Goodman GKS9 User Manual

GKS9

-F

IRED

ARM

URNACE

INSTALLATION INSTRUCTIONS

This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” is available and MUST

BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/Rating Plate on the

furnace for the Kit part number.

Installer: Affix all manuals adjacent to the unit.

(T ype FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

These furnaces comply with requirements embodied in the American National S tandard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety

precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety

warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than

when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a

customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety

practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is

a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

*NOTE: Please contact your distributor or our

website for the applicable Specification Sheet

referred to in this manual.

IO-300J 12/10

Goodman Manufacturing Company , L.P.

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com

Table of Contents

I. Component Identification ............................................................................................................................................... 5

II. Safety .............................................................................................................................................................................. 6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................... 6

III. Product Application ...................................................................................................................................................... 6

IV . Location Requirement s & Considerations.................................................................................................................. 7

GENERAL ......................................................................................................................................................... 7

LEARANCES AND ACCESSIBILITY........................................................................................................................... 8

URNACE SUSPENSION ........................................................................................................................................ 8

XISTING FURNACE REMOVAL .............................................................................................................................. 8

HERMOSTAT LOCATION ....................................................................................................................................... 9

V. Combustion & Ventilation Air Requirements ............................................................................................................... 9

VI. Installation Positions ...................................................................................................................................................11

VII. Horizontal Applications & Considerations ................................................................................................................11

GENERAL ........................................................................................................................................................11

RAIN TRAP AND LINES .....................................................................................................................................11

EVELING ........................................................................................................................................................11

LTERNATE VENT/FLUE CONNECTION .....................................................................................................................11

LTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................ 12

RAIN PAN ..................................................................................................................................................... 12

REEZE PROTECTION ........................................................................................................................................ 12

URNACE SUSPENSION ...................................................................................................................................... 12

VIII. Propane Gas /High Altitude Installations............................................................................................................... 12

IX. Vent/Flue Pipe & Combustion Air Pipe ..................................................................................................................... 12

GENERAL ....................................................................................................................................................... 12

UAL CERTIFICA TION : NON-DIRECT/DIRECT VENT ................................................................................................... 13

ATERIALS AND JOINING METHODS ..................................................................................................................... 13

ROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES ................................................................................. 13

ERMINATION LOCATIONS ................................................................................................................................... 13

ANADIAN VENTING REQUIREMENTS..................................................................................................................... 14

TANDARD FURNACE CONNECTIONS ..................................................................................................................... 14

LTERNATE FURNACE CONNECTIONS ..................................................................................................................... 14

ON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................ 15

IRECT VENT (DUAL PIPE) PIPING ...................................................................................................................... 16

ENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES .................................................. 18

ONCENTRIC VENT TERMINATION ......................................................................................................................... 18

IDE WALL VENT KIT........................................................................................................................................ 18

X. Condensate Drain Lines & Drain Trap........................................................................................................................ 18

GENERAL ....................................................................................................................................................... 18

PRIGHT INST ALLATIONS ..................................................................................................................................... 18

ORIZONTAL INSTALLA TIONS ................................................................................................................................21

XI. Electrical Connections................................................................................................................................................ 22

WIRING HARNESS ............................................................................................................................................ 22

OLT LINE CONNECTIONS ............................................................................................................................ 23

115 V

OLT THERMOSTAT WIRING ............................................................................................................................ 23

24 V

XII. Gas Supply and Piping.............................................................................................................................................. 23

GENERAL ....................................................................................................................................................... 23

AS PIPING CONNECTIONS ................................................................................................................................24

ROPANE GAS TANKS AND PIPING...................................................................................................................... 26

XIII. Circulating Air & Filters ............................................................................................................................................ 26

DUCTWORK - AIR FLOW ..................................................................................................................................... 26

OTTOM RETURN AIR OPENING [UPFLOW MODELS]............................................................................................... 27

ILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ....................................................... 27

PRIGHT INST ALLATIONS ..................................................................................................................................... 27

ORIZONTAL INSTALLA TIONS ................................................................................................................................28

Table of Contents

XIV. Startup Procedure & Adjustment............................................................................................................................. 28

HEA T ANTICIPAT OR SETTING ................................................................................................................................28

RAIN TRAP PRIMING ....................................................................................................................................... 28

URNACE OPERATION ......................................................................................................................................... 28

AS SUPPLY PRESSURE MEASUREMENT .............................................................................................................. 28

AS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................. 29

AS INPUT RATE MEASUREMENT (NA TURAL GAS ONLY) ......................................................................................... 29

EMPERATURE RISE ......................................................................................................................................... 30

IRCULATOR BLOWER SPEEDS ........................................................................................................................... 30

XV. Normal Sequence of Operation................................................................................................................................ 30

POWER UP ..................................................................................................................................................... 30

EATING MODE ............................................................................................................................................... 30

OOLING MODE .............................................................................................................................................. 31

AN ONLY MODE............................................................................................................................................. 31

XVI. Operational Checks .................................................................................................................................................. 31

BURNER FLAME ............................................................................................................................................... 31

XVII. Safety Circuit Description ....................................................................................................................................... 31

GENERAL ....................................................................................................................................................... 31

NTEGRATED CONTROL MODULE .......................................................................................................................... 31

RIMARY LIMIT ................................................................................................................................................ 31

UXILIARY LIMIT............................................................................................................................................... 31

OLLOUT LIMIT ................................................................................................................................................ 31

RESSURE SWITCHES ........................................................................................................................................ 31

LAME SENSOR ............................................................................................................................................... 31

XVIII. Troubleshooting...................................................................................................................................................... 32

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................. 32

IAGNOSTIC CHART .......................................................................................................................................... 32

ESETTING FROM LOCKOUT ............................................................................................................................... 32

XIX. Maintenance ............................................................................................................................................................. 32

ANNUAL INSPECTION .......................................................................................................................................... 32

ILTERS .......................................................................................................................................................... 32

URNERS ....................................................................................................................................................... 33

NDUCED DRAFT AND CIRCULATOR BLOWERS ......................................................................................................... 33

ONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)...................................................................... 33

LAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 33

GNITER (QUALIFIED SERVICER ONLY).................................................................................................................. 33

LUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 33

XX. Before Leaving an Installation ................................................................................................................................. 33

XXI. Repair & Replacement Parts ................................................................................................................................... 33

APPENDIX

Troubleshooting Chart ...................................................................................................................................................... 34

GKS9 Wiring Diagram ...................................................................................................................................................... 36

WARN ING

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT

. IF

YOU INSTALL OR PERFORM SERVICE ON THIS UNIT

. M

ANY JURISDICTIONS

WARN ING

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE

- D

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

- WHAT T O D O IF YO U SMELL GA S:

* D

O NOT TRY TO LIGHT ANY APPLIANCE

* D

- I

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE

ANY PHONE IN YOUR BUILDING

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A

* I

NEIGHBORS PHONE INSTRUCTIONS

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE

* I

FIRE DEPARTMENT

. F

OLLOW THE GAS SUPPLIERS

WARN ING

HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY

CARBON MONOXIDE POI SONING HAZARD

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

TO THE INSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.

TRANSPORTATION DAMAGE

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately. The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4. File the claim with the following support documents within a nine month statute of limitations.

• Original or certified copy of the Bill of Lading, or indemnity

bond.

• Original paid freight bill or indemnity in lieu thereof.

• Original or certified copy of the invoice, showing trade and

other discounts or reductions.

• Copy of the inspection report issued by carrier’s

representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

Keep this literature in a safe place for future reference.

Carbon monoxid e producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.

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

B10259-216

I. COMPONENT IDENTIFICATION

BLOWER COMPARTMENT BURNER COMPARTMENT

1 Gas Valve 2 Gas Line Entrance (Alternate) 3 Combustion Air Intake Connection / “Coupling” 4 Hot Surface Igniter 5 Burners 6 Rollout Limit 7 Flame Sensor 8 Flue Pipe Connection / “Coupling” 9 Flue Pipe (Internal) 10 Primary Limit 11 Pressure Switch 12 Gas Line Entrance 13 Rubber Elbow 14 Flue Pipe Connection (Alternate) 15 Induced Draft Blower

Upflow/Horizontal

16 Electrical Connection Inlets (Alternate) 17 Coil Front Cover Drain Port 18 Drain Line Penetrations 19 Blower Door Interlock Switch 20 24-Volt Thermostat Connections 21 Integrated Control Module

22 Transformer (40 VA) 23 Circulator Blower 24 Auxiliary Limit 25 Gas Manifold 26 Junction Box 27 Coil Front Cover 28 Drain Trap 29 Electrical Connection Inlets

(with fuse and diagnostic LED)

II. SAFETY

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

WARN ING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM

. FOR

ADDITIONAL

WARN ING

HIGH VOLTAGE!

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER

WARN ING

NOT UTILIZE THE HEATING UNIT WITHOUT REASONABLE ROUTINE INSPECTION, MAINTENANCE AND SUPERVISION BUILDING THAT IS OR WILL BE VACANT, CARE SHOULD BE TAKEN TO ROUTINELY INSPECT, MAINTAIN AND MONITOR THE UNIT EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, DRAIN ALL WATER-BEARING PIPES, PROPERLY WINTERIZE THE BUILDING, AND TURN OFF ALL WATER SOURCES FREEZING TEMPERATURES AND IS VACANT, ANY HYDRONIC COIL UNITS SHOULD ALSO BE DRAINED AND AN ALTERNATIVE HEAT SOURCES UTILIZED

. IN

THE EVENT THAT THE BUILDING IS EXPOSED TO

. IF

THE UNIT IS IN A

. IN

THE

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge static electricity accumulated in the body before

touching the unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces.

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

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

3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.).

If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

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

III. PRODUCT APPLICA TION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door). This furnace can be used in the following non-industrial commercial applications:

Schools, Office buildings, Churches, Retail stores Nursing homes, Hotels/motels, Common or office areas

In such applications , the furnace must be installed with the following stipulations:

• It must be installed per the installation instructions provided and per local and national codes.

• It must be installed indoors in a building constructed on site.

• It must be part of a ducted system and not used in a free air delivery application.

• It must not be used as a “make-up” air unit.

• It must be installed with two-pipe systems for combustion air, especially if VOC’s or other contaminants are present in the conditioned space.

• All other warranty exclusions and restrictions apply This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.

This furnace may be used as a construction site heater ONLY if the following conditions are met:

• The vent system is permanently installed per these installation instructions.

• A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.

• Return air ducts are provided and sealed to the furnace.

• A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.

• Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced.

• The input rate and temperature rise are set per the furnace rating plate.

• 100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used.

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation

Air Requirements, Section 5.3.3.

• The furnace heat exchanger, components, duct system,

air filters and evaporator coils are thoroughly cleaned following final construction clean up.

• All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met:

• Gas furnaces must be installed by a licensed plumber or gas fitter.

• A T-handle gas cock must be used.

• If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.

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

WARN ING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT

WARN ING

PREVENT PERSONAL INJURY, PROPERTY DAMAGE OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code ANSI Z223.1, and/or CAN/CSA B149.1-05 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code ANSI Z223.1 can be obt ained from any of the following:

American National Standards Institute 1430 Broadway New York, NY 10018

National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269

CSA International 8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CSA B149.1-05 Installation Codes can also be obtained from:

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

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

IV . LOCATION REQUIREMENTS & CONSIDERA TIONS

GENERAL

WARNING

PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V, Combus-

tion and Ventilation Air Requirements.

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

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

• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.

• Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to Section X, Condensate Drain Lines and Trap for further details.

• Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Section V,

Combustion and Ventilation Air Requirements.

• Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Section VII, Horizontal Applications and Considerations for leveling of horizontal furnaces.

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

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

chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid

cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials

• Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Section V, Combustion and Ventilation Air Requirements for details.

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

• 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. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

TOP

SIDE SIDE

BOTTOM

Upflow Horizontal

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

FURNACE SUSPENSION

If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

PROVIDE 8" MINMUM 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

2"X2"X1/8" ANGLE IRON

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMVOAL

ASSURE FURNACE IS LEVEL FROM

END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL

Suspended Furnace

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system

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

The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47·CSA-2.3 Section 1.23.1.

The following steps shall be followed with each appliance connected to the

venting system placed in operation, while any other appliances connected to the venting system are not in operation:

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

required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149.1-05 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

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

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

d. Follow the lighting instructions. Place the appliance being inspected

in operation. Adjust thermostat so appliance shall operate continuously;

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

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

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

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

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

common venting system must be corrected.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Inst allation Codes.

If resizing is required on any portion of the venting system, use the

appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Installation Codes.

THERMOSTAT LOCATION

The thermostat should be placed approximately five feet from the floor on a vibration-free, inside wall in an area having good air circulation. Do not install the thermostat where it may be influenced by any of the following:

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

cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat, such as an

outside wall.

DRAFTS OR DEAD SPOTS

-BEHIND DOORS

-IN CORNERS

-UNDER CABINETS

Thermostat Influences

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

V . COMBUSTION & VENTILA TION AIR REQUIREMENTS

WARN ING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND OF FLUE GASES MUST BE SUPPLIED AIR BE SUPPLIED INTO THE FURNACE AREA

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air. House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide.

1. Headaches-Nausea-Dizziness, Flu-Like Symptoms.

2. Excessive humidity-heavily frosted windows or a moist “clammy” feeling in the home.

3. Smoke from a fireplace will not draw up the chimney.

4. Flue gases that will not draw up the appliance vent pipe.

. M

OST HOMES REQUIRE OUTSIDE

HOT

COLD

ENTILATION

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code ANSI Z223.1 (Section 5.3), or CSA B149.1-05 Installation Codes (Sections 7.2,

7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code ANSI Z223.1 Section 5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment installed in

buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b) Equipment shall be installed in a location in which the facilities for

ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

vided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be supplied for

ventilation, including all air required for comfort and proper working conditions for personnel.

(e) While all forms of building construction cannot be covered in detail,

air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and

5.3.4.

(f) Air requirements for the operation of exhaust fans, kitchen ventila-

tion systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) All Air from Inside the Building: The confined space shall be pro-

vided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined

space shall be considered in making this determination. Each open-

ing shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.

NOTE: Each opening must have a free area of not less than one square inch per 1 000 BT U of the total input rating of all equ i p ment in the enclosure, but not less than 100 square inches.

Chimney or Gas Vent

Opening

Chimney o r Gas Vent

Ventilation louvers (each end of attic)

NOTE: Th e inlet and ou tlet 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 A i r

Furnace

Water Heater

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

Water Heater

Furnace

Opening

Equipment Located in Confined Spaces; All Air from Inside

Building. See 5.3.3-a.

(b) All Air from Outdoors: The confined space shall be provided with

two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventil ation louver s (each end of attic)

NOTE: Th e inlet and outlet ai r openings must each have a free area of not less than one square inch per 4000 BTU of the total inpu t rating of all equipmen t in the enclosure.

Outlet Air

Water Heater

lternate

air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

Equipment Located in Confined Spaces; All Air from Outdoors—

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated

Attic. See 5.3.3-b

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Equipment Located in Confined Spaces; All Air from Outdoors

Through Ventilated Attic. See 5.3.3-b.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

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

Outlet air duct

Water Heater

Furnace

Inlet air duct

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

enclosure*.

Equipment Located in Confined Spaces; All Air from Outdoors.

See 5.3.3-b.

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of al l e quipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

Water

Furnace

Heater

Alternate Opening Location

Opening

Equipment Located in Confined Spaces; All Air from Outdoors -

Single Air Opening. See 5.3.3-b.

5. When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a.

VI. INSTALLA TION POSITIONS

NOTE: This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” (0270K00012) is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal

Right. This furnace may be installed in an upright position or horizontal

on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.

VII. HORIZONTAL APPLICA TIONS & CONSIDERA TIONS

FURNACE MUST BE LEVEL

ALTERNATE VENT/FLUE LOCATION

GAS LINE WITH DRIP LEG (3" MINIMUM)

DRAIN PAN

FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE

FROM END TO END

4 3/4" MINIMUM DRAIN TRAP CLEARANCE

DRAIN LINE WITH 1/4" PER FOOT DOWNWARD SLOPE

36" MINIMUM SERVICE CLEARANCE REQUIRED

FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0" - 3/4" BELOW THE BACK PANEL

Horizontal Furnace

DRAIN TRAP AND LINES

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4 inches below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Section X, Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.

LEVELING

Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.

ALTERNATE VENT/FLUE CONNECTION

In horizontal installations provisions for alternate flue piping are available for upflow furnaces with left discharge. This configuration allows the flue piping to be run vertically through the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connections may also be used in these positions. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue connections.

When using the horizontal alternate vent configuration, you must use the RF000142 vent drain kit. See following illustration.

NOTE: This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/ Rating Plate on the furnace for the Kit P/N.

GENERAL

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:

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