Goodman GMS8, AMS8, GDS8, ADSS8 User Manual

Service Instructions

®

Goodman® & Amana® Brand

80% Single Stage Gas Furnaces

GMS8, AMS8, GDS8, ADSS8

& 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.

®

RS6612006r2

August 2014

TABLE OF CONTENTS

IMPORTANT INFORMATION........................... 2-3

PRODUCT IDENTIFICATION.......................... 4- 9

ACCESSORIES............................................10- 14

OPERATING INSTRUCTIONS....................15 - 17

PRODUCT DESIGN.....................................18 -36

SYSTEM OPERATION.......................................37

TROUBLESHOOTING ..................................38-39

MAINTENANCE............................................40- 43

SERVICING .................................................44 - 58

SERVICING TABLE OF CONTENTS ................46

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.

IMPORT ANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

T

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

WARNING

GOODM AN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAM AGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAM AGE WHICH

I

MAY RESULT.

MANY JURISDI CTIONS REQU IRE A LICENSE TO INSTALL OR SERVICE HE ATING AND AIR CONDITIONI NG EQUIPME NT.

WARNING

HIGH VOLTAGE

ISCONNECT

D

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

POWER BEFORE SERVICI NG OR

ALL

ULTIPLE POWER SOURCES MAY

M

AILURE TO DO SO M AY CAUSE PROPERTY

F

2

IMPORTANT INFORMATION

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide 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 park ing 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 ope rating in any mode.

CO can cause serious illness including permanent brain damage or death.

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

email us at: hac.consumer.affairs@amanahvac.com

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE

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

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.

3

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.

GMS80 060 3 AN AA 1 2 345 678 910111213

Brand Min or Re visi on G - Good man A - Initial Release

Configuration M - Upflow/Horizontal Majo r Rev isi on C - Downflow/Horizontal A - Initial Release K - Dedicated Upflow B - 1st Revision D - Dedicated Downflow

Gas Vale / Motor N - Natural Gas E- Convertible 2 Stage / High Efficiency X - Low NOx H - Convertible 2 Stage / Single Speed S - Single Stage / Single Speed Cabinet Width

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

MBTU/h Max imu m CFM 40 - 40,000 3 - 1200 CFM 60 - 60,000 4 - 1600 CFM 80 - 80,000 5 - 2000 CFM 100 - 100,000 120 - 120,000 140 - 140,000

B - 1st Revision

Nox

A - 14"

4

PRODUCT IDENTIFICATION

h

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.

AMS 80 060 3 A N A A 1 2 3 4 5 6 7 8 9 10 11 12 13

Bra nd Mi no r Rev is io n A- Amana A - I nitia l Rel eas e

Configu rat ion M - U pfl ow/ Horiz on tal Ma jor Revi sion

Gas Vale / M otor B - 1s t Revisi on H - Co nvertible 2 Stage / Single Speed S - Sin gle S tage / Singl e Spee d Nox

AFUE X - Low NO x 97 - 97% AFUE 80 - 80% AFUE Cabinet Width

MBTU/ 40 - 40,000 C - 21 " 60 - 60,000 D - 24 .5" 80 - 80,000 10 0 - 100 ,00 0 Maximum CFM 12 0 - 120 ,00 0 3 - 1200 CFM 14 0 - 140 ,00 0 4 - 1600 CFM

B - 1s t Revisi on

A - I nitia l Rel eas e

N - N atur al Ga s

A - 1 4" B - 17 .5"

5 - 2000 CFM

Amana Furnace Nomenclature (14 Digits)

A D S S 80 060 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Brand Min or Re vi sion A- Amana A - Initial Release

Configuration M - Upflow/Horizontal Ma jor Revi sion C - Downflow/Horizontal A - Initial Release K - Dedicated Up flow B - 1st Revision D - Dedi cated Downf low

Mot or N - Natural Gas V - Variable Speed/ComfortNet X - Low NOx E - Hi gh Effi ciency S - Single Spee d Cabinet Width

Gas V alve B - 17.5" M - Mo dul ating C - 21" C - 2 Stage D - 24. 5" H - Convertible 2 Stage S - Single Stage Maximum CFM

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

MBTU/ h 40 - 40, 000 60 - 60, 000 80 - 80, 000 100 - 100,000 120 - 120,000 140 - 140,000

B - 1st Revision

Nox

A - 14"

3 - 1200 CFM

5

PRODUCT IDENTIFICATION

MODEL # MFG . # 80 % GAS FURNAC ES

AM S 80403AXAA AM S 80603AXAA AM S 80604BXAA

AMS8

AM S 80804BXAA AM S 80805CXA A AM S 81005CXA A AM S 81205DXA A

AM S81405DNB A

AM S 80403AXAB AM S 80603AXAB AM S 80604BXAB AM S 80804BXAB AM S 80805CXA B AM S 81005CXA B AM S 81205DXA B

AM S81405DNB B

MODEL # M FG . # 80 % G A S F URNA CE S

AD SS 800403AXA A

ADSS8

AD SS 800603AXA A AD SS 800804BXA A AD SS 801005CXAA

AD SS 800403AXA B AD SS 800603AXA B AD SS 800804BXA B AD SS 801005CXAB

Am ana B rand 80% gas furnace, 33 3/8" tall, upflow, horizontal right of left installation positions. Induc ed draft, two-tone gray cabinet and panels. M ulti-speed P SC m otor, 120 volt carbide mini Igniter with integrated circuit board. Left or right s ide gas entry . Stainless steel tubular heat exchanger. Standard altitude rated to 5,500 ft. Firing rate of 20,000 BTUH per burner, #45 gas orifices . Chassis widths 14",17.5", 21", 24.5"

Am ana B rand 80% gas furnace, 33 3/8" tall, upflow, horizontal right of left installation positions. Induc ed draft, two-tone gray cabinet and panels. M ulti-speed P SC m otor, 120 volt carbide mini Igniter with integrated circuit board. Left or right s ide gas entry . Stainless steel tubular heat exchanger. Standard altitude rated to 5,500 ft. Firing rate of 20,000 BTUH per burner, #45 gas orifices . Firs t rev with W hite-Rodgers gas valve. Chass is widths 14",17.5", 21", 24.5"

Am ana B rand 80% gas furnace, 33 3/8" tall, dedicated downflow installation. Induced draft, two-tone gray cabinet and panels. Multi-s peed PS C m otor, 120 volt carbide m ini Igniter with integrated circ uit board. Left or right side gas entry. Stainless steel tubular heat exchanger. Standard altitude rated to 5,500 ft. Firing rate of 20,000 B TUH per burner, #45 gas orific es. Chas sis widths 14",17.5", 21".

Am ana B rand 80% gas furnace, 33 3/8" tall, dedicated downflow installation. Induced draft, two-tone gray cabinet and panels. Multi-s peed PS C m otor, 120 volt carbide m ini Igniter with integrated circ uit board. Left or right side gas entry. Stainless steel tubular heat exchanger. Standard altitude rated to 5,500 ft. Firing rate of 20,000 B TUH per burner, #45 gas orific es. First rev with W hite-Rodgers gas valve. Chassis w idths 14",17.5", 21".

6

PRODUCT IDENTIFICATION

MODE L # M F G. # 80 % GA S FURNA C E S

GMS80403A*A*

GMS8

GMS80603A*A* GMS80604B*A* GMS80804B*A* GM S80805C*A* GM S81005C*A* GM S81205D*A*

Goo dm an Brand 80 % gas furnace, 33 3/8" tall, upflow, horiz ontal right of left installation po sitions. Induced draft, Goodman gray cabinet and panels. Multi-speed PS C motor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right side g as entry. A lum inized stee l tubular heat exc hanger. A vailable in N or X versions ex ce pt 140,000 B TUH m odel. S tandard altitude rated to 4,500 ft. Firing rate of 23,000 B TUH per burner, #43 gas orifices . Chas sis w idths 14",17.5", 21", 24.5"

GMS8

GMS80403A*BA GMS80603A*BA GMS80604B*BA GMS80804B*BA GMS80805C*BA GMS81005C*BA GMS81205D*BA

GMS80403A*BB GMS80603A*BB GMS80604B*BB GMS80804B*BB GMS80805C*BB GMS81005C*BB

G M S8 1405DN CC

GMS80403A*BC GMS80603A*BC GMS80604B*BC GMS80804B*BC GMS80805C*BC GMS81005C*BC GMS81205D*BB

G M S8 1405DN CD

Goo dm an Brand 80 % gas furnace, 33 3/8" tall, upflow, horiz ontal right of left installation po sitions. Induced draft, Goodman gray cabinet and panels. Multi-speed PS C motor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right side g as entry. A lum inized stee l tubular heat exc hanger. S tandard altitud e ra ted to 4,500 ft. (E xc ept GM S 81205 D*BA s tandard altitiude is 5,500 ft) B* rev = firing rate of 20,000 BTU H per burner with #45 gas orifices. Chassis widths 14",17.5", 21",

24.5".

Goo dm an Brand 80 % gas furnace, 33 3/8" tall, upflow, horiz ontal right of left installation po sitions. Induced draft, Goodman gray cabinet and panels. Multi-speed PS C motor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right side g as entry. A lum inized stee l tubular heat exchanger. Standard altitude to 5,500 ft. B* rev = firing rate of 20,000 BTUH per burner with #45 gas orifices. G M S 81405D NCC firing at 22,500 BTUH per burner with #43 gas orifices. Chas sis w idths 14",17.5", 2 1", 24.5" .

Goo dm an Brand 80 % gas furnace, 33 3/8" tall, upflow, horiz ontal right of left installation po sitions. Induced draft, Goodman gray cabinet and panels. Multi-speed PS C motor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right side g as entry. A lum inized stee l tubular heat exchanger. Standard altitude to 5,500 ft. B* rev = firing rate of 20,000 BTUH per burner with #45 gas orifices. G M S 81405D NCC firing at 22,500 BTUH per burner with #43 gas orifices. First re vision with W hite Ro dgers gas valve. Chas s is widths 14" ,17.5", 21", 24.5".

MODE L # MF G. # 80 % GA S F URNA CE S

GDS8

GDS80403A*AA GDS80603A*AA GDS80804B*AA GDS 81005C*AA

Goodman B rand 80% gas furnac e, 33 3/8" tall, dedicated downflow installation, Induced draft, G oodm an gray c abinet an d panels. M ulti-s peed P SC m otor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right sid e gas ent ry. A lum inized st eel tubular heat ex chan ger. firing rate of 23,500 BTUH pe r burner with #43 gas orific es . C has s is width s 14" ,17.5" , 21" , 2 4.5".

GDS8

GDS80403A*BA GDS80603A*BA GDS80804B*BA GDS 81005C*BA

GDS80403A*BB GDS80603A*BB GDS80804B*BB GDS 81005C*BB

GDS80403A*BC GDS80603A*BC GDS80804B*BC GDS 81005C*BC

Goodman B rand 80% gas furnac e, 33 3/8" tall, dedicated downflow installation, Induced draft, G oodm an gray c abinet an d panels. M ulti-s peed P SC m otor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right sid e gas ent ry. A lum inized st eel tubular heat ex chan ger. S tandard altitude rated to 4,500 ft. B* rev = firing rate of 20,00 0 BTU H per burner with #45 gas orifices. Chassis widths 14",17.5", 21", 24.5".

Goodman B rand 80% gas furnac e, 33 3/8" tall, dedicated downflow installation, Induced draft, G oodm an gray c abinet an d panels. M ulti-s peed P SC m otor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right sid e gas ent ry. A lum inized st eel tubular heat ex chan ger. Collector box & pressure s witch change from previous rev. S tandard altitude rated to 5,500 ft. Firing rate of 20,000 BTUH pe r burner with #45 gas orific es . C has s is width s 14" ,17.5" , 21" , 2 4.5".

Goodman B rand 80% gas furnac e, 33 3/8" tall, dedicated downflow installation, Induced draft, G oodm an gray c abinet an d panels. M ulti-s peed P SC m otor, 120 volt carbide m ini Igniter with integrated c ircuit board. Left or right sid e gas ent ry. A lum inized st eel tubular heat ex chan ger. S tandard altitude rated to 5,500 ft. Firing rate of 20,000 B TUH per burner with #45 gas orifices . F irst rev with W hite-Rodgers gas valve. Chassis widths 14",17.5", 21", 24.5".

7

PRODUCT IDENTIFICATION

MODEL # M FG # DESCRIP TI ON

AFE18-60A N/ A

Fo s s il Fu e l Kit.

above/ downstream of a gas or f ossil fuel furnace when used with a heat pum p. It will operate with sing l e and two stage heat pumps and single and two s tage furnaces. T he AFE18-60A con t rol will turn t he he at pump unit off when the furnace is turned on. An anti-short cycle feature initiates a 3 minute timed off delay when the compressor goes off.

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

MODEL # MFG # DES CR IPTION

. For use with upflow furna c e models. This kit is intended to provide a

. This kit allows single stage 80% gas furnaces to operate at the same

EFR01

FTK04

P1221001

P1221002F

FTK04

Exte rnal Filt er Rack Ki t

loc at ion, external to t he furnace cas ing, for installat ion of a permanent filter. The rac k is mounted ov er t he indoor air blower c ompartment area of eit her side panel, and provide filter retention as

well as a location f or attaching return air ductwork.

Furnace Twinning Kit

time from a single thermostat. The two furnaces to be "twinned" must be the exact same model w ith the ir c irculating air blowers set to d eliver the sam e ai r flow at the same time. This kit cannot be used to control more than tw o furnac es.

MODEL # MFG # DESCR IPTION

HANG20

HANG21

N/A

High Altitude Natu r al Gas K it.

20,000 Btu's per cell for higher altitudes. This kit is required when installing these f urnac es above their maximum rated altitude.

High Altitude Natu r al Gas K it.

20,000 Btu's per cell for higher altitudes. This kit is required when installing these f urnac es above their maximum rated altitude.

The kit is designed to convert 80% gas furnace models fired at

8

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIP TION

LPLP03 N/A

LPT-03

MVK-01A MVK-02A

SBT14 SBT17 SBT21

N/A

LP Ga s Low Pressu re Kit

LP gas listed in this manual. This kit includes harness adaptors to work with White-Rodgers single & tw o stage gas v alves ,Ho neyw ell sing le and t wo-s tage gas valves , as well as m odu lating

gas valve s.

LP Co nve rsio n K it

gas . This kit support s both W hite-R od gers and Hon eywell si ngle stag e valves . T he conversion from nat u ral gas (as shipped from the fa c tory) to pr opan e g as req uires: repl acing the burner orif ic e s, replaci ng gas valve regula tor spring (all sing le stag e units ) an d applyi ng ide ntif ication labels.

M as onry V ent Kit.

upf low pos ition onl y and will only be used with interior mas onr y chimneys . Kit incorporat e s a flue hi gh limit safet y switch which will inte ru pt power to the gas valve when a backd raft condition exists.

Downflow Subbase.

ava ilabl e for the fol lowing furnac e widths : 14" wide (SBT14) 17.5" w i de (SBT17) a nd 21" wide (SBT21).

NOx screens must be removed wh en conv erti ng 80% furnaces to this LP kit.

. Designed for applic ation on ga s fired fur nace products installed on

. This ki t co n ver ts

For use with 80% AFUE, 33" tall "H" and "S" model furnac es installed in the

For use wit h 80% dedica ted downflow furnace models. These kits are

s ing le- s tage gas f ired unit s from natural to propane

only

9

ACCESSORIES

AMANA® BR AND "S" Mod el Furnac e Access orie s

MODEL

NUMBE R

SBT 14

SBT 17

SBT21

EFR01

AMU / GMU

AFE180 -60 A

ASAS / GSAS

LPT 03

FTK04

LPLP03

MVK-0 1

HANG21

MVK-0 2

Desc ription

AMS80403A** AMS80603A** AMS80604B**

AMS80804B** AMS80805C** AMS81005C**

AMS81205D** AMS81405D** ADSS80403A** ADSS80603A**

ADSS80804B** ADSS81005C**

Rack

EFR External Filter

Dual Fuel Board

Media Air Cleaners

Elect ronic Air Cleaner

14"

Do w nflow Subba se

····

··· ·

not approved for this model approved for this mo del

·

(1) W/R & HW sing le stage valve (2) AA Rev 5,500 - 10,000 FT

21"

17.5"

Downflow S ubbase

Propane Gas

Downflow Su bbase

(1) (1) (1)

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

(1) (1)

Of f Kit

Conversion K it

LP Low Press ure S hut

··

Twin ning Kit

High Altitude Orifices (2) (2) (2)

(2) (2) (2)

(2) (2) (2) (2)

(2) (2)

W/Pressure Switch

·

Ma sonr y Vent K i t

Mas onry Vent Kit

·

10

ACCESSORIES

MODEL

NUM BER

EFR01

AFE180-60A

GOODMAN® BRAND "S" Model Fur na ce Accessories

SBT14

SBT17

SBT21

AMU / GMU

ASAS / GSAS

LPT03

FTK04

HANG20

LPLP02 LPLP03

MVK-01

HANG21

MVK-02

FSRKG14

FSRKG17

FSRKG21

FSRKG24

Description

GMS80403A**

GMS80603A**

GMS80604B**

GMS80804B**

GMS80805C**

GMS810 05 C**

GMS812 05 D**

GMS814 05 D**

GDS80403A**

GDS80603A**

GDS80804B**

GDS81005C**

14"

Dual Fuel Board

EFR External Filter Rack

Media Air Cleaners

Downflow Subbase

Electronic Air Cleaner

····

··· ·

·

21"

17.5" Propane Gas

Downflow Subbase

(1)

not approved for thi s m odel approved for t hi s mo del (1) W/R & HW si ngle stage valve (2) BA RE V 4, 5 00 - 10, 00 0 FT (exc l u di ng GM S81205D*BA) (3) BB RE V 5, 5 00 - 10, 00 0 FT

(4) AA Rev

(5) GMS 8 1205D* B A 5, 5 00 F T - 10,000 FT

Off Kit

Conversion Kit

LP Low Pressure Shut

··

Twinning Kit

W/Pressure Switch

High Altitude Orifices

(2) (3)

(5)

(2) (3)

W/Pressure Switch

Masonry Vent Kit

·

Masonry Vent Kit

So un d Reduct ion Kit

(4)

11

ACCESSORIES

EXTERNAL FILTER RACK KIT

( EFR01 )

SLOTS IN FILTER CLEAR SCREWS

UNIT SIDE

PANEL

ON UNIT

BLOWE R DE CK

SCREWS

FRONT

OF UNIT

BASE

OF UNIT

RETURN AIR

CUTOUT AREA

LOWER EDGE

SCREW

EFR01 EXTERNAL FILTER RACK KIT

Used on Model s

80% Upflow M o del Furnaces

FILTER RACK ASS EMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

12

ACCESSORY WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

POWER SUPPLY INPUT

FURNACE DEMAND OUTPUT

BLOWER FAN DEMAND OUTPUT

POWER SUPPLY I NPUT (COMMON)

SECOND STAGE FURNACE DEMAND OUTPUT

COM PR ESSOR OU TPUT

SECOND STAGE COM PR ESSOR OU TPUT

REVERSING VALVE OUTPUT

POWER SUPPLY OUT TO THERMOSTA T

CALL FOR REVERSING VALVE

CALL FOR COMPRESSOR

CALL FOR EMERGENCY HEAT

CALL FOR BLOWER FAN

CALL FOR FURNACE HEAT

POWER SUPPLY COMMON OUT TO THERMOSTA T

CALL FOR 2ND STAGE FURNACE HEAT

CALL FOR 2ND STAGE COMPRESSOR

POWER SUPPLY OUT TO HP CONTROL

HP CALL FOR FURNACE (DURING DEFROST)

REVERSING VALVE OUTPUT

COMPRESSOR CONTACTOR O UTPUT

POWER SUPPLY COMMON OUT TO HP CONTROL

ODT (OUTDOOR THERMOSTAT)

2ND STAGE COMPRESSOR DEMAND OUTPUT

F U R N A C E

T H E R M O S T A T

H E A T

P U M P

R W1 G C W2 Y Y2 O

R O Y E G W1 C W2 Y2

R W2 O Y

C OT-NO OT-NC OT-C

Y2

P1-8

P1-7

P1-4

P1-6

P1-5

P1-2

P1-3

P1-1

P2-2

P2-1

P2-7

P2-8

P2-5

P2-9

P2-3

P2-4

P2-6

P3-9

P3-8

P3-7

P3-2

P3-6

P3-3

P3-1

P3-4

P3-5

24VAC

F1

3A

C

24VAC

C

POWER SUPPLY

1.0K

6.8K

+5VDC

E/W1

O

Y

+VDC +5VDC

+VDC

K1

K2

Q1

MICROPROCESSOR

24VAC

+VDC

K4

Q2

W1-FURN W2-HP

G-STAT

G-FURN

Y2-HP

Y2-STAT Y2-FURN

Y-STAT Y-FURN

Y-HP

K3

BREAK FOR ODT

1 2

ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

13

ACCESSORY WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

14

FURNACE TWINING KIT - FTK04 (UTEC Control Board)

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use only with 80% or 90% Single-Stage Furnaces)

OPERATING INSTRUCTIONS

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15

OPERATING INSTRUCTIONS

FOR YOUR SAFETY

READ BEFORE OPERATING

If you do not follow these instructions

WARNING:

explosion may result causing propertyexactly, a fire or

damage, personal injury or

loss of life.

A. This appliance does not have a pilot. It is equipped with a n ignition device which automatically lights to light the burner by hand.

the burner. Do not try B. smell all around the appliance

BEFORE OPERATING

area for gas. Be sure to sme ll next to th e floor becaus e some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not tr y to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot re ac h your gas supplier, call the fire department.

C. Use only your hand to pu s h in or turn the gas control lever. Never use tools. If th e lev er w ill not push in or turn by hand, don't try to repair it, ca ll a qualified service technician. Force or attempted repair may result in a fire or explosion.

D.

Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any ga s control which ha s been underwater.

LIRE AVANT DE METTRE

EN MARCHE LIRE

AVERTISSEMENT:

la lettre les instructions dans le presént m anuel risque de déclencher un incend ie ou une explosion

entraînant des dommages matériels, des lesions corporelles ou la perte de vies humaines.

Cet appareil ne comporte pas de veilleuse. Il est

A.

muni d'un dis positif d'allumage qui allume automatiquemen t le brûl eur. Ne pas tenter d'allume r le brûleur manuellement.

B. AVANT DE LE FAIRE FONCTIONNER,

r enif ler to ut autour de l'appariel po ur decéler une odeur de gaz. Renifler prés du plancher, car certains gaz son t plus lourds que l'air et peuvent s'accumuler au niveau du sol.

QUE FA IR E S'IL Y A UNE ODEUR DE GAZ

Ne pas tenter d'allume r d'appareils.

toucher à aucu n interrupteur; ne pas vous servir

Ne des téléphone s dans le bâtiment.

Appele z immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur de gaz

Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service de s incendies.»

C. Ne pousser ou tourner la manette d'admission du gaz qu'à la main. Ne jam ais emploer d'outil à cette fin.

Si la m anette reste coincée, ne tenter pas de la réparer; appelez un technicien qualifié. Quiconque tente de fo rcer la manette ou de la réparer peut provoquer un e explos ion ou un incendie.»

D. Ne pas se servir de cet appareil s'il a été plongé dans l'eau, même partiellement. Faire inspecter l'appareil par un technicien qualifié et remplacer toutr parti e du systéme de contrôle et toute commande qui ont été plongées dans l'eau.»

Quiconque ne respecte pas à

OPERATING INSTRUCTIONS

1. Read the safety information above on

STOP.

this label.

2. Set the thermostat to lowest setting.

3. Tur n off all electric power to the appliance.

4. This appliance is equipped with an ignition device wh ich automatically light s th e burner. Do not try to light the burner by hand.

5. Push the gas control lever to Position. Do not force.

6. Wait five (5) minute s to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, Follow in the safety information above on this label if you don't sme ll gas, go to next ste p.

7. Push gas control lever to

"ON".

8. Replace access panel.

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

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

STOP. "B"

"OFF”

GAS INLET

ARRIVEE

DU GAZ

ROBINET A GAZ

MANUEL, EN POS

"ON/MARCHE"

MANUAL GAS LEVER SHOWN IN "ON" POS

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

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

3. Push the gas control l ever to Position.

Do not force.

4. Replace control access panel.

"OFF”

MISE EN MARC HE

1. Lisez les instructions de sécurité dans la

ARRÊTEZ

section supérieure de cette étiquette.

.

2. Régler le thermostat à la température la plus basse.

3. Couper l'alimentation électriqu e de l'appareil.

4. Cet appareil menager etant dote d'un systeme d'alluma ge automa ti que, ne pas essa ye r à allumer le brûleur manuellement.

5. Pousse le levier du contrÔle du gaz a

position.

6. Attendre cinq (5) minutes pour laisser echapper tout le gaz. Renifler tout autour de l' appareil, y compri s prés du

plancher, pour décele r une odeur de gaz. Si c ' est le ca s, Passe r à l'etape B des instructions de secu rite

ARRÊTEZ.

sur la portion su perieure de cette etiquette. S'il n'y a pas d'odeur de gaz, passer à l'etàpe suivante.

7. Pousse l e levie r du contrôle du gaz à

position.

8. Remettre en place le panneau d'accés.

9. Mettre l'appareil sous tension.

10. Régler le thermostat à la température désirée.

11. Si l'appareil ne se met pas en marche, suivre les instructions intitulées Comment couper l'admi ssio n de gaz de l'appar eil et appeler un technicien qualifié ou le fournisseu r de gaz.

"OFF/ ARRET”

"ON/MARCHE”

POUR COUPER L'ADMISSION DE GAZ DE L'APP A RE IL

1. Régler le thermostat à la température la plus bassé.

2. Couper l'alimentation électrique de l'appareil s'il faut procéder à des operations d'entretien.

3. Pousse le levier du contrôle du gaz à position. Ne pas forcer.

4. Remettre en place le panneau d'accés.

"OFF/ ARRET"

0140F00681 REV A

16

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 n 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.

ot

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 above on this label.

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 n 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 "ON" POSITION

ot

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! 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.

WA RNING:

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

This furnace must be installed in accordance with the manufacturers instructions and local codes. In the absence of local codes, follow the National Fuel Gas

Code, ANSI Z223.1.

WA RNING:

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 known by the State of California to cause cancer.

Improper

If not

FOR YOUR SAFETY

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

0140F00688 Rev A

17

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,

T

ADJUSTMENT, ALTERATION, SERVI CE OR MAI NTENANCE, RE FER T O THI S MANUAL. QUALIFIED INSTAL LER, SERVICE AGENCY OR THE GAS SUP PLIER.

T

MAY CAUSE SERI OUS ILLNESS OR DEAT H AND WHICH ARE KNOWN TO THE

S

REPRODUCTIVE HARM.

T

DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELEC TRI CAL CO MPONEN TS FROM WATER.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

F

WARNING

HIS PRODUCT CONTAI NS OR PRODUCES A CHEMIC AL OR CHEMICALS WHIC H

TATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DE FECTS OR OTHER

WARNING

O PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

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.

WARNING

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.

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DE ATH DUE TO FIRE,

P

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATI ON, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.

WARNING

O PREVENT PROPERTY DAMAGE, P ERSONAL INJURY OR DEATH DUE TO FIRE ,

T

DO NOT INS TALL THIS F URNACE IN A MOBI LE HOME, TRAI LER, O R 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 1430 Broadway New York, NY 10018

National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269

18

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 EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

T

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 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 combustible 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

• 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 Com- bustion and Ventilation Air Requirements section in this manual or the installation instructions 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 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.

19

PRODUCT DESIGN

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 BLOWER 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 ALLOW FOR

CIRCULATOR BLOWER REMOVAL.

ALTERNATE GAS PIPING

Suspended Furnace

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a vent-

ing 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.

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 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

ASSURE FURN ACE IS LEVE L FRO M

END TO EN D.

ON

90% FURNACES

THE UNI T HAS A SL IG HT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELO W THE BACK OF THE F URNAC E.

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

MAKE SURE

CONDENSATE

DRAIN

REMOVAL.

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 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

A high quality single stage thermostat with a common terminal is recommended.

Thermostat 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.

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

COMBUSTION AND VENTILATION AIR REQUIREMENTS

WARNING

OSSIBLE PROPERT Y DAMAGE, PE RSONAL I NJURY O R DEATH MAY OCCUR

P

IF THE FURNACE IS NOT PROVI DED WITH ENOUGH FRESH AI R FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED T O T HE FURNACE ARE A.

20

PRODUCT DESIGN

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.

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

3

ft

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

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

Required Volume

where:

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

(3) For purposes of this calculation, an infiltration rate greater than 0.60

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

other

= fan-assisted appliances input in Btu per hour

fan

per hour, expressed as a decimal)

ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.2.2(2).

> ________ _________

other

> ________ _________

fan

3

21 ft

ACH 1000 Btu/hr

15 ft

ACH 1000 Btu/hr

I

other

(

3

I

fan

(

)

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.

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 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

9.3.2.3 Indoor Opening Size and Location. Openings used to connect 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.2/1000Btu/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 minimum dimension of air openings shall be not less than 3 in. (80 mm).

NOTE: Each opening must 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.

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

Chimney or Gas Vent

Water Heater

Furnace

Opening

2

21

PRODUCT DESIGN

A

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.

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

each opening shall have a minimum free area of 1 in. (1100 min

2

/kW) of total input rating of all appliances in the enclo-

2

/2000 Btu/hr

sure. [See Figure A.9.3.3.1(2).]

Chimney or Gas Vent

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:

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

cating 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

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

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

Water Heater

lternate

air inlet

Furnace

Inlet Air

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.2/3000 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 no t l ess than one square inch per 3000 BTU of the total input rating of all equipment in the enclo sure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

Ventilation louvers for unheated crawl space

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.

Chimne y or Gas Vent

Ventilation louvers (each end of att ic)

NOTE: The inlet and outlet air openings must each ha ve a free area of not less than one square inch per 4000 BTU of the tota l in pu t ra tin g of all equi p m e n t in the enclosure.

Outlet Air

Water Heater

Furnace

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

Water Heater

Furnace

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

Opening

Alternate Opening Location

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

Figure A.9.3.3.1(1)(b) All Combustion Air

From Outdoors through Ventilated Attic.

calculated in accordance with the following:

22

PRODUCT DESIGN

(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.

(c) The minimum size of outdoor opening(s) shall be the full size

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).

9.3.8.3 Ducts shall serve a single space.

9.3.8.4 Ducts shall not serve both upper and lower combustion air open-

ings 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.

9.3.5 Engineered Installations. Engineered combustion air installa-

tions 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.

9.3.7.1 Louvers and Grilles. The required size of openings for com-

bustion, 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.

9.3.8.6 Horizontal upper combustion air ducts shall not slope downward 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.

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

WARNING

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO

T

ASPHYXIATI ON, NON-CONDENSING GAS FI RED WARM AIR FURNACES MUST BE

CATEGORY I VENTED. DO NOT VENT ANY OF THESE FURNACES USI NG

ATEGORY

C

VENT ING.

III

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.

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 from conveying combustion air, provided 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.

WARNING

TO PREVENT POSSIBLE DEATH OR PERSONAL INJURY DUE TO

ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER'S INDUCED DRAFT APPLIANCES IS NOT ALLOWED.

23

PRODUCT DESIGN

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. For complete details refer to Exisiting Furnace Removal section 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.

WARNING

O PREVENT DEATH OR SERI OUS ILLNESS TO BUILDI NG OCCUPANTS DUE

T

TO FLUE P RODUCTS LEAKING INTO THE BUILDING, PROPE R INSTA LLATION 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.

Masonry Chimneys

Crown

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

Breech

Clean Out

Throat

Damper

Wash

Roof Line

Clay Ti le 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 Assis t ed Forced Air Furnace

Natural Draft Water Heater

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.

24

PRODUCT DESIGN

10' or Less

Proper Chi m ney

Termination?

(Check 1)

Yes

Chimney channel

free of solid and

liquid fu el

appliances?

(Check 2)

Yes

Crown in good

condition

(Check 3)

Yes

Cleanout free of

debris?

(Check 4)

Yes

Liner i n good

condition?

(Check 5)

Yes

No

Line, terminate with

listed vent cap

(Fix 1)

Chan ge venting

arrangements

(Fix 2)

Rebuild crown

(Fix 3)

and/or Reline

(Fix 4)

Reline (Fix 4)

2' Mi n.

Ridge

2' Min.

Wall or Parapet

Chimney

10' or Les s

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 required when distance from walls or parapet is more than 10 feet.

Chimney

Dilution air

available?

(Check 6)

Yes

Comp l e te the

installation.

(Check 7)

No

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.

Hei ght above any

2' Min.

roof surface within 10 feet horizontally.

3' Min.

Ridge

More than 10'

10'

Chimney

Termination More Than 10 Feet From Ridge, Wall or

Parapet

25

PRODUCT DESIGN

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.

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 mortar

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 tap-

ping 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.

26

PRODUCT DESIGN

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 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.

27

PRODUCT DESIGN

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:

• 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, and flue pipe connections.

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

AILURE TO FOLLOW THESE INSTRUCTI ONS CAN RESULT IN BODILY INJURY OR

F

DEA TH. SECTION.

AREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS

C

WARNING

PON COMPLETION OF THE FURNACE INSTAL LATION, CAREFULLY I NSPECT THE

U

ENTIRE FLUE SYSTEM BOTH INS IDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED. PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.

EAKS IN THE FLUE SYSTEM CAN RESULT I N SERIOUS

L

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.

CAUTION

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.

Propane Gas and/or High Altitude Installations

WARNING

POSS IBLE PROPERT Y DAMAGE, PERS ONAL INJURY OR DEATH MAY OCCUR IF

THE CORRECT CONVERSI ON K ITS ARE NOT I NST ALLED. MUST BE APPLI ED TO I NSURE SAFE AND P ROPER FURNAC E OPERAT I ON. CONVERSIONS MUST BE PERFOR MED BY A QUALI FI ED I NSTAL LER OR S ERVI CE AGENCY.

HE APPROPRI ATE KI T S

T

A

LL

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.

28

O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAM AGE, THE INLET

T

GAS SUPPLY PRE SSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLA TE WITH ALL OTHER HOUSEH OLD GAS FIRED APPL IANCES OPERATING.

Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

INLET GAS SUPPLY PRESSURE

Natural Gas Minimum: 4.5" w.c . Maximum: 10.0" w.c.

Propane G as Minimum: 11.0" w.c. Maximum: 13. 0" w.c.

HIGH ALTITUDE DERATE

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

PRODUCT DESIGN

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/ or Pressure Switch) kits.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

PROPANE GAS CONVERSION

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF

P

THE CORRECT CONVER SION KITS ARE NO T I NSTALLED. MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.

This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations.

• Single-stage 80% furnace modelsusing a Honeywell VR8215 single stage valve or a White-Rodgers 36J22 use LPT-03 LP Conversion Kit.

Refer to the specification sheet for the model you are servicing. Refer to the “propane gas and/or High Altitude Installa- tions” section for details.

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the appropriate propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

3

content of the

HE APPROPRIATE KITS

T

A

LL

NOTE: The gas supply pressure on White-Rodger "J" model gas valve, used on single stage furnaces, can be checked with a gas pressure test kit (Part #0151K00000S) available through our authorized distributors.

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the Lighting Instructions Label or the “Put- ting the Furnace Into Operation” section of this manual or the installation instructions for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS

CAUTION

O AVOID POSSIBLE U NSATISFACT ORY OPERATI ON OR EQUI PMENT DAMAGE

T

DUE TO UNDERFIRI NG O F E QUIPMENT, USE THE P ROPER SI ZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PI PE FROM THE METER/TANK TO T HE FURNACE.

The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH )

Length of Nominal Black Pipe Size

Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490

100 38 79 150 305 460

(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific Gravity Gas)

CFH =

BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)

To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.

The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.

1. Use black iron or steel pipe and fittings for the building piping.

2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.

29

PRODUCT DESIGN

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.

5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.

6. Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory .

7. Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

8. Tighten all joints securely.

9. Connect the furnace to the building piping by one of the following methods:

– Rigid metallic pipe and fittings. – Semi-rigid metallic tubing and metallic fittings. Alu-

minum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.

10. Use listed gas appliance connectors in accordance with

their instructions. Connectors must be fully in the same room as the furnace.

11.Protect connectors and semi-rigid tubing against physi-

cal and thermal damage when installed. Ensure aluminum-alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage.

following fittings (starting from the gas valve) to reach the outside of the cabinet (NOTE: On the 90% furnaces the installer must swap the alternate inlet hole plug with the standard inlet grommet in order to seal the cabinet):

• Coupling.

• 90 degree elbow.

• 2 inch close nipple.

• 90 degree elbow.

• Straight pipe, with a ground joint union, to reach the exterior of the furnace. NOTE: A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas connections.

WARNING

T

O AVOID THE POSS IBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH

OR OPEN FLA ME TO TEST FOR LEAKS.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).

PROPANE GAS TANKS AND PIPING

CAUTION

DGES OF SHEET METAL HO LES MAY BE SHARP. USE GLOVES A PRECAUTI ON

E

WHEN REMOVING HOLE PLUGS.

DIRECT/STANDARD INLET PIPING

When gas piping enters directly to the gas valve through the standard inlet hole (upflow through the right side panel), the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace. NOTE: The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration on 90% furnaces. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

INDIRECT/ALTERNATE INLET PIPING

When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the installer must supply the

30

WARNING

ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE I N

P

ANY LOW AREAS OR CONFINED SPACES. PERSONAL INJURY, OR D EATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DET ECTION WARNING DEVI CE.

O PREVENT PROPERTY DAMAGE,

T

A gas detecting warning system is the only reliable way to detect a propane gas leak. Iron oxide (rust) can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas

is suspected, follow the instructions on this page.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

PRODUCT DESIGN

For satisfactory operation, propane gas pressure must be 11 inch WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

Always use a pipe sealant approved for natural gas and LP gas.

Refer to the following illustration for typical propane gas installations and piping.

First Stage Regulator

200 PSIG Maximum

Typical Propane Gas Installation

5 to 15 PSIG (20 PSIG Max.)

Continuous

Second Stage Regulator

11" W.C.

WARNING

F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED E XACTLY, A

I

FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSO NAL INJURY OR LOSS OF LIFE.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

– LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –

WHAT TO DO IF YOU SMELL GAS:

•

• PHONE IN YOUR BUILDING.

• PHONE.

• DEPARTMENT.

INSTALLAT ION AN D SERVICE MUST BE PE RFORMED BY A QUALIF IED INSTALLER ,

– SE RVICE AGENCY OR THE GAS SUPPLIER.

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.

Pipe or Tubing Length

To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879

DO NOT TRY TO LIGHT ANY APPLIANCE.

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

D

IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

FOLLOW THE GAS SUPP LIER’ S IN STRUC TION S.

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

I

Tubing Size, O.D. Type L

Feet

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"

10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 220 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 850 1,700 2,700 4,100 1,600 3,700 50 330 770 1,500 2,400 3,700 1,500 3,400 60 300 700 1,300 2,200 3,300 1,300 3,100

80 260 610 1,200 1,900 2,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 125 200 490 900 1,400 2,300 900 2,100 150 190 430 830 1,300 2,100 830 1,900 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500

Nominal Pipe Size

Schedule 40

WARNING

IF THE GAS FURNACE IS INS TALLED IN A BASEMENT, AN EXCAVATED

AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPL IER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

•

INCE PROPANE GAS I S HEAVIER THAN AIR, ANY LE AKING GAS CAN

S

SETTLE IN ANY LOW AREAS OR CONFINED SPACES.

•

ROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

P

EXCEPT WITH A WARNING DEVI CE.

Sizing Between Second or Second Stage Regulator & Appliance*

Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/ho ur.

Pipe or Tubing

Length

Feet

10 39 92 199 329 501 275 567 1,071 2,205 3,307

20 26 62 131 216 346 189 393 732 1,496 2,299

30 21 50 107 181 277 152 315 590 1,212 1,858

40 19 41 90 145 233 129 267 504 1,039 1,559

50 18 37 79 131 198 114 237 448 913 1,417

60 16 35 72 1,211 187 103 217 409 834 1,275

80 13 29 62 104 155 89 185 346 724 1,066

100 11 26 55 90 138 78 162 307 630 976 125 10 24 48 81 122 69 146 275 567 866 150 9 21 43 72 109 63 132 252 511 787 200 8 19 39 66 100 54 112 209 439 665 250 8 17 36 60 93 48 100 185 390 590

*Data in accordance with NFPA pamphlet No. 54

Tubing Size, O.D. Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

Nominal Pipe Size

Schedule 40

Propane Gas Piping Charts

31

PRODUCT DESIGN

When installing a propane storage tank, the contractor must consider proper tank sizing, safety, efficiency, ground characteristics and aesthetics. For a residential customer, the size may range from 100-1,000 gallons, depending on household use. Typically, a 500 gallon tank is ample for an average four-bedroom home. However, it is best to consult your local propane supplier to ensure the proper sizing for propane storage requirements. Determining the correct tank size for each household is a function of demand, economy, efficiency and convenience. It is a process that requires cooperation between the propane supplier and customer.

ELECTRICAL CONNECTIONS

WARNING

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRI NG TO THE UNIT MUST BE

T

PROPERLY POLARIZED AND GROUNDED.

WARNING

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.

NOTE: Line polarity must be observed when making field connections.

W

A

R

N

I

N

G

N 90% F URNACE UPRI GHT UP FLOW I NSTALL ATIO NS, THE DRAIN TRAP MUST

I

BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION

HIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION

BOX.

T

BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION.

Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel.

HIGH VOLTAGE

ISCONNECT

D

INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PE RSONAL I NJURY OR D EATH.

POWER BEF ORE SERVICING OR

ALL

ULTIPLE POWER SOURCES MAY

M

AILURE TO DO SO MAY CAUSE PROPERTY

F

CAUTION

L

ABEL AL L WIRE S PRI OR TO DI SCON NECTI ON WHE N SER VICIN G CONT ROLS .

WIRING ERRORS CAN COUSE IMPROPER AND DANGEROUS OPERATION. V

ERIFY PROPER OPERATION AFTER SERVICING.

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

CAUTION

DGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION

E

WHEN REMOVING HOLE PLUGS.

NOTE: Wire routing must not interfere with circulator blower

operation, filter removal, or routine maintenance.

WARNING

O AVOID THE RI SK O F ELECTRICAL SHOCK, INJURY, OR DE ATH, THE

T

FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LO CAL CODES OR, IN THEIR ABSENCE, WI TH THE LATEST EDITI ON OF THE

ATIONAL ELECTRIC CODE.

N

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

CHANGING ANY ELECTRICAL WIRING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

F

ULTIP LE POWER

M

AILU RE TO DO SO MAY CA USE

Some furnaces have an integrated ignition control that is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner.

32

PRODUCT DESIGN

HUMIDIFIER WIRING

Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The Humidifier and Electronic Air Cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown below.

OPTIONAL

ACCESORIES

ELECTRONIC

AIR CLEANER

HUMIDIFIER

EAC-H

HUM-H

L

120 VAC

HOT AND

PARK

TERMINALS

12 PIN

CONNECTOR

Accessory Wiring

(certain control boards)

If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must

conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.

The integrated control module humidifier terminals (HUM) are energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

24 VOLT THERMOSTAT WIRING NOTE: Low voltage connections can be made through ei-

ther the right or left side panel. Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

A 40 V.A. transformer and an integrated electronic control are built into the furnace to allow use with most cooling equipment. Consult the wiring diagram, located in the Technical Manual or on the blower door for further details of 115 Volt and 24 Volt wiring.

THERMOSTAT WIRING - SINGLE-STAGE

The single stage furnace will have a "W" terminal and will use a single stage thermostat. The following drawing illustrates the typical field wiring for a heat only single stage system and a single stage heating/single stage cooling system. Refer to the following figures for proper connections to the integrated control module.

A R T U E N

120 VAC

NEUTRAL

TERMINALS

INTEGRATED

CONTROL

MODULE

Heating Room Thermostat

Furnace Control

Heating/Cooling Room Therm o s ta t

WW

Furnace Control

Remote

Condensing

Unit

Typical Field Wiring (24 VAC Control Circuit)

1. Secure the dehumidistat hot wire (typically the black lead) to the terminal marked “R” on the furnace integrated control module.

2. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumidistats.

3. Turn ON power to furnace.

To enable the dehumidify function on the integrated control module, set the dehumidification ENABLE dipswitch from OFF to ON.

Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidication (DEHUM-Stat).

CONTINUOUS FAN OPERATION SINGLE STAGE FURNACES

The single stage furnace control will energize the heating circulator fan speed when the fan switch on the thermostat is turned to the "ON" position.

CIRCULATOR BLOWER SPEED ADJUSTMENT

WARNING

HIGH VOLTAGE

ISCONNECT

D MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO

SO MAY CAUSE PROPERT Y DAM AGE, PERSONAL INJURY OR DEATH .

POWER BEFOR CHANGING SPEED TAPS.

ALL

Connect the correct motor leads to the COOL, HEAT, and PARK terminals. If the heating speed equals cooling speed, use the jumper wire provided. All unused motor leads that are not connected to "PARK" terminals on the control must be taped to prevent shorts.

CIRCULATING AIR AND FILTERS DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of "Air Conditioning Contractors of America" manual D.

33

PRODUCT DESIGN

A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems, Pamphlets No. 90A and 90B.

A return air filter is not supplied with the furnace. The installer must supply a means of filtering all of the return air. Filter(s) shall comply with UL900 or CAN/ULC-S111 Standards. If the furnace is installed without filters, the warranty will be voided.

EXAMPLE:

Filter Size (in2) =

Filter Size (in

2

) =

1400 CFM x 144 in

2

600 ft ./min. (Permanent)

1400 CFM x 144 in

2

300 (Dis posabl e) ft . / m i n.

MINIMUM FILTER SIZES for DISPOSABLE FILTERS

FURNACE INPUT FIL T ER SIZE

40M 60M 483 in

80M 100M 120M 140M

DISPOSABLE NOMINAL 300 F.M. FACE VELOCITY

SIDE RETURN BOTTOM RETURN

Cabinet

Width

(In.)

Nominal

Filter

Size (In.)

All 16x25x1 400 14" 14X25X 1 350

Approx.

Flow A re a

(In.)

Cabinet

Width

(In.)

17-1/2 14X25X1 350

21 16x25x1 400

24-1/2 20X25X1 500

320 in

640 in 800 in 738 in 738 in

Nominal

Filter

Size (In.)

2 2 2 2 2 2

Approx.

Flow Area

(In.)

Refer to Minimum Filter Area tables to determine filter area requirement. NOTE: Filters can also be installed elsewhere in the duct system such as a central return.

One inch throwaway filters should be sized for a face velocity of 300 feet per minute or less (14x25x1 throwaway = 730 CFM maximum, 16x25x1 throwaway = 830 CFM maximum, 18x25x1 throwaway = 940 CFM maximum, 20x25x1 throwaway = 1040 CFM maximum) All other filters should be sized according to their manufacturer's instructions.

To find the miminum filter requirement (in2) for either permanent or disposable filters divide the required airflow (CFM) by the rated velocity of the filter, either 300ft/min for disposable filter or 600ft/min for permanent filter. Multiply the number by 144 in.2 to obtain the minimum filter requirement (in2).

Fil ter S ize = 672i n

Fil ter S ize = 336in

2

Dis posable

2

Perm ane nt

Upflow furnaces with air delivery of less than 1800 CFM:

Use one side return or one bottom return ductwork connection.

Upflow furnaces with air delivery of 1800 CFM or higher:

Use two side returns or one side return and one bottom return connection.

Guide dimples locate the side and bottom return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. An undersized opening will cause reduced airflow. For bottom return connection, remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct.

A closed return duct system must be used, with the return duct connected to the furnace.

NOTE: Ductwork must never

be attached to the back of the furnace. Supply and return

connections to the furnace may be made with flexible joints to reduce noise transmission, if desired. If a central return is used, a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with combustion air or draft. The room, closet, or alcove must not be used as a return air chamber.

When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.

When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

34

UPRIGHT FILTER INSTALLATIONS

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register and a side panel external filter rack kit (upflow filter kit # EFR01). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Refer to the following minimum

PRODUCT DESIGN

filter requirement charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal. If the filter rack is used, the side of the plenum must be at least as tall as dimension "A" shown in the following illustration. For dimension of "A" refer to the following chart.

ADDITIONAL FILTERING ACCESSORIES External Filter Rack Kit (EFR01)

The external filter rack kit is intended to provide a location external to the furnace casing, for installation of a permanent filter on upflow model furnaces. The rack is designed to mount over the indoor blower compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

COUNTERFLOW FILTER INSTALLATION

This furnace has provisions for the installation of return air filters at the counterflow top return. The furnace will accommodate the following filter sizes depending on cabinet size:

Return Air

Optional

Access

Door

COUNTERFLOW TOP RETURN

Cabinet

Width

14 15.1

17 1/2 14.2

21 13.0

24 1/2 11.3

14 20.4

17 1/2 19.7

21 18.8

24 1/2 17.7

14 25.5

17 1/2 25.0

21 24.3

24 1/2 23.4

Filter Area

2

(in

)

600

800

1000

Qty.

2

"A" Min

Filter Size

(in)

15x20x1

20x20x1

25x20x1

Dimension "A:

(in)

Refer to Minimum Filter Area tables to determine filter area requirement. NOTE: Filters can also be installed elsewhere in the duct system such as a central return.

Horizontal Installations

Filter(s) must be installed external to the furnace casing for horizontal installations. For most installations it is preferable to use a central return with filters installed in the duct behind the return air grill. In this way filter replacement is relatively simple by merely removing the grille, rather than going into the attic or crawl space.

NORMAL SEQUENCE OF OPERATION

POWER UP

1. 1 15 V AC power applied to furnace.

2. Integrated ignition control module performs internal checks.

3. Integrated ignition control module LED will light.

4. Integrated ignition control monitors safety circuits continuously.

5. Furnace awaits call from thermostat.

NORMAL HEATING SEQUENCE

1. R and W thermostat contacts close, initiating a call for heat.

2. Integrated control module performs safety circuit checks.

3. The induced draft blower is energized causing pressure switch contacts to close. Induced draft blower remains energized for pre-purge period. Humidifier terminals are energized with induced draft blower .

4. Ignitor warm up begins after pre-purge is completed.

5. Gas valve opens at end of ignitor warm up period, delivering gas to burners to establish flame.

6. The control checks for a signal from the flame sensor within seven (4) seconds after the gas valve is energized. Gas will only continue to flow if a flame signal is present.

7. Circulator blower is energized on heat speed following a fixed thirty (30) second blower on delay. Electronic air cleaner terminals are energized with circulator blower.

8. Furnace runs, integrated control module monitors safety circuits continously.

9. R and W thermostat contacts open, allowing the gas valve to cycle off.

10. Induced draft blower is de-energized following a fifteen (15) -second post purge. Humidifier terminals are deenergized.

1 1. Circulator blower is de-energized following a selectable

heat off delay period (90, 120, 150 or 180 seconds). Electronic air cleaner terminals are de-energized.

12. Furnace awaits next call from thermostat.

The adjustable delay-off timing allows the installer to customize the comfort level.

35

PRODUCT DESIGN

Cooling Mode

The normal operational sequence in cooling mode is as follows:

1. R and Y thermostat contacts close, initiating a call for cool.

2. Integrated control module performs safety circuit checks.

3. Outdoor fan and compressor are energized.

4. Circulator blower is energized on cool speed following a fixed five (5) second on delay. Electronic air cleaner terminals are energized with circulator blower.

5. Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously.

6. R and Y thermostat contacts open, completing the call for cool.

7. Outdoor fan and compressor are de-energized.

8. Circulator blower is de-energized following a fixed forty five (45) second cool off delay period. Electronic air cleaner terminals are de-energized.

9. Furnace awaits next call from thermostat.

Fan Only Mode

The normal operational sequence in fan only mode is as follows:

1. R and G thermostat contacts close, initiating a call for fan.

2. Integrated control module performs safety circuit checks.

3. Circulator blower is energized on heat speed. Electronic air cleaner terminals are energized.

4. Circulator blower runs, integrated control module monitors safety circuits continuously.

5. R and G thermostat contacts open, completing the call for fan.

6. Circulator blower is de-energized. Electronic air cleaner terminals are de-energized.

7. Furnace awaits next call from thermostat.

36

SYSTEM OPERATION

HEATING - Abnormal Operation

The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses. Next, refer to the Troubleshooting Chart on the following pages for an interpretation of the LED signals and to the information in this section for a description of the problem.

1. Internal Control Failure with Integrated Ignition Control. Check for voltage to the furnace and low voltage at the control board. Check for blown fuse on the control board. If the control determines it has an internal fault, it enters a locked-out state. Any of the situations mentioned will cause the diagnostic LED to provide no signal. The control board should only be re- placed after all other checks from the Troubleshooting Chart have been verified.

2. System Lockout. If a flame is not sensed during the first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated for (8) seconds. The gas valve will then be energized. If flame is not sensed in seven (4) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off for more than (5) seconds and less than (20) seconds and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for a minimum of 5 seconds.

NOTE: The control board will automatically reset one hour after lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected. Refer to Troubleshooting Chart on the following pages for aid in determining the cause.

3. Pressure Switch Stuck Closed. If the control senses the pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic light code for this problem is two short flashes followed by a longer pause. The probable cause is either a faulty pressure switch or wiring.

4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close within 5 minutes, the control will go into a 1hour lockout. The control will automatically reset from lockout adn restart the ignition sequence. The diagnostic light code for this problem is three short flashes followed by a pause. The probable causes are either disconnected hose to the pressure switch, faulty pres-

sure switch or wiring, or restricted air intake or flue piping.

5. Open Primary or Auxiliary Limit. If the limit control opens, the air circulator blower will be turned on until the limit closes. The induced draft blower will turn off for 5 seconds then turn off. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, or blower speed set to low.

6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation. The diagnostic flash code for this is a five flashes. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

7. Open Rollout Limit. If the rollout control opens, the air circulator blower will be energized all the time. The diagnostic light code for this problem is six flashes followed by a pause. The probable cause is either restricted flue piping or improper air requirements.

8. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level, the diagnostic light code for this problem will be seven flashes followed by a pause. The probable cause is either a coated/oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.

9. Igniter circuit or poor ground. Improperly connected igniter, bad igniter or poor ground to the equipment. The diagnostic light code for this problem is eight

flashes.

37

TROUBLESHOOTING

TROUBLESHOOTING CHART

Associated

Symptoms of Abnormal

Operation

• Furnace fails to operate.

• Integrated control module diagnostic LED provides no signal.

Associated

LED Code

NONE

Fault Description(s) Possible Causes Corrective Action Fault Description(s) Possible Causes

2

• No 115 volt power to furnace, or no 24 volt power to integrated control module.

• Blown fuse or circuit breaker.

• Integrated control module has an internal fault.

• Manual disconnect switch OFF, door switch open, or 24 volt wires improperly connected or loose.

• Blown fuse or circuit breaker.

• Integrated control module has an internal fault.

• Assure 115 and 24 volt power to furnace integrated control module.

• Check integrated control module fuse (3A). Replace if necessary.

• Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.

• Replace bad integrated control module.

Cautions and

Notes

• Turn power OFF prior to repair.

• Replace

integrated control module fuse with 3A automotive fuse.

• Read precautions in “Electrostatic Discharge” section of manual.

• LED is Steady On.

ON

CONTINUOUS

ON

• Furnace fails to operate.

• Integrated control module diagnostic LED is flashing ONE (1) flash.

• Furnace fails to operate.

• Integrated control module diagnostic LED is flashing TWO (2) flashes.

• Induced draft blower runs continuously with no further furnace operation.

• Integrated control module diagnostic LED is flashing THREE (3) flashes.

• Normal Operation • Normal Operation • None

• Furnace lockout due

1

to an excessive number of ignition “retries” (3 total)1.

• Failure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad igniter or igniter alignment, improper orifices, or coated/oxidized or improperly connected flame sensor.

• Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.

• Pressure switch

2

circuit is closed.

• Induced draft blower is not operating.

• Pressure switch

3

circuit not closed.

• Induced draft blower is operating.

• Induced draft blower pressure switch contacts sticking.

• Shorts in pressure switch circuit.

• Pressure switch hose blocked, pinched or connected improperly.

• Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.

• Incorrect pressure switch setpoint or malfunctioning switch contacts.

• Loose or improperly connected wiring.

• Locate and correct gas interruption.

• Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.

• Replace or realign igniter.

• Check flame sense signal. Sand sensor if coated and/or oxidized.

• Check flue piping for blockage, proper length, elbows, and termination.

• Verify proper induced draft blower performance.

• Replace induced draft blower pressure switch.

• Repair short.

• Inspect pressure switch hose. Repair, if necessary,

• Inspect flue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.

• Correct pressure switch setpoint or contact motion.

• Tighten or correct wiring connection.

1

Integrated control module will automatically attempt to reset from lockout after one hour.

2

LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

• Normal Operation

• Turn power OFF prior to repair.

• Igniter is fragile, handle with care.

• Sand flame sensor with emery cloth.

• See “Vent/ Flue Pipe” section for piping details.

• Turn power OFF prior to repair.

• Replace pressure switch with proper replacement part.

• Turn power OFF prior to repair.

• Replace pressure switch with proper replacement part.

38

TROUBLESHOOTING

TROUBLESHOOTING CHART

Symptoms of Abnormal

Operation

•Circulator blower runs continuously. No furnace operation.

•Integrated control module diagnostic LED is flashing FOUR (4) flashes.

• Induced draft blower and circulation blower runs continuously. No furnace operation.

• Integrated control module diagnostic LED is flashing FIVE (5)

• Circulator blower runs continuously. No furnace operation.

• Integrated control module diagnostic LED is flashing SIX (6) flashes.

Associated LED Code

4

5

6

Fault Description(s)

2

• Primary or auxiliary limit circuit is open.

•Flame sensed with

no call for heat.

• Rollout limit circuit is open.

Possible Causes

• Faulty primary or auxiliary limit switch.

• Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.

• Loose or improperly connected wiring.

• Short to ground in flame sense circuit.

• Flame rollout.

• Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.

• Loose or improperly connected wiring.

• Faulty rollout limit.

Corrective Action

• Check primary/auxiliary limit. Replace if necessary.

• Check filters and ductwork for blockage. Clean filters or remove obstruction.

• Check circulator blower speed and performance. Correct speed or replace blower if necessary.

• Tighten or correct wiring connection.

• Correct short at flame sensor or in flame sensor wiring.

• Check burners for proper alignment.

• Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.

• Check rollout limit. Replace if necessary.

• Check induced draft blower for proper performance. Replace, if necessary.

• Tighten or correct wiring connection.

Cautions and

Notes

• Turn power OFF prior to repair.

• Replace primary/ auxiliary limit with proper replacement part.

• Replace blower with correct replacement part.

• Turn power OFF

prior to repair.

• Turn power OFF

prior to repair.

• See “Vent/Flue

Pipe” section for piping details.

• Replace rollout

limit with correct replacement part.

• Replace induced

draft blower with correct replacement part.

• Normal furnace operation.

• Integrated control module diagnostic LED is flashing SEVEN (7) flashes.

• Furnace fails to operate.

• Integrated control

module diagnostic LED is flashing continu- ously.

1

Integrated control module will automatically attempt to reset from lockout after one hour.

2

LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

CONTINUOUS/ RAPID FLASH

• Flame sense

7

microamp signal is low.

• Polarity of 115 or 24

C

volt power is reversed.

• Flame sensor is coated/ oxidized.

• Flame sensor incorrectly positioned in burner flame.

• Lazy burner flame due to improper gas pressure or combustion air.

• Polarity of 115 volt AC power to furnace or integrated control module is reversed.

• Orange and gray wires to transformer are reversed.

• Poor unit ground.

• Sand flame sensor if coated/oxidized.

• Inspect for proper sensor alignment.

• Check inlet air piping for blockage, proper length, elbows, and termination.

• Compare current gas pressure to rating plate info. Adjust as needed.

• Review wiring diagram to correct polarity.

• Reverse orange and gray wires going to transformer.

• Verify proper ground. Correct if necessary.

• Turn power OFF prior to repair.

• Sand flame sensor with emery clot.

• See “Vent/Flue Pipe” section for piping details.

• See rating plate for proper gas pressure.

• Turn power OFF prior to repair.

39

POLARIZA TION AND PHASING

V

As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing of primary to secondary voltage on transformers becomes more important.

Polarization has been apparent in the Appliance industry since the introduction of the three prong plug, however, the Heating Industry does not use a plug for incoming power, but is hard wired.

Some of the electronic boards being used today, with flame rectification, will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.

CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*

METER READS 24 VOLTS

.

METER READS 120 VOLTS

VOLT / OHM METER

INCOMING POWER

GND

METER READS 0 VOLTS

GND

VOLT / OHM METER

THIS IS THE COMMON OR NEUTRAL LEG

METER READS 120 VOLTS

THIS IS L1 OR THE HOT POWER LEG

These then should be wired to the furnace accordingly.

D

N

G

C

R

N

L1

VOLT / OHM METER

C

R

TRANSFORMER

D

N

G

SECONDARY

VOLT / OHM METER

LINE VOLTA GE (NE UTRAL)

PRIMARY

LINE VOLTA GE L1 (HOT)

VOLT / OHM METER

OLT / OHM

METER

READS 96 VOLTS - IN PHASE

D

N

G

C

R

OLT / OHM

METER

READS 144 VOLTS - OUT OF PHASE

N

L1

If meter reads approximately 96 volts - the primary to secondary are in phase - if reads approximately 144 volts out of phase - reverse low voltage wires.

*NOTE: For flame rectification the common side of the secondary voltage (24 V) is cabinet grounded. If you were to bench test a transformer the primary neutral and secondary common must be connected together for testing purposes.

Some transformers will display phasing symbols as shown

D

N

G

C

NEUTRAL

in the illustration to the left to assist in determining proper transformer phasing.

Checking for polarization and phasing should become a

24 V

R

120 V

L1

habit in servicing. Let's start now. NOTE: Newer integrated ignition controls have a diagnos-

tic flash code for reversed polarity (Refer to Troubleshoot- ing-Diagnostic Chart for LED Codes).

PHASING SYMBOL

40

MAINTENANCE

WARNING

HIGH VOLTAGE

ISCONNECT

D

INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERSONAL I NJURY OR DEATH.

POWER BEFO RE SERV I CING OR

ALL

AILURE TO DO SO MAY CAUSE PROPERTY

F

ULTIPLE POWE R SOURCES MAY

M

CAUTION

IF YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. TOUCHING

THE IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE. QUALIFIED SERVICER S HOULD EVER HANDLE THE IGNITOR.

ONLY A

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.

• Combustion air intake pipe system (where applicable). Check for blockage and/or leakage. Check the outside termination and the connection at the furnace.

• Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame sense.

• Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace.

• Wiring. Check electrical connections for tightness and/or corrosion. Check wires for damage.

• Filters.

AIR FILTER

WARNING

EVER OPERATE FURNACE WIHTOUT A FILTER INSTALLED AS DUST

N

AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE.

Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for proper furnace operation.

Remember that dirty filters are the most common cause of inadequate heating or cooling performance.

Maintenance

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. It is the owner's responsibility to keep air filters clean. When replacing a filter, it must be replaced with a filter of the same type and size.

Filter Removal

Depending on the installation, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflow only), a side panel external filter rack kit (upflow only), or the ductwork above a counterflow furnace. A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be followed to ensure proper unit performance. Refer to the following information for removal and installation of filters.

FILTER REMOVAL PROCEDURE Media Air Filter or Electronic Air Cleaner Removal

Follow the manufacturer’s directions for service.

Upright Counterflow Filter Removal

To remove filters from the ductwork above an upright counterflow installation:

1. Turn off electrical power to furnace.

2. Remove access door in ductwork above furnace.

3. Remove filters.

4. Remove blower compartment door. V acuum compartment. Replace blower compartment door .

5. Replace filters opposite of removal.

6. Replace access door in ductwork.

Horizontal Unit Filter Removal

Filters in horizontal installations are located in the central return register.

INDUCED DRAFT AND CIRCULATION BLOWERS

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

41

MAINTENANCE

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal. If this occurs, a qualified servicer must carefully clean the flame sensor with steel wool. After cleaning, the flame sensor output should be as listed on the specification sheet.

BURNERS

WARNING

HIGH VOLTAGE E

LECTRICAL COMPONE NTS ARE CONTAINE D IN BOTH COMPARTMENTS. DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVER S OR ATTEMPT ANY ADJUSTMENT. SERVICE AGENT AT ONCE IF AN ABNORM AL FLAME APPEARANCE SHOULD DEVELOP .

T

O AVOID ELECTRICAL SHOCK, INJURY OR

C

ONTACT A QUALIFIED

Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermostat. Wait a few minutes since any dislodged dust will alter the normal flame appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.

Check the burner flames for:

1. Stable, soft and blue

2. Not curling, floating, or lifting off.

Burner Flame

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as essential as regular hand tools.

The following is a must for every service technician and service shop.

1. Dial type thermometers or thermocouple meter (optional) - to measure dry bulb temperature.

2. Amprobe - to measure amperage and voltage.

3. Volt-Ohm Meter - testing continuity , capacitors, and motor windings.

4. Inclined Manometer - to measure static pressure, pressure drop across coils, filters, and draft.

5. Water Manometer (12") - to test gas inlet and manifold pressure.

42

Other recording type instruments can be essential in solving abnormal problems, however, in many instances they may be rented from local sources.

Proper equipment promotes faster, more efficient service and accurate repairs resulting in fewer call backs.

HEATING PERFORMANCE TEST

Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Ser-

vice Problem Analysis Guide.

To conduct a heating performance test, the BTU input to the furnace must be calculated.

After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked.

To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.)

EXAMPLE: It is found by the gas meter, that it takes forty (40) seconds for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the furnace. Take this information and locate it on the gas rate chart. Observe the forty (40) seconds, locate and read across to the one (1) cubic foot dial column. There we find the number 90, which shows that ninety (90) cubic feet of gas will be consumed in one (1) hour.

Let's assume the local gas utility has stated that the calorific value of the gas is 1,025 BTU per cubic foot.

Multiplying the ninety (90) cubic feet by 1,025 BTU per cubic foot gives us an input of 92,250 BTUH.

Checking the BTU input on the rating plate of the furnace being tested.

EXAMPLE: INPUT: 92,000 BTU/HR OUTPUT CAP: 84,000

Should the figure you calculated not fall within five (5) percent of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices.

CAUTION

A

LWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS

I

VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS .3 INCH ES WATER CO LUMN FRO M 3.5 INC HES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS.

N NO CASE

To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input.

Since normally propane gas is not installed with a gas meter, clocking will be virtually impossible. The gas orifices used with propane are calculated for 2500 BTU per cubic foot

MAINTENANCE

gas and with proper inlet pressures and correct piping size, full capacity will be obtained.

With propane gas, no unit gas valve regulator is used; however, the second stage supply line pressure regulator should be adjusted to give 11" water column with all other gas consuming appliances running.

The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface.

The amount (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work, cooling coil, registers, etc., applied externally to the unit versus the motor speed tap (direct drive) or pulley adjustments of the motor and blower (belt drive).

A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for temperature rise limitation.

43

SERVICING

1

One

1

CUBIC FEET

GAS RATE -- CUBIC FEET PER HOUR

Seconds for

One

Revolution

10 90 180 360 720 1800 36 25 50 100 200 500 11 82 164 327 655 1636 37 -- -- 97 195 486 12 75 150 300 600 1500 38 23 47 95 189 474 13 69 138 277 555 1385 39 -- -- 92 185 462 14 64 129 257 514 1286 40 22 45 90 180 450 15 60 120 240 480 1200 41 -- -- -- 176 439 16 56 113 225 450 1125 42 21 43 86 172 429 17 53 106 212 424 1059 43 -- -- -- 167 419 18 50 100 200 400 1000 44 -- 41 82 164 409 19 47 95 189 379 947 45 20 40 80 160 400 20 45 90 180 360 900 46 -- -- 78 157 391 21 43 86 171 343 857 47 19 38 76 153 383 22 41 82 164 327 818 48 -- -- 75 150 375 23 39 78 157 313 783 49 -- -- -- 147 367 24 37 75 150 300 750 50 18 36 72 144 360 25 36 72 144 288 720 51 -- -- -- 141 355 26 34 69 138 277 692 52 -- -- 69 138 346 27 33 67 133 265 667 53 17 34 -- 136 340 28 32 64 129 257 643 54 -- -- 67 133 333 29 31 62 124 248 621 55 -- -- -- 131 327 30 30 60 120 240 600 56 16 32 64 129 321 31 -- -- 116 232 581 57 -- -- -- 126 316 32 28 56 113 225 563 58 -- 31 62 124 310 33 -- -- 109 218 545 59 -- -- -- 122 305 34 26 53 106 212 529 60 15 30 60 120 300 35 -- -- 10 3 206 514

1/4

cu/ft

Size of Te st Dial

1/2

cu/ft

1

cu/ft

2

cu/ft

5

cu/ft

Seconds for

One

Revolution

1/4

cu/ft

Size of Tes t D ial

1/2

cu/ft

1

cu/ft

2

5

cu/ft

44

SERVICING

Service Problem No Heat Unsatisfactory Heat

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Power Failure Blown Fuse Loose Connection Shorted or Broken Wires No Low Voltage Faulty Thermostat Faulty Transformer Poor or High Resistance Ground Improper Heat Anticipator Setting Improper Thermostat Location Faulty Limit o r Roll Out Switch Faulty Flame Sensor Faulty Ignition Control Gas Valve or Gas Supply Shut Off Faulty Induced Draft Blower Faulty Blower Motor (PSC & ECM) Broken or Shorted Ignitor Dirty Flame Sensor, Low UA Stuck Gas Valve Faulty Gas Valve Open Auxiliary Limit Improper Air Flow or Distribution Cycling on Limit Del ayed Ignition Flashback Orifice Size Gas Pressure Cracked Heat Exchanger Fur nace Undersi zed Fur nace Oversiz ed Faulty Pressure Switch Blocked or Restricted Flue Open Roll Ou t S witch Bouncing On Pressure Switch

SYMPTOM

Burner Won't Ignite

System Will Not Start

Burn e r Ignites-Locks Out

Burner Shuts Off prior to T'Stat being Satisfied

•

•••••

•

••

•

•••

•

••

•

•••

••

•• •

• •••

•••

••

•

Long Cycles

Short Cycles

Too Much Heat

Soot and /or Fu m es

Not Enough Heat

•• ••

•

•••

•

••

•

Test Voltage S-1 Test Voltage S-4 Check Wiring S-2 Check Wiring S-3A Check Transformer S-4 Check Thermostat S-3A Check Transformer S-4 Measure Ground Resistance S-17B Adjust Heat Antic ip ator Se ttin g S-3B Relocate Thermostat S-316 Test Control S-300 / S-302 Test Flame Sensor S-314 Test Control S-313 Turn Valves to On Po s itio n S-317 Test Induced Draft Motor S-303 Test Blower Motor (PSC & ECM) S-16A,B,C Test Ignitor S-308 Clean Flame Sensor S-314 Repl ace Gas Valve S-3 04 Repl ace Gas Valve S-3 04 Reset Control S-301 Check Duct Static S-200 Check Controls & Temperature Rise S-201 / S-300 Test for Delayed Ignition S-312 Test for Flashback S-309 / S-311 Check Orifices S-306 / S-311 Check Gas Pressure S-307 Check Burner Flames S-305 Replace with Proper Size Furnace S -318 Replace with Proper Size Furnace S -318 Test Pressure Switch S-310 Check Flue/Drawdown Pressure S-310 Test Flame Roll Out Control S-302 Test Negative Pressure S-310

Test Method

Remedy

See Service Procedure Reference

45

SERVICING

SERVICE NUMBERS

S-1 CHECKING VOL TAGE................................................................................................................................. 47

S-2 CHECKING WIRING.................................................................................................................................... 47

S-3A THERMOSTAT AND WIRING ....................................................................................................................... 47

S-3B HEATING ANTICIP ATOR.............................................................................................................................. 47

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT.............................................................................. 48

S-10 CAP ACIT ANCE CHECK .............................................................................................................................. 48

S-15 CHECKING CAPACITOR............................................................................................................................. 48

S-15A RESISTANCE CHECK.........................................................................................................................48

S-16 CHECKING AIR CIRCULATOR BLOWER MOTOR (PSC) ......................................................................49

S-200 CHECKING DUCT ST ATIC........................................................................................................................... 49

S-201 CHECKING TEMPERATURE RISE ............................................................................................................. 50

S-300 CHECKING PRIMARY LIMIT CONTROL...................................................................................................... 50

S-301 CHECKING AUXILIARY LIMIT CONTROL .................................................................................................... 51

S-302 CHECKING FLAME ROLLOUT CONTROL .................................................................................................. 51

S-303 INDUCED DRAFT BLOWER MOTOR.......................................................................................................... 52

S-304 CHECKING GAS VAL VE (REDUNDANT) .................................................................................................... 52

S-305 CHECKING MAIN BURNERS ...................................................................................................................... 52

S-306 CHECKING ORIFICES ................................................................................................................................53

S-307 CHECKING GAS PRESSURE..................................................................................................................... 53

S-308 CHECKING HOT SURFACE IGNIT OR ......................................................................................................... 55

S-309 CHECKING FOR FLASHBACK ................................................................................................................... 56

S-310 CHECKING PRESSURE CONTROL ........................................................................................................... 56

S-311 HIGH ALTITUDE APPLICA TION (USA)......................................................................................................... 56

S-312 CHECKING FOR DELAYED IGNITION ........................................................................................................ 57

S-313 CHECKING INTEGRATED IGNITION CONTROL BOARDS........................................................................ 57

S-314 CHECKING FLAME SENSOR................................................................................................................... 58

46

SERVICING

S-1 CHECKING VOLTAGE

WARNING

CHECKING THERMOSTAT, WIRING AND ANTICIPATOR S-3A THERMOSTAT AND WIRING

HIGH VOLTAGE

ISCONNECT

D

CHANGING A NY ELE CTRI CAL WIRI NG. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH.

POWER BEF ORE SERVICING OR

ALL

M

AILURE TO DO SO MAY CAUSE

F

ULTIPLE POWER

1. Remove the burner door to gain entry to the Junction Box.

2. Remove cover from the Junction Box and gain access to incoming power lines.

With Power ON:

WARNING

INE VOLTAGE NOW PR ESENT

L

3. Using a voltmeter, measure the voltage across the hot and neutral connections.

NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point.

4. No reading - indicates open wiring, open fuse, no

power, or faulty Door Interlock Switch from unit to fused disconnect service. Repair as needed.

5. With ample voltage at line voltage connectors, ener-

gize the furnace blower motor by jumpering terminals R to G on the integrated ignition control.

6. With the blower motor in operation, the voltage should

be 1 15 volts ± 10 percent.

7. If the reading falls below the minimum voltage, check

the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company of the condition.

8. After completing check and/or repair, replace Junc-

tion Box cover and reinstall the service panel doors.

9. Turn on electrical power and verify proper unit opera-

tion.

S-2 CHECKING WIRING

WARNING

ISCONNECT

D

1. Check wiring visually for signs of overheating, damaged insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equivalent.

POWER BEFORE SERVICING.

ALL

WARNING

ISCONNECT

D

POWER BEFORE SERVICING.

ALL

1. Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals.

2. Remove the thermostat low voltage wires at the furnace control panel terminal board.

3. Jumper terminals R to W on the integrated ignition control.

With Power On (and Door Interlock Switch closed):

WARNING

INE VOLTAGE NOW PR ESENT

L

4. Induced Draft Motor must run and pull in pressure

switch.

5. If the hot surface ignitor heats and at the end of the

ignitor warm-up period the gas valve opens and the burners ignite, the trouble is in the thermostat or wiring.

6. With power off, check the continuity of the thermostat

and wiring. Repair or replace as necessary.

If checking the furnace in the air conditioning mode, pro-

ceed as follows.

7. With power off, Jumper terminals R to Y to G.

8. Turn on the power.

9. If the furnace blower motor starts and the condensing

unit runs, then the trouble is in the thermostat or wiring. Repair or replace as necessary.

10. After completing check and/or repair of wiring and

check and/or replacement of thermostat, reinstall blower compartment door .

1 1. Turn on electrical power and verify proper unit opera-

tion.

S-3B HEATING ANTICIPATOR

On older thermostats the heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. Some thermostats have a cycle rate adjustment switch to set cycles per hour.

The heating anticipator setting for furnaces covered in this manual is 0.70 Amps.

47

SERVICING

Cooling Anticipator

The cooling anticipator is a small heater (resistor) in the thermostat. During the "OFF" cycle it heats the bimetal element helping the thermostat call for the next cooling cycle. This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degrees.

The anticipator is fixed in the subbase and is not to be replaced. If the anticipator should fail for any reason, the subbase must be changed.

S-4 CHECKING TRANSFORMER AND Control CIR-

CUIT

A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation.

WARNING

HIGH VOLTAGE

ISCONNECT

D

CHANGING A NY ELE CTRI CAL WI RING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH.

POWER BEF ORE SERVICING OR

ALL

M

AILURE TO DO SO MAY CAUSE

F

ULTIPLE POWER

1. Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module.

2. Remove the thermostat low voltage wires at the furnace integrated control module terminals.

With Power On (and Door Interlock Switch closed):

S-10 Capacitance Check

With power On (and Door Interlock Switch closed):

WARNING

INE VOLTAGE NOW PR ESENT

L

S-15 CHECKING CAPACITOR

The direct drive motors are of the permanent split capacitor design. A run capacitor is wired across the auxiliary and a portion of the main windings. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor to the load.

WARNING

DISCHARGE CA PACITOR THROUGH A 20 TO 30 OHM RESI STOR

BEFORE HANDLING.

Two quick ways to test a capacitor are a resistance and a capacitance check. Refer to the next two figures for proper meter connections for the resistance and capacitance testing of the capacitor.

NOTE: Use a capacitor tester to check capacitance.

WARNING

INE VOLTAGE NOW PRE SENT

L

3. Use a voltmeter, check voltage across terminals R

and C. Must read 24 VAC.

4. No voltage indicates faulty transformer, open fuse,

bad wiring, bad splice, or open door interlock switch.

5. Check transformer primary voltage at incoming line

voltage connections, fuse, splices, and blower door interlock switch.

6. If line voltage is available to the primary side of

transformer and not at secondary side, the transformer is inoperative. Replace.

7. After completing check and/or replacement of trans-

former and check and/or repair of control circuit, reinstall blower compartment door .

8. Turn on electrical power and verify proper unit op-

eration.

S-15A Resistance Check

VOLT / OHM METER

Testing Capacitor Resistance

APAC

C

R

O

T

I

48

SERVICING

WARNING

HIGH VOLTAGE

ISCONNECT

D

INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERS ONAL INJURY OR D EATH.

1. Remove blower compartment door to gain access to capacitor.

2. Discharge capacitor and remove wire leads.

3. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor.

a. Good Condition - indicator swings to zero and

b. Shorted - indicator swings to zero and stops there

c. Open - no reading - replace. Reverse leads.

d. Reverse leads and recheck.

S-16 CHECKING AIR CIRCULATOR BLOWER MO-

TOR (PSC)

DISCONNECT ALL POWER BEFORE SERVICING.

1. Remove blower compartment door to gain access to the circulator blower motor and integrated ignition control.

2. Discharge the capacitor on (PSC) motors. Disconnect the motor wire leads from its connection point at the integrated ignition control module and capacitor if applicable.

3. Using a ohmmeter, test for continuity between each of the motor leads.

4. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained to ground, replace the motor.

5. After completing check and/or replacement of circulator blower motor or induced draft blower motor, reinstall blower compartment door.

6. Turn on electrical power and verify proper unit operation.

POWER BEF ORE SERVICING OR

ALL

AILURE TO DO SO MAY CAUSE PROPERTY

F

ULTIPLE POWER SOUR CES MAY

M

slowly returns toward infinity.

- replace.

Check again no reading - replace.

WARNING

S-200 CHECKING DUCT STATIC

The maximum and minimum allowable external static pressures are found in the specification section. These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment.

The furnace motor cannot deliver proper air quantities (CFM) against statics other than those listed.

Too great of an external static pressure will result in insufficient air that can cause excessive temperature rise, resulting in limit tripping, etc. Whereas not enough static may result in motor overloading.

To determine proper air movement, proceed as follows:

1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure)

2. Measure the static pressure of the supply duct. (Positive Pressure)

3. Add the two (2) readings together for total external static pressure.

NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

If the total external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.

SUPPLY AIR

CUTAWAY OF DUCTWORK TO EXPOSE COIL

INCLINED

MANOMETER

Amana

Electronic Air Cleaner

Caution

High Voltage To avoid personal injury, wait 15 seconds afte r de-energizing uni t before touching unit interior.

RETURN AIR

ISCONNECT

D

POWER BEFORE SERVICING.

ALL

Checking Static Pressure

(80% Furnace Shown, 90% Similar)

49

SERVICING

S-201 CHECKING TEMPERATURE RISE

The more air (CFM) being delivered through a given furnace, the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given furnace specifications and its external static pressure. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the blower performance specification section. Determine and adjust temperature rise as follows:

1. Operate furnace with burners firing for approximately ten minutes. Check BTU input to furnace - do not exceed input rating stamped on rating plate. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.

2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.

S-300 CHECKING PRIMARY LIMIT CONTROL

All use a nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the primary limit.

Location of Primary Limit

SUPPLY AIR

RETURN AIR

Checking Temperature Rise

3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Circulator Blower Speed section in the Product Design section of this manual for speed changing details. Temperature rise is related to the BTUH output of the furnace and the amount of air (CFM) circulated over the heat exchanger. Measure motor current draw to determine that the motor is not overloaded during adjustments.

Primary Limit Control Location

(80% Upflow Furnace Shown, Counterflow Similar)

Style 1 drawing illustrates the Primary Limit used on the 80% furnaces.

Style 1

WARNING

HIGH VO LTAGE

ISCONNECT

D

CHANGI N G A N Y E LE CTR I CA L WIRING. SOURCES MAY BE PRESENT. PROPE RTY DAMAGE , P ERSON AL I NJ URY OR DEAT H.

POWER BEFORE SERVICING OR

ALL

M

AILURE TO DO SO MAY CAUSE

F

ULTIPLE POWE R

1. Remove burner compartment door to gain access to the primary limit.

2. Remove low voltage wires at limit control terminals.

3. With an ohmmeter , test between these two terminals as shown in the following drawing. The ohmmeter should read continuous unless heat exchanger temperature is above limit control setting. If not as above, replace the control.

50

SERVICING

VOLT / OHM METER

RED RESET BUTTON

Testing Primary Limit Control

S-301 CHECKING AUXILIARY LIMIT CONTROL

BLOW E R HOUSIN G

COLOR IDENTIFYING TAB

Testing Auxiliary Limit Control

WARNING

TO AVO ID POSS IBLE FIRE , O NLY RESET T HE A UXILI ARY L IMIT CONT ROL

IF IT SHOULD OPEN A SECOND TIME, A QUALIFIED SERVICER

ONCE. MUST D ETE R MIN E W HY THE AU XIL I AR Y LI MI T O PE NE D BE FO RE RESETTING AGAIN.

S-302 CHECKING FLAME ROLLOUT CONTROL

A temperature activated manual reset control is mounted to the manifold assembly on 80% furnaces,

AUXILIARY LIMIT CONTROL

Auxiliary Limit Control Location

WARNING

HIGH VOLTAGE D

ISCONNECT INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.

ALL

POWER BEFORE SER VICING OR

M

F

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIP LE PO WER SO URCE S MAY

SWITCH

Flame Rollout Switch Location

(80% Upflow Furnace Shown, Downflow Similar)

ROLLOUT

51

SERVICING

The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously.

On single-stage 80% and 90% models, the ignition control diagnostic light will flash (6) six times indicating a trip of the rollout switch.

WARNING

INE VOLTAGE NOW PR ESENT

L

1. Remove the burner compartment door to gain access to the rollout switch(es) mounted to burner bracket.

The servicer should reset the ignition control by opening and closing the thermostat circuit. Then look for the ignitor glowing which indicates there is power to the ignition control. Measure the voltage between each side of the rollout control and ground while the ignition control tries to power the gas valve.

2. Measure the voltage between each side of the rollout control and ground during the ignition attempt. Refer to the following figure.

VOLT / OHM METER

GND

RED RESET BUTTON

S-303 INDUCED DRAFT BLOWER Motor

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

D

INSTA LLI NG TH IS UNI T. BE PRESEN T. DAMAG E, PERS ONAL INJ URY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

1. Remove burner compartment door to gain access to the induced draft blower motor.

2. Disconnect the motor wire leads from its connection point at the induced draft motor .

3. Using a ohmmeter, test for continuity between each of the motor leads.

4. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained to ground, replace the motor.

5. If the windings have a continuity reading, reconnect wires. Turn power on to the furnace and turn the thermostat on in the heating mode. Check voltage for 1 15V at the induced draft motor terminals during the trial for ignition. If you have 1 15V and the motor does not run, replace the induced draft motor .

6. After completing check and/or replacement of induced draft motor, reinst all burner compartment door .

7. Turn on electrical power and verify proper unit operation.

S-304 CHECKING GAS VALVE (Redundant)

A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used.

The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.

COLOR IDENTIFYING TAB

Checking Flame Rollout Switch

a. If no voltage is measured on either side of control it

indicates ignition control or wiring to control problem.

b. If voltage is measured on one side of the control and

not the other it indicates the control is open.

c. If voltage is measured on both sides of the control

the wiring to gas valve or valve is at fault.

3. After check and/or replacement of rollout switch, reinstall burner compartment door and verify proper unit operation.

52

WARNING

D

ISCONNECT

ALL

POWER BEFORE SERVICING

Single stage gas valves should be tested on the furnance with 24 VAC connected to the gas valve and manometers reading supply line and manifold pressures.

S-305 CHECKING MAIN BURNERS

The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.

Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners.

SERVICING

A

.023" - .027"

Beckett Burner

WARNING

DISCONNECT ALL GAS AND ELECTRICAL POWER SUPPLY.

In checking main burners, look for signs of rust, oversized and undersized carry over ports restricted with foreign material, etc, refer to previous drawing. Burner cross-over slots must not be altered in size.

S-306 CHECKING ORIFICES

A predetermined fixed gas orifice is used in all of these furnaces. That is an orifice which has a fixed bore and position as shown in the following drawing.

No resizing should be attempted until all factors are taken into consideration such as inlet and manifold gas pressure, alignment, and positioning, specific gravity and BTU content of the gas being consumed.

The only time resizing is required is when a reduction in firing rate is required for an increase in altitude.

Orifices should be treated with care in order to prevent damage. They should be removed and installed with a box-end wrench in order to prevent distortion. In no instance should an orifice be peened over and redrilled. This will change the angle or deflection of the vacuum effect or entraining of primary air, which will make it difficult to adjust the flame properly. This same problem can occur if an orifice spud of a different length is substituted.

GAS STREAM

B

The length of Dimension "A" determines the angle of Gas Stream "B".

DENT OR BURR

GAS

STREAM

B

A dent or burr will cause a severe deflection of the gas stream.

S-307 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

CAUTION

T

O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON T HE UNIT RATING PLA TE WITH ALL OTHER HOUSE HOLD GAS FIR ED APPLI ANCES OPERATING.

Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed.

The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.

WARNING

DISCONNECT ALL GAS AND ELECTRICAL POWER SUPPLY.

1. Check orifice visually for distortion and/or burrs.

2. Check orifice size with orifice sizing drills.

3. If resizing is required, a new orifice of the same physical size and angle with proper drill size opening should be installed.

WARNING

DISCONNE CT ELECTRICA L POWER AND SHU T OFF GAS SUPPLY .

1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg as shown in the following figures. Refer to Measuring Gas Pressure: Single Stage Valves figure for single stage valve inlet pressure tap connections. Refer to Measuring Gas Pressure: Two-Stage Valves figure for two-stage gas valve inlet pressure tap connections.

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SERVICING

p

NOTE: At either location, a hose fitting must be installed

prior to making the hose connection. NOTE: Use apapter kit #0151K00000S to measure gas pres-

sure on White-Rodgers 36J22 gas valves.

GAS LINE

GAS SHUTOFF VALVE

GAS LINE TO FURNACE

OPEN TO ATMOSPHERE

DRIP LEG CAP WITH FITTING

MANOM ETER HOSE

MANOMETER

Measuring Inlet Gas Pressure

(Alternate Method)

Gas Manifold Pressure Measurement and Adjustment

nace

TO PR EV ENT U NRE LI AB LE OP ER AT ION O R EQ U IPM EN T D AM AGE , TH E

GAS MAN IFOLD PRE SSURE MUS T BE AS SPEC IFIED ON THE UNIT RATING PLATE. ADJUSTING THE GAS VALVE PRESSURE REG ULATOR.

NOTE: Use apapter kit #0151K00000S to measure gas

pressure on White-Rodgers 36J22 gas valves. Only small variations in gas pressure should be made by

adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure.

ONLY MINO R ADJUST MENTS SH OULD BE MA DE BY

CAUTION

WARNING

HIGH VOLTAGE D

ISCONNECT

BEFORE S ERVICI NG O R INS TALLI NG.

ALL

ELECTRIC AL PO WER A ND SHUT OFF GAS SUP PLY

3. Turn ON the gas and electrical power supply and operate the furnace and all other gas consuming appliances on the same gas supply line.

4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the following table.

INLET GAS SUPPLY PRESSURE

Natural Gas Minimum: 4.5" w.c . Maximum: 10.0" w.c.

Propane G as Minimum: 11.0" w.c. Maximum: 13. 0" w.c.

If supply pressure differs from above, make necessary adjustments to pressure regulator, gas piping size, etc., and/ or consult with local gas utility.

WARNING

HIGH VOLTAGE

ISCONNECT

D

SUPPLY BEFORE SERVICI NG OR INSTALL ING THIS UNIT.

ULTI PLE POWER SOURC ES M AY BE PR ES ENT. FAILURE TO

M

DO SO MAY CAUSE PRO PERTY DAMAGE, PERSONAL INJURY OR DE ATH.

ELECTRICAL P OWER AND SHUT O FF GAS

ALL

5. Disconnect manometer after turning off gas at manual shutoff valve. Reinstall plug before turning on gas to furnace.

6. Turn OFF any unnecessary gas appliances started in step 3.

7. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.

8. Turn on electrical power and verify proper unit operation.

1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to Measuring Gas Pressure: Single Stage Valves figure for single stage valve outlet pressure tap connections.

WARNING

INE VOLTAGE NOW PRE SENT

L

3. Turn ON the gas and electrical power supply and operate the furnace.

4. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the table below.

Manifold Gas Pressure

Natural Gas

ane Gas

Pro

The final manifold pressure must not vary more than ± 0.3 “ w.c. from the above specified pressures. Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice.

5. White-Rodgers 36G22 Valves: a. Back outlet pressure test screw (inlet/outlet pres-

sure boss) out one turn (counterclockwise, not more than one turn).

3.5" w.c.

10.0" w.c.

54

SERVICING

b. Attach a hose and manometer to the outlet pressure

outlet pressure boss. c. Turn ON the gas supply. d. Turn on power and close thermostat “R” and “W1”

contacts to provide a call for low stage heat. e. Measure the gas manifold pressure with burners fir-

ing. Adjust manifold pressure using the Manifold Gas

Pressure table shown below. f. Remove regulator cover screw from the outlet pres-

sure regulator adjust tower and turn screw clockwise

to increase pressure or counterclockwise to decrease

pressure. Replace regulator cover screw. i. Turn off all electrical power and gas supply to the

system. j. Remove the manometer hose from the hose barb fit-

ting or outlet pressure boss. k. Turn outlet pressure test screw in to seal pressure

port (clockwise, 7 in-lb minimum).

6. Honeywell VR8215 Valve a. Remove the outlet pressure boss plug. Install an 1/

8" NPT hose barb fitting into the outlet pressure tap.

b. Attach a hose and manometer to the outlet pressure

barb fitting. c. Turn ON the gas supply. d. Turn on power and close thermostat “R” and “W1”

contacts to provide a call for low stage heat. e. Measure the gas manifold pressure with burners fir-

ing. Adjust manifold pressure using the Manifold Gas

Pressure table shown below. f. Remove regulator cover screw from the outlet pres-

sure regulator adjust tower and turn screw clockwise

to increase pressure or counterclockwise to decrease

pressure. Replace regulator cover screw. i. Turn off all electrical power and gas supply to the

system. j. Remove the manometer hose from the hose barb fit-

ting or outlet pressure boss. k. Remove the 1/8" NPT hose barb fitting from the out-

let pressure tap. Replace the outlet pressure boss

plug and seal with a high quality thread sealer.

Gas Valve

On/Off

Selector

Switch

OUTLET

Pressure Regulator

Adjustment

(Under Cap Screw)

White-Rodgers Model 36J22 (Single-Stage)

Outlet Pressure

Inlet Pressure

Tap

INLE T

Tap

Pressure Regulator

Inlet

(under cap screw)

Pressure Tap

Gas Valve On/Off Selector Switch

Honeywell Model VR8215

WARNING

HIGH VOLTAGE D

ISCONNECT

BEFORE SERVICING OR INSTALLI NG.

Propane Gas

ALL

ELECTRICAL POWER AND SHUT OFF GAS SUPPLY

Manifold Gas Pressure

Gas Rate Range Nominal

High Stage 9.7 to 10.3" w.c. 1 0.0 " w.c.

Low Stage 5.7 to 6.3" w.c. 6.0" w.c.

Outlet Pressure Tap

WARNING

HIGH VOLTAGE

ISCONNECT

D

SUPPLY BEFORE SERVICI NG OR INSTALL ING THIS UNIT.

ULTI PLE POWER SOURC ES M AY BE PR ES ENT. FAILURE TO

M

DO SO MAY CAUSE PRO PERTY DAMAGE, PERSONAL INJURY OR DE ATH.

ELECTRICAL P OWER AND SHUT O FF GAS

ALL

7. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.

8. Turn on electrical power and verify proper unit operation.

S-308 CHECKING HOT SURFACE IGNITOR

120V Mini Igniter Single Stage - furnaces use a 120V

carbide mini igniter for ignition. The normal operating temperature is approximately 2550°F - 2876°F. At room temperature a good igniter will have an ohm reading range of 50

- 300.

WARNING

ISCONNECT

D

PO WER B EFO RE SE RVIC ING.

ALL

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SERVICING

1. Remove burner compartment door to gain access to the ignitor.

2. Ignitor cool - approximately 70 - 77°F.

3. Disconnect the ignitor from the Ignition Control.

4. Using an ohmmeter measure the resistance of the ignitor:

Mini Igniter : Carbide Mini Igniter should read between 30 to 300 ohms.

5. Reconnect ignitor.

WARNING

INE VOLTAGE NOW PRESENT

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6. Place unit in heating cycle, measure current draw of ignitor during preheat cycle.

Models using 120V Mini Igniter : Should read approximately 1 amp maximum. The steady

state current at 120V is a nominal of .7 plus or minus .3 amps.

7. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.

S-309 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gasair flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.

Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.

If flashback should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE)..

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

S-310 CHECKING PRESSURE SWITCH

The pressure switch a safety device to prevent the combustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe on the 80% and 90% furnaces.

1. Remove burner compartment door to gain access to pressure switch(es).

2. Remove wires from the pressure switch(es) electrical terminals.

3. Using a VOM check from common terminal to NC (Normally Closed) - should read open.

If switch reads as above proceed to Step 4, otherwise re-

place control.

4. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures.

Induced Draft Blower Pressure Switch

Pressure Switch

Hose

1/4" Tee

Inclined Manometer

Hose to Induced Draft Blower Tap

ID Blower Pressure Switch

Negative Pressure Measurement

(80% Upflow Single-Stage Furnace Shown,

Counterflow Similar)

S-311 HIGH ALTITUDE APPLICATION (USA)

Check your furnace rating plate to determine its rated altitude (either 4500 or 5500 ft). Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure below 4500/5500 feet. This can causepoor combustion and equipment failure. High altitude installations above 4500/5500 feet 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 gasfuel and the combustion air at higher altitude.

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SERVICING

For installations above 4500/5500 feet, please refer to your distributor for required kit(s). 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.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated the appropriate orfice size must be determined based on the BTU/ft gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

S-312 CHECKING FOR DELAYED IGNITION

Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber.

Furnace design makes this extremely unlikely unless safety controls have been by-passed or tampered with. Never bypass or alter furnace controls.

If delayed ignition should occur, the following should be checked:

1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE).

2. Improper burner positioning - burners should be in locating slots, level front to rear and left to right.

3. Carry over (lighter tube or cross lighter) obstructed clean.

4. Main burner orifice(s) deformed, or out of alignment to burner - replace.

S-313 CHECKING INTEGRATED IGNITION

CONTROL BOARDS

3

content of the derated

WARNING

INE VOLTAGE NOW PRE SENT

L

These tests must be completed within a given time frame due to the operation of the ignition control.

NOTE: The models use White-Rodgers 50A55- 289 or 50T55-289 ignition control board.

1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity.

2. Check for 24 volts from W to C terminal on the ignition control. No voltage. Check transformer, room thermostat, and wiring.

If you have 24 volts coming off the transformer but receive approximately 13 volts on the terminal board between (C) and (R), check for blown fuse.

3. Check for 120 volts to the induced draft blower by measuring voltage between Pin 1 (on the 2-pin connector) and Line (Neutral) on the control board. No voltage, replace ignition control.

4. If voltage is present in Steps 1 through 3 and the induced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage between Pin 2 (on the 2-pin connector) and Line (Neutral) on the control board. No voltage, check pressure switch.

5. After the ignitor warmup time, begin checking for 24 volts to the gas valve. Voltage will be present for seven seconds only if proof of flame has been established.

NOTE: Failure to earth ground the furnace, reversing the neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame.

WARNING

TO AVOID THE RI SK OF ELECT RICAL S HOCK, WI RING T O THE UNIT

MUST BE PROPER LY POLARIZE D AND GROUNDED. BEFORE PERFORMING SERVICE LISTED BELOW.

The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than 10 ohms.

The ignition control is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced.

DISCONNECT POWER

DS1

COOL-H

DS2

PARK PARK

LINE-H

1 2

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SERVICING

S-314 CHECKING FLAME SENSOR

A flame sensing device is used in conjunction with the ignition control module to prove combustion. If proof of flame is not present the control will de-energize the gas valve and "retry" for ignition or lockout.

The following drawings illustrate from a bottom view, the approximate distances for the ignitor and flame sensor to the gas inshot burner. You will note they are in the main burner stream, not in the carry over ports as shown in the following figure.

Flame Sensor

4. As soon as flame is established a micro-amp reading should be evident once proof of flame (micro-amp reading) is established, the hot surface ignitor will be deenergized.

5. The Integrated Ignition controls will have 1 to 4 microamps. If the micro-amp reading is less than the minimum specified, check for high resistance wiring connections, sensor to burner gap, dirty flame sensor, or poor grounding.

6. If absolutely no reading, check for continuity on all components and if good - replace ignition control module.

NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool.

Models with Integrated Ignition

Control & Flame Sensor Probe

(80% Upflow Model Shown, Counterflow Similar)

WARNING

HIGH VOLTAGE D

ISCONNECT INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.

ALL

POWER BEFORE SERVICING OR

M

F

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWE R SOURCES MAY

1. Disconnect the orange flame sensor wire from the sensor .

2. Connect a micro-amp meter in series with this wire and the sensor terminal.

3. Place the unit into a heating cycle.

WARNING

INE VOLTAGE NOW PRESENT

L

58