Amana GUCA090AX50, GUCA070AX30, GUCA115AX50, GCCA045AX30, GCCA070AX30 Service Instructions Manual

...

Service

Instructions

40" 90% Condensing Gas Furnaces GUCA, GCCA & Accessories

Model and Manufacturing

numbers listed on page 4.

This manual is to be used by qualified HVAC technicians only. Amana does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.

Heating n Air Conditioning

higher standard of comfor

RS6610002

Revision 0

October 1998

INDEX

Important Safety Information ................................................................................. 3

Product Identification ............................................................................................. 4-13

Furnace Specifications .......................................................................................... 14-15

Blower Performance Specifications....................................................................... 16-18

Combustion and Ventilation Air ............................................................................. 19-28

Condensate Drain Lines and Drain Trap ............................................................... 29-32

Product Design ...................................................................................................... 33-46

System Operation.................................................................................................. 47-51

Polarization and Phasing ....................................................................................... 52

Scheduled Maintenance ........................................................................................ 53-54

Servicing................................................................................................................ 55-73

Wiring Diagrams.................................................................................................... 74-75

Schematics............................................................................................................ 76-78

2 Rev. 0

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES

IF REPAIRS ARE ATTEMPTED BY UNQUALIFIED PERSONS,

WARNING

CAUTION

OWN PRODUCT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT.

DANGEROUS CONDITIONS (SUCH AS EXPOSURE TO ELECTRICAL SHOCK) MAY RESULT. THIS MAY CAUSE SERIOUS INJURY OR DEATH.

AMANA WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU PERFORM SERVICE ON YOUR

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER AFFAIRS DEPT. OR 1-319-622-5511 AMANA HEATING & AIR CONDITIONING CALL and ask for AMANA, IOWA 52204 Consumer Affairs

If outside the United States contact:

AMANA HEATING & AIR CONDITIONING ATTN: INTERNATIONAL DIVISION AMANA, IOWA 52204, USA Telephone: (319) 622-5511

Facsimile: (319) 622-2180

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

DANGER

DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING

CAUTION

WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.

3 Rev. 0

PRODUCT IDENTIFICATION

The model and manuacturing number are used for positive identification of component parts used in manufacturing. At which time engineering and manufacturing changes take place where interchangeability of components are affected, the manufacturing number will change.

It is very important to use the model and manufacturing numbers at all times when requesting service or parts information.

MODEL M/N GUCA045AX30 P1219301F GUCA070AX30 P1219302F GUCA070AX40 P1219303F GUCA090AX40 P1219304F GUCA090AX50 P1219305F GUCA115AX50 P1219306F

GCCA045AX30 P1219501F GCCA070AX30 P1219502F GCCA070AX40 P1219503F GCCA090AX40 P1219504F GCCA090AX50 P1219505F GCCA115AX50 P1219506F

FURNACE ACCESSORY KITS FTK_ Furnace Twinning Kit HANG_High Altitude Natural Gas Kit HALP_ High Altitude LP Kit HAPS_ High Altitude Pressure Switch Kit LPTK_ LP Conversion Kit

MODEL M/N

GUCA045AX30 P1227501F GUCA070AX30 P1227502F GUCA070AX40 P1227503F GUCA090AX40 P1227504F GUCA090AX50 P1227505F GUCA115AX50 P1227506F

GCCA045AX30 P1227601F GCCA070AX30 P1227602F GCCA070AX40 P1227603F GCCA090AX40 P1227604F GCCA090AX50 P1227605F GCCA115AX50 P1227606F

Note: See servicing section for available kits and usage.

ADDITIONAL FURNACE ACCESSORIES CFB_ Counterflow Floor Base EAC_ Electronic Air Cleaner EFR_ External Filter Rack Kit HCVK_ Horizontal Style Concentric Vent Kit MAC_ Media Air Cleaner MAF_ Media Air Filter (Replacement Filter For MAC_) VCVK_ Vertical Style Concentric Vent Kit

Note: For additional accessory kits listed above, see product identification section pages 11, 12 and 13 for available accessories and usage.

4 Rev. 0

PRODUCT IDENTIFICATION

G U C A 045 A X 30

Product Type

G: Gas Furnace

Supply Type

C: Counterflow/Horizontal U: Upflow/Horizontal

Furnace Type

C: Condensing (90%)

Model Family

A: Air Command 90 (40" Height)

Airflow Capability

30: 3.0 Tons 35: 3.5 Tons 40: 4.0 Tons 50: 5.0 Tons

Additional Features

A: Not NOx Certified X: NOx Models

Design Series

A: First Series

Nominal Input

045: 46,000 Btuh 070: 69,000 Btuh 090: 92,000 Btuh 115: 115,000 Btuh

5 Rev. 0

PRODUCT IDENTIFICATION

FOR YOUR SAFETY

READ BEF ORE OPERATING

WARNING:

explosion may result ca using property pers on al injury or

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

BEFORE O P ERAT ING

area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

C. Use only your hand to push in or turn the gas control lever. Never use tools. If the lever will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control syst em and any gas control whic h has been underwater.

If you do not follow these instructions

damage,

loss of life.

try

to light the burner by hand.

not

Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phon e. Fol low the gas suppl ier's ins tr uct i ons . If you cannot reach yo ur gas supplier, call the fire department.

smell all around the appliance

LIRE AVANT DE METTRE

EN MA RCHELIRE

AVERTISSEMENT:

la lettre les instructions dans le présent manuel risque de décl echer un incendie ou une explosion entraînant des dammages matériels, des lésions corp ore ll e s ou la perte de vies humain es .

Cet appareil ne comporte pas de veilleuse. Il est

muni d'un dispositif d'allumage qui allume automatiquement le brûleur. Ne d'allumer le brûleur manuellement.

B. AVANT DE LE FAIRE FONCTIONNER,

renifler tout autour de l'appariel pour déceler une odeur de gaz. Renifler près du plancher, car certains gaz sont plus lourds que l'air et peuvent s'accumuler au niveau du so.l

Qui c onque n e respecte pas á

tenter

pas

QUE FAIRE S'IL Y A UNE ODEUR DE GAZ

Ne pas tenter d'allumer l'appariel Ne touche r aucun int err upteur électrique ; n'utiliser aucun téléphone dans le bâtiment. Appeler immédiatement le fournisseur de gaz en employant le téléphone dún voisin. Re specter à la lettre les instructions du

qu'à la main; ne jamais emploer d'outil à cet effet Si la manette reste coincée, ne pas tenter de la réparer; appeler un technicien qualifié. Quiconque tente de forcer la manette ou de la reparer peut déclencher une explosion ou un incendie.

dans l'eau, complètement ou en partie. Appeler un technicien qualifié pour inspecter l'appareil et remplacer tout partie du système de contrôle et toute commande qui ont été plongés dans

fournisseur de gaz. Si personne ne répond, appeler le service des incendies.

Ne pousser ou tourner le levier d'admission du gaz

Ne pas se servir de cet appareil s'il a été plongé

l'eau.

OPERATING INSTRUC TIONS

1. this label.

2. Set the thermostat to lowest setting.

3. Turn off all power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do

5. Push the gas control lever to Do

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you

then smell gas, in the safety. information above on this label if you don't smell gas, go to next step.

7. Push gas control lever to

8. R eplace access p anel.

9. Turn on all electric power to the appliance.

10.Set thermostat to desired setting.

11.If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas company.

Read the safety information above on

STOP!

not

try to light the burner by hand.

not

force.

STOP!

"ON"

"OFF"

"B"

GAS

INLET

ARRIVEE

DU GAZ

Position.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be perfo rm ed .

3. Push the gas control lever to Do not force.

4. Re pl ace contr ol acce ss panel.

"OFF"

MANUAL GAS

LEVER SHOWN

IN ON POSITION

Position.

ROBINET A GAZ

MANUEL, EN POS

"ON/MARCHE"

O F

MISE EN MARCHE

ARRETÊR!

1. la portion supérieure de cette étiquette.

2. R égler le thermostat à la températur e la plus basse

3. Couper l'alimentation électrique de l'appareil.

4. Cet appareil ménager étant doté d'un système d'allumage automatique, ne allumer le brûleur manuellement.

5. Pousse le levier du contrôle du gaz à position.

6. Attendre cinq (5) minutes pour laisser echapper tout le gaz. Renifler tout autour de l'appareil, y compris près du plancher, pour déceler une odeur de gaz. Si c'est le cas,

ARRETER!

sur la portion supérieure de cette étiquette.

S'il n'y a pas d'odeur de gaz, passer à l'étape suivanté.

7. Pousse le levier du contrôle du gaz à position.

8. Remettre en place le panneau d'accés.

9. Mettre l'appareil sous tension.

10. Régler le thermostat à la température desirée.

11. Si l'appareil ne se met pas en marche, suiyre les instructions intitulées. Comment coupler l'admission de gaz de l'appereil et appeler un technicien qualifié ou le fourrnisseur de gaz.

Lisez les instructions de sécurité sur

essayer à

"OFF/ ARRET"

Passer à l'étape B des instructions de sécuritié

"ON/MARCHE"

POU R CO UP E R L'ADM ISSION

DE GAZ DE L'APPAREIL

1. Ré gl er le therm ostat à l a température la plus basse.

2. Couper l'alimenta tion électrique de l'appareil s'il faut pro céder à des opérat ions d'entr etie n.

3. Pousse le levier du contrôle du gaz à "OFF / ARRET" position. Ne pas forcer.

4. Re mettr e en place le pa nneau d'accès.

11072707

6 Rev. 0

PRODUCT IDENTIFICATION

3/4

1 5/8

1 1/2

Cabinet

Size

Small

Medium

Large

AIR

DISCHARGE

28 3/4

20 3/16

ALTERNATE

GAS SUPPLY

HOLE

LEFT SIDE

DRAIN LINE

HOLES

LOW VOLTAGE

ELECTRICAL HOLE

HIGH VOLTAGE

ELECTRICAL HOLE

SIDE CUT-OUT

25 9/16

BOTTOM CUT-OUT

LEFT SIDE

VIEW

2 5/8

1 3/4

7 3/8

2 1/2

AIR INTAKE PIPE

2" PVC

DRAIN

TRAP

19 3/16

11 3/4

9 3/8

3/4

30 1/4

GUCA

UnitsABCD

045__30 070__30

070__40 090__40

090__50

16-1/2

20-1/2

24-1/2

12-3/8

16-3/8

20-3/8

12-5/8

14-5/8

18-5/8

115__50

All dimensions are in inches.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

POSITION* SIDES FRONT REAR TOP BOTTOM FLUE

Upflow0 3 01C 0

Horizontal6 3 06C 0

* = All positioning is determined as installed unit is viewed from the front. C = If placed on combustible floor, floor MUST be wood ONLY.

(DISCHARGE)

BOTTOM CUT-OUT

FRONT

VIEW

3/4

2 1/16

CONDENSATE

DRAIN TRAP

w/ 3/4" PVC

DISCHARGE

(RIGHT OR LEFT SIDE)

16 5/8

(INCHES)

VENT/FLU E PIPE

2" PVC

27 1/8

30 1/4

32 13/16

2 11/16

19 3/16

4 1/8

2 5/8

11 3/4

7 7/8

6 1/8

DRAIN

TRAP

1 3/4

AIR

DISCHARGE

ALTERNATE AIR INTAKE LOCATION

STANDARD G AS SUPPLY HOLE

ALTERNATE VENT/FLUE LOCATION

RIGHT SIDE DRAIN LINE

HOLES

LOW VOLTAGE ELECTRICAL HOLE

HIGH VOLTAGE ELECTRICAL HOLE

SIDE CUT-OUT

RIGHT SIDE

VIEW

NOTES:

1. Installer must supply one or two PVC pipes: one for combustion air (optional) and one for the flue outlet (required). Vent pipe must be either 2” or 3” in diameter, depending upon furnace input, number of elbows, length of run and installation (1 or 2 pipes). The optional Combustion Air Pipe is dependent on installation/code requirements and must be 2” or 3” diameter PVC.

2. Line voltage wiring can enter through the right or left side of the furnace. Low voltage wiring can enter through the right or left side of furnace.

3. Conversion kits for high altitude natural gas operation are available. Contact your Amana distributor or dealer for details.

4. Installer must supply following gas line fittings, according to which entrance is used:

Left -- Two 90º Elbows, one close nipple, straight pipe Right -- Straight pipe to reach gas valve

ACCESSIBILITY CLEARANCES (MINIMUM):

36” at front is required for servicing or cleaning.

NOTE: In all cases, accessibility clearance shall take precedence over clearances from the enclosure where accessibility clearances are greater.

7 Rev. 0

(

)

3/4

28 3/4

20 1/4

HIGH VOLTAGE

ELECTRICAL HOLE

LOW VOLTAGE

ELECTRIC AL HOLE

LEFT SIDE

DRAIN LINE

HOLES

STANDARD GAS SUPPLY HOLE

18 5/8

UNFOLDED FLANGES

20 5/32

FOLDED FLANGES

AIR

DISCHARGE

2 5/8

4 1/8

PRODUCT IDENTIFICATION

GCCA

2 1/2

AIR INTAKE PIPE

2" PVC

1 3/4

28 5/16

DRAIN

TRAP

11 1/2

9 13/16

32 3/16

3/4

UNFOLDE D FLANGES

(RETURN)

FOLDED FLANGES

DISCHARGE

3/4

2 1/16

CONDENSATE

DRAIN TRAP

w/ 3/4" PVC

DISCHARGE

(RIGHT OR LEFT SIDE)

17 15/16 2

VENT/FLUE PIPE

28 5/16

19 7/8

30 11/16

2" PVC

15 1/2

1 3/4

2 11/16

DRAIN

TRAP

11 5/8

9 3/4

6 1/8

7 3/8

HIGH VOLTAGE ELECTRIC AL HOLE

LOW VOLTAGE ELECTRIC AL HOLE

ALTERNATE VENT/FLUE LOCATION

ALTERNATE AIR INTAKE

2 5/8

RIGHT SIDE DRAIN LINE

HOLES

ALTERNAT E G AS SUPPLY HOLE

AIR

DISCHARGE

LOCATION

Cabinet

Size

Small 16-1/2

Medium 20-1/2 19

Large 24-1/2

Units A B C

045__30 070__30

070__40 090__40

090__50 115__50

15 12-3 /8 13-1/2 15

19 16-3/8 17-1/2

23 20-3/8 21-1/2 23

UnfoldedEFolded

All dimensions are in inches.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

POSITION* SIDES FRONT REAR TOP BOTTOM FLUE

Counterflow 0 3 0 1 NC 0

Horizontal 6 3 0 6 C 0

* = All positioning is determined as installed unit is viewed from the front. C = If placed on combustible floor, floor MUST be wood ONLY. N

= For installati on on non-combustible floors only. A combustible floor subbase

must be used for installations on combustible flooring.

NOTES:

2. Line voltage wiring can enter through the right or left side of the furnace. Low voltage wiring can enter through the right or left side of furnace.

3. Conversion kits for high altitude natural gas operation are available. Contact your Amana distributor or dealer for details.

INCHES

4. Installer must supply following gas line fittings, according to which entrance is used:

Right -- Two 90º Elbows, one close nipple, straight pipe Left -- Straight pipe to reach gas valve

ACCESSIBILITY CLEARANCES (MINIMUM):

36” at front is required for servicing or cleaning.

NOTE: In all cases, accessibility clearance shall take precedence over clearances from the enclosure where accessibility clearances are greater.

8 Rev. 0

PRODUCT IDENTIFICATION

1 33

BLOWER COMPARTMENT BURNER COMPARTMENT

14 15

20 14

Upflow/Horizontal (GUCA Models) Counterflow/Horizontal (GCCA Models)

BURNER COMPARTMENT BLOWER COMPARTMENT

1 Gas Valve 2 Gas Line Entrance (Alternate) 3 Pressure Switch 4 Gas Manifold 5 Combustion Air Intake Connection / “Coupling” 6 Hot Surface Igniter 7 Rollout Limit 8 Burners

9 Flame Sensor 10 Flue Pipe Connection / “Coupling” 11 Flue Pipe (Internal) 12 Combustion Air Intake (Alternate) 13 Primary Limit 14 Gas Line Entrance 15 Flue Pipe Connection (Alternate) 16 Rubber Elbow

17 Induced Draft Blower 18 Coil Front Cover Pressure Tap 19 Coil Front Cover Drain Port 20 Drain Line Penetrations 21 Drain Trap 22 Capacitor 23 Electrical Connection Inlets (Alternate) 24 Integrated Control Module

(with fuse and diagnostic LED) 25 24-Volt Thermostat Connections 26 Transformer (40 VA) 27 Circulator Blower 28 Bottom Return Filter Retainer 29 Blower Door Interlock Switch 30 Junction Box 31 Electrical Connection Inlets 32 Auxiliary Limit 33 Coil Front Cover 34 Combustion Air Inlet Pipe

COMPONENT IDENTIFICATION

9 Rev. 0

PRODUCT IDENTIFICATION

A large array of Amana coils are available for use with the new GUCA and GCCA furnaces, in either upflow, counterflow, or horizontal applications. These coils are available in both cased and uncased models, with or without a TXV expansion device. These new 90%+ furnaces match up with the existing Amana coils as shown in the chart below.

Btuh

Input

45,000 16 1/2" 1 1/2 - 3

70,000 16 1/2" 2 - 3 1/2

70,000 20 1/2" 2 1/2 - 4

90,000 20 1/2" 2 1/2 - 4

90,000 24 1/2" 3 - 5

115,000 24 1/2" 3 - 5

Cabinet

Width

Air Flow

(tons)

CHA_F*C

Cased

A-Coils

CCA18FCC CCA24FCC CCA30FCC CCA36FCC CCA42FCC

CCA30FDC CCA36FDC CCA42FDC CCA48FCC

CCA36FKC CCA48FDC CCA54FCC CCA57FCC CCA60FCC

CCA_FSC

Uncased

A-Coils

CCA18FSC CCA24FSC CCA30FSC CCA36FSC CCA42FSC

CCA48FSC CHA42TSC

CCA54FSC CCA57FSC CCA60FSC

CHA_TCC

Cased

TXV A-Coils

CHA18TCC CHA24TCC CHA30TCC CHA36TCC

CHA42TCC

CHA48TCC CHA54TCC CHA57TCC CHA60TCC

TXV A-Coils

CHA18TSC CHA24TSC CHA30TSC CHA36TSC

CHA48TSC CHA54TSC CHA57TSC CHA60TSC

COIL MATCHES

CHA_TSC

Uncased

CCF_F*C

Horiz.

A-Coils

CCF24FCC CCF30FCC CCF36FCC

CCF24FDC CCF36FDC CCF42FCC CCF48FCC

CCF48FDC CCF60FCC

CHF_TCC

Horiz.

A-Coils

CHF18TCC CHF24TCC CHF30TCC

CHF36TCC CHF42TCC

CHF48TCC

10 Rev. 0

PRODUCT IDENTIFICATION

ACCESSORIES

Floor Base

Part Numbers

CFB16

Used On

Models

GCCA045__30 GCCA070__30

Furnace

Gasket

1" Min.

Duct

3/4"

Plenum

Floor Base

Floor

3/4"

Front View

Used On

Models

GCCA045__30 GCCA070__30

GCCA070__40 GCCA090__40

GCCA090__50 GCCA115__50

Floor Base

Part Numbers

CFB16

CFB20

CFB24

ABCDEFG

18-9/16 23-3/4 29 17-1/2 16-1/2 15 1-11/32

Furnac e Front

Plenum

4-7/16"

Side View

Floor Opening Plenum Size

HJKL

16-1/2 23-3/4 15 18-9/16

20-1/2 23-3/4 19 18-9/16

24-1/2 23-3/4 23 18-9/16

All dimension are in inches.

3/4"

CFB20

CFB24

GCCA070__40 GCCA090__40

GCCA090__50 GCCA115__50

18-9/16 23-3/4 29 21-1/2 20-1/2 19 1-11/32

18-9/16 23-3/4 29 25-1/2 24-1/2 23 1-11/32

COUNTERFLOW FLOOR BASE

23.567

4.500

EFR01 EXTERNAL FILTER RACK KIT

Used On Models

GUCA GCCA

INTERNAL

FILTER

RETAINERS

(80% MODELS

ONLY)

FILTER KIT PLUG FOR

STANDARD ELECTR ICAL INLET

ALTERNATE

ELECTRICAL INLET

LOCATION

(GUCA ONLY)

FRONT

OF UNIT

BASE

OF UNIT

(GUCA ONLY)

All dimension are in inches.

INTERNAL FILTER

RETAINER SCREWS

(80% MODELS ONLY)

UNIT SIDE

PANEL

RETURN AIR

CUTOUT AREA

SLOTS IN FILTER CLEAR SCREWS

ON UNIT

BLOWER DECK

LOWER EDGE

SCREW

SCREWS

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

EXTERNAL FILTER RACK KIT

11 Rev. 0

PRODUCT IDENTIFICATION

(

(2)

ACCESSORIES

MAC1 SPEC IFICATIONS

CAPACITY

MEDIA SERVICE LI FE

MEDIA LISTING

DIMENSIONS

A B C D 22-5/8 E

RESISTANCE

CFM INCHES W. C.

600 .04

800 1000 1200 1400 .15 1600 1800 2000

All dimensions are in inches.

MEDIA AIR CLEANER

Used On Models

GUCA GUCA

600-2000CFM

12 MO.NOMINAL

UL CLASS 2

7-1/4

22-1/8

17-11/16

.05 .09 .12

.18 .22 .27

EAC5 SPECIFICATIONS

RATED CAPACITY

MAX. PRESSURE DROP

CELL WEIGHT

UNIT WEIGHT

POWER CONSUMPTION

ELECTRICAL INPUT

ELECTRICAL OUTPUT

DIMENSION S

A B C 7-3/16 D E F G 22-1/2 H

EAC5 ELECTRONIC AIR CLEANER

Used On Models

GUCA GCCA

2000 CFM

.13 in. w.

12 lbs. each

46 lbs.

48 watts maximum

120 V , 60 HZ, 1

3.2 MA @ 6200 4-1/2

24-7/16

20-5/16

20-3/4 17-3/4

All dimensions are in inches.

MEDIA AIR CLEANER

3400 . @

2-1/8"

30°

E D

3-1/2"

12 Rev. 0

ELECTRONIC AIR CLEANER

PRODUCT IDENTIFICATION

ACCESSORIES

Vertical (VCVK)

Horizontal

(HCVK)

Connection for Fresh Air Intake Pipe to Furnace

Connection for Vent/Flue Pipe

from Furnace

Pipe to Furnace

Tee

Inside

Combustion

Air Intake Pipe

Outside

Seal Penetration

with Caulking

Wall Thick ne ss

3/4" Minimum

13 3/4" Maximum

HVCK Installation

Concentric Vents Kits HVCK and VCVK are suitable for use with the following Amana 90% efficient furnace products:

CONCENTRIC VENT KIT

Used On Models

GUCA GCCA

This kit is not certified for, and must not be applied to any furnace not listed in the above table.

Vent/Flue Termination

with Tee

12" Minimum Above

Grade or Highest

Anticipate Snow Level

Combustion Air

Intake Pipe

Roof Thicknes s

3/4" Minimum 22" Maximum

Interior Section

of Concentric Vent Assembly

Must Be Adequat ely

Secured and Supported

Sanitary Tee

Connection for Fresh Air Intake Pipe to Furnace

VCVK Installation

(Tee, Pipe, & 2" to 4" Reducer)

12" Minimum Above

Roof or Highest

Anticipated Snow Level

Outside

Inside

Connection for

Vent/ Flue Pipe

From Furnace

Vent/Flue

Termination

Seal Penetration

with Flashin and Caulkin

CONCENTRIC VENT CONVERSION KIT

13 Rev. 0

FURNACE SPECIFICATIONS

MODEL

Btuh Input (US) 46,000 69,000 69,000 92,000 92, 000 115,000

Output (US) 42,800 64,400 64,400 86,000 85,300 106,500 Input (CAN) 46,000 69,000 69,000 92,000 90,000 115,000 Output (CAN) 42,800 64,400 64,400 86,000 85,300 106,500 A.F.U.E. 92.0% 92.0% 92.0% 92.0% 92.0% 92.0% Rated External Static (WC) .20 - .50 .20 - .50 .20 - .50 .20 - .50 .20 - .50 .20 - .50 Temper ature Rise °F 35 - 65 35 - 65 35 - 65 35 - 65 35 - 65 35 - 65 ID Blower Pressure Switch Tr ip Point -0.37 -0.37 -0.37 -0.37 -0.37 -0.37 Front Cover Pressure Switch Trip Point -0.37 -0.37 -0.37 -0.37 -0.37 -0.37 Blower Wheel (D x W)" 11 x 6 11 x 7 11 x 9 11 x 9 11 x 9 11 x 10 Blower Horsepower 1/3 1/2 1/2 1/2 3/4 3/4 Blower Speeds 444444 Max CFM @ 0.5 E.S.P. 1196 1406 1643 1544 2128 2029 Power Supply 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 Min. Circuit Ampacity (MCA) 9.0 8.9 8.9 8.9 13.8 14.9 Max. Overcurrent Device 15.0 15.0 15.0 15.0 15.0 15.0 Transformer (VA) 40 40 40 40 40 40 Heat Anticipator 0.7 0.7 0.7 0.7 0.7 0.7 Limit Setting °F 150 150 160 150 150 150 Aux. Limit °F . 150 150 150 150 150 160

Fan Delay Timings On Heating 30 secs. 30 secs. 30 secs. 30 secs. 30 secs. 30 secs. Off Heating * 90 secs. 90 secs. 90 secs. 90 secs. 90 secs. 90 secs. On Cooling 5 sec. 5 sec. 5 sec. 5 sec. 5 sec. 5 sec.

Off Cooling 45 secs. 45 secs. 45 secs. 45 secs. 45 secs. 45 secs. Gas Supply Pressure (Nat/LP) 7" / 11" 7" / 11" 7" / 11" 7" / 11" 7" / 11" 7" / 11" Manifold Pressure (Nat/LP) 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10 " Orifice Size (Nat/LP) #43 / #55 #43 / #55 #43 / #55 #43 / #55 #43 / #55 #43 / #55 Number of Burners 233445 Vent Connector Diameter 2" 2" 2" 2" 2" 2" Combust io n Air Connector Diameter 2" 2" 2" 2" 2" 2" Shipping Weight (lbs.) 131 144 152 166 175 187

GUCA045AX30 GUCA070AX30 GUCA070AX40 GUCA090AX40 GUCA090AX50 GUCA115AX50

* Off Heatin

- This fan del ay timing is adjustabl e (60, 90, 120 or 180 seconds). 90 seconds as shipp ed.

1. These furnaces are manufactured for natural gas operation. Optional LP Conversion Kits are available to convert to propane gas.

2. When these furnaces are installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

3. The total heat loss from the structure as expressed in TOTAL BTU/HR must be calculated by the manufactures method of in accordance with the "A.S.H.R.A.E. GUIDE" or "MANUAL J-LOAD CALCULATIONS" published by the AIR CONDITIONING CONTRACTORS OF AMERICA. The total heat loss calculated should be equal to or less than the heating capacity. Output based on D.O.E. test procedures, steady state efficiency times output.

4. Minimum Circuit Ampacity calculated as: (1.25 x Circulation Blower Amps) + I.D. Blower Amps.

14 Rev. 0

FURNACE SPECIFICATIONS

MODEL

Btuh Input (US) 46,000 69,000 69,000 92,000 92,000 115,000

Output (US) 43,000 65,400 63,300 87,500 86,200 109,100 Input (CAN) 46,000 69,000 69,000 92,000 92,000 115,000 Output (CAN) 43,000 65,400 63,300 87,500 86,200 109,100 A.F.U.E. 92.0% 92.0% 92.0% 92.0% 92.0% 92.0% Rated External Static (WC) .20 - .50 .20 - .50 .20 - .50 .20 - .50 .20 - .50 .20 - .50 Temperature Rise °F 35 - 65 35 - 65 35 - 65 40 - 70 35 - 65 40 - 70 ID Blower Pressure Switch Trip Point -0.37 -0.37 -0.37 -0.37 -0.37 -0 .37 Front Cover Pressure Switch Trip Point -0.37 -0.37 -0.37 -0.37 -0.37 -0.37 Blower Wheel (D x W)" 11 x 6 11 x 7 11 x 9 11 x 9 11 x 9 11 x 10 Blower Horsepower 1/3 1/2 1/2 1/2 3/4 3/4 Blower Speeds 444444 Max CFM @ 0.5 E.S.P. 1195 1366 1590 1581 1987 1903 Power Supply 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 Min. Circuit Ampacity (MCA) 9.0 8.9 8.9 8.9 13.8 14.9 Max. Overcurrent Device 15.0 15.0 15.0 15.0 15.0 15.0 Transformer (VA) 40 40 40 40 40 40 Heat Anticipator 0.7 0.7 0.7 0.7 0.7 0.7 Limit Setti ng °F 170 170 170 150 170 155 Aux. Limit °F. 160 160 160 160 170 160

Fan Delay Timings On Heating 30 secs. 30 secs. 30 secs. 30 secs. 30 secs. 30 secs.

Off Heating * 90 secs. 90 secs. 90 secs. 90 secs. 90 secs. 90 secs. On Cooling 5 sec. 5 sec. 5 sec. 5 sec. 5 sec. 5 sec. Off Cooling 45 secs. 45 secs. 45 secs. 45 secs. 45 secs. 45 secs. Gas Supply Pressure (Nat/LP) 7" / 11" 7" / 11" 7" / 11" 7" / 11" 7" / 11" 7" / 11" Manifold Pressure (Nat/LP) 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" 3.5 " / 10" Orifice Size (Nat/LP) #43 / #55 #43 / #55 #43 / #55 #43 / #55 #43 / #55 #43 / #55 Number of Burners 233445 Vent Connector Diameter 2" 2" 2" 2" 2" 2" Combustion Air Connector Diameter 2" 2" 2" 2" 2" 2" Shipping Weight (lbs.) 132 145 153 167 176 188

GCCA045AX30 GCCA070AX30 GCCA070AX40 GCCA090AX40 GCCA090AX50 GCCA115AX50

* Off Heatin

- This fan delay timing is adjustable (60, 90, 120 or 180 seconds). 90 seconds as shipped.

1. These furnaces are manufactured for natural gas operation. Optional LP Conversion Kits are available to convert to propane gas.

4. Minimum Circuit Ampacity calculated as: (1.25 x Circulation Blower Amps) + I.D. Blower Amps.

15 Rev. 0

BLOWER PERFORMANCE SPECIFICATIONS

GUCA Bl ower Performance

Model

Heating Sp eed

()

As Shipped

GUCA045AX30 MED 2.5 113135111435109736106837101939 968907827

(MED-LO) MED-LO 2.0 903 44 896 44 876 45 844 47 807 49 764 706 652

GUCA070AX30 MED 3.0 1489 40 1450 41 1415 42 1370 43 1324 45 1261 1205 1130

(MED-LO) MED-LO 2.5 1251 47 1226 48 1205 49 1173 50 1135 52 1096 1037 975

GUCA70AX40 MED 3.5 1620 37 1597 37 1565 38 1516 39 1462 41 1410 1318 1235

(MED-LO) MED-LO 3.0 1387 43 1369 43 1313 45 1284 46 1224 48 1167 1095 1024

GUCA090AX40 MED 3.5 1624 49 1561 51 1520 52 1461 54 1381 57 1297 1217 1109

Motor

Speed

HIGH 3.0 1322 --- 1298 --- 1278 --- 1243 --- 1196 --- 1137 1074 1000

LOW 1.5 702 56 68 0 58 657 60 624 63 584 --- 542 485 423 HIGH 3.5 1590 37 1550 38 1505 39 1454 41 1406 42 1343 1266 1194

LOW 2.0 1001 59 988 60 969 61 956 62 929 64 902 859 807 HIGH 4.0 1861 --- 1823 --- 1778 --- 1721 --- 1643 36 1581 1500 1387

LOW 2.5 1193 50 1162 51 1118 53 1072 55 1012 59 961 894 836 HIGH 4.0 1821 43 1768 45 1699 46 1624 49 1544 51 1439 1354 1227

Tons AC

at 0.5" 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

ESP CFM RISE CFM RISE CFM RISE CFM RISE CF M RISE CFM CF M CFM

External Static Pr essure (Inches Water Column)

(HIGH) MED-LO 3.0 1395 57 1363 58 1311 60 1258 63 1201 66 1120 1045 957

LOW 2.5 1212 65 1164 --- 1126 --- 1080 --- 1014 --- 957 882 815 HIGH 5.0 2375 --- 2323 --- 2282 35 2217 36 2128 37 2056 1956 1857

GUCA090AX50 MED 4.0 1752 45 1741 45 1729 46 1682 47 1640 48 1591 1534 1454

(MED-HI) MED-LO 3.5 1504 53 1487 53 1469 54 1443 55 1412 56 1380 1318 1228

LOW 3.0 1274 62 1258 63 1253 63 1222 65 1201 --- 1147 1072 972 HIGH 5.0 2359 42 2298 43 2208 45 2117 47 2029 49 1914 1783 1678

GUCA115AX50 MED 4.0 1849 53 1808 55 1757 56 1722 57 1651 60 1595 1507 1403

(HIGH) MED-LO 3.5 1575 63 1556 63 1527 65 1497 --- 1456 --- 1370 1290 1205

LOW 3.0 1370 --- 1348 --- 1313 --- 1278 --- 1254 --- 1180 1114 1029

1. CFM in charts is with filters(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.

2. All furnaces ship as high speed cooling. Installer must adjust blower speed as needed.

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

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

5. The chart is for information only. For satisfactory operation, external static pressure must not exceed value shown on rating plate. The shaded area indicates ranges in excess of maximum external static pressure allowed when heating.

6 The dashed (----) areas indicate a temperature rise not recommended for this model.

7. The above chart is for U.S. furnaces installed at 0-4000 feet. At higher altitudes, a properly derated unit will have approximately the same temperature rise at a particular CFM, while the ESP at that CFM will be lower.

16 Rev. 0

BLOWER PERFORMANCE SPECIFICATIONS

GUCA Bl ower Performance

Model

Heating Sp eed

()

As Shipped

GCCA045AX30 MED 2.5 1195 ----- 1179 ----- 1136 35 1092 36 1037 38 988 918 839

(MED-LO) MED-LO 2. 0 979 40 949 42 906 43 862 46 816 48 791 736 66 8

GCCA070AX30 MED 3.0 1385 43 1338 44 1300 45 1245 47 1198 49 1138 1075 1008

(MED-HIGH) MED-LO 2.5 116451113552110553106855102758 982931873

GCCA70AX40 MED 3.5 1674

(MED-LO) MED-LO 3.0 1481 40 1407 42 1352 44 1329 44 1234 48 1157 1076 972

GCCA090AX40 MED 3.5 1654 48 1594 49 1531 51 1485 53 1403 56 1263 1239 1157

Motor

Speed

HIGH 3.0 1327 ----- 1342 ----- 1305 ----- 1251 ----- 1195 ----- 1128 1056 969

LOW 1.5 764 52 73 6 54 703 56 668 59 621 63 589 537 477

HIGH 3.5 1594 37 1541 38 1495 40 1426 41 1366 43 1300 1229 1155

LOW 2.0 982 60 95 7 62 924 64 891 -- --- 859 ----- 819 777 724

HIGH 4.0 1911 ----- 1838 ----- 1762 ----- 1674 35 1590 37 1501 1407 1294

LOW 2.5 1282 46 1234 48 1183 50 1117 53 1047 56 987 906 818

HIGH 4.0 1867 42 1797 44 1730 46 1660 47 1581 50 1498 1403 1316

Tons AC

at 0.5" 0.1 0.2 0.3 0.4 0.5 0.6 0. 7 0.8

ESP CFM RISE CFM RISE CFM RISE CFM RISE CF M RISE CFM CF M CFM

External Static Pr essure (Inches Water Column)

1609 37 1551 38 1481 40 1407 42 1329 1234 1157

(HIGH) MED-LO 3.0 1452 54 1407 56 1353 58 1295 61 1225 64 1156 1083 1005

LOW 2.5 1255 63 1206 65 1165 68 1115 ----- 10 56 ----- 997 93 1 849

HIGH 5.0 2313 ----- 2243 35 2171 36 2066 38 1987 40 1889 1785 1655

GCCA090AX50 MED 4.5 1900 41 1862 42 1810 44 1744 45 1674 47 1601 1510 1412

(MED-L0) MED-LO 3.5 1661 47 1615 49 1583 50 1530 52 1480 53 1406 1332 1245

LOW 3.0 1450 54 1415 56 1379 57 1332 59 1284 61 1219 1144 1053

HIGH 5.0 2283 43 2192 45 2108 47 2012 49 1903 52 1829 1727 1636

GCCA115AX50 MED 4.5 1910 52 1860 53 1782 55 1714 57 1658 59 1555 1460 1377

(MED-HI) MED-LO 3.5 1686 58 1644 60 1585 62 1524 65 1460 67 1411 1324 2132

LOW 3.0 1460 67 1410 70 1377 ---- - 1324 ---- - 1288 ----- 1212 1152 1067

2. All furnaces ship as high speed cooling. Installer must adjust blower speed as needed.

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

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

6 The dashed (----) areas indicate a temperature rise not recommended for this model.

17 Rev. 0

BLOWER PERFORMANCE SPECIFICATIONS

18 Rev. 0

COMBUSTION AND VENTILATION AIR

(DIRECT/NON-DIRECT VENT MODELS)

WARNING

Property damage, bodily injury, or death may occur if the furnace and any other fuel-burning appliances are not provided with enough fresh air for proper combustion and ventilation of flue gases. Most homes require outside air to be supplied into the furnace area.

Improved construction and additional insulation in homes has reduced the heat loss and made these homes much tighter around doors and windows so that air infiltration is minimal. This creates a problem to supply combustion and ventilation air for gas fired or other fuel burning appliances.. Any use of appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increases this problem and appliances could be starving for air.

In addition, these energy saving measures mean that your home will retain more water vapor and have a higher relative humidity. High humidity, especially during cold weather, may be damaging to buildings because condensation forms on windows and inside walls.

AIR REQUIREMENTS

Most homes will require that outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA54/ANSIZ223.1 Section 5.3.

5.3.1 General

(a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b) Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

(c) In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be applied for ventilation, including all air required for comfort and proper working conditions for personnel.

(e) While all forms of building construction cannot be covered in detail, air for combustion, ventilation, and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by appliance of one of the methods covered in 5.3.3 and 5.3.4.

(f) Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3b or 5.3.4.

Unconfined Space. For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a)

All Air from Inside the Building:

be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 Btu per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure. The following drawing illustrates the air opening specifications for equipment located in confined spaces; all air from inside building.

The confined space shall

19 Rev. 0

COMBUSTION AND VENTILATION AIR

(DIRECT/NON-DIRECT VENT MODELS)

Equipment Located in Confined Spaces; All Air from

Inside Building. See 5.3.3-a

(b)

All Air from Outdoors:

vided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. The following drawing illustrates the air opening specifications for equipment located in confined spaces; all air from outdoors-inlet air from ventilated crawl space and outlet air to ventilated attic.

The confined space shall be pro-

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. The following drawing illustrates the air opening specifications for equipment located in confined spaces; all air from outdoors through ventilated attic.

Equipment Located in Confined Spaces; All Air

from Outdoors Through Ventilated Attic. See

5.3.3-b.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure. The following drawing illustrates the air opening specifications for equipment located in confined spaces; all air from outdoors.

Equipment Located in Confined Spaces; All Air from

Outdoors—Inlet Air from Ventilated Crawl Space and

Outlet Air to Ventilated Attic. See 5.3.3-b

20 Rev. 0

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

Equipment Located in Confined Spaces; All Air from

Outdoors. See 5.3.3-b.

COMBUSTION AND VENTILATION AIR

(DIRECT/NON-DIRECT VENT MODELS)

4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Ex-

hausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

Vent/Flue Pipe and Combustion Air Pipe

General

WARNING

Failure to follow these instructions can result in bodily injury or death. Carefully read and follow all instructions given in this section.

WARNING

Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure to flue products, including carbon monoxide.

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connectors” other than those shipped with this product.

It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

Dual Certification: Non-Direct/Direct Vent

This furnace is dual certified and may be installed as a nondirect vent (single pipe) or direct vent (dual pipe) appliance. A

non-direct vent

while a and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

Materials and Joining Methods

direct vent

installation requires only a vent/flue pipe,

installation requires both a vent/flue pipe

WARNING

To avoid fire, explosion, or bodily injury, solvent cements must be kept away from all ignition sources (i.e., sparks, open flames, and excessive heat) as they are combustible liquids. Avoid breathing cement vapors or contact with skin and/or eyes.

Two- or three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.

As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

21 Rev. 0

COMBUSTION AND VENTILATION AIR

(DIRECT/NON-DIRECT VENT MODELS)

All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/16” minimum from the plane of one opening to the centerline of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.

Proper Vent/Flue and Combustion Air Piping Practices

Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions.

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed outdoors or in unheated areas must be insulated with 1/2” thick closed cell foam such as “Armaflex” or “Insultube.” Inspect piping for leaks prior to installing insulation.

Termination Locations

Note: Refer to

Location Requirements and Considerations

section for combustion air contaminant restrictions. The following bullets and diagram describe the restrictions

concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to

Vent (Dual Pipe) Piping

Non-Direct Vent (Single Pipe) Piping

sections for specific details on ter-

and

Direct

mination construction.

• All terminations must be located at least 12 inches above ground level or the anticipated snow level.

• Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet.

Note: This provision does not apply to the combustion air intake termination of a direct vent application.

• The vent termination of a

non-direct vent

application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.

• The vent termination of a

direct vent

application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

• The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

• A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

• The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

Note: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.

Other Than

Combustion Air

Termination I ntake

Non-Direct Vent

Vent/Flue Termination

No Terminations Above Walkway

Grade or Highest

Anticipated Snow Level

10'

Forced Air

Inlet

12"

Vent/Flue Termination

12"

Direct Vent

4' 12"

Non-Direct Vent

Vent/Flue Termination

Vent Termination Clearances

Canadian Venting Requirements

In Canada, venting must conform to the requirements of the current CAN/CGA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

The vent shall

not

be located:

• Less than 12 inches above the finished grade line.

22 Rev. 0

COMBUSTION AND VENTILATION AIR

(DIRECT/NON-DIRECT VENT MODELS)

• Less than 36 inches from any building opening or any gas service regulator. For gas service regulators in the Province of Ontario, 72 inches.

• Less than 72 inches from the combustion air intake of another appliance.

• Directly above a gas utility meter or service regulator.

• Over a walkway unless located 84 inches above grade.

Standard Furnace Connections

It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported.

As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or basepan (counterflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.

Vent/Flue Pipe

Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (See “Standard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing.

Note: Do not use other commercially available “no hub connectors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (See

ing Methods

Note: For

section).

non-direct vent

installations, a minimum of one

Materials and Join-

90° elbow must be installed on the combustion air intake coupling to guard against inadvertent blockage.

Non-Direct Vent Installations

A minimum of one 90° elbow must be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

(DIRECT VENT ONLY)

90 PVC

ELBOW

(NON-DIRECT VENT)

CUMBUSTION

AIR PIPE

VENT/FLUE

PIPE

RUBBER

COUPLING

WITH WORM

GEAR CLAMPS

PVC

COUPLING

(DIRECT VENT

UPFLOW

90 PVC ELBOW

(NON-DIRECT VENT)

CUMBUSTION

AIR PIPE

(DIRECT VENT ONLY)

COUNTER FLOW

RUBBER COUPLINGS WITH WORM

GEAR CLAMPS

VENT/FLUE

PIPE

Standard Connections

Alternate Furnace Connections

If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an

"A"

coil, or to upright counterflow installations requiring additional access to a filter or electronic air cleaner, or to horizontal installations desiring vent/flue (and combustion air intake) piping run vertically from the side of the cabinet.

Note: Standard and alternate locations can be combined (i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.

CAUTION

Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs.

Combustion Air Pipe

Direct Vent Installations

upflow

units secure the combustion air intake pipe directly to the air intake coupling. On cure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. Note: Because of probable material conflicts, do not use other commercially available “no hub connectors”. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

counterflow

units se-

Alternate Vent/Flue Location

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps, the “Vent/ Flue Pipe Cuts” figure, and the “Alternate Vent/Flue Location” figure.

Note: Counterflow instructions follow the upflow instructions.

1. Remove and save the four screws securing the vent/ flue coupling to the furnace top panel.

Counterflow

units.

Remove and save the four screws securing the vent/ flue coupling to the furnace basepan. Also remove the three screws securing the furnace’s internal vent/flue piping to the blower deck.

23 Rev. 0

COMBUSTION AND VENTILATION AIR

(

)

(

)

(DIRECT/NON-DIRECT VENT MODELS)

Upflow

Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent/flue pipe.

Upflow

Remove the vent/flue pipe from the furnace.

4. Cut the vent/ flue pipe at the elbow nearest the coupling end of the pipe (See “ Vent/Flue Pipe Cuts” figure). The section of pipe attached to the coupling will reach through the side panel to the induced draft blower. Discard unused pipe and elbows.

Counterflow

Cut the vent/flue pipe 3.718 inches from the blower deck coupling (See “Vent/Flue Pipe Cuts” figure). Save vent/ flue pipe attached to blower deck coupling for use in the alternate location. Discard remaining pipe and elbows.

COUPLING

ELBOWS

5. Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover).

Counterflow

Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (basepan). Plug remaining hole in blower deck with plastic plug included in the drain kit bag.

Upflow

Insert cut section of vent/flue pipe and coupling into alternate vent/flue location. Using a rubber coupling and worm gear hose clamps from the drain kit bag, attach the vent/flue pipe and coupling to the induced draft blower. Secure the coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self drilling screws.

24 Rev. 0

UPFLOW

and

Counterflow

and

Counterflow

units.

and

Counterflow

units

CUT AT ELBOW

NEAREST COUPLING

CUTPI PE INSIDE DECK FLANG E

COUPLING

BLOWER

COUPLING

Vent/Flue Pipe Cuts

units

3.718" BLOWER

FROM

3.718"

DECK

COUNTERFLOW

WARNING

The rubber elbow is not designed to support a load. When the rubber elbow is mounted externally to the furnace cabinet, extreme care must be taken to adequately support field-supplied vent/flue piping. As damage can result in leaks causing bodily injury or death due to exposure to flue gases, including carbon monoxide.

Upflow

For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. Note: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe.

Upflow

For supplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.

UPFLOW

and

Counterflow

and

Counterflow

horizontal installations

REMOVE

PIPE

***

O FF

23PC

* *

ID BLOWER WITH

RUBBER COUPLING

SECURE TO

AND HOSE

REMOVE

PIPE

REMOVE

4 SCREWS

23PC

F F

***

REMOVE

4 SCREWS

AND REL O C A T E

DETATCH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

COUNTERFLOW/UPRIGHT

UPFLOW SIMILAR

CLAMPS

123

OF F

* *

UPFLOW/HORIZONTAL

COUNTERFLOW SIMILAR

Alternate Vent/Flue Location

units

, externally secure the field-

COUNTERFLOW

ADDITIONAL PLUG

FROM DRAIN KIT

EXTERNALLY

RUBBER ELBOW

SECURE TO

ID BLOWER WITH

RUBBER COUPLING

AND HOSE

CLAMPS

SECURE TO

CABINET WITH

* *

23PC

***

MOUNT

SCREWS

REMOVE

PIPE

AND REL O C A T E

DETATCH RUBBE

REMOVE

4 SCREWS

REMOVE

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

+ 54 hidden pages