Goodman ACVC8, AMVC8, GCVC8, GMVC8 User Manual

Service Instructions

Goodman

& Amana® Brand

80% Communicating Gas Furnaces

ACVC8, AMVC8, GCVC8, GMVC8

& Accessories

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

The material in this manual does not supercede manufacturer’s installation and operation instructions.

RS6620001

November 2016

TABLE OF CONTENTS

IMPORTANT INFORMATION ......................... 2 - 4

PRODUCT IDENTIFICATION ...................... 5 - 10

ACCESSORIES ..........................................11 - 12

OPERATING INSTRUCTIONS ...................13 - 15

PRODUCT DESIGN ...................................16 - 41

SYSTEM OPERATION ...............................42 - 45

TROUBLESHOOTING ................................ 46 - 51

SYSTEM OPERATION COMFORTNET™ ... 52 - 57

POLARIZATION AND PHASING ........................ 58

MAINTENANCE ...........................................59 - 61

SERVICING .................................................62 - 80

SERVICING TABLE OF CONTENTS ................ 62

ACCESSORY WIRING DIAGRAMS .............81- 82

WIRING DIAGRAMS..................................... 83- 85

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 FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR

REPAIR (HEREINAFTER

MANUAL SHOULD SERVICE THE EQUIPMENT

BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM

IMPROPER SERVICE OR SERVICE PROCEDURES

ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY

RESULT

. IN

LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY

LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT

INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT

SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR

REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER

TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH

, “

SERVICE

”)

THE EQUIPMENT SPECIFIED IN THIS

. THE

MANUFACTURER WILL NOT

. IF

YOU SERVICE THIS UNIT, YOU

ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE

. I

MPROPER

WARNING

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATER IALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPL IANCE.

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFOR E SERVICING OR

INSTALLING THIS UNIT. BE PR ESENT. DAMAGE, PERSO NAL INJURY OR DEATH.

FAILURE TO DO SO M AY CAU SE PROPERTY

MULTIPLE POWER SOURCES MAY

IMPORTANT INFORMATION

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 INFORMATION LINE GOODMAN® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

customerservice@goodmanmfg.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

hac.consumer.affairs@amanahvac.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

IMPORTANT INFORMATION

CO can cause s erious illness includ ing permanent brain damage or death.

Advertenc ia especia l para la instalación de c alentadores ó manejado ras de aire en áreas cerradas como estacionamientos ó cuartos de servicio.

B10259-216

Las emisiones de monóxido de carbono pueden circular a través del aparato cu ando se opera en cualqu ier modo.

El monóx ido de carbono puede c ausar enfermedad es severas como daño cerebral permanente ó muerte.

RISQUE D'EMPOISONNEMENT AU

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouv ant survenir si un appar eil produisant du monox yde de carbone continue de fonctionner au sein de la zone confinée.

MONOXYDE DE CARBONE

B10259-216

PRODUCT IDENTIFICATION

The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information.

G M V C 80 060 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Brand Minor Rev isi on G- Goodman A - Initial Release

B - 1st Revision Conf igur ati on M - Upflow/Horizontal Major Re visio n C - Downflow/Horizontal A - Initial Release

B - 1st Revision Mot o r V - Variable Speed/ComfortNet Nox

N - Natural Gas Gas Valve X - Low NOx M - Modula ting C - 2 Stage Cabi net Width

A - 14" AFUE B - 17.5" 97 - 97% AFUE C - 21" 80 - 80% AFUE D - 24.5"

MBT U / h Max imum C FM 40 - 40,000 3 - 1200 CFM 60 - 60,000 4 - 1600 CFM 80 - 80,000 5 - 2000 CFM 100 - 100,000 120 - 120,000

A M V C 80 060 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Brand Min or Revision A- A mana® A - Initial Release

B - 1st Revisi on Configuration M - Upflow/Hori zontal Maj or Re vi si on C - Downflow/Horizontal A - Initial Release K - Dedi cated Upflow B - 1st Revision

Nox Mot or N - Natural Gas V - Variable Speed/ComfortNet X - Low NOx E - High Ef fici ency S - Si ngle Speed Cabinet Width

A - 14" Gas Val ve B - 17. 5" M - Modulating C - 21" C - 2 St age D - 24.5" H - Convertible 2 Stage S - Si ngle Stage Maximum CFM

AFUE 4 - 1600 CFM 97 - 97% AFUE 5 - 2000 CFM 80 - 80% AFUE

MBT U/h 40 - 40, 000 60 - 60, 000 80 - 80, 000 100 - 100,000 120 - 120,000

3 - 1200 CFM

PRODUCT IDENTIFICATION

MODEL # MFG #

GMVC80603B*BC GMVC80604B*BC GMVC80803B*BC

GMVC8***BC

GCVC8***BC

AMVC8***BC

ACV C8***BC

GMV C80804C*BC Horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially GMVC80805C*BC commun icati ng ECM motor. 120 volt silicon nitride igniter. L eft or Right gas pipe entry. Models are low GMV C80805D*BC NOx. Aluminized Steel tubular heat exchanger . Available cabinet widths 17.5"and 21. GMVC81005C*BC

GCVC80603BXBC GCVC80803BXBC GCVC80805CXBC GCVC81005CXBC

AMV C80603B*BC AMV C80604B*BC AMV C80803B*BC Amana® Brand 80% communicating capable furn ace, f iri ng at 20,000 BTUH per b urne r, 33 3/8" t all , UPfl ow / AMV C80804C*BC Hori zont al in stallati on positions, 2 stage g as he at, su pport s 2 stage cooli ng, i nduce d draf t. 4 wi re se rial ly AMV C80805C*BC comm unicating ECM motor. 120 volt sil icon nitride igni ter. L eft or Ri ght gas pipe e ntry. Mode ls are low AMV C80805D*BC NOx. Stain less ste el t ubular heat exchanger . Available cabi net widths 17.5"and 21. AMV C81005C*BC

AC VC80603BXBC AC VC80803BXBC AC VC80805CX BC AC VC81005CX BC

DESCRI PTION

Goodman® Brand 80% communicati ng capable furnace, firing at 20,000 BTUH per bu rner, 33 3/8" tall, UPf low /

Goodman® Brand 80% commun icati ng cap able furnace, firing a t 20,000 BTUH p er burner, 33 3/8" ta ll, Downfl ow / Horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon nitride igniter. L eft or Right gas pipe entry. Models are low NOx. Aluminized Steel tubular he at exchanger . Available cabinet widths 17.5"and 21.

Amana® Brand 80% communi cating capable furn ace, f iri ng at 20,000 BTUH per burner, 33 3/ 8" tal l, Downflow / Horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communi cating ECM mo tor. 120 v olt s ilicon nitride igniter. L eft or Right gas pipe entry. Models are low NOx. Stainless steel tubular heat exchanger . Available cabinet widths 17.5"and 21.

PRODUCT IDENTIFICATION

MODEL # MF G # DESCRI P TION

AFE18-60A

CTK01AA

CTK01BA

CTK02**

N/A

CTK01AA

CTK01BA

CTK02**

Fossil Fuel Kit -

above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pum ps and single and two stage furnaces. The AFE18-60A control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature initiates a 3 minute timed off delay when the com pressor goes off.

Communicating Thermostat Kit

necessary part of any communicating system. Designed for use with compatible Air Handlers or Furnaces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two stages of cooling, dual fuel applications, dehumidification, filter maintenance reminders, outdoor temperature display and advanced menus including diagnostics. The CTK01AA kit includes a communicating touchscreen thermostat and sub base, 230V-24V 40va transformer, terminal blocks (2), wire jum pers, mounting screws, installation manual and homeowner guide.

Communicating Thermostat Kit

necessary part of any communicating system. Designed for use with compatible Air Handlers or Furnaces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two stages of cooling, dual fuel applications, dehumidification, filter maintenance reminders, outdoor temperature display and advanced menus including diagnostics. The CTK01BA kit includes a communicating touchscreen thermostat and sub base, terminal blocks (2), installation manual and homeowner guide.

Communicating Thermostat Kit -

any communicating system. Designed for use with compatible Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK02** thermostat features a full color high definition display, advanced programming options including humidification control & heat and cool maximum temperature settings, a USB plug allowing dealers the ability to insert programmed operating parameters and dealer information by use of an online data entry system.

The AFE18-60A control is designed for use where the indoor coil is located

- Digitally communicating touchscreen thermostat, a

Digitally communicating thermostat, a necessary part of

CTK03AA

CTK03AB

CTK03AA

CTK03AB

Communicating Thermostat Kit -

Honeywell. Designed for use with compatible Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AA thermostat features full color high definition display and can be used with RedLINK wireless accessories.

Communicating Thermostat Kit -

Honeywell. Designed for use with compatible Amana ® Brand or Goodman ® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AB thermostat Features full color high definition display and can be used with RedLINK wireless accessories and added capability to control the HUN IN - HUM OUT relay on the PCBKF103, PCBKF104, and PCBKF105 control board.

Digitally communicating touchs creen therm ostat from

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

DEHUM1

EFR01

HA02

P1 227801F

P 1221001

P1 221002F

P1 129112F

Dehumidistat

reduce the airflow in the air conditioning mode to lower the humidity in an occupied home. T his control features a moisture-sen sitive nylon element and also provides positive On-Off settings for manual operation. The control i s a normally closed switch that opens on humidity rise causing the blower to switc h to a lower speed to control the humidity within the structure.

External Fi lter Rack K it

a location, external to t he furnace casing, for installation of a permanent filter. The rack is mount ed over the indoor air blower compartment area of either side panel, and p rovide filter retention as well as l ocation for attaching return air ductwork.

Hig h Altitu de Kit

This kit is required when installing these furnace s above their maximum rated altitude. T his kit contains # 43-49, 55-58 gas orfices. The orfices in the kit have been sele cted as a result of testing wit h the American Gas Association. they will provide appropriate derating at the altitude liste d in the High Altitude Charts as shown in the i nstallation instructions of the kit.

. Wall mou nted, 24 volt hu midity control available as a Dehumidistat used to

. For u se wit h upflow gas furnace models. This kit is intended to provide

. The kit is designed to convert 80% gas furnace models at higher alti tudes.

MO DEL # MFG # DESCRIPTI ON

.For use with furnaces converted to LP gas. This kit includes

LPLP03

N/A

LP Gas Low Pressure Kit

harness adaptors to work with White-Rodgers single & two stage gas valves, Honeywell single and two-stage gas valves, as well as modulating gas valves.

LPM-06

SBT17 SBT21

N/A

LP Conversion Kit

gas valve kit or a Honeywell VR9205 2-stage gas valve kit. Includes regulator springs, #55 orifices, instructions and lable to show the furnace has been converted to L.P.

Downflow Subbase.

available for the following furnace widths: 17.5" wide (SBT17), 21" wide (SBT21)

. For use with 2-stage models using a White-Rodgers 36G54 2-stage

For use with 80% Counterflow furnace models. These kits are

ACCESSORIES

EXTERNAL FILTER RACK KIT

( EFR01 )

SLOTS IN FILTER CLEAR SCREWS

ON UNIT

UNIT SIDE

PANEL

BLOWER DECK

SCREWS

FRONT

OF UNIT

BASE

OF UNIT

RETURN AIR

CUTOUT AREA

LOWER EDGE

SCREW

EFR01 EX TERNAL FILTER RACK KIT

Used on Models

80% Upflow Model Furnaces

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

ACCESSORIES

Model

Number

Description

*MVC80603B *MVC80604B *MVC80803B *MVC80804C *MVC80805C *MVC80805D *MVC80805C

*CV C80603B *CV C80803B *CV C80805C *CV C81005C

EFR01

AFE180-60A

Rack

Dual Fuel Board

●● ●

●●●

EFR External Filter

SBT17

17.5"

Downflow Subba s e

SBT21

21"

Downflow Subba s e

Communicating

CTK0*

Thermostat

Propane Gas

(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

LPM06

Conversion Kit

LPLP03

Shut Off Kit

LP Low Pressure

●

High Altitude Natural (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)

HA-02

Gas Orifices

DEHUM1

Dehumidistat

●

(1) (2)

Not Approved for this model Approved for this model

W/R and HW 2 stage valves 7,000 - 11,000 FT altitude

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

B. BEFORE OPERATING smell around the appliance 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

Do not try to light any appliance. Do not touch any electric switch; do not use any telephone in your building. Immediately call your supplier from a neighbor's phone. Follow the gas suppliers instructions.

If you cannot reach your gas supplier,

call the fire department.

C. Use only your hand to move the gas control switch or knob. Never use tools. If the gas control switch or knob will not operate, 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 under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an automatic ignition system which automatically lights the burners. Do not try to light the burners by hand.

5. Remove control access panel.

6. Move the gas control switch or knob to "OFF".

GAS CONTROL SWITCH SHOWN IN "O N" POS ITION

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP!above on this label. Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

8. Move the gas control switch or knob to "ON".

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

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

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove control access panel.

4. Move the gas control switch or knob to "OFF". Do not force.

5. Replace control access panel.

WARNING: Improper

alteration, service or maintenance can cause injury or property damage. Refer to the user's information manual provided with this

consult a qualified

or the gas supplier.

This furnace must be

instructions and local codes. In the absence of local codes, follow the National Fuel Gas

Code, ANSI Z223.1.

For indoor installation.

PGB & PGJ For outdoor installation only.

If notWARNING:

installed, operated and maintained in accordance with the manufacturer's instructions, this product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the State of California to cause cancer, birth defects or other reproductive harm. This product contains fiberglass insulation. Fiberglass insulation contains a chemical

California to cause cancer.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

0140F00001P

OPERATING INSTRUCTIONS

CONSIGNES DE SECURITE - LIRE

AVANT D'ALLUMER L'APPAREIL

AVERTISSEMENT: Le non-respect des instructions qui suivent peut

entrainer un risque d'incendie ou d'explosion causant des dommages, des blessures ou la mort.

A. Cet appareil comporte pas de veilleuse. Il est muni d'un mecanisme qui allume automatiquement le bruleur. N

B. Sentir tout autour de l'appariel AVANT D'ALLUMER afin de deceler toute fuite de gaz. Assurez-vous de sentir tout pres du plancher car certains gaz sont plus lourds que l'air et se deposeront sur le plancher.

SI VOUS SENTEZ UNE ODEUR DE GAZ: Ne tentez d'allumer aucun appariel.

Ne touchez pas aux interrupteurs electriques; n'utiliser aucun telephone dans l'edifice ou vous vous trouvez. Appelez immediatement votre fournisseur de gaz en utilisant le telephone d'un voisin et suivez les instructions du fournisseur. Appelez les pompiers si vous ne parvenez pas a rejoindre votre fournisseur de gaz.

C. N'utiliser que votre main pour pousser ou tourner le commande du gaz. N'utilisez jamais d'outils. Si vous ne parvenez pas a pousser ou a tourner la commande, ne tentez pas de la reparer; appelez un reparateur qualifie. Forcer la commande ou essayer de la reparer peut entrainer un risque d'incendie ou d'explosion.

D. N'utilisez pas cet appareil si l'une de ses parties a ete dans l'eau. Si cela se produit, demandez immediatement a un reparateur qualifie d'inspecter l'appareil et de remplacer toute piece du systeme de controle et toute commande de gaz ayant ete dans l'eau.

'allumez paz le bruleur manuellement.

0140F00002P

1. UN INSTANT! Lisez d'abord les consignes

INSTRUCTIONS DE SERVICE

de securite ci-dessus.

2. Reglez le thermostat a son point le plus bas.

3. Coupez l'alimentation electrique de l'appareil.

4. Cet appareil est muni d'un mecanisme qui allume automatiquement le bruleur. Ne tentez pas d'allumer le bruleur manuellement.

5. Retirez le panneau d'acces de la commande.

6. Mettez la commande de gaz a la position

ARRET ("OFF").

7. Attendez cinq (5) minutes afin de permettre a tout gaz present d'etre evacue. Si vous sentez une odeur de gaz a ce moment, ARRETEZ! et suivez les consignes de securite donnees au paragraphe B ci-dessus. Si vous ne sentez pas de gaz, passez a l'etape suivante.

8. Mettez la commande de gaz a la position MARCHE ("ON").

9. Remettez la panneau d'acces de la commande en place.

10. Retablissez l'alimenation electrique de l'appareil.

11. Reglez le thermostat a le temperature desiree.

12. Si l'appareil ne fonctionne pas, suivez les instructions intitulees "Arret du gaz" et appelez un reparateur qualifie ou votre fournisseur de gaz.

1. Reglez le thermostat a son point le plus bas.

2. Coupez l'alimentation electrique de l'appareil si vous devez effectuer un entretien.

3. Retirez le panneau d'acces de la commande.

4. Mettez la commande de gaz a la position ARRET ("OFF").

5. Remettez le panneau d'acces de la commande en place.

ARRET DU GAZ

Commande de gaz en position

"MARCHE"

OPERATING INSTRUCTIONS

R M

PRODUCT DESIGN

Safety

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATI ON, SERV ICE OR MAINTENANCE, R EFER TO THI S MANUAL. QUALIFIED INSTALLE R, SERVICE AGENCY OR THE GAS SUPPLIER.

MAY CAUSE SERI OUS ILLNESS OR DEATH AN D WHICH ARE KNOWN TO THE

REPRODUCTIVE HARM.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

TATE OF CALIFORNIA TO CAUSE CANCER, BI RTH DEFECTS OR OTHER

WARNING

Product Application

This product is designed for use as a residential home gas furnace. It is not designed or certified for use in mobile home, trailer, or recreational vehicle applications.

This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches,

Retail stores, Nursing homes, Hotels/motels, Common or office areas. In such applications, the furnace must be installed

with the

installation instructions.

Goodman & Amana® 80% furnaces are ETL certified appliances and are appropriate for use with natural or propane gas. (NOTE: If using propane gas, a propane conversion kit is required).

IMPORTANT NOTE: The 80% furnace 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.

To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and application of this product.

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELEC TRICA L COMPON ENTS FROM WAT ER.

Charge (ESD) Precautions NOTE: Discharge body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in Step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Step 2 before touching control or wires.

4. Discharge any static electricity from your body to ground before removing a new control from its container. Follow Steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

WARNING

OSSIBLE PROPERTY D AMAGE, PERSONAL INJ URY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, S OOT, CONDENSTAION, E LECTRICAL SHOCK OR C ARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, RE PAIR, OPERATI ON, OR MAINTENANCE OF THI S PRODUCT.

WARNING

O PREVENT PROPERTY DAMAGE, PERSONAL INJ URY OR DEATH D UE TO FIRE, DO NOT INSTALL T HIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute 25 West 43rd Street, 4th Floor New York, NY 10036

National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471

PRODUCT DESIGN

CSA International 8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CGA B149 Installation Codes can be obtained from:

CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W, 1R3

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.

Location Requirements and Considerations

WARNING

O PREVENT POSSIBLE EQUI PMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FO LLOWING BULLET P OINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

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

Combustion and Ventilation Air Requirements section in this

manual or the installation instructions for details.

• Centrally locate the furnace with respect to the proposed or existing air distribution system.

• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

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

• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.

80% Furnaces: All installations must be vented in accordance with National Fuel Gas Code, NFPA 54/ ANSI Z223.1 - lateset edition. In Canada the furnaces must be vented in accordance with the National Standard of Canada, CAN/CGA B149.

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

• A special accessory subbase must be used for upright counterflow unit installations over any combus-

tible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.

• Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances:

chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride 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

• To ensure that the enclosed non-direct vent furnace

has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Re-

fer to the Combustion and Ventilation Air Require- ments section in this manual or the installation in-

structions for details.

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

• If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/ bottom” side of the furnace.

Clearances and Accessibility

Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Refer to Specification Sheet for minimum clearances to combustible materials. Clearances

PRODUCT DESIGN

must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

Furnace Suspension

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following figure. If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. The length of rod will depend on the application and the clearances necessary.

PROVIDE 8" MINIMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BL OWER REMOVAL.

3/8" DIAMETER

THREADED ROD

(6 PLACES)

HOLD DOWN

NUTS

SUPPORT

NUTS

GAS PIPING

2"X2"X1/8" ANGLE IRON

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE

TO BLOWER DECK TO AL LOW FOR

CIRCULATOR BLOWER REMOVAL.

ALTERNATE

GAS PIPING

90% Suspended Furnace Shown

(80% Furnace Similar)

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting

system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, latest edition, CSA-2.3b, latest edition Section 1.23.1.

ASSURE FURNACE IS LEVEL FROM

END TO END.

90% FURNACES MAKE SURE

THE UNIT HAS A SLIGHT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE.

CONDENSATE

DRAIN

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL.

that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

c. In so far as practical, close all building doors and windows and all

doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

d. Follow the lighting instructions. Place the appliance being in-

spected in operation. Adjust thermostat so appliance shall operate continuously;

e. Test for draft hood equipped spillage at the draft hood relief

opening after 5 minutes of main burner operation. Use the flame of a match or candle;

f. After it has been determined that each appliance connected to the

venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

g . If improper venting is observed during any of the above tests, the

common venting system must be corrected.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149

Installation Codes.

Thermostat Requirements NOTE: A single-stage thermostat with only one heating stage

may be used to control ComfortNet™ compatible furnaces. The application of a single-stage thermostat does not offer “true” thermostat-driven two-stage operation, but provides a

timed transition from low to high fire. The furnace will run on

low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.

To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position. Turn power back on. Refer to the following figure.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch,

as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine

PRODUCT DESIGN

Heat OFF Delay DIP Switches

ONOFF

Thermostat

Stage Delay

Move to the ON position to select two-stage thermostat or OFF to select single stage thermostat

Move to the ON position to select Auto transition delay or OFF for 5 minute transition delay

Dehumidistat Requirements

A dehumidistat can be used in conjunction with the twostage variable speed furnace to lower the humidity in the conditioned space. The dehumidistat will improve dehumidification of the conditioned air by prompting the furnace to reduce the speed of the circulator blower during operation in the cooling mode. To be compatible with these furnaces, a dehumidistat must operate on 24 VAC and utilize a switch

which opens on humidity rise. Refer to Electrical Connec- tions - 24 Volt Dehumidistat Wiring section in this manual

or the installation instructions for correct installation procedure.

Thermostat and Dehumidistat Location

In an area having good air circulation, locate the thermostat and dehumidistat (if applicable) about five feet high on a vibration-free inside wall. Do not install the thermostat or dehumidistat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat and dehumidistat, such as an outside wall.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH MAY OCCUR

IF THE FURNACE I S NOT PR OVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTIL ATION OF F LUE GASES. MOST HOMES REQUI RE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/ CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI

Z223.1 Section 9.3.

9.3* Air for Combustion and Ventilation.

9.3.1 General.

9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for

appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.

DRAFTS OR DEAD SPOTS

-BEHIND DOORS

-IN CORNER S

-UNDER CABINETS

HOT

COLD

Thermostat Influences

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

Exception No. 1: This provision shall not apply to direct vent appliances.

9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s instructions.

9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.

9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in

PRODUCT DESIGN

determining the adequacy of a space to provide combustion air requirements.

9.3.2 Indoor Combustion Air . The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 except that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total required volume shall be the sum of the required volume calculated for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.

9.3.2.1* Standard Method. The minimum required volume shall be 50

per 1,000/Btu/hour (4.8m3/kW).

9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be determined as follows:

(1) For appliances other than fan-assisted, calculate using the following

equation: Required Volume

> ________ _________

other

(2) For fan-assisted appliances, calculate using the following equation:

Required Volume

> ________ _________

fan

where:

= all appliances other than fan-assisted input in Btu per

other

fan

hour

= fan-assisted appliances input in Btu per hour

ACH = air change per hour (percent of volume of space exchanged

per hour, expressed as a decimal)

21 ft

ACH 1000 Btu/hr

15 ft

ACH 1000 Btu/hr

other

(

fan

(

)

NOTE: Each opening mu st have a free area of not less than one square inch per 1000 BT U of the total input rating of all equipment in the enclosure, but not less than 100 square inches.

Chimney or G as Vent

Water Heater

Furnace

Opening

Figure A.9.2.3.3.(1) All Combustion Air from Adjacent

Indoor Spaces through Indoor Combustion Air Openings.

(2) Combining spaces in different stories. The volumes of spaces in

different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW) of total input rating of all appliances.

9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

(3) For purposes of this calculation, an infiltration rate greater than

0.60 ACH shall not be used in the equations in 9.3.2.2(1) and

9.3.2.2(2).

(1)*Where directly communicating with the outdoors or where commu-

nicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of total input rating of all appliances in the enclosure. [See Figure

9.3.2.3 Indoor Opening Size and Location. Openings used to connect

A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]

indoor spaces shall be sized and located in accordance with the following:

(1)*Combining spaces on the same story. Each opening shall have a

minimum free area of 1 in.

/1000Btu/hr (2200 mm2/kW) of the total input rating of all appliances in the space but not less than 100 in. (0.60m2). One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The mini- mum dimension of air openings shall be not less than 3 in. (80 mm).

lternate

air inlet

Chimney or Gas Vent

Water Heater

Furnace

Ventilation louver s for unheated crawl sp ace

Ventilation louver s (each end of atti c)

Outlet Air

Inlet Air

NOTE: The inlet and outlet a ir openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipm e nt in the enclosure.

Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors -

Inlet Air from Ventilated Crawl Space and Outlet Air

to Ventilated Attic.

PRODUCT DESIGN

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipmen t in the enclosure.

Outlet A ir

Water Heater

Furnace

Inlet air duct [ends 1 ft (300 mm) above floor]

Figure A.9.3.3.1(1)(b) All Combustion Air From Outdoors through Ventilated Attic.

(2)*Where communicating with the outdoors through horizontal ducts,

each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(2).]

Chimney or Gas Vent

NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*.

Furnace

Water Heater

Outlet air duct

Inlet air duct

Figure A.9.3.3.1(2) All Combustion Air From Outdoors

through Horizontal Ducts.

9.3.3.2* One Permanent Opening Method. One permanent open-

ings, commencing within 12 in. (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (see Figure A.9.3.3.2) and shall have a minimum free area of the following: (1) 1 in.

/3000 Btu/hr (700 mm2 per kW) of the total input rating of all

appliances located in the enclosure, and

(2) Not less than the sum of the areas of all vent connectors in the

space.

NOTE: The single opening must have a free area of not less than one square inch per 30 00 BT U o f the total in p ut rat i ng of all e quipment in the enclosure, but not less than the sum of the areas of all vent connecto rs in the c o nfined space.

Chimney or Gas Vent

Water Heater

Furnace

Opening

Alternat e Opening Locatio n

Figure A.9.3.3.2 All Combustion Air

From Outdoors through Single Combustion Air Opening.

9.3.4 Combination Indoor and Outdoor Combustion Air. The use of

a combination of indoor and outdoor combustion air shall be in accordance with (1) through (3) (see example calculation in Annex J]:

(1) Indoor Openings: Where used, openings connecting the interior

spaces shall comply with 9.3.2.3.

(2) Outdoor Opening(s) Location. Outdoor opening(s) shall be located

in accordance with 9.3.3.

(3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be

calculated in accordance with the following:

(a) The ratio of the interior spaces shall be the available volume of

all communicating spaces divided by the required volume.

(b) The outdoor size reduction factor shall be 1 minus the ratio of

interior spaces.

of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

9.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied form outdoors at the minimum rate of 0.35 ft3/min per 1000 Btu/hr (0.034 m3/min per kW) for all appliances located within the space.

9.3.6.1 Where exhaust fans are installed, additional air shall be provided to replace the exhausted air.

9.3.6.2 Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation.

9.3.6.3 Where combustion air is provided by the building’ s mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

9.3.7 Louvers, Grilles, and Screens.

PRODUCT DESIGN

9.3.7.1 Louvers and Grilles. The required size of openings for combustion, ventilation, and dilution air shall be based on the net free area of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position.

9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh.

9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.

9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with

9.3.8.1 through 9.3.8.8.

9.3.8.1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity.

Exception: Within dwellings units, unobstructed stud and joist spaces shall not be prohibited fr om conveying combustion air , pr ovided that not more than one fireblock is removed.

9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances.

9.3.8.3 Ducts shall serve a single space.

Category I Venting (Vertical Venting) (80% Furnaces Only)

WARNING

TO PREVENT POSSIBLE PERSONAL INJ URY OR DEAT H DUE TO

ASPHYXIATION, NON-CO NDENSING GAS FIRED WARM AIR FURNACES MUST

ATEGORY I VENTED. DO NOT VENT ANY O F THESE FUR NACES USING

CATEGORY III VENTIN G.

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: SingleStage and Two-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 CAN/CGA B149.2 - 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

O PREVENT POSSI BLE DEATH OR PERSO NAL INJURY DUE T O

ASPHYXIAT ION, COMMON VE NTING WITH OTHER MA NUFACTURER'S INDUCED DRAFT APPLIANCES IS NOT ALLOWED.

9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air.

9.3.8.5 Ducts shall not be screened where terminating in an attic space.

9.3.8.6 Horizontal upper combustion air ducts shall not slope down-

ward toward the source of combustion air.

9.3.8.7 The remaining space surrounding a chimney liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.

Exception: Direct vent appliances designed for installation in a solid fuel-burning fireplace where installed in accordance with the manufacture’s installation instructions.

9.3.8.8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level.

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

MODEL

UPFLOW COUNTE RFLOW

MINIMUM VENT

60 4 Inch 4 Inch 80 4 Inch 4 Inch

100 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, the venting system may be too

PRODUCT DESIGN

large to properly vent the remaining attached appliances.

For complete details refer to Existing Furnace Removal sec-

tion of this manual. 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 NFPA 54/ANSI Z223.1.

Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace ("Top" is as viewed for an upflow installation). The induced draft blower can be rotated 90 degrees for Category I venting. Refer to the following figure. For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/ CGA B149.1 and CAN/CGA B149.2 - latest editions and amendments.

Masonry Chimneys

NOTE: This furnace is not design certified to be horizontally

vented.

WARNING

TO PREVENT DEATH OR SERIOUS IL LNESS TO BUILDING OCCUPA NTS DUE

TO FLUE PRODUCTS LEAKING INTO THE B UILDING, PROPER INSTALLATION OF GASKETS AND SCREWS IS ESSENTIAL FOR PROVIDING A GAS TIGHT SEAL BETWEEN THE PARTITION PANEL AND THE INDUCED DRAFT BLOWER.

Make sure all wires are at least one inch from flue pipe. Relocate junction box to right side of cabinet if necessary.

Refer to Electrical Connections section of this manual for

instructions.

Crown

Clay Tile Size Generally 12" x 12" (24" Length)

Breech

Clean Out

Throat

Damper

Wash

Clay Tile Size: 8" x 8" x12"

(Each x 24" Length)

Attic Floor

1/2" to 1" Air Space

Second Floor

First Floor

F.A.F. Vent Connector

Fan Assisted Forced Air Furnace

Natural Draft Water Heater

Roof Line

Water Heater Vent Connector

Basement Floor

Typical Multiple Flue Clay Tile Chimney

Checklist Summary

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

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

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

PRODUCT DESIGN

10' or Less

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

Liner in good

condition?

(Check 5)

Yes

Line, terminate with

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

2' Min.

Wall or Parapet

Chimney

10' or Less

2' Min.

Chimney

3' Min.

Termination 10 Feet Or Less From Ridge, Wall or

Parapet

More than 10'

3' Min .

: No Height

NOTE

Wall or Parapet

above parapet requi red when distance from walls or parapet is more than 10 feet.

Chimney

Dilution air

available?

(Check 6)

Yes

Complete the

installation.

(Check 7)

Reline (Fix 4)

Check 1 - Proper chimney termination.

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

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

Height above any

2' Min .

roof surface with in 10 feet horizontally.

3' Min .

Ridge

More than 10'

10'

Chimney

Termination More Than 10 Feet From Ridge, Wall or

Parapet

Check 2 - Any solid or liquid fuel appliances vented into this chimney channel.

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

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

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

PRODUCT DESIGN

Check 3 - Chimney Crown Condition.

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

a) Crown leaning b) Bricks missing c) Mortar missing d) Tile liner cracked e) No tile liner f) Salt staining at mortar joints. (White stains, and mor-

tar becomes sandy and/or erodes.)

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

Check 4 - Debris in Cleanout

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

A chimney without a cleanout could become partially blocked by debris. If no cleanout is present, the chimney must be relined (Fix 4).

Remove the cleanout cover, and examine the cleanout for debris. If significant amounts of any of the following are found:

• Fuel oil residue

• Bricks

• Mortar or sand

• Pieces of the tile liner

• Rusted pieces of the metallic liner

reline the chimney (Fix 4).

Check 5 - Liner Condition.

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

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

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

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

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

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

The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4).

Finally, confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA tables and rules.

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

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

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent connectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an approved fire clay tile

reline the chimney (Fix 4). Next, measure the size of the liner. It may be possible to do

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

Check 6 - Dilution Air.

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

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance’s vent connector does not include a vent damper.

If dilution air will not be available, the chimney must be relined (Fix 4).

Check 7 - Complete the Installation.

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

PRODUCT DESIGN

the following factors which may render the tile liner unsuitable for use as a vent:

• Extremely cold weather

• Long vent connectors

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

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

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

Fix 1 - Liner Termination.

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

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

For further information on relining, see Fix 4.

Fix 2 - Change Venting Arrangements

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

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

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

If none of the above options are practical, the 80% furnace may need to be vented vertically with B vent.

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

Fix 3 - Rebuild the Crown.

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

Fix 4 - Relining.

Relining options include B vent and flexible liners. If the chimney has diagonal offsets, B vent probably cannot

be used. If B vent is to be used, it must be supported adequately.

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

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

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

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

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

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

• If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine, a liner of AL29-4C stainless steel should be used. Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine bleaches, paint strippers, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds.

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

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

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

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

PRODUCT DESIGN

• It is required by the liner manufacturer’s instructions.

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

• It is required by your local building codes.

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

• The local climate is very cold.

• The chimney is very tall.

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

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

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

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

Horizontal Applications and Considerations

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and/or combustion air pipe connections, etc. Never install a furnace on its back. Furnace and coil must be adequately supported.

Propane Gas and/or High Altitude Installations

WARNING

OSSIBLE PRO PERTY DA MAGE, PERSO NAL IN JURY OR DEATH MAY OCCUR IF THE CORRECT CONV ERSI ON KITS ARE NOT IN STALLE D. MUST BE APPLIE D TO I NSURE SAFE AN D PROPER FURNAC E OPERAT ION. CONVERSIONS MUS T BE PERFORMED BY A QUALIF IE D INSTA LLER OR SERV ICE AGENCY.

THE APPROPRIATE KI TS

ALL

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.

High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.

Refer to the Accessories Charts in this manual or product

Specification Sheet for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

WARNING

Alternate Electrical and Gas Line Connections

Furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR

DEATH.

CAREFU LL Y RE AD AN D FOL LO W AL L I NST RU CTI ON S GI VEN IN TH IS

SECTION.

WARNING

UPON COMPLETION OF THE FURNA CE INSTALLATIO N, CAREFULLY I NSPECT THE

ENTIRE FLUE SYSTEM BO TH INSIDE AND OUTSIDE THE FURNACE TO ASS URE IT IS PROPERLY SEALED. PERSONAL INJURY OR DE ATH DUE TO EXPOS URE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.

LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS

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.

GAS SUPPLY AND PIPING

The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.

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