Goodman GME8, AMEH8 User Manual

Service Instructions

GME8 & AMEH8

Modified Two Stage Furnace

with EEM Motor

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.

RS6621001

July 2013

TABLE OF CONTENTS

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

PRODUCT IDENTIFICATION .......................... 4-6

ACCESSORIES............................................... 7-8

OPERATING INSTRUCTIONS ............................9

PRODUCT DESIGN .................................... 10-30

SYSTEM OPERATION ................................ 31-33

TROUBLESHOOTING................................. 34-35

POLARIZATION & PHASING .............................36

MAINTENANCE ............................................ 37-38

SERVICING .................................................. 39-53

SERVICING TABLE OF CONTENTS ................41

ACCESSORY WIRING DIAGRAM .....................54

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

WARNING

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

WARNING

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE 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 DAMAGE WHICH

MAY RESULT.

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

WARNING

HIGH VOLTAG E D

ISCONNECT ALL POWER BEFOR E SERVICING OR

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

FAILURE TO DO SO M AY CAU SE PROPERTY

MULTIPLE POWER SOURCES MAY

IMPORTANT INFORMATION

Speci al War ning for Inst allation of Furnace or Air Handling Units in Enclosed A reas such as Garage s, Utility Ro oms or Parki ng A r eas

Carbon monoxide producing devic es (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as un ve n tilated garages, ut ility rooms or parking areas because of the danger of c a rbon monoxide (CO) poison ing resulting from the exha ust 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)circu l a ted throughout the structure if t he furnace or air han dler is operating in any mode.

CO can cause serious illness in clud ing per man e nt brain dama ge or deat h.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINE GOODMAN® BRAND PRODUCTS

TOLL FREE

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

email us at:

customerservice@goodmanmfg.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE

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

email us at:

hac.consumer.affairs@amanahvac.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

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.

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.

A M E H 96 060 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Brand Minor Rev ision A- Amana A - Initial Release G- Good man B - 1st Re visi on

Configuration Maj or R evi si on M - Upflow/Horizontal A - Initial Release C - Downflow/Horizontal B - 1st Re visi on K - Dedicated Upflow D - De dicated Downf low Nox

Mot or X - Low N Ox V - Variable Speed/ComfortNet E - High Effi ciency Cabinet Wi dth S - Single Speed A - 14"

Gas Valve C - 21" M - Modul ating D - 24. 5" C - 2 Stage H - Convertibl e 2 Stage Maximum CFM S - Single Stage 3 - 1200 CFM

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

N - N atural Gas

B - 17. 5"

4 - 1600 CFM

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

PRODUCT IDENTIFICATION

MO DEL # MFG . # 80% G A S FURNACES

AMEH8

GME8

AMEH800603B* AMEH800805C* AMEH800805D*

AMEH801005C

GME8*****AA GME8 *****AB GME8*****AC

GME806 03B*BA GME8[080,100]5C*BA GME8[080,100]5C*BB

GME808 05D*AA

GME8*****CA GME8*****CB

GME806 03B*BB

GME808 05C*BB

GME808 05D*AA

GME810 05C*BB

Amana

installation positions. Induced draft, two tone cabinet and panels. EcoTech EEM motor, two stage gas v alve with timed sec ond stage operation, can acc ommodate two stage condensing unit operation. 120 v olt silicon nit r ide hot surf ac e ignit ion wit h integrated circ uit boar d. Left or r ight side gas entr y. St ainless steel tubular heat exchanger. Chassis widths 17.5", 21", 24. 5" . M eets <2% cabinet low leak.

G oodman

Draft, new grey painted cabinet and front panels, X-13 motor, standardized blower decks and a 120V silicon nitr ide ignit er . Left or right gas pipe entry. The f urnac es also feature an integrated electr onic ignition contr ol and aluminiz ed steel t ubular heat ex c hanger. Chassis sizes ar e 17. 5" and 21" wide. ***AB models used a r ound nose inducer motor. ***AC models revert back t o J ak el square nose inducer.

G oodman

Induc ed Draft, new grey painted cabinet and f r ont panels, E c oT ec h™ motor, standardized blower decks and a 120V silicon nitride igniter. Left or r ight gas pipe entry. The furnaces also f eature an integrated electr onic ignit ion c ont r ol, and aluminized steel tubular heat ex c hanger. Chassis sizes are 14" , 17.5" , 21" and 24.5" wide. ***B A and the D*AA models have reduc ed f ir ing rates (060: 60,000 BTU / 080: 80, 000B T U / 100: 100,000BTU)

G oodman

Induc ed Draft, new grey painted cabinet and f r ont panels, E c oT ec h™ motor, standardized blower decks and a 120V silicon nitride igniter. Left or r ight gas pipe entry. The furnaces also f eature an integrated electr onic ignit ion c ont r ol, and aluminized steel tubular heat ex c hanger. Chassis sizes are 14" , 17.5" and 21" wide. ***CB models use a Honey well gas valv e.

G oodman

B ran d 80% G as Furn ace

B ra nd 80% Gas Furnace

, 33 3/8" tall, Upflow/Horiz ontal Left or Right of left

, 39" tall, Upflow/Horizontal Left or Right, Induced

, 33-3/8" tall, Upflow/Horizontal Left or Right,

PRODUCT IDENTIFICATION

MODEL # MFG. # DESCRIPT I ON

The AFE18-60A control is designed f or use where the indoor c oil is

. F or use with curr ent architec tural grey Goodman® and Amana

. For use with current arc hitectur al grey Goodman® and A mana

. F or use with G oodman® and A mana® Brand 90% upflow

. T he k it is designed to convert 80% gas furnace models

AFE18-60A N/A

AMU1620 AMU1625 AMU2020 AMU2025

GMU1620 GMU1625 GMU2020 GMU2025

ASAS-10 ASAS-11 ASAS-12 ASAS-18

EFR01

HANG20 N/A

P1251305F P1251306F P1251307F P1251308F

N/A

P1251301F P1251302F P1251303F P1251304F

P1221001

P1221002F

Fossil Fuel Kit.

located above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18-60A control will tur n t he heat pump unit of f when t he furnace is turned on. An anti-short c ycle feat ure init iates a 3 minute t imed off delay when the compressor goes off.

Media Air Cleaner

Brand 80% and 90% v ar iable speed furnace models. The Amana (AMU*) and G oodman (GMU*) M edia Air Cleaner is a high ef ficiency air filtration devic e designed to remov e dirt, dust, pollen and other microscopic part ic les from the air passing through it. Flex ible perfor mance range up to 2, 000 CFM c apacity . The air cleaner should be inst alled in t he system so that all the system air is circulat ed through the air c leaner. The air cleaner will only r emove the airborne contaminants delivered t o it. Maximum per formance is obtained when the sy stem blower is set f or c ontinuous operation. Carbon f ilters (optional) are available.

Electronic Air C leaner

Brand 80% and 90% v ar iable speed furnace models. The High-Eff ic iency Electr onic Air Cleaner is designed to r emov e air c ontaminants down to .01 microns. Carbon filt er s (optional) r emov e odors. Dual indicat or lights show unit operat ion at a glance. Elect r onic pr oving swit c h cycles the air cleaner O n/ Off with the system fan. Durable powder-coat paint finish r esists corrosion.

External Fil t er Rack Kit

model s. This kit is intended t o pr ovide a location, external to t he furnace casing, f or installation of a per manent filter . The rack is mounted ov er t he indoor air blower compartment area of either side panel, and prov ide f ilter r etention as well as a locat ion for attaching return air ductwork.

Hig h Altitud e N atural Gas Ki t

fired at 20,000 B t u's per cell for higher alt itudes. This kit is required when installing these furnaces rated at 4,500 ft abov e their maximum r at ed altitude.

HANG21 N/A

LPLP03 N/A

LPM-06 N/A

Hig h Altitud e N atural Gas Ki t.

fired at 20,000 B t u's per cell for higher alt itudes. This kit is required when installing these furnaces rated at 5,500 ft abov e their maximum r at ed altitude.

LP Gas Low Pressure K it

80% and 90% single stage and two stage gas fired fur nace pr oducts installed on LP gas listed in this manual. T his kit includes harness adapt ors to work with Whit eRodgers single & t wo stage gas valves, Honeywell single and two stage gas valves, as well as modulating gas v alves.

LP Conversion Kit

models or t wo stage variable speed models using a White-Rodgers 36G54 t wo stage gas valve kit or a Honeywell V R9205 t wo stage gas valve kit. Includes regulat or springs, #55 orific es, instructions and a label t o show the fur nac e has been conv erted to L.P.

. F or use with G oodman® and A mana® Brand t wo stage Hybrid

The kit is designed to convert 80% gas furnace models

. Designed for applicat ion on G oodman® and A mana® Brand' s

ACCESSORIES

AMANA® BRAND AMEH8 Model Furnace Accessories

MODEL

NUMBER

Descript io n

AMU / GMU

AFE180-60A

Dual Fuel Kit

ASAS / GSAS

HEPA / DMHEPA

Electronic Air Cleaner

HEPA Air Cleaner

Media Air Cleaners

EFR01

LPM06

HANG21

High Altitude Kit

EFR External Filter Rac

LPM05

LPLP03

Off Kit

Propane Gas

Conversion Kit

LP Low Pressure Shut

AMEH800603B**

AMEH800805C*

AMEH800805D*

AMEH801005C*

······

(2) (1)

GOODMAN® GME8 Model Furnace Accessories

MODEL

NUMBER

Description

GME80603B *

GME80805C*

GME80805D *

GME81005C*

EFR01

AMU / GMU

Media Air Cleaners

EFR External Filter Rack

···

··· ·

···

HA-02

HANG20

ASAS / GSAS

High Altitude Kit

Electronic Air Cleaner

(3) (4) (5) (1) (2 )

HANG21

High Altitude Kit

LPM05

Propane Gas

Conversion Kit

(1) (2 )

LPM06

LPLP03

Conversion Kit

LP Low Pressure Shut

1 2

AFE180-60A

Off Kit

Dual Fuel Kit

···

W / R 2 stg gas valve

Honeywell 2 s t g gas valve

Approved for this model

HEPA / DMHEPA

HEPA Air Cleaner

Not approved for this m odel Approved for this model

1 W /R 2 st g gas valve 2 W /R or Honey well 2 stg gas valve 3 AA Revision 4 AB Revision 5 BB Revision

ACCESSORIES

EXTERNAL FILTER RACK KIT

(EFR01)

SLOTS IN FILTER CLEAR SCREWS

ON UNIT

BLOWER DECK

SCREWS

UNIT SIDE

PANEL

FRONT

OF UNIT

BASE

OF UNIT

RETURN AIR

CUTOUT AREA

LOWER EDGE

SCREW

EFR01 EXTERNAL FILTER RACK KIT

U sed on Models

80% Upflow M ode l Fu rnaces

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

OPERATING INSTRUCTIONS

FOR Y OUR S AFETY READ BEFORE OPERATING

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

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

B. BEFORE OPERATING smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

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

If you cannot reach your gas supplier,

call the fire department.

C. Use only your hand to move the gas control switch or knob. Never use tools. If the gas control switch or knob will not operate, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

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

5. Remove control access panel.

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

GAS CONTROL SWITCH SHOWN IN "ON" POSITION

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

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

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

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

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to its lowest setting.

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

3. Remove control access panel.

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

5. Replace control access panel.

WARNING: Improper alteration, service or

maintenance can cause injury or property damage.

Refer to the user's information manual provided with this

consult a qualified or the gas supplier.

This furnace must be

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

Code, ANSI Z223.1.

For indoor installation.

PGB & PGJ For outdoor installation only .

If notWARNING:

installed, operated and maintained in accordance with the manufacturer's instru ctions, this product could expose you to substances in fuel combust ion 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 insu la tion contains a chemic al

California to cause cancer.

FOR YOUR SAFETY

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

0140F00001P

OPERATING INSTRUCTIONS

CONSIGNES DE SECURITE - LIRE

AVANT D'ALLUMER L'APPAREIL

AVERTISSEME NT: Le non-respect des instr uct ions qui suivent peut

entrainer un r i sque d'incendie ou d'explosion causant des dommages, des blessures ou la mort.

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

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

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

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

C. N'utiliser que votre main pour pousser ou tourner le commande du gaz. N'utilisez jamais d'outils. Si vous ne parvenez pas a pousser ou a t ourner la commande, ne tentez pas de la reparer; appelez un reparateur qualifie. Forcer la commande ou essayer de la reparer peut entrainer un risque d'incendie ou d'explosion.

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

'allumez paz le bruleur manuellement.

0140F00002P

1. UN INSTANT! Lisez d'abord les consignes

INSTRUCTIONS DE SERVICE

d e securi te ci-dessus.

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

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

4. Cet appareil est muni d'un mecanisme qui allume automatiquement le bruleur. Ne tentez pa s d'allum er le bruleur manuellement.

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

6. Mettez la commande de gaz a la position

ARRET ("OFF").

7. Attendez cinq (5) minutes afin de permettre a t ou t gaz present d'etre evacue. Si vous sentez une odeur de gaz a ce moment, ARRETEZ! et suivez les consignes de securite donnees au paragraphe B ci-dessus. Si vous ne sentez pas de gaz, passez a l'etape suivante.

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

9. Remettez la panneau d'acces de la commande en plac e.

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

11. Reglez le thermostat a le temperature desiree.

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

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

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

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

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

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

ARRET DU GAZ

Commande de gaz en position

"MARCHE"

PRODUCT DESIGN

Safety

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

WARNING

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

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

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

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

REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

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

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

unit. An electrostatic discharge can adversely affect electrical components.

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

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

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

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

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

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.

The GME8 and AMEH8 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

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY O R DEATH DUE TO FIRE ,

EXPLOSION, SMOKE, SOOT , CONDENSTAION, EL ECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM I MPROPER INSTALLATION, REPAIR, OPERATIO N, OR MAINTENANCE OF THIS PRODUCT.

WARNING

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

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

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

American National Standards Institute 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

PRODUCT DESIGN

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

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

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

Location Requirements and Considerations

WARNING

O PREVENT POSSIBLE EQUI PMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

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

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

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

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

• 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.

• 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 sup- ply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combus- tion 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.

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.

PRODUCT DESIGN

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.

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, 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 horizon-

tal 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 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

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

NOTE: The GME8 and AMEH8 hybrid furnaces require a single stage thermostat. These furnaces utilize a control board with single stage or two stage capability. The second stage feature is established by setting a dip switch on the board, either one stage or two stage. All of the second stage timing is then controlled by dipswitch 3 on the circuit board.

HEAT OFF

DELAY

MODE

SECOND

STAGE

ONLY

100

SECOND

DELAY

2-STAGE

MINUTES

F F

In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. 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.

N O

150

SECOND

DELAY

1-STAGE

AUTO

PRODUCT DESIGN

• 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 PROPERTY DAMAGE , PERSONAL I NJURY OR DEAT H MAY OCCUR

IF THE FURNAC E IS NOT P ROVIDED WITH ENOUGH FRESH AIR FOR PROP ER COMBUSTION AND VENTILAT ION OF FLUE GASES. MOST HOMES REQUI RE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

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

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

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

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

54/ANSI Z223.1 Section 9.3.

9.3* Air for Combustion and V entilation.

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 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 ft 3 per 1,000/Btu/hour (4.8m3/kW).

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

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

the following equation:

Required Volume

other

ACH (1000 Btu/hr)

21 ft

> ________ _________

other

9.3.1 General.

9.3.1.1 Air for combustion, ventilation, and dilution of flue

gases for appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through

9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.

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

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

equation: Required Volume

where:

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

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

= all appliances other than fan-assisted input in Btu

other

fan

than 0.60 ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.2.2(2).

per hour

= fan-assisted appliances input in Btu per hour

exchanged per hour, expressed as a decimal)

> ________ _________

fan

15 ft

ACH (1000 Btu/hr)

fan

PRODUCT DESIGN

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.2 (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.

Chimney or Gas Vent

Water Heater

Furnace

Opening

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

communicating 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 a ir openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.

Outlet Air

Water Heater

lternate

air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

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.

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

Indoor Spaces through Indoor Combustion Air

Openings.

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

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

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

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

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inle t 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

Furnace

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

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

(2)*Where communicating with the outdoors through hori-

zontal ducts, each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1 100 min2/kW) of total input rating of all appliances in the enclosure. [See Figure

A.9.3.3.1(2).]

PRODUCT DESIGN

Chimney or Gas Vent

NOTE: The air duct openings must have a free a r ea 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 perma-

nent openings, 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 connec-

tors in the space.

NOTE: The single opening mus t have a free area of not le ss t han one square inch pe r 3 00 0 BT U of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

Water Heater

Furnace

Opening

Alternate Opening Location

Figure A.9.3.3.2 All Combustion Air

From Outdoors through Single Combustion Air

Opening.

9.3.4 Combination Indoor and Outdoor Combustion Air.

The use of a combination of indoor and outdoor combustion air shall be in accordance with (1) through (3) (see example

calculation in Annex J]:

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

interior spaces shall comply with 9.3.2.3.

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

be located in accordance with 9.3.3.

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

shall be calculated in accordance with the following:

(a) The ratio of the interior spaces shall be the avail-

able 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.

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).

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

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

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

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

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

9.3.7 Louvers, Grilles, and Screens.

9.3.7.1 Louvers and Grilles. The required size of openings

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

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

9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main

PRODUCT DESIGN

burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.

9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with 9.3.8.1 through 9.3.8.8.

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

Exception: Within dwellings units, unobstructed stud and joist spaces shall not be prohibited 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.

9.3.8.3 Ducts shall serve a single space.

9.3.8.4 Ducts shall not serve both upper and lower combus-

tion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air.

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

Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and does not have to be "gas tight." NOTE: SingleStage and Two-Stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing in some instances common venting with natural draft appliances (i.e. water heaters).

All installations must be vented in accordance with National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CGA B149.1 and CAN/CGA B149.2 - latest editions and amendments.

NOTE: The vertical height of the Category I venting system must be at least as great as the horizontal length of the venting system.

WARNING

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

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

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

MODEL

60 4 Inch 80 4 Inch

100 5 Inch

MINIMUM VENT

UPFLOW

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

TO PREVENT POSSIBLE PERSONAL INJ URY OR DEAT H DUE TO

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

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

CATEGORY III VENTING.

Under some conditions, larger vents than those shown above may be required or allowed.

When an existing furnace is removed from a venting system serving other appliances, the venting system may be too

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.

NOTE: This furnace is not design certified to be horizontally vented.

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