODES.

 

 

 

6.TORECALLTHELAST5FAULTS,MOSTRECENTTOLEASTRECENT,DEPRESSSWITCHFORMORETHAN2SECONDS

 

 

WHILEINSTANDBY(NOTHERMOSTATINPUTS).

 

 

 

 

0140F00658 REV.A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

44

*(M,D)H8 WIRING DIAGRAM

UNIT.

MAY

 

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO

CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

 

 

 

 

 

WARNING:DISCONNECT POWER BEFORE

SERVICING.WIRING TO UNIT MUST BE

PROPERLY POLARIZED AND GROUNDED.

24 VAC

HUMIDIFIER

 

 

C

G R W Y

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

 

G

L

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

S

 

 

 

 

 

 

 

 

AUTO

5 MIN

 

D

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

1 STG

2 STG

MODE

 

 

 

 

 

 

 

150 SEC

100 SEC HT

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

 

 

 

 

 

10

11

12

 

 

 

 

FF

DLY

 

 

WH

 

 

 

 

 

 

7

8

9

 

 

 

BL

 

 

 

 

 

 

 

 

 

 

 

 

4

5

6

FUSE

BR

 

 

 

DIAGNOSTIC LED

 

1

2

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SEE NOTE 6

 

 

 

 

 

 

 

 

 

 

 

 

INTEGRATED

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL MODULE

 

 

 

-HIHEAT

 

 

 

 

 

 

 

FS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

RD

RD

 

 

BL

 

 

 

COOL

 

 

 

 

PU

 

 

RD

 

 

 

 

 

 

 

LINENEUTRAL

 

 

 

 

 

 

 

 

YL

YL

2

OR

 

 

 

H-LOHEATH-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

AUXILIARY

LIMITS

BR

 

 

 

HUMIDIFIER

INTEGRATED

 

 

 

 

 

 

CONTROL MODULE

 

 

 

XFMR (6)

GND

 

 

 

 

 

 

 

 

 

 

GND (8)

 

C2

 

 

 

 

MVC (9)

 

GAS

 

 

 

MVH (12)

HI

VALVE

 

 

 

 

 

 

 

 

MVL (2)

 

M1

 

C

 

 

 

ID BLOWER

 

 

 

 

 

 

 

 

 

 

AUXILIARY

PRESSURE

24VTHERMOSTATCONNECTIONS

 

 

 

LIMIT CONTROLS

SWITCH

G

 

PS (10)

 

C

NO

 

 

 

 

Y

TO

PSO (4)

 

 

 

 

 

 

 

 

 

 

MICRO

HLI (7)

 

 

 

 

W

 

HLO (1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AUTO RESET

 

R

 

 

 

 

PRIMARY

 

 

RO2 (11)

 

LIMIT

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

RO1 (5)

 

 

 

 

 

 

 

MANUAL RESET ROLLOUT

 

 

 

 

LIMIT CONTROL(S)

 

 

 

XFMR (3)

(SINGLE CONTROL ON SOME MODELS)

 

 

 

 

24 VAC

 

 

 

 

 

 

 

 

 

 

 

 

40 VA

 

 

 

 

 

TRANSFORMER

 

 

XFMR-H

 

 

115 VAC

XFMR-N

 

 

 

 

 

FLAME SENSOR

 

 

 

FP

 

HOT SURFACE

 

 

 

 

 

 

 

 

 

 

 

IGNITER

 

PU

WH

XFMR-H LINE-H EAC-H

 

 

BK

WH(N)

OR(MEDLOW) RD(LOW)

 

 

 

 

 

PARK

 

 

 

 

INTEGRATEDCONTROLMODULE

BK

24V

BR WH BL

CICULATOR BLOWER

CAP

BK(HI) BL(MED)

BR BR

 

 

 

 

 

 

 

115V

 

 

 

 

 

 

 

XFMR

 

 

 

 

 

 

WH

 

 

 

 

 

 

 

IGN

IND

H

L

E O

 

 

A

 

 

T-

 

 

H

COOL-H

I

-H

 

H

 

 

T

A

E

 

 

 

H

 

 

 

IGN-N

ID

BLWR IND-N

CIRCULATOR

BLWR CIR-N

INTEGRATEDCONTROLMODULE

 

 

 

 

 

BK

 

 

 

 

 

 

ELECTRONIC

 

 

 

 

GR

 

 

 

15 PIN PLUG

 

 

EAC-H

AIR CLEANER

EAC-N

 

 

 

 

 

 

 

ON SOME MODELS

 

 

 

 

 

 

 

 

 

 

 

BLOWER COMPARTMENT

LINE-H

 

 

LINE-N

 

 

 

 

 

 

 

BURNER COMPARTMENT

 

JUNCTION BOX

 

 

 

 

 

 

 

 

 

 

 

 

 

WH

BK

 

 

 

DOOR SWITCH

 

 

24 VAC

DOOR

 

 

 

 

 

 

 

 

 

HUMIDIFIER

SWITCH

 

 

 

 

 

 

 

SWITCH LOCATED IN BLOWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMPARTMENT ON SOME MODELS

 

NO

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RD

 

RD

OR

 

 

 

WARNING:

 

 

 

 

 

 

 

 

 

 

 

DISCONNECT POWER

 

 

 

 

 

 

 

 

 

 

 

 

DISCONNECT

 

 

 

 

 

 

 

YL

PRESSURE

YL

 

 

WH

WH

 

 

 

 

BEFORE SERVICING.

 

 

 

 

 

 

PRIMARY LIMIT

 

SWITCH

 

WIRING TO UNIT

 

 

 

 

 

 

RD

 

 

 

 

 

 

 

 

 

 

 

 

 

YL

 

 

 

 

MUST BE

 

 

 

 

 

 

 

 

 

 

 

 

 

PROPERLY

 

 

 

 

 

 

 

 

YL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POLARIZED

 

 

 

 

 

 

 

 

 

 

 

 

WH

 

 

 

 

 

 

 

 

 

 

 

 

BK

 

AND GROUNDED.

L

GND

N

 

 

 

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BL

 

 

 

 

OVERCURRENT PROTECTION DEVICE

 

 

 

 

 

 

WH

BK

 

 

 

 

 

 

 

 

 

 

 

PM

C

HI

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

JUNCTION

 

 

 

 

 

 

 

1

3

2

 

 

 

 

 

 

 

 

 

 

HOT

WH

 

 

 

BOX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SURFACE

2 STAGE

 

 

 

 

LINE-N

 

 

 

 

 

 

IGNITER

 

 

 

 

 

 

 

 

 

 

GAS VALVE

 

 

 

 

GND

 

 

 

 

 

 

 

(HONEY WELL)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LINE H

 

 

 

 

 

 

PU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INDUCED DRAFT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLOWER

 

TO 115 VAC/ 1/60HZ

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PU

 

 

PU

FLAME

 

 

 

POWER SUPPLY WITH

 

 

 

 

 

 

 

 

 

 

 

 

 

OVERCURRENT PROTECTION

 

 

 

 

 

 

 

 

 

SENSOR

 

 

 

 

 

 

 

 

 

ROLLOUT LIMITS

 

 

 

DEVICE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(SINGLE CONTROL ON SOME MODELS)

 

 

 

 

 

 

 

 

0 STEADY ON = NORMAL OPERATION

 

 

 

 

LOW VOLTAGE (24V)

 

EQUIPMENT GND

 

OFF

= CONTROL FAILURE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

1 FLASH =

SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED)

 

 

LOW VOLTAGE FIELD

 

FIELD GND

2 2 FLASHES = PRESSURE SWITCH STUCK CLOSED

 

 

 

HI VOLTAGE (115V)

 

FIELD SPLICE

3 3 FLASHES = PRESSURE SWITCH STUCK OPEN

 

 

 

HI VOLTAGE FIELD

 

 

 

 

 

 

 

4 4 FLASHES = OPEN HIGH LIMIT

 

 

 

 

 

 

SWITCH (TEMP.)

 

 

 

 

 

 

JUNCTION

 

5 5 FLASHES = FLAME SENSE WITHOUT GAS VALVE

 

 

 

 

 

 

IGNITER

 

 

 

 

TERMINAL

 

 

 

6 FLASHES = OPEN ROLLOUT OR OPEN FUSE

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH (PRESS.)

7 7 FLASHES = LOW FLAME SIGNAL

 

 

 

 

INTERNAL TO

 

 

 

 

 

 

 

 

8 8 FLASHES = CHECK IGNITER OR IMPROPER GROUND

 

 

INTEGRATED CONTROL

 

OVERCURRENT

 

 

 

PLUG CONNECTION

 

PROT. DEVICE

C RAPID FLASHES = REVERSED 115 VAC POLARITY/VERIFY GND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTES:

 

 

 

 

 

 

 

 

COLOR CODES:

PK PINK

 

 

1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.

 

 

 

 

 

2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING.

 

YL YELLOW

BR BROWN

 

 

 

3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE

 

 

OR ORANGE

WH WHITE

 

REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE

 

PU PURPLE

BL BLUE

 

RATING OF AT LEAST 105 °C. USE COPPER CONDUCTORS ONLY.

 

 

 

 

4. BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION

 

GR GREEN

 

GY GRAY

 

 

 

 

REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE

BK BLACK

 

RD RED

 

 

 

CORRECT COOLING CFM. (SEE SPEC SHEET FOR AIR FLOW CHART)

 

 

 

 

 

 

 

 

 

5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.

 

0140F00662 REV. A

 

 

6. TO RECALL THE LAST 5 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH

 

 

 

FOR MORE THAN 2 SECONDS WHILE IN STANDBY(NO THERMOSTAT INPUTS).

 

 

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Goodman Manufacturing Company, L.P.

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com

© 2009-2010 Goodman Manufacturing Company, L.P.

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