Page 1
NOTE TO
INSTALLER:
This manual must be left
with the equipment user.
®
Model 480BAV
Upflow and
481BAV
Downflow/Horizontal
USER’S INFORMATION MANUAL FOR THE OPERATION AND
MAINTENANCE OF YOUR NEW GAS-FIRED FURNACE
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• 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.
— Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
®
Page 2
WELCOME TO
TOD AY’S
GENERATION OF
COMFORT
Congratulations! Your new , higher efficiency gas furnace is a sound investment which will reward you and your
family with years of warm memories
winter after winter.
Not only is your new furnace energy
efficient, it is also extremely reliable.
Spend just a few minutes with this
booklet to learn about the operation of
your new furnace—and the small
amount of maintenance it takes to keep
it operating at peak efficiency. Years
went into the development of your ne w
furnace. T ake a little time now to assure
its most efficient operation for years to
come.
MODEL 480BAV
Upflow Furnace
UPFLOW FURNACE COMPONENTS
Relief Box
1
2
Rating Plate
3
Gas Valve Control Knob or Electric Switch (On/Off)
4
Gas Valve
5
Gas Burner
6
Flame Sensor
7
Filter Retainer
8
Air Filter
9
Blower and Blower Motor
10
Draft Safeguard Tube and Switch
11
Gas Manifold
12
Manual Reset Limit Switch
1
2
MODEL 481BAV
Downflow/Horizontal
Furnace
1
2
3
4
5
6
7
8
10
11
12
13
14
13
Hot Surface Ignitor
14
Blower Door Safety Switch
9
3
2
Page 3
DOWNFLOW/HORIZONTAL
FURNACE COMPONENTS
1
2
1
Manual-Reset Auxiliary Limit Switch (When Used)
2
Blower and Blower Motor
3
Relief Box
4
Gas Valve Control Knob or Electric Switch (On/Off)
3
4
5
6
7
IMPORTANT FACTS
Your furnace must have adequate airflow for efficient combustion and safe
ventilation. Do not enclose it in an airtight room or “seal” it behind solid
doors. To minimize the possibility of
serious personal injury , fire, damage to
your furnace, or improper operation;
carefully follow these safety rules:
• Keep the area around your furnace
free of combustible materials, gasoline, and other flammable liquids and
vapors.
• Do not cover the furnace, store trash
or debris near it, or in any way block
the flow of fresh air to the unit.
• Combustion air must be clean and not
contaminated with chlorine or fluorine.
These compounds are present in many
13
8
9
10
11
12
5
6
7
8
9
10
11
12
13
4
products around the home, such as:
water softener salts, laundry bleaches,
detergents, adhesives, paints, varnishes, paint strippers, waxes, and
plastics.
Make sure the combustion air for your
furnace does not contain any of these
compounds. During remodeling be
sure the combustion air is fresh and uncontaminated. If these compounds are
burned in your furnace, the heat exchangers and metal vent system may
deteriorate.
• A furnace installed in the attic or
other insulated space must be kept free
and clear of the insulating material.
Examine the furnace area when installing the furnace or adding more insulation. Some materials may be
combustible.
NOTE:
Do not use this furnace if any
part has been under water . Immediately
call a qualified service technician to inspect the furnace and to replace any
part of the control system and any gas
control which has been under water.
5
NOTE:
The qualified installer or
agency must use only factory-authorized replacement parts, kits, and
accessories when modifying or repairing this product.
This furnace contains safety devices
which must be manually reset. If the fur-
3
Gas Valve
Gas Burner
Rating Plate
Blower Door Safety Switch
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch (2)
Hot Surface Ignitor
Flame Sensor
nace is left unattended for an extended
period of time, have it checked periodically for proper operation. This precaution will prevent problems associated
with no heat, such as frozen water pipes,
etc. See “Before You Request a Service
Call” section in this manual.
SAFETY
CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to gas and
electrical components. Only trained
and qualified personnel should install,
repair, or service heating equipment.
Untrained personnel can perform basic
maintenance functions such as cleaning and replacing air filters. All other
operations must be performed by
trained service personnel. Observe
safety precautions in this manual, on
tags, and on labels attached to the furnace and other safety precautions that
may apply.
Recognize safety information: This is
the safety-alert symbol . When you
see this symbol on the furnace and in
instructions or manuals, be alert to the
potential for personal injury.
Understand the signal words—DANGER, WARNING, and CAUTION.
These words are used with the safetyalert symbol. DANGER identifies the
!
Page 4
•
most serious hazards which will result
in severe personal injury or death.
WARNING signifies hazards which
could result in personal injury or death.
CAUTION is used to identify unsafe
practice, which
would result in minor
personal injury or product and property
damage.
ST AR TING Y OUR
FURNA CE
Instead of a continuously burning pilot
flame, your furnace uses an automatic
hot surface ignition system to light the
burners each time the thermostat calls
for heat.
guards:
• Never attempt to manually light the
burners with a match or other source of
flame.
• Read and follow the operating instructions on the furnace, especially
the item that reads as follows:
Wait 5 minutes to clear out any gas.
Then smell for gas, including near the
floor. If you smell gas,
“B” in the safety information above on
this label. If you don’t smell gas, go to
the next step.
• If a suspected malfunction occurs
with your gas control system, such as
the burners not lighting when they
should, refer to the shutdown procedures on the furnace or in the next section to turn off your system, then call
your dealer as soon as possible.
Follow these important safe-
STOP! Follow
!
WARNING
Should overheating occur, or
the gas valve fail to shut off the
gas supply, turn off the manual
gas valve (See Fig. 8) to the furnace BEFORE turning off the
electrical supply. A failure to
follow this warning could result in a fire or explosion, and
personal injury or death.
CHECK AIR FILTER: Before
attempting to start your furnace, be
sure the furnace filter is clean and in
place. (See the maintenance section
of this manual.) Then proceed as
follows:
®
STEPS FOR STARTING
YOUR FURNACE
1. Set your room thermostat to the
lowest temperature setting.
(See Fig. 7.)
2. Close the external manual gas
valve. (See Fig. 8.)
6
3. Turn OFF the electrical supply
to your furnace.
(See Fig. 9.)
C
L
O
S
E
7
4. Remove the furnace access
door(s).
a. Downflow/Horizontal—remove
blower door after removing 2
screws, then remove the control
door. (See Fig. 10.)
b. Upflow—remove control door.
(See Fig. 11.)
5. The gas valve will hav e EITHER a
control knob or control switch to
turn off and on. Turn the control
knob or switch on the gas valve to
the OFF position and wait 5 minutes. (See Fig. 12 or 13.)
6. After waiting 5 minutes, turn the
control knob or switch on the gas
valve to the ON position. (See Fig.
14 or 15.)
7. Replace the access door(s). See
Fig. 16 for upflow and Fig. 17 for
downflow. Replace control door
first on downflow furnaces. Then
8
9
replace blower door (secure with 2
screws).
8. Turn ON the electrical supply to
the furnace. (See Fig. 18.)
9. Open the external manual gas
valve. (See Fig. 19.)
10. Set the room thermostat to a temperature slightly above the room
temperature. This will automatically signal the furnace to start.
The inducer motor will start, and
the hot surface ignitor will energize. When hot, the ignitor will
have an orange glow.
10
11
4
Page 5
Setting the thermostat back a few
degrees—and compensating for
the difference with warmer clothing—can make a big difference in
your fuel consumption on
F
O
F
extremely cold days. The few
degrees at the top of your thermostat “comfort level” are the most
costly degrees to obtain.
When the room temperature drops below the temperature selected on the
16
thermostat, the furnace will be automatically switched on. When the room
temperature reaches the degree se-
12
lected on the thermostat, the furnace
will be automatically switched off.
Some thermostats have a “fan” mode
1
M
O
O
F
F
F
F
ON
3
P
2
C
with 2 selections: A UTO or ON. When
set on AUTO, the furnace blower cycles on and off, controlled by the thermostat. In the ON position, the
furnace blower runs continuously except for a 45-sec delay at the “call for
17
heat. ” This keeps the temperature level
in your home more evenly balanced. It
also continuously filters the indoor air.
ON
1
M
O
F
F
ON
3
P
2
C
11. After 15 to 70 sec, the gas valve
permits gas to flow to the main
burners where it is ignited. Hot
flames begin to warm the furnace’ s
heat exchanger . After a time delay
of approximately 45 sec, the furnace blower is switched on.
13
14
15
18
O
P
E
N
19
NOTE:
If the main burners fail to ignite, the furnace control system will go
through 3 more ignition cycles. Then,
if burners fail to ignite, the system will
lockout. If lockout occurs, or the
blower does not come on—shut down
your furnace and call your dealer for
service.
12. Set your thermostat to the temperature that satisfies your comfort
requirements. SUGGESTION:
SHUTTING DOWN
YOUR FURNACE
Should you ever suspect a malfunction
in your furnace, you will need to turn
the furnace off. The following procedures must be followed:
1. Set your room thermostat to the
lowest temperature setting. (See
Fig. 20.)
2. Close the external manual gas
valve. (See Fig. 8 on page 4.)
3. Turn OFF the electrical supply to
your furnace. (See Fig. 21.)
4. Remove the control access door on
your furnace. (See Fig. 10 or 11.)
On upflow furnaces, removing the
blower access door is not required.
5. Turn the control knob or switch on
the gas valve to the OFF position.
(See Fig. 22 or 23.)
®
20
5
Page 6
!
WARNING
Turn off electrical power supply to your furnace before removing the access doors to
service or perform maintenance. A failure to follow this
warning could result in personal injury or death.
21
F
O
F
22
1
M
O
O
F
F
F
F
ON
3
P
2
C
23
6. Replace the control access door.
(See Fig. 16 or 17.)
7. If the furnace is being shut down
because of a malfunction, call
your dealer as soon as possible.
PERFORMING
ROUTINE
MAINTENANCE
With the proper maintenance and care,
your furnace will operate economically
and dependably. Basic maintenance,
which can easily be accomplished by
following the directions, is found on
this and the following pages. Howe ver ,
before beginning maintenance, follow
these safety precautions:
!
CAUTION
Although special care has
been taken to minimize sharp
edges, be extremely careful
when handling parts or reaching into the furnace.
FILTERING OUT
TROUBLE
A dirty filter will cause excessive stress
on the furnace blower motor and can
cause it to overheat and automatically
shut down. The furnace filter should be
checked every 3 or 4 weeks and cleaned
if necessary.
If your furnace filter needs replacing,
be sure to use the same size and type of
filter that was originally supplied. Use
the Furnace Filter Table and compare
your furnace size with the proper filter
size.
!
CAUTION
Never operate your furnace
without a filter in place. Doing
so may damage the furnace
blower motor. An accumulation of dust and lint on internal
parts of your furnace can
cause a loss of efficiency.
The air filter for upflow furnaces is
normally located in the blower compartment. Filters for the downflow furnaces are normally located in the
return-air plenum above the blower. If
the filters have been installed in another
location, contact your dealer for instructions. To inspect, clean, and/or replace the air filter(s), follow these
steps:
UPFLOW FURNACES ONLY:
•
1. Turn OFF the electrical supply to
the furnace. (See Fig. 21.)
2. Remove control and blower access
doors.
24
25
3. Push filter retainer toward the
bracket opening to release the filter. (See Fig. 24.)
26
4. Gently remove the filter and carefully turn the dirty side up (if dirty)
to avoid “spilling” dirt from the filter. (See Fig. 25.)
5. Inspect the filter. If torn, replace
the filter.
6 Wash the filter (if dirty) in a sink,
bathtub, or outside with a garden
hose. Al ways use cold tap water . A
mild liquid detergent may be used
if necessary. Spray water through
the filter in the opposite direction
of airflow. Allow filter to dry.
7. Reinstall the clean filter.
8. Put filter retainer back in the
bracket opening and lock it in
place.
9. Replace the blower and control
access doors and turn ON electrical power to your furnace. (See
Fig. 16, 17, and 26.)
6
Page 7
NOTE:
•
For upflow models only—if
side return ducts are used, 2 filters may
be required in some models. The procedure listed above may be used to remove side filters.
27 28
DOWNFLOW/HORIZONTAL
FURNACES ONLY:
T wo filters are located in the return-air
plenum above the blower (above lineof-sight) resting in the V-shaped channel on top of the furnace. (See Fig. 27.)
1. Turn OFF electrical supply to the
furnace. (See Fig. 21.)
2. Remove blower access door after
removing 2 screws.
3. Remove the left-side filter by tipping the filter toward the center—
raise it from the V-shaped channel
in which it rests. (See Fig. 27
and 28.)
4. Lower filter down along side of
the blower and remove from the
furnace.
5. To remove the second filter, lift
from V-shaped channel and
remove the same way as left side
filter.
6. Inspect the filters. If torn, replace
the filter.
7. W ash the filters (if dirty) in a sink,
bathtub, or outside with a garden
hose. Al ways use cold tap water . A
mild liquid detergent may be used
if necessary. Spray water through
the filter in the opposite direction
of airflow. Allow filter to dry.
8. Reinstall clean filters.
9. Replace blower door (secure with
2 screws) and turn ON electrical
power to your furnace.
UPFLOW FURN ACE FILTER
TABLE
FURNACE
CASING
WIDTH
14-3/16 (1)16x25x1* (1)14x25x1* Cleanable
17-1/2 (1)16x25x1* (1)16x25x1* Cleanable
21 (1)16x25x1* (1)20x25x1* Cleanable
24-1/2 (2)16x25x1* (1)24x29x1* Cleanable
FILTER SIZE
Bottom
Return
FILTER
TYPESide Return
DOWNFLOW/HORIZONTAL
FURNA CE FILTER TABLE
FURNACE
CASING WIDTH
14-3/16 (2)16x20x1* Cleanable
17-1/2 (2)16x20x1* Cleanable
24-1/2 (2)16x20x1* Cleanable
Factory-provided with the furnace. Filters may be field modified by cutting to
size. Alternate sizes and additional filters may be ordered from your dealer.
FILTER SIZE FILTER TYPE
21 (2)16x20x1* Cleanable
COMBUSTION AREA
AND VENT SYSTEM
Inspect the combustion area and vent
system before each heating season. An
accumulation of dirt, soot, or rust can
mean a loss of efficiency and improper
performance. Buildups on the main
burners can cause faulty firing. This
“delayed ignition” is characterized by
an alarmingly loud sound. If your furnace makes a loud noise when the main
burners are ignited, shut down the furnace—call your servicing dealer.
Use your flashlight and follow these
steps for inspecting the combustion
area and vent system of your furnace:
1. Turn off the electrical supply to
the furnace and remove the access
doors. (See Fig. 9 and 10, or 11.)
2. Carefully inspect the gas burner
(see Fig. 29) for dirt, rust, or scale.
Then inspect the relief box, flue
connection area, and the vent pipe
for rust.
29
NOTE:
If dirt, rust, soot, or scale accumulations are found, call your servicing dealer. DO NOT OPERATE THE
FURNACE.
3. Inspect the vent pipe for a sag,
holes, or a disconnection. A horizontal vent pipe must slope
upward. If rusty joints or seams, or
signs of water leakages are found
call your dealer for service.
7
*
!
WARNING
If holes are found—or if the
vent pipe is obstructed or is
not connected—toxic fumes
can escape into your home. DO
NOT OPERATE YOUR FURNACE. Call your dealer for service. A failure to follow this
warning could result in personal injury or death.
4. Replace the access doors and
restore electrical power to the furnace. Be sure bottom door flange
is inside of the furnace casing.
(See Fig. 16, 17, and 26.)
5. Start the furnace and observe its
operation. If possible, watch the
burner flames. Are they burning
bright blue? If not (or if you suspect some other malfunction), call
your servicing dealer.
BEFORE YOU REQUEST
A “SERVICE CALL”
BEFORE YOU CALL FOR
SERVICE, CHECK FOR
SEVERAL EASILY SOLVED
PROBLEMS:
• Check for sufficient airflow. Check
the air filter for dirt. Check for blocked
return-air or supply-air grilles. Be sure
they are open and unobstructed. If this
is not the cause, call your servicing
dealer.
If your furnace is not operating at all,
check the following list for easily
solved problems:
• Is your thermostat set above room
temperature? Is the HEAT mode
selected?
• Is the electrical power supply switch
ON? Is the blower access door firmly
in place? Are an y fuses blo wn? (There
is a fuse on the furnace control board.)
Has a circuit breaker tripped?
• Is the manual shutoff valv e in the gas
supply pipe leading to the furnace
open? Does the lever point in the same
direction that the pipe runs (open)? Or
is it at right angles (closed)?
NOTE:
next checks, turn OFF the electrical
power supply to the furnace. Remove
the access doors.
• Is the control knob or switch on the
gas valve turned to the ON position? If
this or the preceding check shows an
interruption in the gas supply , mak e
Before proceeding with the
Page 8
sure the gas has not been shut off for
safety reasons. If nothing else seems to
be wrong, follow the startup procedures
found on pages 4 and 5 of this booklet.
• If for some reason the vent is blocked,
the draft safeguard switch will shut off
the furnace. Reset the switch by pushing the button located on top of the
switch (see page 3 for switch location).
If the switch trips a second time, turn
off the furnace and call for service.
DOWNFLOW/HORIZONTAL
•
—Check the manual-reset
ONLY
auxiliary limit switch (when used)
located on the blower housing. If the
blower motor fails, this switch will shut
off the furnace. Reset it by pushing the
button on the switch. If it trips again,
turn off the furnace and call for service.
• Check the manual-reset limit
switch(es) located near the burners. If
the furnace has experienced a hightemperature condition, due to inadequate combustion air, these switches
will shut off the furnace. Reset the
switch(es) by pushing the button on the
switch. If the switch trips a second time,
turn off the furnace and call for service.
• If your furnace still fails to operate,
call your servicing dealer for troubleshooting and repairs. Tell your dealer
the model and serial numbers for your
furnace. (You should have them recorded on page 8 of this booklet.) By
knowing exactly which furnace you
have, the dealer may be able to offer
suggestions over the phone, or save
valuable time through knowledgeable
preparation for the service call.
REGULAR DEALER
MAINTENANCE
In addition to the type of routine maintenance you might be willing to do,
your furnace should be inspected regularly by a properly trained service technician. An annual inspection (or
biennial inspection, at least) should include the following:
1. Inspection of all flue product passages—including the burners, heat
exchanger, relief box, and vent
pipe.
2. Inspection of all combustion
and ventilation air passages and
openings.
3. Close check of all gas pipes leading to (and inside of) your furnace.
4. Inspection, cleaning, and lubrication (when required) of the blower
motor and wheel.
NOTE:
Refer to the unit Service Procedures for blower motor oiling information. When required, the motor
must be oiled by a qualified service
technician.
5. Routine inspection and cleaning/
replacement of the air filter.
6. Inspection of all supply- and
return-air ducts for obstructions,
air leaks, and insulation. Any
problems found should be
resolved at this time.
7. Inspection of furnace installation
for proper support and any obvious deterioration of the furnace.
The support must be sound and
without sags, gaps, cracks, etc.,
around the furnace base so as to
provide an air seal between the
support and furnace.
8. A check for loose connections
attaching individual components.
Inspection of all electrical wiring
and their connections.
9. Operational check of the furnace
itself to determine working condition. Repair or adjustment should
be made at this time.
Ask your servicing dealer for
further details about an economical
service contract that covers seasonal
inspections.
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State Zip
Telephone
FURNACE
Product No.
Model No.
Serial No.
SPLIT-SYSTEM
OUTDOOR UNIT:
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.
© 1996 BDP Co. Indpls., IN 46206 Printed in U.S.A.
8
Catalog No. PA-3348-011 1-96
Cancels OM04-18 OM04-25
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