Amana VR8205 User Manual

A
t
®
Heating ¡ Air Conditioning
higher standard of comfor
GUI* & GCI*
Installation Instructions
Gas Fired Warm Air
Furnace
Table of Contents
To The Owner .............................................................................. 2
To The Installer............................................................................ 2
I. Safety and Unit Location ..................................................... 3
II. General Information ............................................................. 4
III. Air Requirements................................................................. 4
IV. Category I Venting (Vertical Venting) ................................. 6
V. Masonry Chimneys .............................................................. 8
VI. Gas Piping .......................................................................... 1 2
VIl. Electrical Wiring................................................................. 16
VIlI. Circulating Air and Filters ................................................ 18
IX. Sequence of Operation (Integrated Ignition Control) .... 21
X. Start-Up, Adjustments, and Checks ................................ 2 1
XI. Maintenance ....................................................................... 27
Affix this manual, Specification Sheet and Users
Information Manual adjacent to the furnace.
Amana Forced Air Central Furnace Design Complies With Requirements Embodied in The American National Standard / National Standard of Canada Shown Below.
ANSI Z21.47•CAN/CGA-2.3 Central Furnaces
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.
October 1997(1)
Fayetteville, TN 37334
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 should not supersede existing practices but should be considered as supplemental information.
Amana
10759818
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 neighbor’s phone. Follow the gas supplier’s 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
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the furnace before shutting off the electrical supply.

To The Owner

It is important that you fill out the owner’s registration card and mail it today. This will assist Amana in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the Model, Manufacturing and Serial Numbers, plus the installation date.
Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe place, so you can find it, if necessary.
If additional operating instructions are required, call the dealer where the purchase was made.

To The Installer

Before installing this unit, please read this manual to familiarize yourself on the specific items which must be adhered to, such as maximum external static pressure to unit, air temperature rise, minimum or maximum CFM, motor speed connections, and venting. These furnaces are designed for Category I venting only.
WARNING
To prevent possible death or personal injury due to asphyxiation, Amana Non­Condensing Gas Fired Warm Air Furnaces must be Category I vented. Do not vent any of these furnaces using Category III venting.
Keep this literature in a safe place for future reference.
2

I. Safety and Unit Location

WARNING
To prevent personal injury or death due to improper installation, adjustment, alteration, service, or, maintenance refer to this manual or for additional assistance or information consult 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
To prevent possible death, personal injury or equipment damage due to fire, the following points must be observed when installing the unit.
WARNING
To prevent possible death, personal injury or property damage due to electrical shock, the furnace must be located to protect the electrical components from water.
NOTE: This unit must not be used as a “construction
heater” during the finishing phases of construction on a new structure. This type of use may result in premature failure of the unit due to extremely low return air tempera­tures and exposure to corrosive or very dirty atmospheres.
WARNING
To prevent possible death, personal injury or property damage, do not install this unit in a mobile home, trailer or recreational vehicle.
ADDITIONAL SAFETY CONSIDERATIONS
• This furnace is approved for Category I Venting only.
• When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.
• Do not install the furnace where the combustion air is exposed to the following substances: permanent wave solutions, 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 installed near an area which will be frequently con­taminated by these substances, the furnace should be sealed from this area so that little contaminated air can reach the furnace. The furnace must still have an adequate supply of combustion air, either from a nearby uncontaminated room or from outdoors. For details, see “AIR REQUIREMENTS” Section III.
• 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.
• When installed horizontally, the furnace must be in­stalled with the access doors vertical so that the burners fire horizontally into the heat exchanger. The unit cannot be installed with the access doors on top or bottom. (See Specification Sheet)
• Allow clearances from the enclosure as shown on Specification Sheet for fire protection, proper opera­tion, and service access. These clearances must be permanently maintained. The combustion and venti­lating air openings in the front and top panels of the furnace must never be obstructed.
• This furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.
• When the furnace is used in connection with a cooling unit, the furnace must be upstream of, or in parallel with, the cooling unit. For details see Section VIlI.
• On 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, insure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout.
Counterflow Installation over a combustible floor.
installation over a combustible floor becomes neces­sary, use an accessory subbase as shown on the Specification Sheet. Follow the instructions with the subbase for proper installation. 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.)
• 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.
ADDITIONAL LOCATION CONSIDERATIONS
• The furnace should be as centralized as is practical with respect to the air distribution system.
• Do not install the furnace directly on carpeting, tile, or combustible material other than wood flooring.
• When suspending the furnace from rafters or joists, use 3/8" threaded rod and 2” x 2” x 3/8” angle as shown on the Specification Sheet. The length of the rod will depend on the application and clearance necessary.
If
3
• When installed in a residential garage, the furnace must be positioned so the burners and ignition source are located not less than 18 inches (457 mm) above the floor and protected from physical damage by vehicles.

III. Air Requirements

COMBUSTION AND VENTILATION AIR

II. General Information

WARNING
Possible death, personal injury or property damage due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, repair, operation, or maintenance on this product.
To ensure the furnace operates safely and efficiently, it must be installed, operated and maintained in accordance with these installation and operating instructions, all local building codes and ordinances, or, in their absence, with the latest edition of the National Fuel Gas Code, ANSI Z223.1*, and/or CAN/CGA B149 Installation Codes.
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.
*Obtain from: American National Standards Institute 1430 Broadway New York, NY 10018
TRANSPORTATION DAMAGE
Check the furnace for any shipping damage. If damage is found, contact the company where the furnace was pur­chased.
While checking for transportation damage, remove all pack­aging material and dispose or recycle according to local codes.
THERMOSTAT LOCATION
Locate the thermostat about 5 feet high on a vibration-free inside wall, in an area having good air circulation
Do not install the thermostat where it may be affected by:
• drafts or dead spots behind door, in corners or under cabinets.
• hot or cold air from ducts.
• radiant heat from sun or appliances.
• concealed pipes and chimneys.
• unheated (uncooled) areas behind the thermostat, such as an outside wall.
Consult the instructions packaged with the thermostat for mounting instructions.
WARNING
Possible death, personal injury or property damage may occur if the furnace and 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 build­ings has reduced the heat loss, making these buildings much tighter around doors and windows so air infiltration is minimal. This creates a problem supplying combustion and ventilation air for gas fired and other fuel burning appli­ances. Use of appliances pulling air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increases this problem causing appliances to starve for air.
This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed combustion) furnace. The burner box is present only to help reduce sound transmission from the burners to the occupied space.
AIR REQUIREMENTS
Most homes will require outside air 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/ANSI Z223.1 Section
5.3.
5.3.1 General:
(a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the build­ing. They do not apply to (1) direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.
(b) Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient tem­perature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.
4
(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 supplied for ventilation, including all air required for comfort and proper working conditions for personnel.
(e) While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.
(f) Air requirements for the operation of exhaust fans, kitchen 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.
Space, Unconfined. For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.
5.3.3 Equipment Located in Confined Spaces: (a)
from Inside the Building:
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. (Figure 1 )
The confined space shall be
All Air
Figure 1
Equipment Located in Confined Spaces; All
Air from Inside Building. See 5.3.3-a
.
(b)
All Air from Outdoors:
provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure (Figure 2).
The confined space shall be
Figure 2
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
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 (See Figure 3).
5
Figure 3
Equipment Located in Confined Spaces; All
Air from Outdoors Through Ventilated Attic.
See 5.3.3-b.
5.3.5 Louvers and Grilles:
In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
5.3.6 Special Conditions Created by Mechanical Ex­hausting or Fireplaces:
Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring spe­cial attention to avoid unsatisfactory operation of installed gas utilization equipment.

IV. Category I Venting (Vertical Venting)

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. (Figure 4)
*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.
Figure 4
Equipment Located in Confined Spaces; All
Air from Outdoors. See 5.3.3-b.
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.
WARNING
To prevent possible death or personal injury due to asphyxiation, Amana Non­Condensing Gas Fired Warm Air Furnaces must be Category I vented. Do not vent any of these furnaces 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 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, NFPA 54/ANSI Z223.1 - latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CGA B149.1 and .2
- latest editions and amendments. 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 death or personal injury due to asphyxiation, common venting with other manufacturer’s induced draft appliances is not allowed.
Common venting with specific Amana Category I 80% furnaces is allowed with the addition of a common vent kit (CVK) for each appliance. Contact the local installing dealer, distributor or Amana directly for more information.
6
The minimum vent diameter for the Category I venting system is as shown below:
MINIMUM VENT DIAMETER
MODEL GUI* GCI*
45 3 Inch 4 Inch 70 4 Inch 4 Inch
90 4 Inch 4 Inch 115 5 Inch 5 Inch 140 5 Inch 5 Inch
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
large to properly vent the remaining attached appliances. The following steps shall be followed with each appliance
remaining connected to the common venting system placed in operation, while the other appliances remaining con­nected to the common venting system are not in operation.
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size and
horizontal pitch as required in the National Fuel Gas Code, ANSI Z223.1, or the CAN/CGA B149 Installation Codes and these instructions. Determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
(c) Where practical, close all building doors, windows, and
all doors between the space where the appliances remain connected to the common venting system are located and other spaces of the building. Turn on all gas appliances not connected to the common venting sys­tem and operate on high speed all exhaust fans (range hoods and bathroom), except summer exhaust fans. Close fireplace dampers.
(d) Following the lighting instructions, place the furnace
being inspected in operation. Adjust thermostat so appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
(f) After it has been determined that each appliance re-
maining connected to the common 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 in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the common venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code, ANSI Z223.1.
Upflow or Horizontal units
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 counterclockwise for Category I venting, with the airflow horizontal left to right (Figure 5). For horizontal installations, a 4-inch single wall pipe can be used to extend the induced draft blower outlet
, the venting system may be too
are shipped with the induced
1/2” beyond the furnace cabinet. 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/ CGA B149 - latest editions and amendments.
Figure 5
Upflow Rotated Induced Draft Blower
Counterflow units
blower discharging from the top of the furnace. (“Top” as viewed for an counterflow installation.) The induced draft blower can be rotated 90 degrees counterclockwise for Category I venting, with the airflow horizontal right to left (Figure 6). For horizontal installations, a 3-inch B-vent pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. 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/ CGA B149 - latest editions and amendments.
Supply
Air
are shipped with the induced draft
Vent
Return
Air
Figure 6
Counterflow Rotated Induced Draft Blower
To rotate the induced draft blower counterclockwise pro­ceed as follows:
1. Disconnect electrical power from furnace.
WARNING
To prevent death or personal injury due to electrical shock, disconnect electrical power.
2. Remove the round cutout from the side of the furnace. Note: The assembly, starting from the outside, is
induced draft blower, outer gasket, rotation plate, inner gasket, partition panel (See Figure 7).
7
Figure 7
g
g
Blower Assembly
3. Remove and save the four screws which hold the rotation plate on the partition panel. Note that one of the screws which hold the induced draft blower on the rotation plate needs to be removed.
4. Turn the rotation plate 90 degrees counterclockwise. The inner gasket must turn with the rotation plate.
5. Reinstall the rotation plate on the partition panel, using the four screws removed in step 3. Tighten screws to provide an airtight seal.
6. Make sure all wires are at least one inch from flue pipe. Relocate junction box to right side of cabinet if nec­essary. Refer to Section Vl for instructions.

V. Masonry Chimneys

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 the masonry chimney as a pathway for properly sized metal liner or Type B metal vent.
Crown
Clay Tile Size Generally 12" x 12" (24" Len
th)
Wash
Roof Line
Clay Tile Size: 8" x 8" x12"
(Each x 24" Len
th)
WARNING
To prevent death or serious illness to building occupants due to flue products leaking into the building, proper installation of gaskets and screws is essential for providing a gas tight seal between the partition panel and the induced draft blower.
Attic Floor
1/2" to 1" Air Space
Second Floor
Throat
Clean Out
Damper
Breech
F.A.F. Vent Connector
Fan Assisted Forced Air Furnace
First Floor
Natural Draft Water Heater
Figure 8
Typical Multiple Flue Clay Tile Chimney
8
Water Heater Vent Connector
Basement Floor
CHECKLIST SUMMARY
This checklist serves as a summary of the items to be checked before venting an Air Command 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.
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, page 12.
Proper Chimney
Termination?
(Check 1)
Yes
Chimney channel
free of solid and
liquid fuel
appliances?
(Check 2)
Yes
Crown in good
condition?
(Check 3)
Yes
Cleanout free of
debris?
(Check 4)
Yes
Line, terminate with
No
No
No
No
listed vent cap
(Fix 1)
Change venting
arrangements
(Fix 2)
Rebuild crown
(Fix 3)
and /or Reline
(Fix 4)
Reline (Fix 4)
2' Min.
Ridge
10' or Less
2' Min.
Wall or Parapet
Chimney
10' or Less
2' Min.
Chimney
3' Min.
3' Min.
Liner in good
condition?
(Check 5)
Yes
Dilution air
available?
(Check 6)
Yes
Complete the
installation.
(Check 7)
No
No
Reline (Fix 4)
Reline (Fix 4)
Figure 9
Termination 10 Feet Or Less From Ridge,
Wall or Parapet
9
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