American Standard Noncondensing Gas Furnaces User Manual

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User’s Information Guide

325034- 2

Noncondensing Gas Furnaces

Upflow / Horizontal and Downflow / Horizontal

 

 

 

WARNING: Disconnect power to the

 

WARNING: If the information in this manual

 

 

 

 

 

 

 

is not followed exactly, a fire or explosion may

 

 

unit before removing the blower door. Failure to

 

result causing property damage, personal in-

 

 

 

 

 

follow this warning could result in property damage,

 

jury or loss of life.

 

 

 

 

 

personal injury or death.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

— Do not store or use gasoline or other

 

 

flammable vapors and liquids in the

 

 

vicinity of this or any other appliance.

WARNING: BODILY INJURY CAN RESULT FROM

 

 

 

 

 

— WHAT TO DO IF YOU SMELL GAS

HIGH VOLTAGE ELECTRICAL COMPONENTS, FAST MOVING FANS,

 

AND COMBUSTIBLE GAS. FOR PROTECTION FROM THESE

 

 

 

 

INHERENT HAZARDS DURING INSTALLATION AND SERVICING,

 

 

 

 

THE ELECTRICAL SUPPLY MUST BE DISCONNECTED AND THE

 

Do not try to light any appliance. MAIN GAS VALVE MUST BE TURNED OFF. IF OPERATING CHECKS

Do not touch any electrical switch;

MUST BE PERFORMED WITH THE UNIT OPERATING, IT IS THE

 

do not use any phone in your build-

TECHNICIANS RESPONSIBILTY TO RECOGNIZE THESE HAZARDS

 

AND PROCEED SAFELY.

 

ing.

 

 

 

Immediately call your gas supplier from a neighbor’s phone. Follow the

gas supplier’s instructions.

WARNING: DO NOT USE THIS UNIT IF

 

• If you cannot reach your gas sup-

 

ANY PART HAS BEEN UNDER WATER. IMMEDIATELY

 

plier, call the fire department.

 

CALL A QUALIFIED SERVICE TECHNICIAN TO

 

 

 

 

— Installation and service must be per-

INSPECT THE FURNACE AND TO REPLACE ANY

 

PART OF THE CONTROL SYSTEM AND ANY GAS

 

formed by a qualified installer, service

CONTROL WHICH HAS BEEN UNDER WATER.

 

agency or the gas supplier.

Pub. No. 32-5034-02

 

 

© American Standard Inc. 2001

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Improper servicing could result in dangerous operation, serious injury, death, or property damage.

GENERAL INFORMATION

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the installation instructions provided with the furnace and this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. American Standard Inc. or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

Safety signal words are used to designate a degree or level of seriousness associated with a particular hazard. The signal words for safety markings are DANGER,

WARNING, and CAUTION.

a.DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations.

b.WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

c.CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices and hazards involving only property damage.

There must be a free flow of fresh air sufficient for efficient combustion and safe ventilation of your furnace. Do not allow the louvers on the front panels of your furnace to become blocked as this will restrict the flow of fresh air.

The combustion air for your furnace must be fresh uncontaminated air. Paints, varnishes, laundry bleaches, detergents, many household cleaners, water softening salts, adhesives, and all such products release fumes containing compounds which could lead to early heat exchanger and vent system deterioration. Do not store these type of products near your furnace and consider fresh air for your furnace during construction or remodeling.

Neverstoregasoline,combustiblematerials,orother flammable liquids or vapors near your furnace.

If you have a problem, check the "Problem Solver" section of this manual before you call for a possibly unneeded service call.

Parts and controls of this furnace are unique. Should service or modification be required, be sure your servicer uses only factory authorized parts, kits, or accessories for this furnace.

WARNING:

These furnaces are not approved or intended for installation in manufactured (mobile) housing, trailers, or recreational vehicles. Failure to follow this warning could result in property damage, personal injury, or death.

WARNING:

Do not touch igniter. It is extremely hot. Failure to follow this warning could result in severe burns, other injury, property damage, or death.

CAUTION:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation and operation instructions for the venting system's operation could result in carbon monoxide poisoning or death.

Page 2

Pub. No. 32-5034-02

Filter maintenance reduces energy use.

WARNING: Disconnect power to the

unit before removing the blower door. Failure to follow this warning could result in property damage,

personal injury or death.

A clean filter saves money.

When the furnace circulates and filters the air in your home, dust and dirt particles build up on the filter. Excessive accumulation can block the airflow, forcing the unit to work harder to maintain desired temperatures.

And the harder your unit has to work, the more energy it uses. So you pay more any time your system is running with a dirty filter.

CAUTION: Never operate your unit for either heating or cooling with filters removed.

Help ensure top efficiency by cleaning the filter once a month. If you have an upflow furnace, you can wash or

change the filter once a month. Clean it twice a month during seasons when the unit runs more often.

Your furnace came from the factory with a cleanable filter. You can clean the filter with a vacuum, OR you can wash it with a household detergent. Good quality, high velocity filters may be used for replacements in upflow furnaces.

With the new patented filter rack on the upflow models, all cleaning or replacing of filters is quick and easy. Clean filters guarantee optimum performance of your system.

Replacing your filter.

When replacing your furnace filters, use a high velocity type filter. On upflow furnaces, standard size 1" thick high velocity filters will fit into the patented filter rack which will automatically adjust in width to fit. Filters are available from your dealer.

How to remove your filter.

WARNING: Disconnect power to the

unit before removing the blower door. Failure to follow this warning could result in property damage, personal injury or death.

The upflow furnace blower door has a hinge at the bottom which allows the door to tilt forward for filter servicing or replacement without the door being removed. The furnace filter in the bottom or side configuration can be removed by simply turning the two latches on the blower door 1/4 turn and tilting the door forward.

Blower Door Hinge and Bottom Filter Rack Installation

The blower door may be removed if necessary by tilting the door outward 2 to 3 inches, then pulling up. The door will slide out of the hinge for removal. For replacement, simply insert the blower door bottom into the space between the furnace base front and the hinge, then tilt inward and latch.

Typical Upflow Right Side Return Filter Installation

Pub. No. 32-5034-02

Page 3

Filter Rack Assembly

The filter rails are spring loaded for automatic adjustment to allow standard size, locally obtainable replacement filters. The filter rack itself slides to adjust to the required width needed for bottom or side return. Always insert the chamfer (angle edged sides) end first.

CHAMFER

END OF

FILTER GOES

INTO FILTER

RACK FIRST

The furnace filter may be secured with filter retaining brackets for right side return on smaller furnaces. To replace filters on these furnaces, remove the blower access door, push back to flex the filter and clear the filter retaining bracket at the front of the unit. Gently pull the filter out. After cleaning, replace the filter in the same manner making sure that filter is secured in place in both front and back filter retaining brackets of the unit. Replace blower access door.

Page 4

Air filters may also be located outside of the furnace using a SIDE FILTER FRAME.

UPFLOW ONLY

Upflow / Horizontal Furnace Filters

The Upflow/Horizontal furnace, when installed horizontally, requires a horizontal filter kit. The filters may be located remote to the furnace or in the return air duct near the furnace. Check with your dealer for the location of your filters.

An upflow/horizontal furnace in horizontal return air filter application, as shown, features two 14" x 20" x 1" filters in the 14-1/2"wide furnace cabinets; or two 16" x 20" x 1" filters in the17-1/2",21", and24-1/2"wide furnace cabinets.

UPFLOW/HORIZONTAL WITH FILTER KIT

To replace filters, remove the filter access door, lift the filter from the lower bracket and shift the filter to the side to free the top filter from the bracket and slide the filters out through the filter access door. After cleaning, replace the filters in the same manner making sure that the filters are secured in place in both top and bottom filter brackets. Replace filter access door.

Air filters may also be located outside of the furnace using a remote filter grille. The filter grille could be in a hallway, wall, or in the ceiling. Check with your dealer for the exact location of your filter and the method of changing the filters.

Pub. No. 32-5034-02

FACTORY SUPPLIED UPFLOW FURNACE

RETURN AIR FILTERS

UPFLOW FURNACE RETURN AIR FILTERS

CABINET

QTY*

CABINET

CABINET

WIDTH

BOTTOM FILTER

SIDE FILTER

 

 

 

 

 

14-1/2"

1

14" X 25" X 1"

17-1/2"X 25" X 1"

 

 

 

 

17-1/2"

1

17" X 25" X 1"

17-1/2"X 25" X 1"

 

 

 

 

21"

1

20" X 25" X 1"

17-1/2"X 25" X 1"

 

 

 

 

24-1/2"

1

24" X 25" X 1"

17-1/2"X 25" X 1"

 

 

 

 

*NOTE - On 5 or 6 ton airflow models, if the airflow requirement exceeds 1800 CFM, these models will require filters on both sides;OR 1 sideand the bottom;OR just the bottom.

WARNING: Disconnect power to the

unit before removing the blower door. Failure to follow this warning could result in property damage, personal injury or death.

Downflow Furnace Filters

Downflow/Horizontal furnaces use 2 standard size permanent type air filters which may be located remote to the furnace or in the return air duct. Check with your dealer for the location of your filters.

A downflow/horizontal furnace vertical return air filter application, as shown, features two 14" x 20" x 1" filter in the 14-1/2"wide furnace cabinets; or two 16" x 20" x 1" filter in the17-1/2",21", and24-1/2"wide furnace cabinets.

DOWNFLOW FILTER

A downflow/horizontal furnace with horizontal return air filter application, as shown, features two 14" x 20" x 1" filter in the 14-1/2"wide furnace cabinets; or two 16" x 20" x 1" filter in the17-1/2",21", and24-1/2"wide furnace cabinets.

DOWNFLOW/HORIZONTAL FILTER

DOWNFLOW FILTER TABLE

REQUIRED FILTERS - DOWNFLOW

CABINET WIDTH

FILTER QUANTITY & SIZE

 

 

 

14-1/2"

2 - 14" X 20" X

1"

 

 

 

17-1/2"

2 - 16" X 20" X

1"

 

 

 

21"

2 - 16" X 20" X

1"

 

 

 

24-1/2"

2 - 16" X 20" X

1"

 

 

 

Pub. No. 32-5034-02

Page 5

The problem solver.

A furnace is not a household appliance. It is complex and requires professional maintenance and repair.

That’s why attempts at “do-it-yourself”repairs on an inwarranty unit may void the remainder of your warranty.

Other than performing the simple maintenance recommended in this manual, you should not attempt to make any adjustments to your furnace. Your dealer will be able to take care of any questions or problems you may have. A periodic inspection of your furnace should be made by a qualified service agency at the start of each heating season.

Keep your furnace looking like new for years.

Clean the enamel finish of your furnace with ordinary soap and water. For stubborn grease spots, use a household detergent. Lacquer thinner or other synthetic solvents may damage the finish.

WARNING:

Do not touch igniter. It is extremely hot. Failure to follow this warning could result in severe burns, other injury, property damage, or death.

CAUTION:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

Save time and money. Before calling for service, check the following:

Problem

 

Possible Trouble

 

Possible Remedy

No Heating - Blower

1.

Thermostat set incorrectly.

1.

Adjust thermostat See operating

Does not operate

 

 

 

instructions

 

2.

Blown fuse or tripped circuit breaker.

2.

Replace or reset protective device

 

 

 

 

or call for servicer.

 

3.

Defective component.

3.

Most controls are automatic and will

 

 

 

 

recycle. If your unit still does not

 

 

 

 

operate call for servicer.

 

4.

Burner does not ignite.

4.

Call servicer.

 

5.

Main gas line turned off.

5.

Have gas company check.

 

6.

Blower door removed or ajar.

6.

Close door securely to restore power

 

 

 

 

to blower and gas valve.

 

7.

Lockout

7.

Turn power on-off-on-offtwice

 

 

 

 

in 30 secs.

 

 

 

 

 

Insufficient Heating -

1.

Dirty air filters.

1.

Clean or replace filters.

Blower operates

 

 

 

 

continuously

2.

Blocked supply or

2.

Make sure registers are open and

 

 

return registers.

 

No obstacles blocking off the air.

 

 

 

 

No Heat - Vent motor

Restricted or plugged furnace

1.

Remove drain clamps to condensate

is running

condensate drain.

 

trap and drain pan outlet

 

 

 

2.

Flush or clear drain blockage.

 

 

 

3.

Reinstall clamps.

 

 

 

 

 

Unusual Noise

 

 

 

Call your servicer

 

 

 

 

 

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation and operation instructions for the venting system's operation could result in carbon monoxide poisoning or death.

Page 6

Pub. No. 32-5034-02

Maintenance information.

Never stop the cooling system by shutting off the main power.

If the main power to your air conditioner is ever disconnected for more than three hours, turn off the thermostat. Then wait for at least three more hours after the power has been restored before turning the thermostat back on. Failure to follow this procedure could result in damage to your air conditioning system.

1. GENERAL INSPECTION - Examine the furnace installation for the following items:

a.All flue product carrying areas external to the furnace (i.e. chimney, vent connector) are clear and free of obstruction.

b.The vent connector is in place, slopes upward and is physically sound without holes or excessive corrosion.

c.The return air duct connection(s) is physically sound, is sealed to the furnace and terminates outside the space containing the furnace.

d.The physical support of the furnace should be sound without sagging, cracks, gaps, etc., around the base so as to provide a seal between the support and the base.

e.There are no obvious signs of deterioration of the furnace.

WARNING:

Do not touch igniter. It is extremely hot. Failure to follow this warning could result in severe burns.

2.BLOWERS - The blower size and speed determine the air volume delivered by the furnace. The blower motor bearings are factory lubricated and under normal operating conditions usually do not require servicing. Annual cleaning of the blower wheel and housing is recommended for maximum air output, and this must be performed only by a qualified servicer or service agency.

3.IGNITER - This unit has a special hot surface direct ignitiondevicethatautomaticallylightstheburners.Please note that it is very fragile and should be handled with care.

CAUTION: Do not touch igniter. It is extremely hot.

4. BURNER - Gas burners do not normally require scheduled servicing, however, accumulation of foreign material may cause a yellowing flame or delayed ignition. Either condition indicates that a service call is required. For best operation, burners must be cleaned annually using brushes and vacuum cleaner.

Turn off gas and electric power supply. To clean burners, remove top burner bracket and lift burner from orifice.

NOTE: Be careful not to break igniter when removing burners. Clean burners with brush and/or vacuum cleaner. Reassemble parts by reversal of the above procedure.

Pub. No. 32-5034-02

NOTE: On LP (propane) units, some light yellow tipping of the outer mantle is normal. Inner mantle should be bright blue.

Natural gas units should not have any yellow tipped flames. This condition indicates that a service call is required. For best operation, burners must be cleaned annually using brushes and vacuum cleaner.

NOTE: On LP (propane) units, due to variations in BTU content and altitude, servicing may be required at shorter intervals.

5.HEAT EXCHANGER / FLUE PIPE - These items must be inspected for signs of corrosion, and/or deterioration at the beginning of each heating season by a qualified service technician and cleaned annually for best operation.

6.CIRCUIT PROTECTION - If blower or gas valve fail to operate, the cause could be the circuit breaker or a loose or blown fuse. Replace fuse or reset circuit breaker.

7.OPERATION - Your warm air furnace should not be operated in a corrosive atmosphere. Paint solvents, cleaning chemicals, spray propellants, and bleaches should not be used in the vicinity of the furnace during normal operation.

8.COOLING COIL CONDENSATE DRAIN - If you have a cooling coil installed with your furnace, condensate drains should be checked and cleaned periodically to assure that condensate can drain freely from coil to drain. If condensate cannot drain freely water damage could occur.

9.AIR CIRCULATION - To ensure increased comfort, blower on this unit may be operated continuously for both heating and cooling. This will result in constantly filtered air and aid in maintaining more even temperatures by avoiding temperature stratification throughout the conditioned area. To accomplish constant air circulation, set your thermostat fan switch to "ON".

Page 7

WARNING: Disconnect power to the

unit before removing the blower door. Failure to follow this warning could result in property damage, personal injury or death.

WARNING: DO NOT USE THIS UNIT IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.

For your safety.

Furnace area must be kept clear and free of combustible materials, gasoline, and other flammable vapors and liquids.

Air for combustion and ventilation.

The flow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings provided in the casing of furnace must be kept free of obstructions which would restrict airflow, thereby affecting efficiency and safe operation of your furnace.

Also, air openings provided to the area in which the furnace is installed and the space around the furnace shall not be blocked or obstructed. Keep this in mind should you choose to remodel the area which contains your furnace. Furnaces must have air for proper performance.

If additional insulation is added after the furnace is installed, the area around the furnace must be inspected to ensure it is free and clear of insulation. If this furnace is installed in an attic or other insulated space it must be kept free and clear of all insulating materials as some insulating materials are combustible.

Manual Main Gas Shut-offValve May Be Located on the Left or Right Side

Manual Main Gas Shut-offValve May Be Located on the Top or Bottom Side

NOTE THE LOCATION OF THE MANUAL MAIN GAS SHUTOFF VALVE FOR YOUR FUR-

NACE.

Have your installer or servicer show you the location if you have any questions.

Page 8

Pub. No. 32-5034-02

To light furnace.

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury, or loss of life.

Lighting instructions.

Your furnace is equipped with a hot surface direct ignition device.

WARNING.

Do not attempt to manually light the furnace.

1.Please read all safety information in this book before operating furnace.

2.Set thermostat to lowest setting. Turn off all electric power to furnace.

3.Remove control access panel.

4.Turn gas cock knob on main gas valve with unit clockwise to “OFF” position. If external gas cock is used, turn to “OFF” position. Allow 5 minutes for any gas within the unit to escape. LP gas being heavier than air may require forced ventilation. If you smell gas STOP! Follow the “What To Do If You Smell Gas” instructions on the front cover of this book. If you don’t smell gas, go to next step.

5.Turn gas cock knob counterclockwise to “ON” marker.

6.Replace control access panel.

7.Turn on main electrical supply and set thermostat to desired setting. Combustion blower will start and ignition device will start to heat up. After approximately 15 seconds main gas valve will open and burners will ignite.

8.When thermostat is satisfied, main burners will extinguish.

9.If main burners fail to ignite, lower thermostat setting or disconnect electrical supply, wait 5 minutes, raise thermostat setting above indicated temperature.

10.If furnace will not light, turn “OFF” all gas and electricity to unit and call servicer or gas supplier.

For complete shutdown.

Turn gas cock knob on main gas valve to “OFF” position. Disconnect electrical supply to unit.

CAUTION: If this is done during the cold weather months, provisions must be taken to prevent freeze-upof all water pipes and water receptacles.

Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. If your furnace should fail to operate, damage could result, such as frozen water pipes.

Safety cutoff device (thermal limit).

All models are equipped with a fusible link behind gas valve. In case of main gas valve malfunction and consequent overheating, link will open and close off flow of all gas. See instruction label on front panel of heat exchanger.

Your furnace may have a "Knob Switch" or a "Toggle Switch" to turn the gas ON or OFF.

Pub. No. 32-5034-02

Page 9

Limited Warranty

High Efficiency Induced Draft Gas Furnace

UE, DE, UD-R,DD-R,UD-RV,DD-RV,

UD-C,DD-C,CUB and CDB

Models Less Than 20 Tons for Residential Use* (Parts Only)

This limited warranty is extended by American Standard Inc., to the original purchaser and to any succeeding owner of the real property to which the Gas Furnace is originally affixed, and applies to products purchased and retained for use within the U.S.A. and Canada.

If any part of your Gas Furnace fails because of a manufacturing defect within five years from the date of the original purchase, Warrantor will furnish without charge the required replacement part. Any local transportation, related service labor, air filters, and diagnosis calls, are not included.

In addition, if the steel heat exchanger fails because of a manufacturing defect within the sixth through twentieth year from the date of original purchase, Warrantor will furnish without charge a replacement heat exchanger. Any local transportation, related service labor, air filters, and diagnosis calls, are not included.

This limited warranty does not cover failure of your gas furnace if it is damaged while in your possession, failure attributable or caused by unreasonable use of the gas furnace and/or failure to properly maintain the gas furnace as set forth in the Use and Care manual.

This limited warranty applies to product installed on or after 10/1/2001 where product is manufactured after 1/1/2000. This limited warranty is not retroactive to any installations prior to 10/1/2001 or on product produced prior to 2000.

THE LIMITED WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, AND IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied limited warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Parts will be provided by our factory organization through an authorized service organization in your area listed in the yellow pages. If you wish further help or information concerning this limited warranty, contact:

American Standard Inc.

Troup Highway

Tyler, TX 75711-9010

Attention: Manager, After Sales Support

GW-615-4001

* This limited warranty is for residential usage of this equipment and not applicable when this equipment is used for a commercial application. A commercial use is any application where the end purchaser uses the product for other than personal, family or household purposes.

Warranty Information

Service Information

It’s always a good idea to keep records which will save you time

Call your installing dealer if the unit is inoperative. Before

and money. If it’s necessary to have your FURNACE repaired,

you call, always check the following to be sure service is

the service man will want to know if your unit is still under

really required:

Warranty. To save time, take a few minutes to record the

a. Be sure the main switch that supplies power to the unit is

following information here:

in the “ON” position.

Model Number:_____________________________________

b. Replace any burned-outfuses or reset circuit breakers.

Serial Number: _____________________________________

c. Be sure the thermostat is properly set.

Date of Purchase:___________________________________

 

Extended warranties are available from the manufacturer through your dealer. The limited warranty is backed by the manufacturer and any representations made about extending the limited warranty would be backed by the manufacturer if and only if an extended warranty agreement was received from the manufacturer.

Page 10

Pub. No. 32-5034-02