Goodman AKSS9/GKS9 Installation Instructions Manual
AKSS9/GKS9
G
AS
-F
IRED
W
ARM
A
IR
F
URNACE
INSTALLATION INSTRUCTIONS
This furnace is shipped from the factory as a Dedicated Upflow.
A Blocked Drain Kit (part #0270K00012) is available and MUST BE USED
if the furnace is installed Horizontal Left or Horizontal Right.
Installer: Affix all manuals adjacent to the unit.
(T ype FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
These furnaces comply with requirements
embodied in the American National S tandard
/ National Standard of Canada ANSI
Z21.47·CSA-2.3 Gas Fired Central Furnaces.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety
precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than
when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a
customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety
practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is
a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.
*NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.
IO-300O
05/2013
© 2006-2008, 2010-2013 Goodman Manufacturing Company, L.P .
Goodman Manufacturing Company , L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
Table of Contents
I. Component Identification ............................................................................................................................................... 5
II. Safety considerations ...................................................................................................... ............................................... 5
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................... 6
III. Product Application ....................................................................................................................................................... 6
IV . Location Requirements & Considerations .................................................................................... .............................. 7
GENERAL ......................................................................................................................................................................... 7
LEARANCES AND ACCESSIBILITY ........................................................................................................................................... 8
C
FURNACE SUSPENSION ........................................................................................................................................................ 8
E
XISTING FURNACE REMOVAL............................................................................................................................................... 8
THERMOSTAT LOCATION....................................................................................................................................................... 8
V . Combustion & V entilation Air Requirements ................................................................................................................ 9
VI. Installation Positions ................................................................................................................................................... 11
VII. Horizontal Applications & Considerations................................................................................................................ 11
ENERAL ....................................................................................................................................................................... 11
G
D
RAIN TRAP AND LINES .................................................................................................................................................... 11
LEVELING ....................................................................................................................................................................... 11
LTERNA TE VENT/FLUE CONNECTION ................................................................................................................................... 11
A
A
LTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................................ 12
DRAIN PAN ..................................................................................................................................................................... 12
FREEZE PROTECTION ........................................................................................................................................................ 12
FURNACE SUSPENSION ...................................................................................................................................................... 12
VIII. Propane Gas /High Altitude Inst allations ................................................................................................................ 12
IX. Vent/Flue Pipe & Combustion Air Pipe....................................................................................................................... 12
GENERAL ....................................................................................................................................................................... 12
DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT .................................................................................................................. 13
MA TERIALS AND JOINING METHODS ...................................................................................................................................... 13
PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ................................................................................................. 13
TERMINA TION LOCATIONS ................................................................................................................................................... 13
CANADIAN VENTING REQUIREMENTS ..................................................................................................................................... 14
STANDARD FURNACE CONNECTIONS ..................................................................................................................................... 14
ALTERNATE FURNACE CONNECTIONS .................................................................................................................................... 14
NON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................................ 15
DIRECT VENT (DUAL PIPE) PIPING ...................................................................................................................................... 16
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES .................................................................. 19
CONCENTRIC VENT TERMINATION ......................................................................................................................................... 20
SIDE WALL VENT KIT ...................................................................................................................................................... 20
X. Condensate Drain Lines & Drain Trap ........................................................................................................................ 20
GENERAL ....................................................................................................................................................................... 20
UPRIGHT INSTALLATIONS .................................................................................................................................................... 20
HORIZONTAL INSTALLATIONS ............................................................................................................................................... 21
XI. Electrical Connections ................................................................................................................................................ 22
WIRING HARNESS ............................................................................................................................................................ 22
115 VOLT LINE CONNECTIONS ........................................................................................................................................... 22
24 VOLT THERMOSTAT WIRING........................................................................................................................................... 23
24 VOLT HUMIDIFIER ........................................................................................................................................................ 23
XII. Gas Supply and Piping............................................................................................................................................... 23
GENERAL ....................................................................................................................................................................... 23
GAS PIPING CONNECTIONS ................................................................................................................................................ 24
PROPANE GAS TANKS AND PIPING ...................................................................................................................................... 25
XIII. Circulating Air & Filters ............................................................................................................................................. 26
DUCTWORK - AIR FLOW ................................................................................................................................................... 26
CHECKING DUCT STATIC .................................................................................................................................................... 26
BOTTOM RETURN AIR OPENING [UPFLOW MODELS]............................................................................................................... 27
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ....................................................................... 27
UPRIGHT INSTALLATIONS .................................................................................................................................................... 28
HORIZONTAL INSTALLATIONS ............................................................................................................................................... 28
XIV . S t artup Procedure & Adjustment ............................................................................................................................. 28
HEAT ANTICIPATOR SETTING ............................................................................................................................................... 28
2
Table of Contents
DRAIN TRAP PRIMING ....................................................................................................................................................... 28
F
URNACE OPERATION ........................................................................................................................................................ 28
AS SUPPLY PRESSURE MEASUREMENT ............................................................................................................................... 28
G
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ................................................................................................... 29
G
AS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ......................................................................................................... 30
TEMPERATURE RISE .......................................................................................................................................................... 30
IRCULATOR BLOWER SPEEDS ........................................................................................................................................... 30
C
XV . Normal Sequence of Operation ................................................................................................................................. 31
P
OWER UP .................................................................................................................................................................... 31
EA TING MODE ................................................................................................................................................................ 31
H
COOLING MODE ............................................................................................................................................................... 31
F
AN ONL Y MODE ............................................................................................................................................................. 31
XVI. Operational Checks .................................................................................................................................................. 31
BURNER FLAME ............................................................................................................................................................... 31
XVII. Safety Circuit Description ....................................................................................................................................... 32
ENERAL ....................................................................................................................................................................... 32
G
I
NTEGRATED CONTROL MODULE........................................................................................................................................... 32
PRIMARY LIMIT ................................................................................................................................................................ 32
AUXILIARY LIMIT .............................................................................................................................................................. 32
ROLLOUT LIMIT ............................................................................................................................................................... 32
PRESSURE SWITCHES ....................................................................................................................................................... 32
FLAME SENSOR ............................................................................................................................................................... 32
XVIII. Troubleshooting ...................................................................................................................................................... 32
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................. 32
DIAGNOSTIC CHART .......................................................................................................................................................... 32
RESETTING FROM LOCKOUT ............................................................................................................................................... 33
XIX. Maintenance .............................................................................................................................................................. 33
ANNUAL INSPECTION ......................................................................................................................................................... 33
FIL TERS ......................................................................................................................................................................... 33
BURNERS ....................................................................................................................................................................... 33
INDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................................... 33
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ....................................................................................... 33
FLAME SENSOR (QUALIFIED SERVICER ONLY) ....................................................................................................................... 33
IGNITER (QUALIFIED SERVICER ONLY )................................................................................................................................... 33
FLUE PASSAGES (QUALIFIED SERVICER ONL Y) ...................................................................................................................... 33
XX. Before Leaving an Installation................................................................................................................................... 34
XXI. Repair & Replacement Parts .................................................................................................................................... 34
TROUBLESHOOTING CHART ................................................................................................................................................. 36
BLOWER PERFORMANCE DATA ............................................................................................................................................ 37
AKSS9/GKS9 Wiring Diagram.......................................................................................................................................... 39
SPECIAL INSTRUCTIONS FOR PRODUCTS IN THE STATE OF MASSACHUSETTS ................................................................................. 40
G
OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR
PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE
PROCEDURES
YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR
PROPERTY DAMAGE WHICH MAY RESULT
REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR
CONDITIONING EQUIPMENT
WARN ING
. IF
YOU INSTALL OR PERFORM SERVICE ON THIS UNIT
. M
ANY JURISDICTIONS
.
3
,
WARN ING
IF
THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS
- D
AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE
.
.
- WHAT T O D O IF YO U SMELL GA S:
* D
O NOT TRY TO LIGHT ANY APPLIANCE
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE
- I
* D
ANY PHONE IN YOUR BUILDING
* I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A
NEIGHBORS PHONE
INSTRUCTIONS
* I
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE
NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER
FIRE DEPARTMENT
. F
OLLOW THE GAS SUPPLIERS
.
.
.
.
WARN ING
S
HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT
OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY
.
TRANSPORTATION DAMAGE
All units are securely packed in shipping containers tested according
to International Safe Transit Association specifications. The carton
must be checked upon arrival for external damage. If damage is found,
a request for inspection by carrier’s agent must be made in writing
immediately.
The furnace must be carefully inspected on arrival for damage and
bolts or screws which may have come loose in transit. In the event of
damage the consignee should:
1. Make a notation on delivery receipt of any visible damage to
shipment or container .
2. Notify carrier promptly and request an inspection.
3. With concealed damage, carrier must be notified as soon as
possible - preferably within five days.
4. File the claim with the following support documents within a
nine month statute of limitations.
• Original or certified copy of the Bill of Lading, or indemnity
bond.
• Original paid freight bill or indemnity in lieu thereof.
• Original or certified copy of the invoice, showing trade and
other discounts or reductions.
• Copy of the inspection report issued by carrier’s
representative at the time damage is reported to carrier.
The carrier is responsible for making prompt inspection of damage
and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.
Keep this literature in a safe place for future reference.
CARBON MONOXIDE POI SONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxid e producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
CO can cause serious illness including permanent brain damage or death.
B10259-216
-
TO THE INSTALLER
Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including
but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air
temperature rise, minimum or maximum CFM, and motor speed connections.
4
I. COMPONENT IDENTIFICATION
3
6
4
5
6
7
24 Auxiliary Limit
25 Gas Manifold
26 Junction Box
27 Coil Front Cover
28 Drain Trap
8
9
29 Electrical Connection Inlets
25
2
1
27
29
26
17
18
24
23
22
Upflow/Horizontal
1 Gas Valve
2 Gas Line Entrance (Alternate)
3 Combustion Air Int ake Connection / “Coupling”
4 Hot Surface Igniter
5 Burners
6 Rollout Limit
7 Flame Sensor
8 Flue Pipe Connection / “Coupling”
9 Flue Pipe (Internal)
10 Primary Limit
11 Pressure Switch
12 Gas Line Entrance
13 Rubber Elbow
14 Flue Pipe Connection (Alternate)
15 Induced Draft Blower
16 Electrical Connection Inlets (Alternate)
17 Coil Front Cover Drain Port
18 Drain Line Penetrations
19 Blower Door Interlock Switch
20 24-Volt Thermost at Connections
21 Integrated Control Module
(with fuse and diagnostic LED)
22 Transformer (40 V A)
23 Circulator Blower
10
11
12
13
14
15
16
17
18
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper
installation and operation, thoroughly read this manual for specifics
pertaining to the installation and application of this product.
This furnace is manufactured for use with natural gas. It may be field
converted to operate on L.P . gas by using the appropriate L.P. conversion kit listed in the PROPANE GAS/HIGH ALTITUDE INSTALLA-
TIONS section of this manual
Install this furnace only in a location and position as specified in
CATION REQUIREMENTS & CONSIDERATIONS section and IN-
II. SAFETY CONSIDERA TIONS
LO-
STALLATION POSITIONS section of this manual.
Provide adequate combustion and ventilation air to the furnace as
28
19
specified in COMBUSTION & VENTILA TION AIR REQUIREMENTS
section of this manual.
Combustion products must be discharged to the outdoors. Connect
this furnace to an approved vent system only, as specified in VENT/
FLUE PIPE & COMBUSTION AIR PIPE section of this manual.
Never test for gas leaks with an open flame. Use a commercially avail-
20
able soap solution made specifically for the detection of leaks to check
all connections, as specified in GAS SUPPL Y AND PIPING section of
this manual.
21
Always install a furnace to operate within the furnace’s intended temperature-rise range with a duct system which has external static pressure within the allowable range, as specified on the furnace rating plate
OPERATIONAL CHECKS section of these instructions.
and
When a furnace is installed so that supply ducts carry air circulated by
the furnace to areas outside the space containing the furnace, the
return air shall also be handled by duct(s) sealed to the furnace casing
and terminating outside the space containing the furnace.
A gas-fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIREMENTS AND CON-
SIDERATIONS section of this manual.
This furnace may be used as a construction site heater only if certain
conditions are met. These conditions are listed in the PRODUCT
APPLICATION section of this manual.
WARNING
TO
PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR
MAINTENANCE, REFER TO THIS MANUAL
ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER
SERVICE AGENCY OR THE GAS SUPPLIER
T
HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM
. FOR
.
.
ADDITIONAL
,
WARNING
HIGH VOLTAGE!
O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR
T
DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST
BE LOCATED TO PROTECT THE ELECTRICAL
COMPONENTS FROM WATER
.
5
WARN ING
DO
NOT UTILIZE THE HEATING UNIT WITHOUT REASONABLE ROUTINE
INSPECTION, MAINTENANCE AND SUPERVISION
BUILDING THAT IS OR WILL BE VACANT, CARE SHOULD BE TAKEN TO
ROUTINELY INSPECT, MAINTAIN AND MONITOR THE UNIT
EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING
TEMPERATURES AND WILL BE VACANT, DRAIN ALL WATER-BEARING
PIPES, PROPERLY WINTERIZE THE BUILDING, AND TURN OFF ALL
WATER SOURCES
FREEZING TEMPERATURES AND IS VACANT, ANY HYDRONIC COIL
UNITS SHOULD ALSO BE DRAINED AND AN ALTERNATIVE HEAT
SOURCES UTILIZED
. IN
THE EVENT THAT THE BUILDING IS EXPOSED TO
.
. IF
THE UNIT IS IN A
. IN
THE
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge static electricity accumulated in the body before
touching the 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 non-installed (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the control
prior to discharging your body’s electrostatic charge to
ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution not
to recharge your body with static electricity; (i.e., do not move
or shuffle your feet, do not touch ungrounded objects, etc.).
If you come in contact with an ungrounded object, repeat
step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or new
controls to their containers before touching any ungrounded
object.
III. PRODUCT APPLICA TION
This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for
outdoor applications. The furnace must be installed indoors (i.e., attic
space, crawl space, or garage area provided the garage area is enclosed with an operating door).
This furnace can be used in the following non-industrial commercial
applications:
Schools, Office buildings, Churches, Retail stores
Nursing homes, Hotels/motels, Common or office areas
In such applications , the furnace must be installed with the following
stipulations:
• It must be installed per the installation instructions
provided and per local and national codes.
• It must be installed indoors in a building constructed on
site.
• It must be part of a ducted system and not used in a free
air delivery application.
• It must not be used as a “make-up” air unit.
• It must be installed with two-pipe systems for combustion
air, especially if VOC’s or other contaminants are present
in the conditioned space.
• All other warranty exclusions and restrictions apply This
furnace is an ETL dual-certified appliance and is
appropriate for use with natural or propane gas (NOTE: If
using propane, a propane conversion kit is required).
Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:
Non-direct vent (single pipe) central forced air furnace in
which combustion air is taken from the installation area
or from air ducted from the outside or,
Direct vent (dual pipe) central forced air furnace in which
all combustion air supplied directly to the furnace burners
through a special air intake system outlined in these
instructions.
This furnace may be used as a construction site heater ONLY if the
following conditions are met:
• The vent system is permanently installed per these
installation instructions.
• A room thermostat is used to control the furnace. Fixed
jumpers that provide continuous heating CANNOT be
used.
• Return air ducts are provided and sealed to the furnace.
• A return air temperature range between 60ºF (16ºC) and
80ºF (27ºC) is maintained.
• Air filters are installed in the system and maintained
during construction, replaced as appropriate during
construction, and upon completion of construction are
replaced.
• The input rate and temperature rise are set per the furnace
rating plate.
• 100% outside air is provided for combustion air
requirements during construction. Temporary ducting can
be used.
NOTE: Do not connect the temporary duct directly to the
furnace. The duct must be sized according to the
instructions under Section V, Combustion and Ventilation
Air Requirements, Section 5.3.3.
• The furnace heat exchanger, component s, duct system, air
filters and evaporator coils are thoroughly cleaned following
final construction clean up.
• All furnace operating conditions (including ignition, input rate,
temperature rise and venting) are verified according to these
installation instructions.
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
• Gas furnaces must be installed by a licensed plumber or
gas fitter.
• A T -handle gas cock must be used.
• If the unit is to be installed in an attic, the passageway to and
the service area around the unit must have flooring.
T o ensure proper installation and operation, thoroughly read this manual
for specifics pertaining to the installation and application of this product.
6
WARN ING
P
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL
SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER
INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS
PRODUCT
.
WARN ING
TO
PREVENT PERSONAL INJURY, PROPERTY DAMAGE OR DEATH DUE
TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME
TRAILER OR RECREATIONAL VEHICLE
.
,
T o ensure proper furnace operation, install, operate and maintain the
furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow
the latest edition of the National Fuel Gas Code ANSI Z223.1, and/or
CAN/CSA B149.1-05 Installation Codes, local plumbing or waste water codes, and other applicable codes.
A copy of the National Fuel Gas Code ANSI Z223.1 can be obt ained
from any of the following:
American National Standards Institute
1430 Broadway
New York, NY 10018
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
A copy of the CAN/CSA B149.1-05 Installation Codes can also be
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
The rated heating capacity of the furnace should be greater than or
equal to the total heat loss of the area to be heated. The total heat
loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.
IV . LOCATION REQUIREMENTS & CONSIDERA TIONS
GENERAL
WARN ING
TO
PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST
BE OBSERVED WHEN INSTALLING THE UNIT
.
Follow the instructions listed below when selecting a furnace location.
Refer also to the guidelines provided in Section V, Combustion and
Ventilation Air Requirements.
• Centrally locate the furnace with respect to the proposed or
existing air distribution system.
• Ensure the temperature of the return air entering the furnace
is between 55°F and 100°F when the furnace is heating.
• 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. Refer to Section IX, Vent/Flue
Pipe and Combustion Air Pipe -Termination Locations for
appropriate termination locations and to determine if the piping
,
system from furnace to termination can be accomplished
within the guidelines given. NOTE: The length of flue and/
or combustion air piping can be a limiting factor in the location
of the furnace.
• Locate the furnace so condensate flows downwards to the
drain. Do not locate the furnace or its condensate drainage
system in any area subject to below freezing temperatures
without proper freeze protection. Refer to Section X,
Condensate Drain Lines and Trap for further det ails.
• Ensure adequate combustion air is available for the furnace.
Improper or insufficient combustion air can expose building
occupants to gas combustion products that could include
carbon monoxide. Refer to Section V, Combustion and
Ventilation Air Requirements.
• Set the furnace on a level floor to enable proper condensate
drainage. If the floor becomes wet or damp at times, place
the furnace above the floor on a concrete base sized
approximately 1-1/2" larger than the base of the furnace.
Refer to the Section VII, Horizontal Applications and
Considerations for leveling of horizontal furnaces.
• Ensure upflow or horizontal furnaces are not installed directly
on carpeting, or any other combustible material. The only
combustible material allowed is wood.
• Exposure to contaminated combustion air will result in safety
and performance-related problems. Do not install the furnace
where the combustion air is exposed to the following
substances:
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
• Seal off a non-direct vent furnace if it is installed near an
area frequently contaminated by any of the above
substances. This protects the non-direct vent furnace
from airborne contaminants. 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. Refer to the Section V,
Combustion and Ventilation Air Requirement s for details.
• If the furnace is used in connection with a cooling unit, install
the furnace upstream or in parallel with the cooling unit.
Premature heat exchanger failure will result if the cooling
unit is placed ahead of the furnace.
For vertical (upflow or downflow) applications, the minimum
cooling coil width shall not be less than furnace width minus
1”. Additionally , a coil inst alled above an upflow furnace or
under a counterflow furnace may be the same width as the
furnace or may be one size larger than the furnace. Example:
a “C” width coil may be installed with a “B” width furnace.
For upflow applications, the front of the coil and furnace must
face the same direction.
• If the furnace is installed in a residential garage, position the
furnace so that the burners and ignition source are located
7
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. Clearances must also accommodate an installation’s gas,
electrical, and drain trap and drain line connections. If the alternate
vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX,
Vent Flue Pipe and Combustion Air Pipe for details. 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.
TOP
SIDE SIDE
BOTTOM
Upflow Horizontal
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.
Refer to the Specification Sheet applicable to your model* for minimum clearances to combustible surfaces. 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 joists, use 3/8" threaded rod
and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary .
3/8" DIAMETER
THREADED ROD
(6 PLACES)
HOLD DOWN
NUTS
SUPPORT
NUTS
2"X2"X1/8" ANGLE IRON
(3 PLACES)
PROVIDE 8" MINMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL
POSITION AS CLOSE AS POSSIBLE
TO BLOWER DECK TO ALLOW FOR
CIRCULATOR BLOWER REMVOAL
Suspended Furnace
ASSURE FURNACE IS LEVE L FROM
END TO END AND HAS A SLIGHT
FORWARD TILT WITH THE FRONT
OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE FURNACE
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
REMOVAL
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 prop-
erly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the American National Standard/National S tandard of Canada for Gas-Fir ed Central Furnaces ANSI Z21.47·CSA-2.3 Section 1.23.1.
The following steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and horizontal pitch, as
required by the National Fuel Gas Code, ANSI Z223.1 or the CSA
B149.1-05 Installation Codes and these instructions. Determine that
there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;
c. In so far as practical, close all building doors and windows and all
doors between the space in which the appliance(s) connected to the
venting system are located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom
exhausts, so they shall operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers;
d. Follow the lighting instructions. Place the appliance being inspected
in operation. Adjust thermostat so appliance shall operate continuously;
e. Test for draft hood equipped 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 ANSI Z223.1 and/or CSA B149.1-05 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 B149.1-05 Installation
Codes.
THERMOSTAT LOCATION
The thermostat should be placed approximately five feet from the
floor on a vibration-free, inside wall in an area having good air
circulation. Do not install the thermostat where it may be influenced by any of the following:
• Drafts, or dead spots behind doors, in corners, or under
cabinets.
• Hot or cold air from registers.
• Radiant heat from the sun.
• Light fixtures or other appliances.
• Radiant heat from a fireplace.
• Concealed hot or cold water pipes, or chimneys.
• Unconditioned areas behind the thermostat, such as an
outside wall.
8
DRAFTS OR DEAD SPOTS
V
-BEHIND DOORS
-IN CORNERS
-UNDER CABINETS
HOT
COLD
Thermostat Influences
Consult the instructions packaged with the thermostat for mounting
instructions and further precautions.
V. COMBUSTION & VENTILATION AIR REQUIREMENTS
WARN ING
TO
AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND
OF FLUE GASES MUST BE SUPPLIED
AIR BE SUPPLIED INTO THE FURNACE AREA
. M
OST HOMES REQUIRE OUTSIDE
.
Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors
and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances
that pull air out of the house (clothes dryers, exhaust fans, fireplaces,
etc.) increase the problem by starving appliances for air .
House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide.
1. Headaches-Nausea-Dizziness, Flu-Like Symptoms.
2. Excessive humidity-heavily frosted windows or a moist
“clammy” feeling in the home.
3. Smoke from a fireplace will not draw up the chimney .
4. Flue gases that will not draw up the appliance vent pipe.
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 ANSI Z223.1 (Section 5.3),
or CSA B149.1-05 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 ANSI Z223.1 Section 5.3.
5.3.1 General:
(a) The provisions of 5.3 apply to gas utilization equipment installed in
buildings and which require air for combustion, ventilation and dilution
of flue gases from within the building. They do not apply to (1) direct
vent equipment which is constructed and installed so that all air for
combustion is obtained from the outside atmosphere and all flue gases
are discharged to the outside atmosphere, or (2) enclosed furnaces
which incorporate an integral total enclosure and use only outside air
for combustion and dilution of flue gases.
(b) Equipment shall be installed in a location in which the facilities for
,
ENTILATION
ventilation permit satisfactory combustion of gas, proper venting and
the maintenance of ambient temperature at safe limits under normal
conditions of use. Equipment shall be located so as not to interfere
with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.
(c) In addition to air needed for combustion, process air shall be provided
as required for: cooling of equipment or material, controlling dew point,
heating, drying, oxidation or dilution, safety exhaust, odor control, and
air for compressors.
(d) In addition to air needed for combustion, air shall be supplied for ven-
tilation, including all air required for comfort and proper working conditions for personnel.
(e) While all forms of building construction cannot be covered in detail, air
for combustion, ventilation and dilution of flue gases for gas utilization
equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.
(f) Air requirements for the operation of exhaust fans, kitchen ventilation
systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.
5.3.2 Equipment Located in Unconfined Spaces:
In unconfined spaces (see definition below) in buildings, infiltration may
be adequate to provide air for combustion ventilation and dilution of flue
gases. However, in buildings of tight construction (for example, weather
stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may
need to be provided using the methods described in 5.3.3-b or 5.3.4.
Space, Unconfined.
For purposes of this Code, a space whose volume is not less than 50 cubic
feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the
space in which the appliances are installed through openings not furnished
with doors, are considered a part of the unconfined space.
5.3.3 Equipment Located in Confined Spaces:
(a) All Air from Inside the Building: The confined space shall be pro-
vided with two permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume
of all spaces meets the criteria for an unconfined space. The total
input of all gas utilization equipment installed in the combined space
shall be considered in making this determination. Each opening shall
have a minimum free area of 1 square inch per 1,000 BTU per hour
of the total input rating of all gas utilization equipment in the confined
space, but not less than 100 square inches. One opening shall be within
12 inches of the top and one within 12 inches of the bottom of the
enclosure.
NOTE: Each openi ng mu st have
a free area of not less than one
square inch per 1000 BTU of
the total input rating of all equipment in the enclosure, but not
less than 100 square inches.
Equipment Located in Confined Spaces; All Air from Inside Building.
See 5.3.3-a.
Chimney or Gas Vent
Water
Heater
Furnace
Opening
Opening
9
(b) All Air from Outdoors: The confined space shall be provided with
A
two permanent openings, one commencing within 12 inches of the top
and one commencing within 12 inches of the bottom of the enclosure.
The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the
outdoors.
1. When directly communicating with the outdoors, each opening
shall have a minimum free area of 1 square inch per 4,000 BTU
per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Ventilation louvers
(each end of attic)
NOTE: The inl et and ou tlet ai r
openings must each have a free
area of not less than one square
inch per 4000 BTU of the
total inpu t rat in g of all equipment
in the enclosure.
Outlet Air
Water
Heater
lternate
air inlet
Furnace
Ventilation louvers for
unheated crawl space
Inlet Air
Equipment Located in Confined Spaces; All Air from Outdoors—Inlet
Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic.
See 5.3.3-b
2. When communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 square inch per
4,000 BTU per hour of total input rating of all equipment in the
enclosure.
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 equipment
in the enclosure.
Outlet Air
Equipment Located in Confined Spaces; All Air from Outdoors
Water
Heater
Furnace
Inlet air duc t
[ends 1 ft (300 mm)
above floor]
Through Ventilated Attic. See 5.3.3-b.
3. When communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 square inch per
2,000 BTU per hour of total input rating of all equipment in the
enclosure.
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
Outlet air duct
Water
Heater
Furnace
Inlet air duct
*If the appliance room is located against an outside wall and the air openings communicate
directly with the outdoors, each opening shall have a free area of not less than one square inch
per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.
Equipment Located in Confined Spaces; All Air from Outdoors. See
5.3.3-b.
enclosure*.
4. When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts shall not be less than
3 inches.
NOTE: The single opening must hav e
a free area of not less than one
square inch per 3000 BTU of
the total input rating of all equipment in the enclosure, but not less than
the sum of the areas of all vent
connectors in the confine d space.
Equipment Located in Confined Spaces; All Air from Outdoors -
Single Air Opening. See 5.3.3-b.
Chimney or Gas Vent
Furnace
Water
Heater
Opening
Alternate
Opening
Location
5. When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per 3,000
BTU per hour of total input rating of all equipment in the enclosure.
5.3.4 Specially Engineered Installations:
The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.
5.3.5 Louvers and Grilles:
In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used
shall not be smaller than 1/4 inch mesh. If the area through a design of
louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area
is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free
area. Louvers and grilles shall be fixed in the open position or interlocked
with the equipment so that they are opened automatically during equipment operation.
10
5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:
Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside
Building. See 5.3.3-a.
VI. INSTALLATION POSITIONS
LEVELING
Leveling ensures proper condensate drainage from the heat exchanger
and induced draft blower . For proper flue pipe drainage, the furnace
must be level lengthwise from end to end. The furnace should also be
level from back to front or have a slight tilt with the access doors
downhill (approximately 3/4 inches) from the back panel. The slight
tilt allows the heat exchanger condensate, generated in the recuperator
coil, to flow forward to the recuperator coil front cover.
NOTE: This furnace is shipped from the factory as a Dedicated Upflow .
A “Blocked Drain Kit” (0270K00012) is available and MUST BE USED
if the furnace is installed Horizontal Left or Horizontal Right.
This furnace may be installed in an upright position or horizontal on
either the left or right side panel. Do not install this furnace on its
back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow
furnaces, return air ductwork must be attached to the basepan. NOTE:
Ductwork must never be attached to the back of the furnace. Contact
your distributor for proper airflow requirements and number of required
ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.
VII. HORIZONTAL APPLICA TIONS & CONSIDERA TIONS
NOTE: This furnace is shipped from the factory as a Dedicated Upflow .
A “Blocked Drain Kit” is available and MUST BE USED if the furnace
is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating
Plate on the furnace for the Kit P/N.
GENERAL
Horizontal applications, in particular, may dictate many of the
installation’s specifics such as airflow direction, ductwork connections, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from
an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:
ALTERNATE VENT/ FLUE
LOCATION
FURNACE MUST BE LEVEL
FROM END TO END
FURNACE MUST BE LEVEL
OR SLIGHTLY TILTED FORWARD
WITH THE DOORS 0" - 3/4"
BELOW THE BACK PANEL
ALTERNATE VENT/FLUE CONNECTION
In horizontal installations provisions for alternate flue piping are available for upflow furnaces with left discharge. This configuration allows
the flue piping to be run vertically through the furnace. Refer to the
“Recommended Installation Positions” figure for further detail. The
standard piping connections may also be used in these positions.
Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for de-
tails concerning the conversion to the alternate vent/flue connections.
When using the horizontal alternate vent configuration, you must use
the RF000142 vent drain kit. See following illustration.
4 3/4" MINIMUM
DRAIN TRAP
GAS LINE WITH
DRIP LEG (3" MINIMUM)
DRAIN PAN
FURNACE MUST BE SUPPORTED
AT BOTH ENDS AND MIDDLE
CLEARANCE
36" MINIMUM SERVICE
CLEARANCE REQUIRED
Horizontal Furnace
DRAIN TRAP AND LINES
In horizontal applications the condensate drain trap is secured to the
furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4 inches below the furnace must be provided for the drain
trap. Additionally , the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Section X,
Condensate Drain Trap and Lines for further details. If the drain trap
and drain line will be exposed to temperatures near or below freezing,
adequate measures must be taken to prevent condensate from freezing.
DRAIN LINE WITH 1/4" PER FOOT
DOWNWARD SLOPE
11
VIII. PROPANE GAS /HIGH AL TITUDE INSTALLATIONS
WARN ING
P
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION
A QUALIFIED INSTALLER OR SERVICE AGENCY
. ALL
CONVERSIONS MUST BE PERFORMED BY
.
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.
For furnaces being converted to LP gas, it is strongly recommended
that a LPLP03 kit also be installed. The use of this kit will prevent
the furnace from firing when the LP gas supply pressure is too low
to support proper combustion.
High altitude installations may require both a pressure switch and
an orifice change. These changes are necessary to compensate
for the natural reduction in the density of both the gas fuel and the
combustion air at higher altitude.
For installations above 7000 feet, please refer to your distributor
for required kit(s).
. THE
Recommended Installation Positions
NOTE: Alternate “vertical” piping connections can not be used when
an upflow furnace is installed with supply air discharging to the right.
In either case, use the standard flue and combustion air piping
connections.
ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS
This furnace has 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.
DRAIN PAN
A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).
FREEZE PROTECTION
Refer to Section VII, Horizontal Applications and Conditions - Drain
Trap and Lines.
FURNACE SUSPENSION
If the furnace is installed in a crawl space it must 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. Refer to Sec-
tion IV, Location Requirements and Considerations - Furnace Suspension for further details.
Altitude Gas Kit Orifice
Natural None #43 3.5" w.c .
0-7000
2
Propane
2
Supports both Honey well and White-Rodgers 1-st age valves
NOTE: In Canada, gas furnaces are certified to 4500 fee t.
LPT-03*
#55 10.0" w. c.
Manifold
Pressure
Pre ssure
Switch
None
Contact the distributor for a tabular listing of appropriate manufacturer’s
kits for propane gas and/or high altitude installations. The indicated
kits must be used to insure safe and proper furnace operation. All
conversions must be performed by a qualified installer, or service
agency .
IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE
GENERAL
WARN ING
F
AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY
INJURY OR DEATH
INSTRUCTIONS GIVEN IN THIS SECTION
. C
AREFULLY READ AND FOLLOW ALL
.
WARN ING
U
PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY
INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF
THE FURNACE TO ASSURE IT IS PROPERLY SEALED
FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH
DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON
MONOXIDE
.
. L
EAKS IN THE
12
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