Armstrong EG7H SERIES Installation And Maintenance Instructions Manual

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4 'GAS-FIRED HIGH Part No. 395 18H092 бае___ 8-15-92
Pc IT EFFICIENCY FURNACE
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Installation and
Maintenance Instructions
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FOR YOUR SAFETY FOR YOUR SAFETY
If you smell gas: Do not store or use gasoline
1. Open windows. or other flammable vapors
2. Don’t touch electrical switches. and liquids in the vicinity of
3. Extinguish any open flame. .
4. Immediately call your gas supplier. this or any other appliance.
ARMSTRONG
Bellevue Ohio 44811 y APPROVED A
ie
Part No. 39518H092 Date 8-15-92
395186092 Page _2 of 13
a
Supersedes
FOR U.S.A. MODELS, INSTALLATION SHALL BE MADE IN AC-
CORDANCE WITH THE REQUIREMENTS OF THE LOCAL UTILITY,
ANY OTHER AUTHORITIES HAVING JURISDICTION, OR WITH
THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE, ANSI
2223.1. FOR CANADA, INSTALLATIONS SHALL COMPLY WITH
THE LATEST EDITION OF CAN/CGA-B149.1 & .2 INSTALLATION
CODES, LOCAL PLUMBING OR WASTE WATER CODES, AND
OTHER APPLICABLE LOCAL CODES. THESE UNITS ARE NOT
CERTIFIED FOR USE IN MOBILE HOMES OR TRAVEL TRAILERS.
THESE INSTRUCTIONS MUST BE PLACED ON OR NEAR THE FUR-
NACE IN A CONSPICUOUS PLACE.
GENERAL
All models are suitable for closet or utility room installation. The fur-
nace design is certified by the American Gas Association in com-
pliance with the latest edition of American National Standard 221.47
Central Furnaces, and by the Canadian Gas Associalion in com-
pliance with the latest edition of the National Standard of Canada
CAN/CGA-2.3 Gas-Fired Gravity and Forced Air Central Furnaces,
for operation with natural gas or propane gas. Consult the rating
plate on your furnace for gas type before installing.
The maximum hourly heat loss of each heated space shall be
calculated in accordance with the procedure described in the cur-
rent manuals of Air Conditioning Contractors of America, or by any
other recognized method which is suitable for local conditions, pro-
vided the results obtained are in substantial agreement with, and
not less than, those obtained using the procedure described in the
manuals. If the furnace is used in conjunction with a cooling unit,
the furnace must be installed in parallel with, or on the upstream
side of the evaporator coil to avoid condensation on the heating ele-
ment. In a parallel installation, dampers or other means must be
provided to prevent chilled air from entering the furnace. If the air
control is manually operated, an interlock must be provided to pre-
vent operation of either unit unless the dampers are in full heat or
full cool position.
UNPACKING
FURNACE 1$ SHIPPED IN ONE PACKAGE COMPLETELY ASSEM-
BLED AND WIRED EXCEPT FOR THE DRAIN TRAP ASSEMBLY. See
Figure 3 for installation. The thermostat is shipped in a separate
carton when ordered. If any damage is found at time of delivery,
proper notation should be made on the carrier's freight bill. Damage
claims should be filed with the carrier at once. Claims of shortages
should be filed with the seller within five (5) days.
Check the rating plate. Make sure correct model has been received.
LOCATION
To provide proper operation and satisfactory performance, care
must be taken in choosing the location for this furnace. The at-
if
mosphere in which the furnace operates must be free of con-
taminants such as chlorides and sulfates.
The furnace shall be installed so the electrical components are pro-
tected from water.
The furnace should be well centralized with respect to the duct
distribution system and set on a firm, level foundation.
A gas-fired furnace for installation in a residential garage must be
installed so that the burner(s) and the ignition source are located
not less than 18 inches above the floor and that the furnace is
located or protected to avoid physical damage by vehicles. CARE
MUST ALSO BE GIVEN IN CHOOSING A LOCATION SO THAT CON-
DENSATE TRAP AND DRAIN LINE DO NOT FREEZE.
All normal servicing of the furnace can be performed from the front.
If installed in a closet or utility room provide 27 inches clearance in
front for service if the door to the room is not in line with the front of
the furnace. The opening to the room must be wide enough to allow
the furnace to enter and to permit the replacement of any other ap-
pliance in the room.
The furnace may be installed in a closet provided the following
minimum clearances to combustible materials are maintained. The
furnace is not to be installed directly on carpeting, tile or other com-
bustible material other than a wooden floor. Clearance for the
cabinet are as follows: Sides - O inches; Rear - O inches; Front - 4
inches; Flue Pipe - 0 inches; Plenum Top - 1 inch.
The counterflow furnace is certified for installation on combustible
flooring provided a special base assembly is used. The part number
for the special base is noted on the rating plate, located in the
burner compartment. Check the part number on the base to make
sure the proper base is available.
When counterflow unit is installed on a combustible floor, one (1)
inch clearance must be provided between supply duct and floor.
ACCESSIBILITY CLEARANCES MUST TAKE PRECEDENCE OVER
FIRE PROTECTION CLEARANCES. PROVIDE SUFFICIENT
CLEARANCE FOR CONDENSATE DRAIN TRAP.
CAUTION: DO NOT STORE COMBUSTIBLE MATERIALS NEAR FUR-
NACE OR WARM AIR DUCTS. THE MATERIAL MAY IGNITE BY
SPONTANEDUS COMBUSTION CREATING A FIRE HAZARD.
OUTLET DUCT
For Canadian units the outlet duct must provide a removable access
panel. The opening should be accessible when the furnace is installed
in service. Smoke or reflected light may be observed inside the casing
to indicate the presence of leaks in the heat exchanger. The cover for
the opening shall be attached in such a manner as to prevent leaks.
The recommended opening size is 6” x 14” for all sizes.
DUCT CONNECTION—COUNTERFLOW MODELS
If a unit is installed on a non-combustible floor, unit may be installed
directly over supply duct or plenum.
If installation is made on a combustible floor, the special base
assembly must be used. Cut hole on floor two (2) inches larger in
each direction than duct size.
Part No. 39518H092 Date 8-15-92
Supersedes 395186092 Page 3 of 13
The four angles on the base assembly should recess into floor open-
ings and base should rest on all four outside flanges. Construct duct
connections with 1% inch - 2 inch right angle flanges and long
enough to extend below floor joists. Drop duct connections through
top of base assembly with right angle flanges in good contact with
glass lape on top of base assembly. Carefully position furnace over
right angle duct flanges. See View A.
A return air duct system is recommended. If the unit is installed in a
confined space or closet, a return connection must be run, full size,
to a location outside the closet. The air duct in the closet must be tight
‚to prevent any entrance of air from the closet into the circulating air.
Furnace
ase À
Base Assembly a >
Woven Glass Tape —-j—
? 7 Uuct Connection
|
Pi; | VIEW A
Combustible Flooring — Зи |
COMBUSTION AIR & VENTILATION
WARNING: Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. When considering
combustion air requirements, enough air must also be
provided to meet the need of all fuel-burning appliances
and exhaust fans.
UNCONFINED SPACE
Ап unconlined space is defined as ''a space whose volume 15 more
than 50 cubic feet per 1,000 BTU per hour of the combined input
rating of all appliances installed in that space.”
In a furnace installed in a ventilated attic or craw! space, it is
assumed that infiltration is sufficient to supply the required air.
However, in a building of unusually tight construction, additional
ouldoor air should be provided.
CONFINED SPACE
A confined space is defined as ''a space whose volume is less than
90 cubic feet per 1,000 BTU per hour of the combined input rating
of all appliances installed in that space.”
Adequate provisions for combustion air, ventilation of furnace and
dilution of the gases must be made. See Section 5.3, Air for Com-
‚ bustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1
latest edition, Canadian Standards CAN/CGA-B149.1 & .2 or ap-
plicable provisions of the local building code. When a furnace is in- -
stalled in an unconfined space in a building, it can be assumed that
filtration will be sufficient to supply the required air. If the furnace is
installed in a confined space within the building and combustion air
is taken from the heated space, the combustion air and ventilating
air must enter and leave the space through two (2) permanent open-
ings of equal area. One (1) opening shall be located within twelve
(12) inches of the ceiling and the other within twelve (12) inches of
the floor, each having a free area on one (1) square inch per 1,000
BTU/HR of total input rating of all appliances within the space and
not less than 100 square inches each. If the furnace is installed in a
space within a building of tight construction, make-up air must be
supplied from outdoors. In this case one (1) opening shall be within
twelve (12) inches of the ceiling and one (1) opening within twelve
(12) inches of the floor. Each opening shall have a free area of one
(1) square inch per 4,000 BTU/HR if combustion air ducts are ver-
tical. If horizontal combustion air ducts are run, one (1) Square inch
per 2,000 BTH/HR of the total input rating of all appliances within
the enclosure is required.
WARNING—COMBUSTION AIR OPENING MUST BE KEPT FREE OF
OBSTRUCTIONS. ANY OBSTRUCTION MAY CAUSE IMPROPER
BURNER OPERATION AND MAY RESULT IN A FIRE HAZARD OR
PERSONAL INJURY.
CONTAMINATED COMBUSTION AIR
The recommended source of combustion air is to use outdoor air.
However, the use of indoor air in most applications is acceptable if
these guidelines are followed:
1. li the furnace is installed in a confined space, the necessary
combustion air must come from the outdoors by way of attic,
crawl space, air duct, or direct opening.
2. If indoor combustion air option is used, there must be no ex-
posure to the installations or substances listed below.
3. All provisions for indoor combustion air must meet the re-
quirements for combustion air supply indicated in the National
Fuel Gas Code, 2223.1 latest edition, Section 5.3, and/or any
applicable local codes. In Canada, follow the current edition of the
B149.1 or .2, Installation code for combustion air requirements.
4. The following types of installation will require OUTDOOR AIR
tor combustion, due to chemical exposures:
° Commercial buildings
° Buildings with indoor pools
2 Furnaces installed in laundry rooms
° Furnaces installed in hobby or cralt rooms.
° Furnaces installed near chemical storage areas.
Exposure to the following substances in the combustion air supply
will also require OUTDOOR AIR for combustion:
° Permanent wave solutions
° Chlorinated waxes and cleaners
° Chlorine based swimming pool chemicals
° Water softening chemicals
° De-icing salts or chemicals _
2 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
o © 0 0 0
Part No. 39518H092 Date 8-15-92
Supersedes 39518G092 * Page 4 of 13 _
RETURN AIR AND FILTER RACK UPFLOW (See Figure 1)
Where the furnace is installed in a confined space and there is not a
complete return duct system, a return duct must be run to an un-
confined area. The air duct must be tight to prevent any entrance of
air from the confined space into the circulating air stream.
For upflow furnaces return air connection can be made on either
side or the bottom of the furnace. A filter and an external filter rack
are provided for side return (see instructions below for installation).
If bottom return is used, a filter and rack of the proper size should
be provided. Models with higher CFM requiring filter areas over 400
square inches, may be installed with return air connections on both
sides, or an external filter rack, with a required filter area, must be
used. Refer to product specifications. A side return air cabinet is
also available, the use of which can improve the appearance of the
installation.
INSTALLATION EXTERNAL SIDE FILTER RACK
This furnace comes equipped with a filter rack or racks which are
located in the blower compartment. To install filter assemblies, the
following steps must be taken:
1. Cut a 14 inches high by 22 inches wide opening in side or sides
of cabinet, using the lanced corners as locating points.
2. Loosen the four (4) screws at the base of the side panel.
3. Slide the outer flange of filter frame into base and rear panel
flange.
4. Add two (2) #8 x 2 sheet metal screws to top flange of rack in-
to engagement holes found in side panels. Tighten screws al
base. |
SIDE RETUAN
UPFLOW FURNAGE SINE
PANEL
A/A DUET
FILTER RACK ZT ANGLE: 2 REQUIRED
—— FILTER SLIDES IN FROM FILTER
FRONT OF UNIT
AOTTOM AE TIAN UFFLOW FURMAGE
ane
A
le A
Corner Lances _
Ara Panel
Plana. —
-“_, Filter
Rack
LL — =
Fase PMange -
UFFLOW FURNAGE
FIGURE 1
NOTE: A bottom return filter kit is available from the manufacturer.
FILTER - COUNTERFLOW
The filter can be installed either on the left or right side of the unit
depending on which side the return air duct is installed.
To install the filters, remove the two (2) upper blower compartment
panels and install the filter as shown in Figure 2 if the return air
duct is installed coming off the return air plenum on the right side.
If the return duct is installed on the left side. remove the two (2)
screws holding the side filter rack and install the side filter rack on
the left side of the furnace in holes provided in the unit. Install filter
opposite than what is shown in Figure 2.
Return air
plenum
|
Return |
air duel .
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FILTER
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< ———— Side filter rack
COUNTERFLOW FURNACE
FIGURE 2
VENTING
General
The high efficiency of this furnace is accomplished by the removal of
both sensible and latent heat from the combustion flue gases. The
removal of the latent heat results in the condensation of moisture
from the flue gases. This condensation occurs in the secondary heat
exchanger and also in the vent system; therefore the following
special considerations and instructions must be followed to assure
“the proper venting of this furnace and other appliances. All venting
must be in accordance with codes having jurisdiction and these in-
Stallation instructions.
This is a Category IV Furnace (USA)
The furnace shall not be connected to any type B, BW, or L vent or
vent connector and shall not be connected to any portion of a factory
built or masonry chimney.
Do not use more than five (5) 90° elbows, DWV/PVC (Poly-Vinyl-
Chloride), excluding vent termination. Two (2) 45° elbows are equal
to one (1) 90° elbow. |
Do not vent this appliance into a masonry chimney or any other type
of vent passage not designed or intended for use with condensating
appliances.
Part No. 39918H092 Date 8-15-92
Supersedes 395186092 Page _9 of _13
Do not connect the flue system of this appliance to a common vent
with any other appliance.
When replacing a furnace which has been connected to a common
vent with other appliances the remaining vent system and ap-
pliances should be inspected and evaluated for proper operation.
When an existing furnace is removed from a venting system serving
other appliances, the venting system is likely to be too large to pro-
perly vent the remaining attached appliances.
The following steps shall be followed with each appliance remaining
connected to the common venting system placed in operation, while
the other appliances remaining connected to the common venting
system are not in operation.
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and horizon-
tal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies which could cause an
unsafe condition.
Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryer and any appliance
not connected to the common venting system. Turn on any ex-
haust fans, such as range hoods and bathroom exhausts, so
they will operate at a maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
Follow the lighting instructions. Place the appliance being in-
spected in operation. Adjust thermostat so appliance will
operate continuously.
(e) Test for spillage at the draft hood relief opening after 5 minutes
of main burner operation. Use the flame of a match or candle.
(f) After it has been determined that each appliance remaining con-
nected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning appliance to their
‘previous conditions of use.
(9) If improper venting is observed during any of the above tests,
the common venting system must be corrected.
See National Fuel Gas Code ANSI 7223.1 latest edition, Cana-
dian Standards CAN/CGA-B149.1 & .2 latest edition, to correct
improper operation of common venting system.
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Vent Materials
Five (5) items are supplied with this furnace.
1. А neoprene connecting clamp for connecting the vent system to
the combustion blower assembly.
2. A trap assembly to collect the condensate from the heat ex-
changer and vent system.
3. А two (2) inch vent tee is provided to be connected to the drain
trap assembly.
4. A screen is provided to be inserted inside the termination elbow.
9. Ahose clamp to be used on the end of the condensate drain tube
where it connects to the trap assembly.
In addition to Ihe above listed items, on the 100,000 BTUH model a
3 to 2 inch reducing coupling is furnished to be located on top of the
drain trap tee for a 3 inch vent line.
All other venting materials, pipe and fittings, for this furnace are to
be two (2) inch or three (3) inch PVC (Poly-Vinyl Chloride) or CPVC
(Chlorinated Poly-Vinyl Chloride) schedule 40 minimum. NOTE: IN-
STALLATION OF 100,000 BTU FURNACE MUST BE DONE WITH
THREE (3) INCH VENT PIPE OF THE SAME RATING. Elbows used to
connect vertical runs to horizontal runs should be the type
DWV/PVC (Poly-Viny! Chloride) to provide the correct slope for
horizontal runs. Horizontal runs should not be allowed to sag as
water may collect in low spots and cause blocked flue switch to
open. In areas where flue pipe may be subject to abnormal stress or
damage, schedule 80 PVC pipe should be used or protection must
be provided for the flue pipe. .
All joints are to be sealed using a PVC sealer-primer and a Solvent
cement such as Genova 15015 or equivalent. Follow all instructions
and recommendations of the cleaner-primer and solvent cement
manufacturer when making joints.
All pipe, fittings, primers, solvent cement and procedures must
conform to the following ANSI-ASTM standards.
PVC pipe and fittings shall be manufactured from compounds hav-
ing a minimum cell classification of 12454B or 12454C as defined
by ASTM Standard D1784, Rigid Poly (Vinyl Chloride) (PVC) Com-
pounds and Chlorinated Poly (Vinyl Chloride) (CPVC) compounds;
or CPVC pipe and fittings shall be manufactured from compounds
having a minimum cell classification of 23447A or 23447B as defin-
ed by ASTM Standard D1784.
Vent termination for horizontal venting through side wall must be a
two (2) or three (3) inch PVC elbow oriented with opening to the bot-
tom. USE THREE (3) INCH ELBOW FOR THE 100,000 BTU FUR-
NACE. The opening in the vent termination should be protected with
2 inch mesh screen. See Figure 5 for further description.
VENT LENGTH
This appliance is certified for use with a maximum of 25 feet of
horizontal vent length with 5 elbows (for a total equivalent length of
90 feet) not including the vent terminator. The minimum length cer-
tified is 3 feet and one elbow. Elbows are equivalent to 5 feet of
Straight length vent pipe. Thus, 5 feet of vent pipe can be added or
removed for each elbow deleted or added to fabricate the total max-
imum allowable 50 foot length:
Examples: 30 feet of pipe and
4 elbows:
20 feet of pipe and
6 elbows.
Part No. 39518H092 Date____8-15-92
Supersedes Page 6 of _13
39518G092
Vent Termination Location
Vertical vents should extend through the roof a minimum of two (2)
feet and should not be obstructed for a minimum of ten (10) feet in
any direction.
The horizontal vent system shall terminate at least 4 feet below, 4
feet horizontally from, or 1 foot above any door, window, or gravity
air inlet into the building. The vent system shall terminate at least 3
feet above any forced air inlet located within 10 feet. The bottom of
the vent terminal shall be located at least 12 inches above grade,
minimum of 12 inches above normal snow level.
Minimum horizontal clearance of 4 feet (6 feet in Canada) from elec-
tric meters, regulators, and relief equipment or within six (6) feet of
any gas service regulator vent outlet except that with the approval of
the authority having jurisdiction.
In addition to the above requirements, consideration must be given
to prevent unwanted ice buildup from the vent condensate. The vent
should not be located on the side of a building where the prevailing
winter winds could trap the moisture causing it to freeze on the
walls or on overhangs (under eaves). The vent location should not
discharge over a sidewalk, patio or other walkway, where the con-
densate could cause surface to become slippery.
installation
Connect the vent system and drain trap assembly to the outlet of the
combustion air blower using the supplied neoprene connecting
clamp and a supplied two (2) inch tee. The trap assembly must be
readily accessible for cleaning and in the same confined space with
the furnace. For additional clearance to cold air return or other
obstacles a two (2) inch street elbow may be used to move drain
assembly toward the front of the unit. See Figure 3.
Route the condensate drain tubing in a manner so that the tubing
won t kink.
Flue Gases
lo Outdoors FIGURE 3
2" or 3 Inch Round pvc | Induced Draft Neoprene Г
oe nn Burn Connection Flue Gases
Pipe Sire. 3 Clamp 16 Delano
{Nol Furnished) = S
= : . 2* or 3° Inch Round
2 Inch 24H r (Q || РУС Schedule
std РУС Mato | pea 40 Slandard
; ; 1 CT Pipe Size
Pipe Tee. ra vs *
щи! h
Sch. 40 = | 2% Inch Ls (Nol Furnished)
| РУС Nipple A Overtiow
hi 2” Inch .
Overtlow м 574. РУС
Pi 5
L Trap Assembly 4 sch.
(Furnished) A
e Trap Assembly
| Y Clear Plastic (Furnished)
Drain Line From Unit ~
STANDARD CONSTRUCTION
ALTERNATE CONSTRUCTION
The vent system must be supported with mounting straps to prevent
any weight load from being applied to the vent blower. Horizontal
vent pipe must be supported every five (5) feet and vertical pipe
should be supported every ten (10) feet to prevent sagging and pro-
vide rigid support.
For vertical runs through confined space where flue pipe cannot be
inspected, it is recommended the flue pipe be installed in four (4)
inch diameter chase with proper fire stops to prevent damage to flue
pipe. Use five (5) inch diameter chase when three (3) inch PVC pipe
is used. >
Refer to Figure 4 and 5 for recommended venting installations.
The evaporator drain must not be connected to the overflow opening
of the tee on the furnace drain trap assembly. If this were done and
the drain line downstream of this fitting became blocked, the fur-
nace heat exchanger could fill with water draining from the
evaporator coil.
THE OVERFLOW MUST BE LEFT OPEN
FIGURE 4
10°
Fret
Minimum
IT 4
2° Fi. Minimum
oa en
sain 2 or I’ Inch РУС
Storm Collar
——— Flashing
= fire Stop
dG Fire Stop
| J Recommend Use a 4° Diameter Chase
with @ Pipe or 5° Chase with
3° Pipe. 016 Wall Galvanized
or Aluminum Seal Joints with G Е
RTV-106 or Equivalent
30° Feel Maximum ce
Vertical Rise ie
4 г À. Fire Stop at Each Floor 022 Minimum
Galvanized Steel or Aluminum
For Venting Material See Material
Section of this Instruction
Use no more than five (5) 90°
long Sweep elbows nol including veal termination
CAUTION: THE VENT SYSTEM OF THIS FURNACE
MUST BE SELF SUPPORTING AND NOT
APPLY ANY WEIGHT LOAD TO THE COMBUSTION BLOWER.
Form Loop In Drain Hose to Make Trap,
hen Fill Trap wilh Water.
Part No. 39518H092 Date 8-15-92
Page _7 of 13
Supersedes 395186092 Е
т e FIGURE 5
IN
aL
Prolect Terminal Openings
With Inch Mesh Screen
\ inch Long Section Pipe
HORIZONTAL VENT TERMINAL
м
25 Feel Maximum Horizontal Vent Terminal
Run Pitch % Inch Per Foot
Minimum
For Vent Material See
Material Section Ol
This Instruction
\
Height To Provide
I?" laches Clearance
To Maximum Snow Level
|
CAUTION: THE VENT SYSTEM OF
THIS FURNACE MUST BE SELF SUPPORTING
AND HOT APPLY ANY WEIGHT LOAD TO THE
COMBUSTION BLOWER.
Use no more than five (5) 90°
long sweep elbows nol including vent termination,
Form Loop in Drain Hose to Make Trap.
hen Fill Trap with Water.
UTILITY CONNECTIONS
Electrical
ALL WIRING SHOULD BE DONE IN ACCORDANCE WITH THE
LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, AN-
SI/NFPA, NO. 70 IN CANADA: CSA C22.1 CANADIAN ELECTRICAL
CODE, PART I, OR WITH LOCAL CODES, WHERE THEY PREVAIL.
Using wiring with a temperature limitation for type T wire (63°F),
(36°C) rise; run the 115 volt, 60 hertz electric power supply
through a fused disconnect switch to the junction box of furnace
and connect as shown in the wiring diagram, located on the inside
of the control-access panel.
Install thermostat according to directions furnished with it. Select a
location away from drafts and direct sunshine, Set heat anticipator
to amperage draw of complete system, as measured or as shown on
wiring diagram.
Furnace must be electrically grounded in accordance with local
codes or in the absence of local codes, with the latest edition of the
National Electric Code, ANSI/NFPA-70 or CSA C22.1, Canadian
Electrical Code, Part |.
Gas
Piping must be tight and non-hardening pipe compound resistant to
propane gas must be used.
Gas line to the furnace must be of adequate size to prevent undue
pressure drop.
Consult the local utility for complete details on special requirement
in sizing gas piping.
Connect the gas pipe to the furnace control valve providing a ground
joint union as close to the controls as is possible to facilitate removal
of controls and manifold. Provide a drip leg on the outside of the fur-
nace.
Manual shutolf valve with N_P_T. plugged lapping
accessible for test gauge connection.
Union
N Union —,
Toa Ni dd TK,
ой Tea —_
Drip Leg Late Extand Drip ue)
Lag lo Floor >
Сар — ] Cap AL
UPFLOW FURNACE COUNTERFLOW FURNACE
FIGURE 6
GAS SUPPLY PIPING (TESTING)
A manual shut-off valve with a 1/8° N.P.T. plugged tap accessible
for test-gauge connections shall be installed in the gas line, outside
the unit, five (5) feet above the floor, or in accordance with any local
codes.
The pilot is factory connected and requires no additional piping. A
pilot gum filter may be installed in the pilot supply line if required by
the local utility company.
=
WARNING— NEVER USE AN OPEN FLAME TO CHECK FOR
GAS LEAKS. IF THERE IS A GAS LEAK, EXPLOSION OR IN-
JURY CAN RESULT.
LEAK CHECK
After gas piping is completed, carefully check all piping connections
(factory and field) for gas leaks. Use a leak detecting solution or
other preferred means.
CAUTION - Some soaps used for leak detection are corrosive to cer-
tain metals. Carefully rinse piping thoroughly after leak detection
has been completed. Do not use matches, candles, flame or other
sources of ignition to check for gas leaks.
Part No. 39518H092 Dale 8-15-92
395186092 _ Page 8 ot 13
supersedes
The furnace must be isolated from the gas-supply piping system by
closing individual manual shutoff valve during any pressure testing
of gas-supply piping system at test pressure equal to or less than ‘2
PSIG or 14” W.C. CAUTION: IF THE PIPING SYSTEM IS TO BE
TESTED AT PRESSURES IN EXCESS OF ‘2 PSIG, THE FURNACE
AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE DISCONNECTED
FROM THE GAS-SUPPLY PIPING SYSTEM. THE GAS VALVE SUP-
PLIED WITH THIS FURNACE IS RATED АТ ‘2 PSIG MAXIMUM. ANY
HIGHER PRESSURE MAY RUPTURE THE PRESSURE-REGULATOR
DIAPHRAGM AND WILL CAUSE OVER-FIRING OF THE BURNERS
AND IMPROPER BURNER OPERATION. THE OVER-FIRING MAY
RESULT IN CREATION OF CARBON MONOXIDE WHICH MAY
RESULT IN ASPHYXIATION.
FURNACE CHECK-OUT
Before leaving, the installer should make the following checks to en-
sure that the controls are functioning properly.
Gas Supply Pressure
The gas pressure measured al manual shutoff valve (Reference
Figure 6), installed external to the unit, must fall within the follow-
ing standards.
MINIMUM NOMINAL MAXIMUM
Natural Gas 5 7 9
Propane Gas 11 12 14
This check should be performed both with no gas appliance
operating and with all gas appliances operating. Large variations
between these two checks can be caused by improper supply piping
or a defective regulator.
Gas Regulator
Gas input must never exceed the input capacity shown on the rating
plate. The furnace is equipped for rated inputs with manifold
pressure as follows:
NATURAL GAS 3.5” W.C.
PROPANE GAS 10” W.C.
The manifold pressure can be measured by removing the piping
plug in the downstream side of the gas valve and connecting a water
manometer or gauge.
Turn gas valve ON. To adjust the regulator, turn the adjusting screw
on the regulator clockwise to increase pressure and input,
counterclockwise to decrease pressure and input.
Only small variations in gas input may be made by adjusting the
regulator. In no case should the final manifold pressure vary more
than 0.3” W.C. from the above specified pressures.
Check furnace rate by observing gas meter, making sure all other
gas appliances are turned off. The test hand on the meter should be
timed for at least one revolution. Note the number of seconds for one
revolution.
=
a
BTU/HR. INPUT EQUALS -
Cubic feet per revolution
No. seconds per revolution
x 3600 x Heating Value
The heating value of your gas can be obtained from your local utility company.
HIGH ALTITUDE
For U.S.A. Installations Only:
Ratings shown on the rating plate are for elevations up to 2,000
feet. For elevations above 2,000 feet, ratings should be reduced at a
rate of four (4) percent for each 1,000 feet above sea level. See Na-
tional Fuel Gas Code 2223.1 (latest edition).
FOR CANADIAN INSTALLATIONS: For elevations from 2000 - 4500
feet above sea level a 10% drop in rate is required from that shown
for 0 -2000 feet.
High altitude conversions may be made by the manufacturer's
authorized representative, in accordance with the requirement of the
manufacturer, provincial or territorial authorities having jurisdiction
and in accordance with the requirements of the CAN/CGA-B149.1 or
6149.2 Installation Code. A high altitude conversion kit available {rom
the manufacturer, approved for this purpose must be used.
For Your Safety
Read Before Operating
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EX-
ACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PRO-
PERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
A. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by hand.
B. BEFORE OPERATING smell all around the appliance area for gas.
Be sure to smell next to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
e Do not try to light any appliance.
e Do not touch any electric switch; do not use any phone in your
building.
e Immediately call your gas Supplier from a neighbor's phone.
Follow the gas supplier's instructions.
e If you cannot reach your gas supplier, call the fire depart-
ment.
C. Use only your hand to turn the gas control knob. Never use
tools. If the knob will not turn by hand, don't try to force or
repair it, call a qualified service technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this applicance if any part has been under water. Im-
mediately call a qualified service technician to inspect the ap-
pliance and to replace any part of the control system and any gas
control which has been under water.
Part No. 39518H092
Supersedes 395186092
Operating Instructions
1. STOP! Read safety information above.
2. set Ihe thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4
. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by
hand.
HONEYWELL VR-8200 SERIES
GAS
INLET
9. Remove control access panel.
6. Turn the gas control knob clockwise( to ‘‘OFF"’.
7. Wait five (5) minutes to clear out any gas. Then smell for gas, in-
cluding near the floor. If you smell gas, STOP! Follow **B” in the
Safely information above. If you don't smell gas, go to next step.
8. Turn gas control knob counterclockwise ©) to **ON"’.
9.. Replace control access panel.
. Turn on all electric power to the appliance.
. Set thermostat to desired setting.
. | the appliance will not operate, follow the instructions ''То
Turn Off Gas To Appliance'” and call your service technician or
gas Supplier.
18 Turn Off Gas To Appliance
. set the thermostat to lowest setting.
-2. Turn off all electric power to the appliance if service is to be per-
formed.
3. Remove control access panel.
4. Turn the gas control knob clockwise Cy to ‘‘OFF''. Do not
force.
9. Replace control access panel.
CAUTION: If at any time ignition is slow and burner does not seem
to be operating correctly, check manifold pressure. It should be
10.0” to 10.5” W.C. PRESSURE FOR LPG/PROPANE.
The furnace is designed to obtain rated input at 10.0” W.C.
To check this pressure:
1. Turn off gas valve.
2. Remove plug on valve marked ''OUTLET PRESSURE"’
3. Install water manometer.
Turn gas valve ''ON'' If manifold pressure must be adjusted remove
cap from pressure regulator and turn adjustment screw clockwise to
increase pressure, counterclockwise to reduce pressure. After
checking pressure, turn gas off, remove manometer fitting and
replace pipe plug and regulator cap. Put furnace in operation and
leak check plug for leaks using soapy solution.
BURNER AND PILOT:
See Figure 7 and 8 For Visual View
Manifold Main Burner
Le -
— A ai
= —_ en
E =
Se er Se
Y
geen
— =
FIGURE 7
B - Upper Flame
Darker Blue with
А - Lower Mantel
Light Blue in Color
Nat. Gas 34” High no Yellow Tippings
Light Blue in Color Darker Blue with
Propane Gas Ye” High Slight Yellow Tipping
Pilot Burner
Pilot
FOR NATURAL GAS
Before making burner adjustments, permit furnace to burn 5-10
minutes. The air shutters are factory set with 1/2 inch opening ,
however, if yellow tipping occurs, loosen the air shutter locking
screws and push shutter forward until yellow disappears. Tighten
locking screws.
FOR PROPANE GAS
Before making burner adjustments, permit furnace to burn 5-10
minutes. Loosen air shutter locking screw. Close air shutter until
you have a distinct yellow flame then push air shutter forward until
flame has approximately 1/8 inch yellow tip. Tighten locking screw.
Part No. 39518H092 Date 8-15-92
Supersedes 395186092 Page _10 of _13_
TEMPERATURE RISE
Check temperature rise and, if necessary, adjust blower speed to
maintain temperature rise within the range shown on the unit rating
plate.
BLOWER SPEEDS
All blower motors are permanently lubricated.
To change blower speeds, use the following procedure:
1-Turn off electrical power to unit.
2-Refer to the wiring diagram and connect the desired speed tap for
cooling and heating on the blower control board. Remaining speed
laps must be connected to dummy terminals. (M1, M2). If you
must use the same speed tap for both heating and cooling, install
a piggyback terminal on the speed tap using a short jumper wire
with 1/4” quick connect terminals on both ends to jumper the
HEAT and COOL speed on the blower control board.
Direct-drive blowers contain motors which do not require oiling.
To remove blower for servicing or replacement, disconnect electrical
power. Remove blower door. Blower is fastened to blower division
panel. Remove these screws and lift out blower assembly
(counterflows) or slide out (upflows). When removing blower
assembly, the electrical leads must be disconnected at the control
board or the motor terminal block.
LIMIT CONTROL
Limit control - Factory Set: No adjustment necessary.
FAN CONTROL
The fan on time of 30 seconds is not adjustable. Fan off time (time
that blower operates after the heat demand has been satisfied) can
be adjusted by one of two methods depending on the blower control
board manufacturer. Change the direction of either [A] screw ог [В]
screw to give the desired timing as shown below or move the delay
off jumper to the desired timing. The unit is shipped with factory fan
off setting of 120 seconds. Fan off time will affect comfort and is ad-
justable to satisfy individual application.
ION
60 SEC 90 SEC 120 SEC 150 SEC
BLOWER DELAY OFF JUMPER SETTING
HEATCRAF T
iy ly A
60 SEC 90 SEC 120 SEC 150 SEC
BLOWER DELAY OFF SCREW SETTINGS
HONEYWELL
Interlock (Blower Door) Switch
When blower door is removed, the interlock switch breaks the
power supply to burner controls and blower motor.
Roll-Out Switch
This furnace is equipped with a manual reset roll-out switch for the
purpose of preventing furnace operation with a blocked heat ex-
changer, or under other abnormal conditions that would cause
burner flames to burn outside the combustion chamber. To manual-
ly reset this switch, push and release the button on top. If the fur-
nace does not operate, or if this switch must repeatedly be reset,
call a Service Technician.
MAINTENANCE
It is recommended that this furnace be inspected by a qualified Ser-
vice Technician at the beginning of each heating season.
Disconnect electrical power to the unit before doing any service.
Turn off main gas valve before breaking gas connections.
Furnace Start-Up and Check-Out Procedure
After maintenance has been performed or the heat exchanger clean-
ed and re-assembled, the following checks should be performed.
FILL TRAP WITH WATER, turn unit on, check the contro! operating
pressure and flame appearance when main blower is cycled on and
off. Any fluctuation in this pressure or variation in flame appearance
are an indication of air leakage between the circulating air compart-
ment and heat exchangers. The source of the leakage must be
found and repaired. Control operating pressure is measured at the
pressure tap directly above the coil drain connection. Install a tee to
allow the pressure switches to remain connected. Normal pressure
is negative 1.40 to negative 1.60 inch water column. The normally
open pressure switch will remain open if pressure is excessively low
(excessive leakage or blocked flue). If pressure is excessively high
(restricted coil or plugged coil drain) flame roll-out will occur and
roll-out switch will open.
Filter
The air filter should be cleaned at least every three (3) months.
More frequent service is required if unusually dirty conditions are
encountered.
This unit is supplied with a permanent filter. To clean this filter,
shake filter to remove excess dirt, use vacuum cleaner or wash in
soapy or detergent water and replace after filter is dry. Filter should
not be oiled after washing.
If electronic air cleaner or other filter media has been installed,
clean per the manufacturers instructions.
Part No. 39518H092 Date 8-15-92
Supersedes 395186092 Page 11 of 13
Blower TO CLEAN
Installation is to be adjusted to obtain a temperature rise within the
range specified on the appliance rating plate.
The direct drive blower in this unit will provide an air temperature
rise at a static pressure as noted on the rating plate. If a duct
system with less resistance is used, a lower air temperature will
result. To increase the air temperature rise, add restriction to the
return air system. The direct drive motors have permanently
lubricated bearings and therefore do not require oiling. On the
upflow furnace, the blower can be removed for servicing by remov-
ing screws under burners in the blower partition panel. The blower
will slide out on side supporting rails.
Main Burners (See Figure 7 for visual view)
Distorted flame, yellow tipping of the natural gas main burner flame
or more than 1/8 inch high yellow tips on propane gas may be caused
by lint accumulation or dirt inside burner or burner ports, lint at air
inlet between air shutter and manifold pipe or obstruction over main
burner orifice. Use soft brush or vacuum to clean allected areas. If
it is necessary lo remove burners:
1. Turn off gas supply and electrical supplies to furnace.
2. Remove pilot assembly, disconnecting sensor lead and ignition
lead from ignition control.
3. Remove burner support angles (2).
4. Push burner assembly forward, off of orifice spuds and then
remove burner assembly.
Reassemble, reverse above procedure.
an
Primary Heat Exchanger—Cleaning
To clean flue passages, proceed as follows:
1. Turn off gas supply and electricity. Remove screws fastening
flue plate and flue plate gasket. If flue plate has holes in any sur-
face or flue plate gasket is damaged, replace with new flue plate
and gasket when unit is reassembled.
2. Remove the screws securing the burner shield located above
burners.
3. Remove four (4) screws that secure manifold assembly to the in-
ner front panel. Break union in gas piping and remove burners
and manifold assembly as unit.
4. Clean flue passages with wire brush and vacuum cleaner.
3. After cleaning, inspect heat exchanger for deterioration. If any
holes or cracks are observed in any surface of heat exchanger,
replace with new heat exchanger.
Inspect burners and clean, if required.
Reassemble parts removed in reverse order.
Turn on gas. Check for leaks. Turn on electrical supply.
Check unit for normal operation per Furnace Start-Up and
Check-Out Procedure.
= = io
Secondary Heat Exchanger (Exterior)
Remove rear panel to clean bottom of fins.
|| rear panel cannot be readily removed, remove blower assembly
for accessibility to coil (applies to upflow only).
Clean fins with suitable brush or vacuum cleaner attachment. If any
fins are damaged, use a fin comb to straighten.
Secondary Heat Exchanger Internal Cleaning and Removal
1. Remove top front collector plate cover.
2. Inspect inside of upper collector box and tube inlets for soot
and/or dirt accumulation.
3. If cleaning is needed, fashion a.1/4 inch or 3/8 inch tube ex-
tension with a 90° curved end. Adapt other end for connection
to a garden hose or garden sprayer.
4. Insert curved end of adapter tube, center over each tube and
flush with water. Remove bottom cap from trap assembly and
place a suitable container under the trap to collect water flush-
ed through cells.
If further cleaning is required, the secondary heat exchanger sur-
face must be removed from the furnace, proceed as follows:
5. Remove rear panel.
6. Remove the combustion air blower assembly, drain tubing and
connecting tubing for pressure switches.
7. Remove four (4) nuts that secure top coil box to primary heat
exchanger collector box and the screw in the embossed hole
above flue outlet in the inner-front panel.
8. Remove four (4) screws from left side panel that secure lower
section of secondary heat exchanger to this panel.
9. Remove secondary heat exchanger out the rear of the unit.
. Remove screws that secure top box to coil.
11. Remove turbulators from each tube and any contaminants from
the turbulators.
12. Use a small diameter bottle brush to clean the inside of each
tube. |
13. Rinse each tube with clear water.
14. If bottom coil box drain becomes blocked, remove screws that
secure box to bottom coil. Glean pan and replace. To assure
gas tight seal, add a 1/4 diameter bead of GE RTV106 sealant
around flange of pan before assembly to coil.
15. Install turbulators in each tube.
16. Apply 1/4 diameter bead of GE RTV106 high temperature
sealant around top flange of coil plate. Add top coil box and
secure box to coil plale.
17. If silicone gasket on front of top coil box is damaged, add a new
gasket or apply a ring of 1/4 diameter bead of RTV106 before
attaching coil box to heat exchanger collector box, using four
(4) nuts previously removed.
Supersedes 39518G092 Page 12 of 18
18. Install combustion air blower, tubing and collector cover and
reassemble furnace.
19. Check unit for normal unit operation per Furnace Start-Up and
Check-Out Procedures.
Removal of Primary Heat Exchanger
should it be necessary to remove primary heal exchanger proceed
as follows:
+ 1. Remove secondary heat exchanger as described above.
2. Remove manifold and burners as described under cleaning
Durners.
3. Remove screws that secure inner front panel to heat exchanger
and slide oul heat exchanger carefully to avoid damage to in-
Sulation.
Before replacing heat exchanger, repair any damaged insulation
with aluminum foil tape.
Sequence of Operation—Spark Ignition
1. When thermostat calls for heat, the combustion blower is
energized. When proper combustion air is proven, the normally
open pressure switch closes supplying power to the ignition
control. The electric spark and pilot valve are then energized to
produce a pilot flame.
2. The sensing probe proves the presence of the pilot flame and
internal switching action de-energizes the spark.
3. The sensor will cause contacts on the ignition control to close
energizing the main gas valve solenoid, causing the main valve
to open and ignition occurs. The sparking circuit is discon-
nected assuring that the main burner(s) can never be ignited
by the electric spark.
4.. If the pilot Нате goes out for any reason, it will automatically
reset and will repeat normal start-up operation.
PARTS LIST
The following repair parts are available from your local ARMSTRONG
AIR OR AIR-EASE DEALER.
When ordering parts, include the complete furnace model number
and serial number which are printed on the rating plate located on
the furnace.
CONTROL GROUP
Transformer
Limit Control
Gas Valve
Ignition Control
Flame Sensor
Blower Door Interlock Switch
Pressure Switch-Normally Open
Flame Roll-Out Protector Switch
Drain Trap Assembly
Combustion Blower Assembly
Blower Control Center
Aux Limit (if used)
Blower Group
Blower Housing Assembly
Blower Wheel
Blower Motor
Blower Motor Mount
Blower Capacitor
Burner Group
Gas Manifold
Main Burner Orifices
Pilot Burner Assembly
Pilot Orifice
Main Burners
Heat Exchanger Group
Heat Exchanger-Primary
Heat Exchanger-Secondary
ACCESSORIES
Propane Conversion Kit
High Altitude Kit
Upflow Bottom Return Filter Kit
Counterflow Filter Kit
Counterflow Combustible Floor Kit
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, SERVICE
OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY
DAMAGE. CONSULT A QUALIFIED INSTALLER, SER-
VICE AGENCY OR THE GAS SUPPLIER FOR INFORMA-
TION OR ASSISTANCE.
8-15-92
Date
39518H092
Part No.
ol 13
13
Page
395186092
Supersedes
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