Lennox MPGA 075 B3, MPGA 050 B3, MPGA 075 B4, MPGA 125 B5, MPGA 100 B5 Application Manual

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APPLICATION GUIDE
GAS FURNACE
Fit’s All 80
English/02-2004
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Page 3
UPFLOW, DOWNFLOW OR HORIZONTAL GAS-FIRED
TABLE OF CONTENTS
AFFIX LABEL HERE
INSTALLATION AND SERVICING INSTRUCTIONS
NON-CONDENSING
WARM AIR FURNACE
Issue 0240
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Furnace Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location/Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air for Combustion & Ventilation . . . . . . . . . . . . . . . . . . . . . . . . 8
Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Start-Up Operation & Checkout . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Servicing The Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Do not store or use gasoline or other flammable vapors and liquids in the
WHAT TO DO IF YOU SMELL GAS:
vicinity of this or any other appliance.
Do not try to light any appliance.
Installation and service must be performed by a qualified installer, service agency or the gas supplier. Installation by an unqualified person may lead to equipment damage and/or a hazardous condition which may cause bodily injury and harm and, as such, at the sole discretion of the manufacturer, the entire warranty may be
Extinguish any open flame.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier from
a neighbor's phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.
voided and be of no further force and effect.
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SAFETY
The following is a list of safety precautions and their locations in this manual.
These safety rules and precautions must be followed when installing this furnace.
1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.
2. Install this furnace only in a location and position as specified in The
Location/Placement Section on page 6 of these instructions.
3. Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section on page 8 of these instructions.
4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in Venting on page 12 of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in The Gas Connection section on page 16 of these instructions.
6. Always install furnace to operate within the furnace's intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in Furnace Specifications on page 3 of these instructions. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See page 11 for Ducting.
8. A gas-fired furnace for installation in a residential garage must be installed as specified in The Location / Placement section on page 7 of these instructions.
9. The furnace is not to be used for temporary heating of buildings or structures under construction. As noted on page 6 under Introduction.
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FURNACE BLOWER SPECIFICATIONS AND AIR FLOW DATA
BLOWER
SYSTEM
MPGA050B3
(10X6 WHEEL)
(1/3HP MOTOR)
MPGA075B3
(10X6 WHEEL)
(1/3HP MOTOR)
MPGA075B4
(12X9 WHEEL)
(1 HP MOTOR)
MPGA100B4
(10X9 WHEEL)
(1 HP MOTOR)
MPGA100B5
(12X9 WHEEL)
(1 HP MOTOR)
BLOWER
SPEED
EXTERNAL STATIC (IN. W.C.)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
MPGA125B5
(12X12 WHEEL)
(1 HP MOTOR)
NOTES:
1. Air flow values in cubic feet per minute (CFM).
2. Data taken without filters in place or A/C evaporator in place.
When operating the furnace in the heating mode, the static pressure and the temperature rise (supply air temperature minus return air temperature) must be within those limits specified on the rating label. Failure to follow this warning could lead to severe furnace damage.
Turn OFF all gas and electrical power to furnace before performing any maintenance or service on unit. (Unless specific test requires gas and electrical supplies.) Failure to take this precaution may result in personal injury due to electrical shock or uncontrolled gas leakage.
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FURNACE WIRING SPECIFICATIONS
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The furnace cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. The unit must also be electrically grounded in accordance with local codes, or in the absence of local codes, with the latest edition of the (U.S.) National Electrical Code ANSI/NFPA No. 70 or CSA Standard C22.1; Part 1 Canadian Electrical Code, if an external electrical source is utilized. DO NOT use gas piping as an electrical ground.
INTRODUCTION
This furnace is design certified by CSA International as a Category I furnace using air from inside the structure for
combustion.
It is shipped as a packaged unit, complete with burners and controls, and requires a line voltage (115V) connection to
the junction box, a thermostat hook-up as per the wiring diagram and a gas line connection. This furnace can be installed
in either upflow, downflow or horizontal airflow positions. The design of this furnace is NOT CSA Certified for installation in recreation vehicles, in manufactured (mobil) homes, outdoors or for temporary construction heating.
This furnace has been designed to interface with split system cooling equipment (approved by a nationally recognized testing laboratory) so as to provide "year round air conditioning". The blower has been sized for both heating and cooling and the furnace controls include a cooling fan relay.
The furnace installation must conform with local building codes or in the absence of local codes, with the latest edition of the (U.S.) National Fuel Gas Code ANSI Z223.1 (NFPA-54) or Canadian Natural Gas and Propane Installation Codes CSA B149.1.
For complete information on installation standards consult the (U.S.) National Fuel Gas Code, obtainable from the National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269 or the American Gas Association, 1515 Wilson Boulevard Arlington, VA 22209 or the Canadian installation codes obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Etobicoke, Ontario, Canada M9W 1R3.
This furnace is designed for minimum continuous return-air temperature of 60°F dB or intermittent operation down to 55°F dB such as when used with a night setback thermostat. Return-air must not exceed a maximum continuous temperature of 85°F dB.
These instructions are written for individual residential installation only. For multi-unit installation or commercial applications, please contact manufacturer for recommendations.
LOCATION / PLACEMENT
Site Selection: This furnace may be located in an attic, closet, basement, crawl space, alcove or suspended from the
ceiling of a utility room or basement. Select a location that will meet all requirements for safety, clearances, ventilation and combustion air, ductwork design, gas piping, electrical wiring and venting.
Clearances: The following minimum clearances, or greater, must be provided between the furnace and adjacent
construction.
TABLE 1 MINIMUM INSTALLATION CLEARANCES
"UPFLOW" POSITION "DOWNFLOW" POSITION "HORIZONTAL" POSITION
Suitable for alcove or closet installation† on combustible flooring at minimum clearance from adjacent construction not less than the following:
Top Sides Back Front Vent
2" 1" 1" 6" 6" with single wall vent 2" 1" 1" 3" 1" with B1 vent
For closet installation see Air for Combustion and Ventilation.
Suitable for alcove or closet installation† on non­combustible flooring at minimum clearance from adjacent construction not less than the following: * Installation on combustible flooring only when installed on special base (see model & rating label for proper special base).
Suitable for attic, alcove or closet installation† on combustible flooring at minimum clearance from adjacent construction not less than the following: * Line contact only permissible between lines formed by intersection of the top and two sides of the furnace jacket and building joist, studs, or framing.
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Failure to comply with all of the clearances will create a fire hazard.
The furnace should also be located as near to the center of the air distribution system as possible, and should be installed level.
This furnace may be installed on non-combustible flooring or on wood flooring, however, it must not be installed directly on carpeting, tile or any other combustible material. In the downflow position, it must be installed on non-combustible flooring or on the special base listed on the rating label.
In a horizontal position, line contact is only permissible between lines formed by the intersection of the furnace top, the front and back sides, and building joists, studs or framing (See Figure 1).
Figure 1
HORIZONTAL LINE CONTACT
Do not place combustible material on the furnace jacket. Failure to comply with this warning will create a fire hazard.
This furnace is not watertight and is not designed for outdoor installation. This furnace shall be installed in such a manner as to protect the electrical components from water. Outdoor installation would lead to a hazardous electrical condition and to premature furnace failure.
Furnace must not lean back. It must be level or tilt up to 2° to the front. (See Figure 1.)
A clearance of at least 30" should be provided at the front of the unit for servicing. For attic installations, the passageway and servicing area adjacent to the furnace should be floored.
If the furnace is to be installed in a crawl space, consult local codes. (Use of a concrete pad 1" to 2" thick is recommended.)
If the furnace is to be suspended from the ceiling, it will be necessary to use steel pipe straps around each end of the furnace. These straps should be attached to the furnace with sheet metal screws and to the rafters with bolts. The furnace may also be suspended by using an angle iron frame bolted to the rafters. (See Table on page 3 for size and weight of furnace.) Care must be taken to allow for service access.
If a furnace is to be installed in a residential garage, it must be installed so the burners and the ignition source are located not less than 18" above the floor and the furnace must be located or protected to avoid physical damage by vehicles.
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AIR FOR COMBUSTION AND VENTILATION
Contaminated Combustion Air:
This furnace is not to be installed in a structure defined as having contaminated combustion air. Allowing exposure to substances containing chlorine or fluoride could harm the furnace and void the warranty. Substances to avoid include, but are not limited to:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De-icing salts or chemical
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
Unrefined gases
Contaminated combustion air may cause premature failure of the heat exchanger that may lead to a hazardous condition and/or bodily harm, or loss of life.
Adequate Ventilation and Combustion Air:
This section is provided to give guidelines for the introduction of air for ventilation and combustion air. The total quantity of air provided to the installation area must equal the requirements of all gas appliances in the area.
Adequate facilities for providing air for combustion and ventilation must be provided in accordance with the latest edition of the National Fuel Gas Code ANSI Z223.1/NFPA54 or CSA B149.1 Natural Gas and Propane Installation Codes, or applicable provisions of the local building codes.
The furnace shall be installed in a location in which the facilities for ventilation permits satisfactory combustion of gas, proper venting and maintenance of ambient temperature at safe limits under normal conditions of use. The furnace shall be located so as not to interfere with proper circulation of air.
In addition to air needed for combustion, ventilation in the form of process air must be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust and odor control. Air must be supplied for ventilation, including all air required for comfort and proper working conditions for personnel.
For purposes of this instruction the following
definitions apply:
Confined Space: A space whose volume is less
than 50 cubic feet per 1000 Btu/hr of the aggregate input rating of all appliances installed in that space.
Unconfined Space: A space whose volume is not
less than 50 cubic feet per 1000 Btu/hr 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.
If the installation area meets the definition of "Unconfined Space" and does not have additional air requirements as described, the furnace may be installed without making special provisions for combustion and ventilation air.
Whenever this furnace is installed in an area along with one or more gas appliances, the total Btu/hr input of all appliances must be included when determining the free area requirements for combustion and ventilation air openings.
Do not block the combustion or ventilation air openings in the furnace. Any blockage will result in improper combustion and may result in a fire hazard or unsafe condition.
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If ventilation and/or combustion air must be supplied to the "Confined Space" from inside the building structure, two permanent openings to an additional room of sufficient volume as to combine the volumes of the spaces to meet the criteria for an "Unconfined Space" must be created. Each opening must have a free area of not less than one square inch per 1000 Btu per hour of total input of all appliances within the "Confined Space" (but not less than 100 square inches). These openings must be located 12 inches from the top and bottom of the furnace area respectively and must be at least 3 inches long on the smaller side of the opening (See Figure 2). Neither opening can be blocked at any time.
Figure 2 CONFINED SPACE / INDOOR AIR
TOTAL INPUT
(Btuh)
40,000 60,000
80,000 100,000 120,000 140,000 160,000
EXAMPLE:
50,000 Btuh Furnace & 10,000 Btuh Water Heater = 60,000 Btuh Total Input = 12" Dia. Round Duct.
MIN. FREE AREA
(Sq. In.)
100 100 100 100 120 140 160
ROUND DUCT
(Dia. In.)
12 12 12 12 13 14 15
If ventilation and/or combustion air must be supplied to the "Confined Space" from outside the building structure, two permanent openings to the outdoors must be created. Each opening must have a free area of not less than one square inch per 4000 Btu per hour of total input of all appliances within the "Confined Space". These openings must be located 12 inches from the top and bottom of the furnace area respectively (See Figures 3, 4, and 5). Neither opening can be blocked at any time.
Figure 3 CONFINED SPACE / OUTDOOR AIR
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TOTAL INPUT
(Btuh)
40,000 60,000
80,000 100,000 120,000 140,000 160,000
EXAMPLE:
50,000 Btuh Furnace & 10,000 Btuh Water Heater = 60,000 Btuh Total Input = 5" Dia. Round Duct.
MIN. FREE AREA
(Sq. In.)
10 15 20 25 30 35 40
ROUND DUCT
(Dia. In.)
4 5 5 6 6 7 8
Page 12
Figure 4
Figure 5
CONFINED SPACE / OUTDOOR AIR
FROM ATTIC
CONFINED SPACE / OUTDOOR AIR
FROM ATTIC & CRAWL SPACE
When horizontal ducts are used to supply air from the outdoors, they must 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 must not be less than 3 inches. Each opening must have a free area of not less than one square inch per 2,000 Btu per hour of total input of all appliances within the "Confined Space". These openings must be located 12 in. from the top and bottom of the furnace area. Neither opening can be blocked at any time (See Figure 6).
Figure 6
CONFINED SPACE / OUTDOOR
AIR THROUGH HORIZONTAL DUCTS
Furnaces installed with combustion air drawn from a heated space which includes exhaust fans, fireplaces, or other devices that may produce a negative pressure should be considered confined space installations.
For an attic installation it is important to keep insulation 12" or more away from any furnace openings. Some types of insulating materials may be combustible.
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DUCTING
The proper sizing of warm air ducts is necessary to insure satisfactory heating operation. Ductwork should be in accordance with the latest editions of (U.S.) NFPA-90A (Air Conditioning Systems) and NFPA-90B (Warm Air Heating and Air Conditioning Systems) or Canadian equivalent.
Ductwork Recommendation:
The supply duct work should be attached to the flanged opening provided at the discharge end of the furnace. See page 3 "Furnace Specificatons" for the dimensions of this opening.
A left, right, or bottom return air opening must be used as determined by the layout of the installation. An externally mounted air filter is required.
This furnace has a two piece bottom panel. For bottom or end duct return, remove the back portion of the bottom panel by removing the four (4) screws - two (2) on each side toward the back of the furnace (See Figure 7). Tilt furnace toward the front, the back portion of the panel will drop down. Then the back portion can be removed by pulling toward the back of the furnace.
Figure 7
BOTTOM PANEL REMOVAL
Knockouts are provided on both sides of the furnace to facilitate the cutout required to the return air ductwork.
Furnace cutouts must be the full size specified by the corner markers. Undersized cutouts will adversely affect the airflow capability of the furnace and could cause overheating of the heat exchanger.
The following recommendations should be followed when installing the ductwork:
1. Install locking-type dampers in all branches of the
individual ducts to balance out the system. Dampers
should be adjusted to impose the proper static at the
outlet of the furnace.
2. Noncombustible flexible duct connectors are
recommended to connect both the supply and return
ducts to the furnace.
3. In cases where the return air grille is located close to
the blower inlet, there should be at least one 90° air
turn between blower and return grille. Further
reduction in sound can be accomplished by installing
acoustical air turning vanes and/or lining the inside of
the duct with acoustical material.
4. It is recommended that the supply duct be provided
with a removable access panel. This opening shall
be accessible when the furnace is installed and shall
be of such a size that the heat exchanger can be
viewed for possible openings using light assistance or a probe can be inserted by sampling the air stream. The access panel shall be designed so as to prevent leaks when locked in position. If an air conditioning coil is installed, the access panel to the coil can be used for this purpose.
When supply ducts carry air circulated by the furnace to areas outside the spaces containing the furnace, the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space containing the furnace. Incorrect ductwork termination and sealing will create a hazardous condition that could lead to bodily harm.
Air openings, intake and outlet pipes, return air grilles and warm air registers must not be obstructed.
To Convert to Downflow Position:
1. Convert the combustion blower to side flue exit, as outlined on page 14.
2. Install proper special base per Table 2 for installation on combustible flooring (follow instructions supplied with special base).
3. It is recommended that the return air be connected to the bottom panel of the furnace when it is installed in the downflow position.
NOTE: SPECIAL SUB-BASE NOT REQUIRED WHEN
FURNACE IS MOUNTED ON A METAL CASED EVAPORATOR COIL.
Table 2
SPECIAL BASE INSTALLATION
MODEL MPGA050B3
MPGA075B3 MPGA075B4
MPGA100B4 20066502 68L78
MPGA100B5 MPGA100B5
NOTE: Installation on combustible flooring only when
SPECIAL BASE
NUMBER 20066501 68L77
20066503 68L79
CAT. NO.
installed on one of the above listed special bases or as identified on the furnace model and rating label.
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Filters:
Air filters must be used in every installation. For side return installations, air filters must be installed external to the furnace casing. An external filter rack kit with filter (parts No. 20069901 or Cat. No. 68L75 12 / 15½" x 25" sizes and 20069902 or Cat. No. 68L76 for 15½" / 19" x 25" sizes) is available as an optional accessory.
For bottom (end) return installations, the above optional external rack may be used, if the unit was not provided with a internal filter. Minimum filter size and suggested filter materials are shown in Table 3. (If different type filter is used, it must be an equivalent high airflow capacity.)
2. In parallel flow installation, dampers must be provided to direct air over the furnace heat exchanger when heat is desired and over the cooling when cooling is desired.
IMPORTANT: The dampers should be adequate to
prevent cooled air from entering the furnace, and if manually operated, must be equipped with means to prevent operation of either the cooling unit or furnace unless the damper is in the full cool or full heat position.
Table 3 EXTERNAL FILTER RACK SIZE
MODEL
050-3 075-3
075-4 100-3 15 ½ X 25 15 ½ X 25
100-5 125-5
SIDE
RETURN
15 ½ X 25 12 X 25
15 ½ X 25 19 X 25
BOTTOM/END
RETURN
When installing the furnace with cooling equipment for year round operation, the following recommendations must be followed for series or parallel air flow:
1. In series flow applications, the coil is mounted after
the furnace in an enclosure in the supply air stream.
The furnace blower is used for both heating and
cooling airflow.
VENTING
Venting for the furnace must be to the outside and in accordance with local codes or requirements of the local utility. In the absence of local codes, venting must conform to the applicable sections of the latest edition of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes, and the vent manufacturers instructions.
This furnace is CSA International certified as a Category I forced air appliance and can not be vented
into a vent system with any Category II, III or IV appliance. It must be vented vertically, or nearly
vertically, unless installed with a listed mechanical venter in accordance with horizontal venting instructions. It must not be connected to any portion of a mechanical draft system operating under positive pressure
The 3" (in.) to 4" (in.) vent adaptor coupling (supplied with unit) MUST BE USED. It must be connected directly to the outlet of the combustion blower using a field supplied corrosion resistant sheet metal screw (See Figure 8).
The coil MUST be installed on the air discharge side of the furnace. Under no circumstances should the air flow be such that cooled, conditioned air can pass over the furnace heat exchanger. This will cause condensation in the heat exchanger and possible failure of the heat exchanger that could lead to a fire hazard and/or hazardous conditions that may lead to bodily harm. Heat exchanger failure due to improper installation will not be covered by warranty.
Figure 8
VENT ADAPTOR MOUNTING
Pre-Installation Vent System Inspection:
Before this furnace is installed, it is highly recommended that any existing vent system be completely inspected.
For a chimney or "B" vent, this should include the following:
1. Inspection for any deterioration in the chimney or "B"
vent. If deterioration is discovered, the chimney must
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be repaired or the "B" vent must be replaced.
2. Inspection to ascertain that the vent system is clear and free of obstructions. Any blockage must be cleared before installing this furnace.
3. Cleaning the chimney or "B" vent if previously used for venting a solid fuel burning appliance or fireplace.
4. Confirming that all unused chimney or "B" vent connections are properly sealed.
5. Verification that the chimney is properly lined and sized per the applicable codes.
Masonry Chimney:
This furnace can be common vented into an existing
tile lined masonry chimney provided:
1. The chimney is currently serving at least one drafthood equipped appliance.
2. The vent connectors and chimney are sized in accordance with the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes. This furnace must NOT vented ALONE into an
existing masonry chimney (either tile lined or unlined) unless the chimney is also lined with either a type B vent system or a listed single wall, metal lining system. Both of these systems must be sized in accordance with the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes.
Before venting this furnace into a chimney, check the
chimney for deterioration and repair if necessary. This furnace must not be vented into a chimney serving a separate appliance designed to burn solid fuel. Type"B" vent connectors must be used on all installations and it must be sized per the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes.
Type "B" Vent:
The furnace is also approved for use with a "B" vent
that terminates through the roof. Refer to the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes for proper sizing and set-up of this furnace with "B" vent for a dedicated vent system or a common vented system.
Horizontal Venting:
This furnace is design certified by CSA International
for horizontal venting through an outside wall by use of one of the following auxiliary draft inducer kits:
Table 4 AUXILIARY DRAFT INDUCERS
Vent Kit MFR Model * Furnace Input
Field Controls Co.
Tjernlund Products Inc.
* See rating label on this furnace for input
Vent Length: Max. 60 ft. - Min. 12 ft.
Follow instructions included with venting kit for proper installation and setup.
SWG-4G
SS1 OR SS1C
GPAK-J 50000, 75000 or 100000 GPAK-1 100000 or 125000
Vent Diameter: 4 in.
50000, 75000, 100000 or
125000
50000, 75000, 100000 or
125000
Location Requirements for Horizontal Venting:
Locate the vent terminal adhering to the following
minimum clearances:
1. Vent terminal must be located at least one (1') foot above the grade or at least one (1') foot above the normal expected snowfall.
2. Avoid installing vent terminal above public walkways. If this is not possible, install the terminal at least seven (7') feet above the walkway.
3. Vent terminal should be at least four (4') feet to the side of and at least one (1') foot above doors and windows.
4. Vent terminal should be at least three (3') feet above any forced air inlet located within ten (10') feet.
5. Vent terminal should be located at least six (6') feet from the combustion air intake of another appliance.
6. Vent terminal should be located at least four (4') feet above any electric or gas meters, regulators, and relief equipment.
General Venting Requirements:
This furnace may be common vented only with other
Category I appliances. Common venting is allowed as permitted by National and/or local codes. Refer to the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes for proper sizing and set up.
The vent must be terminated with a listed vent cap or
roof assembly. This venting must be installed in accordance with the vent manufacturer's instructions and be in accordance with all local codes and/or National Codes. Follow Figure 9 for vent exit options.
The following requirements are provided for a proper
venting system:
1. Be sure that the chimney flue is clear of any dirt or debris.
2. Be sure that the chimney is not servicing an open fireplace.
3. Never reduce the pipe size below the outlet size of the furnace without checking the applicable sections of the (U.S.) National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes.
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4. All pipe should be supported using the proper clamps and/or straps. These supports should be at least every four (4') feet.
5. All horizontal runs of pipe should have at least a 1/4" (in.) per foot of upward slope from the furnace to the vent terminal.
6. All runs of pipe should be as short as possible with as few turns as possible.
7. Seams should be tightly joined and checked for leaks.
8. The flue pipe must not extend into the chimney but be flush with the inside wall.
9. The chimney or vent pipe must extend at least three (3') feet above the highest point where it passes through a roof of a building and at least two (2') feet higher than any portion of a building within a horizontal distance of ten (10') feet. It shall also extend at least five (5') feet above highest connected equipment flue collar.
Figure 9
VENT EXIT OPTIONS
combustion blower adaptor plate to the flue collector box, taking care to support the blower assembly so that it does not fall.
4. Rotate the blower 90° (degrees) clockwise, so that the outlet of the blower is pointing toward the right side panel of the furnace.
5. Insure that the gasket is in place between the blower adaptor plate and the flue collector box. Reattach the blower assembly to the flue collector box, using the four (4) screws removed in step 3. Be sure that the screws are properly tightened and that the gasket seals the plate to the box.
6. Reconnect the pressure switch tubing to the combustion blower.
7. (Optional) Install vent pipe guard. Kit Number 20284801.
Figure 10
VENT PIPE GUARD KIT
10. The 3" to 4" vent adaptor coupling must be used to connect to the combustion blower outlet. It must be installed directly to the combustion blower outlet (See Figure 8).
To Convert to Side Flue Exit:
1. Remove the louver door from the furnace. (Be sure the side vent exit knock-out is removed from the right side panel of the cabinet. See Figure 9.)
2. Disconnect the pressure switch tubing from the combustion blower.
3. Remove the four (4) screws that secure the
For Horizontal Positions:
It is not necessary to reposition any of the components of the furnace in order to install it in either horizontal position. As outlined above, it is permissible to use the side vent exit for the horizontal-left position, if desired.
Checking For Vent Oversizing:
If this furnace is replacing a furnace that is attached to a venting system serving other appliances, the venting system is likely to be too large to properly vent all of the attached appliances. An improperly sized venting system can lead to condensation, leakage, or spillage.
20541501 Issue 0240 Page 14 of 26
Page 17
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed
into operation could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into
operation, while all other appliances connected to the venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. As 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.
4. Close fireplace dampers.
5. 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 are operating at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and
Propane Installation Codes.
9. 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-fired burning appliance to their previous conditions of use.
ELECTRICAL CONNECTIONS
When installed, the furnace must be electrically grounded in accordance with local codes or, in the absence of local codes, with the (U.S.) National Electrical Codes, ANSI/NFPA 70 or CSA Standard C22.1; Part 1 Canadian Electrical Code. For proper installation refer to furnace rating label for electrical ratings and for the field wiring of this unit refer to furnace wiring specifications on page 5 or alternately from the wiring diagram on page 28. In all instances, other than wiring for the thermostat, the wiring to be done and any replacement of wire shall conform with the temperature limitation for Type T wire [63°F rise (35°C)].
The electrical connections and the thermostat connections are made at the openings on either side panel of the unit in the control box area. Either side may be used as convenient, but the provided hole plugs must be inserted in the unused holes.
The control system depends on the correct polarity of the power supply. Connect "Hot" (H) wire and "Ground" (G) wire as shown in furnace wiring specification on wiring diagram. Use reference Table on page 3 (Furnace Specifications), for over current protection, max unit amp
rating and wire size. Use copper wire only for 115V­supply service to unit. When replacing any original internal wiring, use only 105°C, 16 AWG copper wire.
Instructions for wiring the thermostat are packed in the thermostat (field supplied) box. Make the thermostat connections as shown in furnace wiring specifications at the 24-volt terminal board located in the control box.
When installing optional accessories to this appliance, follow the manufacturer's installation instructions included with the accessory.
The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or approved conduit when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning can result in an electrical shock, fire, bodily harm, or loss of life.
20541501 Issue 0240 Page 15 of 26
Page 18
GAS CONNECTIONS
Gas piping shall be of such size and so installed as to provide a supply of gas sufficient to meet maximum demands without undue loss of pressure between the gas meter and the furnace. It is recommended that the gas line to the furnace shall be a separate line direct from the meter, unless the existing gas line is of ample capacity. Refer to gas pipe capacity table in the National Fuel Gas Code ANSI Z223.1/NFPA54, and/or CSA B149.1 Natural Gas and Propane Installation Codes.
If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do no use a connector which has previously serviced another gas appliance.
Use a joint compound (pipe dope) that is resistant to the action of liquefied petroleum gases or any other chemical constituents of the gases to be conducted through the piping.
For proper furnace operation the maximum gas supply pressure is 14" w.c. and the minimum gas supply pressure is 4.5" w.c. - Natural (11" w.c. - LP) as shown on rating label.
Before any system of gas piping is finally put into service, it should be carefully tested to determine if it is gas tight. Check all piping for leaks using soapy water and a brush. The piping must stand a pressure of six (6) inches of mercury (3 PSIG) for a period of ten (10) minutes or as required by local authority.
Figure 11
GAS CONTROL PIPING
Figure 12
TYPICAL GAS SERVICE CONNECTION
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
The furnace and its individual shutoff valve must be disconnected from the supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.5kPa or 14"w.c.).
The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 PSIG (3.5kPa or 14"w.c.). Failure to follow the above procedures could lead to a hazardous condition and bodily harm.
This furnace is manufactured for use with Natural gas and must be converted using the proper LP conversion kit for use with LP (Propane) gas. For LP (Propane) gas, a tank regulator is required to reduce supply pressure to 12"-13"w.c. For manifold pressure see Table 6.
A main manual shut off valve must be used in the gas piping. The shut off type and location must follow local codes and should always be in an accessible but protected location. In the absence of local codes the recommended methods for installing the gas piping to the furnace are shown in Figures 11 and 12.
The gas valve contains two threaded ports for a 1/8" NPT tap in order to test incoming gas pressure and outgoing manifold pressure (See Figure 13).
Many soaps used for leak testing are corrosive to certain metals. Piping must be rinsed thoroughly with clean water after leak check has been completed.
Never use an open flame when testing for gas leaks! Use of an open flame could lead to a fire or explosion.
20541501 Issue 0240 Page 16 of 26
Page 19
THEORY OF OPERATION
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Page 20
STARTUP AND OPERATIONAL CHECKOUT
Do not use this furnace as a construction heater. Use of this furnace as a construction heater exposes the furnace to abnormal conditions, contaminated combustion air and the lack of air filters. Failure to follow this warning can lead to premature furnace failure and/or vent failure which could result in a fire hazard and/or bodily harm.
The automatic gas valve controls the flow of gas to the main burners. The ignition system control switch built into the automatic valve body has 2 positions: "OFF" and "ON" (Figure 13). To shut off gas manually:Rotate switch from "ON" to "OFF" position. When in "OFF" position, the main burners are extinguished.
This furnace is equipped with an automatic hot­surface ignition control and does not require the manual lighting for furnace operation.
1. Be sure all electrical power is OFF.
2. Check all wiring using proper wiring diagram on inside of the control box cover.
3. Turn ON the electrical power.
4. Set the gas control knob in the "ON" position.
5. Set the thermostat above room temperature.
6. The ignitor will spark and the main burner will ignite.
Figure 14
TYPICAL FLAME APPEARANCE
(Main Burners)
Figure 13
GAS CONTROL DIAGRAM
Do not attempt to manually light the burners. Failure to follow this warning can lead to electrical shock that could result in bodily harm.
7. Recheck for leaks in the manual shut off valve, gas control valve and gas connections using a soap solution.
Never use an open flame when testing for gas leaks! Use of an open flame could lead to a fire or explosion.
Many soaps used for leak testing are corrosive to certain metals. Piping must be rinsed thoroughly with clean water after leak check has been completed.
After the ductwork connections have been made, gas piping and electrical wiring completed and the furnace has been properly vented, the unit should be started and adjusted for proper operation. Check off the following steps as they are completed.
20541501 Issue 0240 Page 18 of 26
Manifold Pressure Adjustment:
Turn OFF the gas and electrical before
preceeding! Remove the manifold pressure tap pipe
plug from the gas valve (Figure 13 outlet pressure tap) and install a pressure tap and connect it to a manometer. Turn on the gas and electrical supplies, then measure the manifold pressure with the furnace in operation.
Page 21
Remove the cap to access the screw for input adjustment (Figure 13 Pressure Regulator). Turn
regulator-adjusting screw IN to increase pressure, OUT to decrease pressure. Replace the cap. Measure
the manifold pressure.
For Natural gas, best results are obtained with a manifold pressure of 3.2" to 3.5"w.c. For units that have been converted to LP (Propane) gases, a manifold pressure of 10"w.c. is necessary. After proper adjustment, turn OFF gas, replace manifold pressure tap pipe plug and turn ON gas.
At higher altitudes and varying heating valves, manifold pressure or orifice changes maybe required. Consult Tables 7 and 8 for appropriate values. Failure to follow this warning could lead to a hazardous furnace operating condition and result in serious bodily injury or loss of life.
Determining Furnace Input - Natural Gas ONLY: NOTE: Louvered access door of furnace must be in
place when checking gas input.
TABLE 5
Gas Rate (Cubic Feet per Hour)
TEST DIAL
Seconds for
One
Revolution
10 160 360 720 12 150 300 600 14 129 257 514 16 113 225 450 18 100 200 400 20 90 180 360 22 82 164 325 24 75 150 300 26 69 138 276 28 64 129 258 30 60 120 240 32 56 113 226 34 53 106 212
1/2
Cubic
Feet
Cubic
1
Foot
2
Cubic
Feet
Seconds for
One
Revolution
36 50 100 200 38 47 95 190 40 45 90 180 42 43 86 172 44 41 82 164 46 39 78 156 48 37 75 150 50 36 72 144 52 35 69 138 54 34 67 134 56 32 64 128 58 31 62 124 60 30 60 120
1/2
Cubic
Feet
TEST DIAL
1
Cubic
Foot
2
Cubic
Feet
4. Calculate the furnace input using the following formula:
BTUH = Cubic Ft/Hr x BTU/Cubic Foot
The local gas supplier should be able to provide the heating value of the gas, in BTU/cubic foot. If a specific value is not available, use 1000 BTU/cubic foot for Natural gas or 2500 BTU/cubic foot for Propane (LP).
1. Turn OFF all other gas appliances (except for pilot burners) served by the same gas meter.
2. With furnace operating in full heat cycle, note how many seconds it takes for one full revolution of the smallest dial on the meter. Typically, this will be a 1/2 - or - 1 - cubic foot test dial.
3. Using the number of seconds for one revolution and the size of the meter dial, determine the cubic foot per hour of gas flow by using the formula provided below or Table 5.
Cubic Ft/Hr =
Number of Dial Revolutions x Cubic Foot/Revolution x 3600 Time (in seconds) Required for Number of Timed Revolutions
Furnace input should be maintained within ± 2% of the value on the rating plate or appropriate altitude derate. Adjust manifold pressure or change main orifices size if required.
5. Calculate the unit's actual input rate. Example: If the heating value of the natural gas is 1015
Btu/cu. and it takes 60 seconds to burn 2 cu. ft. of gas then:
Input = 1015 Btu/cu. ft. X 1 rev X 2 cu. ft./rev. X 3600
60 sec.
Input = 121,800 Btu/hr.
20541501 Issue 0240 Page 19 of 26
Page 22
Burner Orifice Sizing:
The furnace is supplied with standard orifices for the
gas shown on the rating plate. Table 6 shows combinations of heating values and specific gravities for various gases, from which proper input can be obtained.
If changing orifices is required, remove the manifold
from the furnace (following the instructions found on page
23) and replace orifices as required by Table 6, the
altitude derating section of this instruction or as local code dictates.
TABLE 6
Burner Orifice Selection
Type of Gas@Manifold Press.
(Heating Value-Specific Gravity)
Btu per Cu. Ft.
Orifice
Size
(Drill #)
Natural Manifold Press.= 3.5"w.c.
800-0.6
900-0.6 1000-0.6 1100-0.6
40 41 42 43
Propane Manifold Press.= 10"w.c.
2500-1.53
54
After securing the manifold assembly, replace all other components and/or wiring, being sure that all connections and screws are tightened properly.
Altitude Derating:
The following information is provided as guidelines for altitude derating and is not meant to supersede any state or local codes. Local codes have priority over any others and in some case might limit your options in dealing with an altitude derate situation.
NOTE: In Canada for altitudes up to 4500 ft. (1372 m)
see the rating label on this furnace for proper manifold pressure and orifice size. Certification for installations at altitudes over 4500 ft. (1372 m) is the jurisdiction of local authorities.
Check with your local gas company to find out if the gas supply in your area is derated. Gas deration negates the necessity of performing any adjustment on the furnace.
If your gas supply is not derated, and regardless of the type of gas used, installation of this furnace at elevations above 2,000 ft. requires an input reduction at the rate of four percent (4%) for each 1,000 ft. above sea level.
Unless an orifice change is specified by an applicable code, or the furnace is to be installed above 6,999 feet, the recommended method of altitude derating this furnace is to appropriately lower your manifold pressure. The appropriate manifold pressures based on the elevation and the heating value can be found in Table 7.
TABLE 7
High Altitude Manifold Pressure Derate
(with standard 42 orifice Natural / 54 orifice LP sizes)
Altitude
(Feet)
0-999 4.32 3.88 3.50 3.16 2.84 10 1000-1999 4.32 3.88 3.50 3.16 2.84 10 2000-2999 3.67 3.29 2.97 2.68 2.41 8.46 3000-3999 3.38 3.04 2.74 2.47 2.22 7.74 4000-4999 3.11 2.79 2.52 2.27 2.04 7.05 5000-5999 2.88 2.58 2.33 2.10 1.89 6.40 6000-6999 2.64 2.37 2.14 1.93 1.73 5.77
* Heating-Value based on atmospheric pressure of 30 inhg and 60°F temperature.
*Heating Value of Natural Gas
(BTU/FT3)
900 950 1000 1050 1100 2500
LP
Propane
If local codes require an orifices change or if the furnace installation is above 6,999 feet. The appropriate orifice size based on the elevation and the heating value can be found in Table 8. Sizing of the orifice must be based on the previously mentioned 4% derate for each 1,000 feet for installations at/or above 2,000 feet rule and the orifices must be drilled in such a way as to assure concentricity. Hand drilling of orifices is unacceptable.
TABLE 8
High Altitude Orifice Size Derate
Altitude
(Feet)
2000-2999 N.C. N.C. 43 43 44 N.C. 3000-3999 N.C. N.C. 43 44 44 N.C. 4000-4999 43 43 44 44 45 55 5000-5999 43 44 44 45 46 55 6000-6999 44 44 45 46 47 55 7000-7999 44 45 46 47 48 56 8000-8999 45 46 47 48 48 56 9000-9999 46 47 48 48 49 56
10000-10999 47 48 49 49 50 57
* Heating-Value based on atmospheric pressure of 30 inhg and 60°F temperature.
*Heating Value of Natural Gas
(BTU/FT3)
900 950 1000 1050 1100 2500
LP
Propane
Hand drilling of orifices is never acceptable since it could lead to delayed ignition, overfiring, improper combustion, flashback and flame rollout. All these conditions could lead to a fire hazard and bodily harm, or loss of life.
Blower Adjustment Checkout:
Prior to any blower adjustment, electrical service must be turned OFF.
This furnace is equipped with a 3 speed direct drive motor to deliver a temperature rise within the range specified on the rating label, between the return and supply plenums, at the external duct static pressure noted on the rating label.
20541501 Issue 0240 Page 20 of 26
Page 23
Adjust the blower speed so that the temperature rise is within the rise specified on the rating plate. Consult the wiring diagram for speed changes on the direct drive motor.
Limit Control Checkout:
After the furnace has been in operation for at least 15 minutes, restrict the return air supply by blocking the filters or closing the return registers and allow the furnace to shut down on high limit. The main burners will shut OFF and the main blower and combustion blower should continue to run. Remove the restriction and the burners should come back on in a few minutes.
Figure 16
FLAME ROLLOUT SWITCH
Flame Rollout Switch:
This unit is equipped with two (2) manual reset flame­rollout switches that protects against improper venting of the flue gases from the heat exchanger due to blockage causing heat (or flames) to "rollout" into the burner box from the heat exchangers, either safety device will activate and shut off power to the automatic gas valve before there is damage to the furnace. The loss of power to the gas valve will shut off the gas burners. Should this occur, it will be necessary to determine the cause of the rollout, correct the condition that caused it, and reset the flame-rollout switch.
The furnace should be allowed to cool-off before attempting to reset the switch. Failure to follow these instructions could result in injury due to burns!
The switch located behind the burner access panel is accessed by removing the burner access panel from the furnace, and is reset by pushing in the button in the middle of the switch (between the two wire connections ­ See Figure 16). Very little force is required to push the reset button, and a "click" should be heard when the switch resets.
Pressure Switch Check:
To check the operation of the pressure switch vent safety control, remove the vent adaptor from the combustion blower. Place the furnace into operation. Gradually cover up the blower outlet; the main burners should shut OFF. Remove the restriction and the unit should relight. Replace the vent adaptor and reseal the opened joints as required.
The operational checkout is now complete. Be sure to adjust the thermostat to the desired setting and inform the homeowner how to operate the furnace system before leaving the job site.
If the pressure switch activates to shut the furnace down, the vent system must be checked and cleared. Failure to do so may result in serious bodily harm or nuisance furnace shutdown and/or a hazardous condition that may lead to property damage, personal injury or death.
20541501 Issue 0240 Page 21 of 26
Page 24
SEQUENCE OF OPERATION
Direct ignition system control
20541501 Issue 0240 Page 22 of 26
Page 25
SERVICING THE FURNACE
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury, death or property damage.
Before servicing, disconnect all electrical power to furnace.
Wehn servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.
Verify proper operation after servicing.
The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools. If you are at all uncertain, contact your dealer for qualified maintenance and service since improper service could lead to furnace shutdown or a hazardous condition which could lead to an unsafe condition and bodily harm.
Combustion Component Check:
The heat exchanger, gas burners and venting system must be checked each year, prior to the heating season, by a qualified dealer/serviceman.
The following procedures should be performed:
1. Remove the burner/manifold assembly from the
furnace, follow the instructions found on this page.
2. Place the burner/manifold assembly on a flat work
area and vacuum the burners. It might be necessary
to use a soft bristly brush to remove dirt and then
vacuum.
3. Disconnect wiring to combustion blower.
4. Disconnect wiring to pressure switch, and remove
pressure switch.
5. Remove the burner opening inlet plate and the flue
collector box with the combustion blower attached.
This will expose both the burner and flue openings of
the primary heat exchangers.
6. Vacuum the length of each heat exchanger tube
using a straight attachment into the burner openings
and the flue openings.
7. Replace the flue collector box, burner opening inlet
plate, and burner/manifold assembly. Insure that all
gaskets are properly positioned and that no leaks
exist.
8. Reattach all wiring and piping as per the wiring diagram and installation instructions.
9. Turn on utilities and check for leaks using soapy water and a brush.
10. A visual check of the main burner should be made at the beginning of each heating season.
11. Check the input rate and adjust if necessary.
12. Perform a safety check of the limit control and pressure switch.
13. Check the air filter, clean and/or replace as necessary.
14. Replace the appropriate access panels or door.
Never use an open flame when testing for gas leaks! Use of an open flame could lead to a fire or explosion!
Many soaps used for leak testing are corrosive to certain metals. Piping must be rinsed thoroughly with clean water after leak check has been completed.
Manifold (or Burner/Manifold) Removal/Replacement:
1. Make sure that all utilities (gas and electricity) are turned off upstream of the furnace.
2. Remove the louvered access door by sliding the door straight up, swinging the bottom of the door away from the furnace, and pulling the door down and out of the furnace (See Figure 17).
3. Disconnect the gas line from the gas valve. Be sure that a wiring diagram is available, or be ready to mark any wires that are disconnected. Unplug the three connectors from the gas valve.
Figure 17
FURNACE PANEL REMOVAL
20541501 Issue 0240 Page 23 of 26
Page 26
4. Disconnect wires from rollout switch.
5. Remove manifold or burner/manifold assembly. Manifold ONLY
a. Remove the No. 10 screws that secure the
manifold pipe to both legs of the manifold assembly. The manifold pipe must be
supported during this step, or it could fall and damage the furnace or cause bodily injury!
b. Slide the manifold pipe (with valve and orifice)
forward, out of the furnace.
Burner/Manifold Assembly a. Remove the No. 10 screws that secure the
burner/manifold assembly legs to the furnace.
The manifold pipe must be supported during this step, or it could fall and damage the furnace or cause bodily injury!
b. Slide the burner/manifold assembly forward, out
of the furnace until the assembly is clear of the manifold retention pins.
c. Rotate the assembly slightly, in order for the legs
to clear the sides of the cabinet, and remove through the front of the furnace.
8. To reinstall the manifold pipe or burner/manifold assembly, reverse the above steps.
Blower Removal/Replacement:
Removal
1. Turn OFF all electrical power to the furnace.
2. Remove the control box access panel and blower access panel.
3. Unplug wires from the blower assembly to the control box.
4. Remove the four (4) screws securing the control box in the unit (two (2) in the cabinet at the sides of the blower door opening and two (2) at the top rear of the control box). Be sure to support the control box so that it does not fall!
5. Rotate the control box out of the cabinet and support it so that no strain is placed on any wiring. It may be necessary to disconnect the electrical supply and thermostat wiring from the control board.
6. Remove the blower retaining screws from the front of each blower leg (See Figure 18). These are the two (2) screws located in the blower compartment that secure the blower legs to the blower partition panel.
7. Slide the blower forward about two (2) inches. This will disengage the rear of the blower legs from the blower partition. Rotate the front of the blower down to clear the control box mounting tabs on the underside of the blower partition, and continue sliding the blower forward until it is out of the unit. Take care to clear the control box mounting tabs. If necessary, disconnect the auxiliary limit leads on the sides of the blower housing.
Replacement
1. Place the blower in the blower opening of the unit and reconnect the auxiliary limit leads.
2. Slide the blower back, into the unit, taking care to clear the control box mounting tabs.
3. When the blower is about halfway into the cabinet, rotate the rear of the blower UP so that the rear of the blower legs engage the side rails in the blower partition.
4. Continue sliding the blower into the unit until the front of the blower housing is behind the control box mounting tabs. Rotate the front of the blower UP until the legs lie flat against the bottom of the blower partition, then slide blower fully into position. The rear of the blower should be against the stop in the partition and the rear of the blower legs should be under the partition.
5. Reattach the two (2) blower securing screws, the control box, any disconnected wiring, the blower access panel, and the control box access panel.
Lubricating Motors:
Direct drive motor and blower assemblies are factory
lubricated and normally do not require oiling. If oiling is required lubrication of the blower motor is to be preformed only by a qualified service agency. If the blower motor on this furnace is to be replaced it must only be replaced with one of the motors as listed in the Furnace Blower Specifications on page 3.
Figure 18
BLOWER REMOVAL AND REPLACEMENT
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Page 27
TROUBLE SHOOTING With LED Indicator Assistance
20541501 Issue 0240 Page 25 of 26
Page 28
WIRING DIAGRAM
20541501 Issue 0240 Page 26 of 26
Page 29
USER'S INFORMATION MANUAL
Gas-Fired Furnace
READ ALL INSTRUCTIONS IN THIS MANUAL AND RETAIN THIS AND ALL ADDITIONAL INSTRUCTIONS FOR FUTURE REFERENCE.
Congratulations...
...you have one of the most modern gas furnaces made. Your unit has been carefully selected to keep you warm and comfortable during the winter months. It will deliver superb performance with only minimal help from you.
FIRE OR EXPLOSION HAZARD
To keep your operating costs low and to eliminate unnecessary service calls, we have provided a few guidelines. These guidelines will help you understand how your gas furnace operates and how to maintain it so you can get years of safe and dependable service.
GAMA Certified
The Gas Appliance Manufacturers Association (GAMA) symbol verifies that Annual Fuel Utilization Efficiency (AFUE) ratings for our gas furnaces have been derived from U.S. Government standard tests.
CSA International Design Certified
The CSA International symbols on each nameplate is your assurance that your furnace design meets nationally recognized standards for safety and performance.
Failure to follow safety warnings exactly could result in serious injury death or property damage.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this or any other appliance.
— What to do if you smell gas:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
— Installation and service must be
performed by a qualified installer, service agency or the gas supplier.
20541401 issue 0229 Page 1 of 6
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATING YOUR FURNACE . . . . . . . . . . . 2
Lighting Instructions . . . . . . . . . . . . . . . . . 2
Temperature Control . . . . . . . . . . . . . . . . . 3
Fan Operation . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE OF YOUR FURNACE . . . . . . 4
Periodic Inspections . . . . . . . . . . . . . . . . . 4
Cleaning/Replacing the Filter . . . . . . . . . . . 5
Parts Replacement Guide . . . . . . . . . . . . . 6
Page 30
For your safety ­Read before operating
Here are a few "Do's and Don'ts"
Do become familiar with the instructions.
A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary.
Do check to see that your home has adequate insulation, weatherstripping, caulking, and storm windows. Elimination of infiltration of outside air and drafts can save up to 40% of your fuel bill.
Do consider adding a humidifier to your heating system. Higher indoor humidity slows evaporation of perspiration, making the home seem warmer.
Don't waste fuel by setting your thermostat too high. Energy conservation experts recommend a daytime thermostat setting of 68°F, with a lower setting at night.
Don't turn off the furnace when you expect to be away for more than a day. Instead, lower the thermostat setting a few degrees. You can then restore normal comfort level quickly and save fuel too.
Don't block registers with furniture.
Don't put a lamp, TV, or radio too near your thermostat. This will cause it to give a false reading.
The furnace area must be kept clear and free of combustible materials, gasoline, and other flammable vapors and liquids. Failure to do so could cause actions that may result in property damage, personal injury, or loss of life.
Operating Your Furnace
Lighting Instructions
1. STOP! Read the previous safety information.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the furnace.
4. Remove the burner compartment access panel.
5. This appliance is equipped with an automatic ignition. device. Do not try to light the burners by hand.
6. Move the gas control knob to "OFF" (see Figure 1).
If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury, or loss of life.
These furnaces are equipped with an ignition device which automatically lights the burners. Do not try to
light the burners by hand.
Before operating, smell around the furnace area for gas.
Be sure to smell next to the floor because some gas is heavier than air and will settle to the lowest point. Refer to "What to do if you smell gas" on page 1 if the odor of gas is present.
Use only your hand to adjust the gas control switch;
never use tools. If the switch will not move by hand,
don't try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
Do not use this furnace if any part has been under water.
Figure 1
7. Wait 5 minutes to clear out any gas, then smell for gas (including at the bottom of the unit near the ground). If you smell gas, stop and follow the directions in "What to do if you smell gas" on page
1. If you don't smell gas, continue to next step.
8. Move the gas control switch to "ON".
9. Replace the burner compartment access panel.
10. Turn on all electric power to the furnace.
20541401 issue 0229 Page 2 of 6
Page 31
11. Set the thermostat to the desired setting.
12. If the furnace will not operate, follow the instructions in "To Turn Off Gas to Furnace" and call your service technician or gas supplier.
To Turn Off Gas to Furnace
1. Set the thermostat to the lowest setting.
Fan Operation
You may wish to increase your comfort by setting your system for continuous air circulation of the indoor air. The fan switch on the thermostat permits you to do this.
With the switch in the "ON" position the fan will operate continuously. "AUTO" position gives fan operation only when the unit is in either heating or cooling.
2. Turn off all electric power to the furnace if service is to be performed.
3. Remove the burner compartment access panel.
4. Move the gas control switch to "OFF" (see Figure 1). Do not force.
5. Replace the burner compartment access panel.
Temperature Control
There are many types and styles of thermostats. Yours may look different from the one pictured in Figure 2, depending on the type of thermostat and whether cooling was installed with the system. However, almost all thermostats perform the same basic functions described in the following section.
What to do if your unit is not heating properly
If your furnace is operating but fails to provide complete comfort, check the following before calling for service:
1. Be sure the thermostat setting is correct.
2. Check to see if the filter is clean.
3. Be sure air can circulate freely throughout your home. Do not block supply registers or return grilles with furniture or rugs.
And if you also have cooling...
4. Keep surface of the outdoor coil free from dirt, lint, paper, or leaves.
5. Check and clean indoor coil, if necessary. (This check should be made at the start of each cooling season by your service technician).
What to do if your unit fails to operate
1. Be sure the main switch that supplies power to the furnace is in the "ON" position.
2. Replace any burned-out fuses or reset circuit breakers.
3. Be sure the thermostat is properly set.
Figure 2
4. If the furnace still does not start, call your service technician.
Thermostat Operation
There are two (2) switches located on the thermostat (see Figure 2). One switch controls the heating and cooling (if applicable) functions. The other switch is for "FAN" operation, either continuous or automatic. On the thermostat is the temperature range for the heating
Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.
temperature and the cooling temperature desired. To put the system into operation, push the switch to
either "HEAT" or "COOL" position. After you have chosen the type of operation you desire, move the thermostat dial or lever to select the temperature you would like the system to maintain.
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Page 32
Maintenance Of Your Furnace
Always shut off all power to the unit before attempting any of the following maintenance procedures. Failure to do so may result in personal injury.
There are routine maintenance steps you should take to keep your furnace operating efficiently. This maintenance will assure longer life, lower operating costs, and fewer service calls. In addition to the maintenance procedures listed in this manual, there are also other service and maintenance procedures that require the skills of a service person who has specialized tools and training. (See "Servicing the Furnace" section of the Installation and Servicing part of this booklet.) Personal injury can
result if you are not qualified to do this work. Please
call your dealer when service is needed.
Cleaning
The cabinet of the furnace can be cleaned with soap and water. Grease spots can be removed with a household cleaning agent. The cabinet can be kept attractive by polishing with automotive wax at least twice a year.
authorized dealer at once to obtain a qualified service inspection:
• Rust, flakes, or other deposits
• Coatings
• Corrosion
Even if no unusual rust or other conditions are observed,
it is recommended that the furnace be inspected and serviced at least once per year by a qualified service technician. Regular inspection and planned
maintenance will assure many years of economical performance from your gas furnace.
Combustion Air
Adequate combustion and ventilation air must reach your gas furnace to provide for proper and safe operation. Do not block or obstruct air openings on the furnace, air openings communicating with the area in which the furnace is installed and the spacing around the furnace. Any obstruction of this airflow can cause an unsafe condition which may result in death or permanent injury.
Installations Around Insulation
Insulating materials may be combustible. Therefore, a furnace installed in an attic or other insulated space must be kept free and clear of insulating materials. Make sure to examine the furnace area when the furnace is installed or additional insulation has been added.
Periodic Inspections
Your gas furnace is designed to give many years of efficient, satisfactory service. However, the varied air pollutants commonly found in most areas can affect longevity and safety. Chemicals contained in everyday household items such as laundry detergents, cleaning sprays, hair sprays, deodorizers, and other products which produce airborne residuals may have an adverse affect upon the metals used to construct your appliance.
It is important that you conduct periodic physical inspections of your appliance, paying special attention to the gas burner and the flue outlet from the furnace. These components are located at the front of the unit. A flashlight will be useful for these inspections. Make one inspection prior to the beginning of the heating season and another during the middle.
Furnaces located in a closet, alcove, or utility room must have provision for adequate air supply by means of upper and lower grilles in the door, or by the introduction of outside air, or both. National Fuel Gas Code, ANSI Z223.1 (latest edition), CAN/CGA B149.1 & .2 Installation Codes (latest edition), and local requirements are generally alike. However, local codes take precedence.
Venting and Furnace Support
Venting of this furnace must comply with our published instructions. Be sure the installer has followed these requirements. If not, you should request the installer to comply as soon as possible.
For your safety, please note the following:
1. 80% furnaces may be common vented with another appliance in certain circumstances. Refer to the installation instructions and Category I Venting Tables, Nationa Fuel Gas Code ANSI Z223.1 (latest edition), for proper installation guidelines. In Canada, see CAN/CGA B149.1 & .2 Installation Codes (latest edition).
Should you observe unusual amounts of any of the following conditions, it is important that you call your
20541401 Issue 0229 Page 4 of 6
2. This furnace is not designed for use with a vent damper. Use of such a device will not improve the efficiency of this furnace.
Page 33
The vent from your furnace may rise vertically and terminate above the roof. When horizontal venting an 80% furnace, an approved sidewall venter must be used. Refer to the installation instructions for further information on horizontal venting of an 80% furnace.
Make sure all flue product carrying areas and materials external to the furnace (i.e vent terminals, etc..) are clear and free of any obstruction, slope upward, and have no holes or leaks.
Check to see that the furnace cabinet is sound and firmly supported, without sagging. There should be no cracks or gaps between the furnace and the base or floor, which would permit entry of unfiltered air.
It is important that the outside area where the vent terminates is kept clear of any obstructions which might block or impede the venting of the furnace. Should venting become blocked at anytime, your furnace is equipped with a special safety control to prevent operation of the furnace until the condition has been corrected. Contact your dealer if you desire more information about this safety feature.
If your air distribution system has a central return air filter­grille, you do not need a filter in your furnace. Clean the filter-grille the same way permanent filters are cleaned.
Table 1 EXTERNAL FILTER RACK SIZE
SIDE
RETURN 15 ½ X 25 12 X 25 15 ½ X 25 15 ½ X 25 15 ½ X 25 19 X 25
Safety Interlock Switch
BOTTOM/END
RETURN
The blower compartment door on your high efficiency gas furnace is equipped with a safety interlock switch that will automatically shut off your complete system (including blower) once the door is removed. This is for your personal safety. Be sure to check your furnace for proper operation once the door or panel has been replaced.
If the system does not operate once the panel has been replaced, try removing and replacing it once again. If the furnace still does not operate, call your dealer for service.
Should any unusual conditions be observed during your inspections, call an authorized service dealer immediately.
For proper venting terminations, see the Installation Instructions furnished with the furnace.
Return Air
Ascertain that all return air duct connections are tight and sealed to the furnace cabinet and that all return air grilles or registers are located outside the space containing the furnace.
Cleaning/Replacing the Filter
It is very important to clean or replace the air filter regularly. Dirty filters are the most common cause of inadequate heating or cooling performance and can sharply increase the operational costs of your unit. In some cases, they can double the cost. The air filter
should be inspected at least every 6 weeks and cleaned or replaced as required.
Your furnace may use either a disposable filter or a permanent filter. The type of filter may be indicated on a label attached to the filter. If a disposable filter is used, replace with the same type and size. If a permanent filter is used, clean filter and place back in furnace. To clean a permanent filter, shake filter to remove excess dirt and/or use a vacuum cleaner. Wash filter in soap or detergent water and replace after filter is dry. Permanent filters do not need to be oiled after washing.
Rollout Switch
This unit is equipped with a manual reset high temperature sensor or rollout switch. In the unlikely event of a sustained main burner flame rollout, the rollout switch will shut off the flow of gas by closing the main gas valve. The switch is located inside the gas burner area. Flame rollout can be caused by blockage of the power vent system, a blocked heat exchanger, or improper gas pressure or adjustment. If this event occurs, the unit will not operate properly. The gas supply to the unit should be shut off and no attempt should be made to place it
in operation. The system should be inspected by a
qualified service technician.
Lubrication
Lubrication of the bearings in the circulating air blower motor and the combustion blower motor is not recommended.
Burner Flame
While the furnace is in operation, observe the main burner flames. Compare these observations to Figure 3 to determine if proper flame adjustment is present. If your observations indicate improper flame adjustment, call your authorized service dealer for service.
Permanent filters may be replaced with disposable filters. Refer to Table 1 when selecting the proper size and quantity of disposable filter.
20541401 Issue 0229 Page 5 of 6
Page 34
Figure 3
Do not attempt to adjust flame! Your service
representative will perform this adjustment correctly.
PARTS REPLACEMENT INFORMATION GUIDE
Warranty Procedure
When warranty parts are required:
1. Be prepared to furnish the following information:
a. Purchaser's name b. Complete model number, serial number, and
date of installation.
c. An accurate description of the problem or
defective parts.
2. Contact your dealer or distributor.
Keep this User's Information Manual (including Warranty) and proof of purchase for your records. Your warranty is determined from your date of installation. If proof of your date of installation is not supplied, the warranty will be based on the manufacture date code.
Failure to follow the correct warranty procedure could result in disallowance of warranty claim.
CASING GROUP GAS CONTROL GROUP BLOWER GROUP
Top Panel Manifold Blower Housing Front Door Burner Blower Motor Blower Door Shield Top & Bottom Blower Wheel Orifice Capacitor Ignitor Blower Support Leg Gas Control Sensor
ELECTRICAL GROUP HEAT EXCHANGER GROUP INDUCER GROUP
Access Door Primary Heat Exchanger Pressure Switch Limit Switch Burner Inlet Plate Inducer Blower & Motor Fan Timer Control Board Flue Box Transformer Rollout Switch Door Interlock Switch Auxiliary Limit Switch
TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local
telephone directory under the "Heating Equipment" or "Air Conditioning Contractors & Systems" headings for dealer listing or see the first page of the installation instruction section of this manual for the name and address to contact.
Have available the Model No. and Serial No. located on the unit rating plate to insure correct replacement part.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause personal injury or property
damage. Consult a qualified installer, service agency, or your local gas supplier for information or assistance.
20541401 Issue 0229 Page 6 of 6
Page 35
Owner Record
Furnace Model # Serial # Installation Date
INSTALLED BY:
Dealer Address Telephone # License # Contact Person
Other Equipment Installed: Equipment Type Model # Serial # Installation Date Equipment Type Model # Serial # Installation Date Equipment Type Model # Serial # Installation Date
WHEN FRENCH IS REQUIRED!
ATTENTION: MR. INSTALLER OR HOMEOWNER
TO OBTAIN INSTALLATION INSTRUCTIONS, USER'S INFORMATION MANUAL AND FURNACE
MARKINGS IN FRENCH CONSULT WITH YOUR DEALER OR LOCAL DISTRIBUTOR:
HAVE AVAILABLE THE MODEL NO. AND SERIAL NO. LOCATED ON THE UNIT RATING PLATE TO
INSURE THE CORRECT FRENCH INSTRUCTION PACKET.
POUR OBTENIR DE LA DOCUMENTATION EN FRANÇAIS!
À L'ATTENTION DE L'INSTALLATEUR OU DU PROPRIÉTAIRE
POUR OBTENIR LES INSTRUCTIONS D'INSTALLATION, LE MANUEL DE L'USAGER ET LES
MARQUAGES EN FRANÇAIS, CONSULTEZ VOTRE MARCHAND OU LE DISTRIBUTEUR DE VOTRE RÉGION:
AYEZ EN MAIN LE MODELE ET LE NUMÉRO DE SÉRIE INDIQUÉS SUR LA PLAQUE SIGNALÉTIQUE
DE L'APPAREIL POUR OBTENIR LA POCHETTE D'INSTRUCTIONS EN FRANÇAIS APPROPRIÉE.
Page 36
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OTHER EUROPEAN COUNTRIES,
AFRICA,
MIDDLE-EAST :
FA-AGU-0204-E
Due to Lennox's ongoing commitment to quality, Specifications, Ratings and Dimensions subject to change without notice and without incurring liability. Improper installation, adjustment, alteration, service or maintenance can cause property damage or personal injury. Installation and service must be performed by a qualified installer and servicing agency.
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