INSTALLATION INSTRUCTIONS FOR *M(H,S)8 / *D(H,S)8 / *HS8 / GME8 GAS FURNACE
(CATEGORY I )
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA2.3 Gas Fired Central Furnaces.
®
C
US
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer, you have an obligation to know the product better than the customer.
This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself
in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough
to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting.
Most dealers have a list of specific, good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices.
However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
NOTE: Please contact your distributor or our website listed below
for the applicable Specification Sheet referred to in this manual.
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
IO-417A
11/2011
5151 San Felipe Suite 500 • Houston, TX 77056
www.goodmanmfg.com • www.amana-hac.com
© 2011 Goodman Manufacturing Company, L.P.
Table of Contents
ADDITIONAL SAFETY CONSIDERATIONS ...................................................................................................... 6
SHIPPING INSPECTION ........................................................................................................................... 6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ..................................................................................... 6
TO THE INSTALLER .............................................................................................................................. 6
IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY ................................................................. 6
PRODUCT APPLICATION ............................................................................................................................... 7
LOCATION REQUIREMENTS AND CONSIDERATIONS ................................................................................................ 8
CLEARANCES AND ACCESSIBILITY ............................................................................................................ 9
INSTALLATION POSITIONS ...................................................................................................................... 9
HORIZONTAL INSTALLATION .................................................................................................................... 9
FURNACE SUSPENSION .......................................................................................................................... 9
EXISTING FURNACE REMOVAL .............................................................................................................. 10
THERMOSTAT LOCATION ...................................................................................................................... 10
COMBUSTION AND VENTILATION AIR REQUIREMENTS .......................................................................................... 10
CATEGORY I VENTING (VERTICAL VENTING) ..................................................................................................... 11
EXTERIOR MASONRY CHIMNEYS (CATEGORY I FURNACES ONLY) ......................................................................... 12
CHECKLIST SUMMARY ........................................................................................................................ 12
CHECK 1 - PROPER CHIMNEY TERMINATION. ............................................................................................. 13
CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL ...................................... 13
CHECK 3 - CHIMNEY CROWN CONDITION. ................................................................................................ 14
CHECK 4 - DEBRIS IN CLEANOUT .......................................................................................................... 14
CHECK 5 - LINER CONDITION. ............................................................................................................... 14
CHECK 6 - DILUTION AIR. ................................................................................................................... 14
CHECK 7 - COMPLETE THE INSTALLATION. ............................................................................................... 15
FIX 1 - LINER TERMINATION ................................................................................................................. 15
FIX 2 -CHANGE VENTING ARRANGEMENTS ............................................................................................... 15
FIX 3 - REBUILD THE CROWN ............................................................................................................... 15
FIX 4 - RELINING .............................................................................................................................. 15
ELECTRICAL CONNECTIONS ........................................................................................................................ 16
WIRING HARNESS .............................................................................................................................. 16
115 VOLT LINE CONNECTIONS ............................................................................................................. 16
FOSSIL FUEL APPLICATIONS ................................................................................................................ 16
JUNCTION BOX RELOCATION ................................................................................................................ 17
24 VOLT THERMOSTAT WIRING ............................................................................................................ 17
GME8 FURNACE WITH 2-STAGE CONDENSER FIELD WIRING ....................................................................... 17
SETTING THE HEAT ANTICIPATOR ........................................................................................................... 18
115 VOLT LINE CONNECTION OF ACCESSORIES ........................................................................................ 18
(ELECTRONIC AIR CLEANER) ................................................................................................................ 18
24 VAC HUMIDIFIER .......................................................................................................................... 19
GAS SUPPLY AND PIPING ........................................................................................................................... 19
HIGH ALTITUDE DERATE ...................................................................................................................... 19
PROPANE GAS CONVERSION ................................................................................................................ 19
GAS PIPING CONNECTIONS .................................................................................................................. 20
UPFLOW INSTALLATIONS ..................................................................................................................... 20
COUNTERFLOW INSTALLATIONS .............................................................................................................. 21
GAS PIPING CHECKS ......................................................................................................................... 21
PROPANE GAS TANKS AND PIPING ......................................................................................................... 21
2
Table of Contents
CIRCULATING AIR AND FILTERS .................................................................................................................... 22
DUCTWORK - AIR FLOW ...................................................................................................................... 22
CHECKING DUCT STATIC ..................................................................................................................... 22
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ............................................ 23
UPRIGHT INSTALLATIONS ..................................................................................................................... 23
CIRCULATION AIR FILTERS ................................................................................................................... 23
HORIZONTAL INSTALLATIONS ................................................................................................................ 23
SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL) ................................................................................ 23
POWER UP ...................................................................................................................................... 23
HEATING MODE ................................................................................................................................. 24
(MODE DIP SWITCH IS SET TO “1 STG” POSITION) .................................................................................. 24
(MODE DIP SWITCH IS SET TO “2 STG” POSITION) ................................................................................. 24
COOLING MODE ................................................................................................................................ 24
FAN ONLY MODE .............................................................................................................................. 25
START-UP PROCEDURE AND ADJUSTMENT ....................................................................................................... 25
FURNACE OPERATION .......................................................................................................................... 25
FURNACE START-UP ........................................................................................................................... 25
FURNACE SHUTDOWN ......................................................................................................................... 25
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. 25
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... 28
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................ 29
TEMPERATURE RISE ........................................................................................................................... 29
CIRCULATOR BLOWER SPEED ADJUSTMENT ............................................................................................. 30
CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ...................................................................................... 30
SETTING FURNACE OPERATING MODE (*DH8, *ME8, AND *MH8 MODELS ONLY) ............................................ 30
OPERATIONAL CHECKS .............................................................................................................................. 31
BURNER FLAME ................................................................................................................................ 31
AUXILIARY LIMIT CONTROL ................................................................................................................. 31
SAFETY CIRCUIT DESCRIPTION .................................................................................................................... 31
GENERAL ......................................................................................................................................... 31
INTEGRATED CONTROL MODULE ............................................................................................................. 31
PRIMARY LIMIT ................................................................................................................................ 31
AUXILIARY LIMIT ............................................................................................................................... 31
ROLLOUT LIMITS .............................................................................................................................. 32
PRESSURE SWITCHES ......................................................................................................................... 32
FLAME SENSOR ................................................................................................................................ 32
TROUBLESHOOTING ................................................................................................................................... 32
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... 32
DIAGNOSTIC CHART ........................................................................................................................... 32
FAULT RECALL ................................................................................................................................ 32
RESETTING FROM LOCKOUT ................................................................................................................ 32
3
Table of Contents
MAINTENANCE ......................................................................................................................................... 32
ANNUAL INSPECTION ........................................................................................................................... 33
FILTERS .......................................................................................................................................... 33
FILTER MAINTENANCE ......................................................................................................................... 33
FILTER REMOVAL .............................................................................................................................. 33
INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS ................................................................................. 33
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... 33
IGNITER (QUALIFIED SERVICER ONLY) ..................................................................................................... 33
BURNERS ......................................................................................................................................... 33
CLEANING (QUALIFIED SERVICER ONLY) ........................................................................................................ 34
BEFORE LEAVING AN INSTALLATION ............................................................................................................... 34
REPAIR AND REPLACEMENT PARTS .............................................................................................................. 34
COMPONENT IDENTIFICATION ................................................................................................................. 35 - 36
APPENDIX ......................................................................................................................................... 37
TROUBLESHOOTING CHART .................................................................................................................. 37
BLOWER PERFORMANCE DATA ............................................................................................................. 40
*M(H/S)8 ................................................................................................................................. 40
*(D/H)S8 ................................................................................................................................. 41
GME8 ..................................................................................................................................... 42
*(M, D, H)S8 WIRING DIAGRAM .................................................................................................. 43
GME8 WIRING DIAGRAM ............................................................................................................ 44
*(M,D)H* WIRING DIAGRAM......................................................................................................................45
4
SAFETY PRECAUTIONS
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure
proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this
product.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS 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.
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
WARNING
CO can cause serious illness including permanent brain damage or death.
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
B10259-216
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
WARNING
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION , MAINTENANCE AND SUPERVISION. IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED . IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE , ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER.
WARNING
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK , THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER.
5
SAFETY PRECAUTIONS
ing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and non-installed
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnaces near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING CATEGORY III VENTING.
PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS OUTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.
ADDITIONAL SAFETY CONSIDERATIONS
•
•
This furnace is approved for Category I Venting only.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
SHIPPING INSPECTION
All units are securely packed in shipping containers tested
according to International Safe Transit Association specifications. The carton must be checked upon arrival for external
damage. If damage is found, a request for inspection by carrier’s
agent must be made in writing immediately.
TO THE INSTALLER
The furnace must be carefully inspected on arrival for damage
and bolts or screws which may have come loose in transit. In
the event of damage the consignee should:
1. Make a notation on delivery receipt of any visible damage
to shipment or container.
2. Notify carrier promptly and request an inspection.
3. With concealed damage, carrier must be notified as soon
as possible - preferably within five days.
4. File the claim with the following support documents within
a nine month statute of limitations.
•
Original or certified copy of the Bill of Lading, or
indemnity bond.
•
Original paid freight bill or indemnity in lieu thereof.
•
Original or certified copy of the invoice, showing trade
and other discounts or reductions.
•
Copy of the inspection report issued by carrier’s
representative at the time damage is reported to carrier.
Before installing this unit, please read this manual thoroughly
to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external
static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or
maximum CFM, and motor speed connections, and venting.
These furnaces are designed for Category I venting only.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT
WARRANTY
Your warranty certificate is supplied as a separate document
with the unit installed by your contractor. Read the limited warThe carrier is responsible for making prompt inspection of dam- ranty certificate carefully to determine what is and is not covage and for a thorough investigation of each claim. The distribu- ered and keep the warranty certificate in a safe place. If you are
tor or manufacturer will not accept claims from dealers for trans- unable to locate the warranty certificate please contact your
portation damage.
installing contractor or contact customer service (877-254-4729)
to obtain a copy.
Keep this literature in a safe place for future reference.
IMPORTANT: To receive the Lifetime Heat Exchanger Limited
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
Warranty (good for as long as you own your home) and the 10NOTE: Discharge body’s static electricity before touching unit. year Parts Limited Warranty, online registration must be comAn electrostatic discharge can adversely affect electrical com- pleted within 60 days of installation. Online registration is not
required in California or Quebec. Complete warranty details
ponents.
available from your local dealer or, for Goodman® brand prodUse the following precautions during furnace installation and ucts, visit www.goodmanmfg.com, and for Amana® brand prodservicing to protect the integrated control module from dam- ucts, visit www.amana-hac.com.
age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos6
PRODUCT APPLICATION
To register your Goodman ® brand unit, go to
www.goodmanmfg.com and click “Warranty Registration”.
Complete the registration as prompted.
•
To register your Amana® brand unit, go to www.amana-hac.com
and click “Warranty Registration”. Complete the registration
as prompted.
•
•
Product limited warranty certificates for models currently in production can be viewed at www.goodmanmfg.com or www.amanahac.com. If your model is not currently in production or does
not appear on the website, please contact your installing contractor or contact customer service (877-254-4729) to obtain a
copy of your warranty certificate.
•
Each product overview page contains a Product Warranty link;
by clicking on it you will be able to view the limited warranty
coverage for that specific product. To view warranty registration
information, click on the Product Warranty text on the left navigation panel on the home page of each website. The Online
Product Registration pages are located in this same section.
•
PRODUCT APPLICATION
Air filters are installed in the system and maintained
during construction, replaced as appropriate during
construction, and upon completion of construction are
replaced.
The input rate and temperature rise are set per the
furnace rating plate.
100% outside air is provided for combustion air
requirements during construction. Temporary ducting
can be used.
NOTE: Do not connect the temporary duct directly to
the furnace. The duct must be sized according to the
instructions under Combustion and Ventilation Air
Requirements, Section 5.3.3.
The furnace heat exchanger, components, duct
system, air filters and evaporator coils are thoroughly
cleaned following final construction clean up.
All furnace operating conditions (including ignition, input
rate, temperature rise and venting) are verified
according to these installation instructions.
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
This furnace is primarily designed for residential home-heating
applications. It is NOT designed or certified for use in mobile
homes, trailers or recreational vehicles. Neither is it designed
or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area
provided the garage area is enclosed with an operating door).
•
•
•
This furnace can be used in the following non-industrial commercial applications:
Schools, Office buildings, Churches, Retail stores,
Nursing homes, Hotels/motels, Common or office areas
Gas furnaces must be installed by a licensed plumber
or gas fitter.
A T-handle gas cock must be used.
If the unit is to be installed in an attic, the passageway
to and the service area around the unit must have
flooring.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
In such applications , the furnace must be installed with the
following stipulations:
•
It must be installed per the installation instructions
provided and per local and national codes.
•
It must be installed indoors in a building constructed
on site.
•
It must be part of a ducted system and not used in a
free air delivery application.
•
It must not be used as a “make-up” air unit.
•
All other warranty exclusions and restrictions apply.
To ensure proper furnace operation, install, operate and
maintain the furnace in accordance with these installation and operation instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CSA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
This furnace may be used as a construction site heater ONLY
1430 Broadway
if the following conditions are met:
New
York, NY 10018
•
The vent system is permanently installed per these
installation instructions.
National Fire Protection Association
1 Batterymarch Park
•
A room thermostat is used to control the furnace. Fixed
Quincy, MA 02269
jumpers that provide continuous heating CANNOT be
used.
CSA International
•
Return air ducts are provided and sealed to the furnace.
8501 East Pleasant Valley
•
A return air temperature range between 60ºF (16ºC)
Cleveland, OH 44131
and 80ºF (27ºC) is maintained.
7
LOCATION REQUIREMENTS AND CONSIDERATIONS
•
A copy of the CAN/CSA B149 Installation Codes can also be
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
•
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved method
or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of
America.
•
•
In the USA, this furnace MUST be installed in accordance with
the latest edition of the ANSI Z223.1 booklet entitled “National
Fuel Gas Code” (NFPA 54), and the requirements or codes of
the local utility or other authority having jurisdiction. In Canada,
this furnace must be installed in accordance with the current
CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing
or waste water codes and other applicable codes. Additional
helpful publications available from the NFPA are, NFPA 90A Installation of Air Conditioning and Ventilating System and NFPA
90B - Warm Air Heating and Air Conditioning System.
•
•
All venting shall be in accordance with PART 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable local building and/or air conditioning codes. These publications are available from:
•
National Fire Protection Association, Inc.
1 Batterymarch Park, Quincy, MA 02269
NOTE: Furnaces with NOx screens meet the California NOx
emission standards and California seasonal efficiency standards. ANNUAL inspections of the furnace and its vent system
is strongly recommended.
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
If the furnace is installed in an application where the
typical operating sound level of a furnace is deemed
objectionable, an optional sound reduction kit is
available. Consult your local distributor for more details.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
Ensure adequate combustion air is available for the
furnace. Improper or insufficient combustion air can
expose building occupants to gas combustion products
that could include carbon monoxide. Refer to Section
V, Combustion and Ventilation Air Requirements.
The furnace must be level. If the furnace is to be set
on a floor that may become wet or damp at times, the
furnace should be supported above the floor on a
concrete base sized approximately 1-1/2" larger than
the base of the furnace.
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible
material. The only combustible material allowed is
wood.
Exposure to contaminated combustion air will result
in safety and performance-related problems. Do not
install the furnace where the combustion air is exposed
to the following substances:
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
LOCATION REQUIREMENTS AND CONSIDERATIONS
Your unit model type determines which installation procedures
must be used. For *MH8, *MS8, and GHS8 models, you must
follow instructions for Horizontal Left, Horizontal Right or Upflow installations only. These furnaces are not approved for
Downflow installations.
Downflow models GD(H,S) ARE NOT APPROVED FOR HORIZONTAL OR UPFLOW INSTALLATIONS. For these models,
use only the instructions for downflow installation only.
•
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT.
•
Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in Section V,
Combustion and Ventilation Air Requirements.
•
Centrally locate the furnace with respect to the
proposed or existing air distribution system.
•
8
If the furnace is used in connection with a cooling unit,
install the furnace upstream or in parallel with the
cooling unit coil. Premature heat exchanger failure
will result if the cooling unit coil is placed ahead of the
furnace.
If the furnace is installed in a residential garage,
position the furnace so that the burners and ignition
source are located not less than 18 inches (457 mm)
above the floor. Protect the furnace from physical
damage by vehicles.
If the furnace is installed horizontally, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace.
LOCATION REQUIREMENTS AND CONSIDERATIONS
•
•
•
•
Do not connect this furnace to a chimney flue that
serves a separate appliance designed to burn solid
fuel.
For counterflow installations, the air conditioning coil
must be downstream from the heat exchanger of the
furnace.
Counterflow installation over a noncombustible floor.
Before setting the furnace over the plenum opening,
ensure the surface around the opening is smooth and
level. A tight seal should be made between the furnace
base and floor by using a silicon rubber caulking
compound or cement grout.
Counterflow installation over a combustible floor. If
installation over a combustible floor becomes
necessary, use an accessory subbase (see
Specification Sheet applicable to your model for details).
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material including wood. Follow the instructions with
the subbase for proper installations. Do not install the
furnace directly on carpeting, tile, or other combustible
material other than wood flooring. (NOTE: The subbase
will not be required if an air conditioning coil is installed
between the supply air opening on the furnace and the
floor.
VEN T
B1-V EN T S IN G LE
1"
6"
SID ES
FR O N T
B AC K
1"
3"
0"
TO P
(P LE N U M )
1"
Top clearance for horizontal configuration - 1"
INSTALLATION POSITIONS
An upflow furnace may be installed in an upright position or
horizontal on either the left or right side panel. Do not install
this furnace on its back. For vertically installed upflow furnaces,
return air ductwork may be attached to the side panel(s) and/
or basepan. For horizontally installed upflow furnaces, return
air ductwork must be attached to the basepan. For counterflow
furnaces, return ductwork must be attached to the top end of
the blower compartment.
NOTE: Ductwork must never be attached to the back of the
furnace.
H ORIZONTALINSTALLATION
Line contact to framing is permitted when installed in the horizontal configuration. Line contact is defined as the portion of
the cabinet that is formed by the intersection of the top and
side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PROTECTION CLEARANCE. A gas-fired furnace for installation in
a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed directly on carpeting, tile, or other combustible materials other
than wood flooring.
Vent Pipe Clearance to Combustibles6" using Single Wall Connector or 1"
using B-1 vent.
Top - 1"
Back - 0"
FURNACE SUSPENSION
If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances necessary.
Side
Clearance - 1"
Front Clearance - 3"
•
•
•
Adequate combustion/ventilation air must be supplied
to the closet.
Furnace must be completely sealed to floor or base.
Combustion/ ventilation air supply pipes must terminate
12" from top of closet and 12" from floor of closet. DO
NOT remove solid base plate for side return.
Return air ducts must be completely sealed to the
furnace and terminate outside the enclosure surfaces.
Suspended Furnace
CLEARANCES AND ACCESSIBILITY
Unobstructed front clearance of 24" for servicing is recommended.
9
COMBUSTION & VENTILATION CATEGORY I VENTING AIR REQUIREMENTS
EXISTING FURNACE REMOVAL
•
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be
too large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada
for Gas-Fired Central Furnaces ANSI Z21.47-Latest Edition, CSA-2.3-Latest Edition Section 1.23.1. The following
steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and
horizontal pitch, as required by the National Fuel Gas
Code, ANSI Z223.1 or the CAN/CSA B149 Installation
Codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition;
c. In so far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they shall
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers;
d. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so
appliance shall operate continuously;
e. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle;
f.
After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas
burning appliance to their previous conditions of use;
g. If improper venting is observed during any of the above
tests, the common venting system must be corrected.
•
•
•
•
•
•
Drafts, or dead spots behind doors, in corners, or under
cabinets.
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat, such as
an outside wall.
HOT
COLD
Thermostat Influences
Consult the instructions packaged with the thermostat for mounting instructions and further precautions.
COMBUSTION AND VENTILATION AIR REQUIREMENTS
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA.
Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
heating/cooling costs but have created a problem supplying
combustion and ventilation air for gas fired and other fuel burnCorrections must be in accordance with the latest edition of ing appliances. Appliances that pull air out of the house (clothes
the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CAN/ dryers, exhaust fans, fireplaces, etc.) increase the problem by
CSA B149 Installation Codes.
starving appliances for air.
If resizing is required on any portion of the venting system, use
the appropriate table in Appendix G in the latest edition of the
National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA B149
Installation Codes.
House depressurization can cause back drafting or improper
combustion of gas-fired appliances, thereby exposing building
occupants to gas combustion products that could include carbon monoxide.
THERMOSTAT LOCATION
If this furnace is to be installed in the same space with other
In an area having good air circulation, locate the thermostat gas appliances, such as a water heater, ensure there is an
about five feet high on a vibration-free inside wall. Do not install adequate supply of combustion and ventilation air for the other
the thermostat where it may be influenced by any of the follow- appliances. Refer to the latest edition of the National Fuel Gas
ing:
10
EXTERIOR
MASONRY
CHIMNEYS - CATEGORY I FURNACES ONLY
Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation Under some conditions, larger vents than those shown above
Codes or applicable provisions of the local building codes for may be required or allowed. When an existing furnace is redetermining the combustion air requirements for the appliances. moved from a venting system serving other appliances, the
venting system may be too large to properly vent the remaining
This furnace must use indoor air for combustion. It cannot be attached appliances.
installed as a direct vent (i.e., sealed combustion) furnace.
Upflow or Horizontal units are shipped with the induced draft
Most homes will require outside air be supplied to the furnace blower discharging from the top of the furnace. (“Top” is as
area by means of ventilation grilles or ducts connecting directly viewed for an upflow installation.) The induced draft blower can
to the outdoors or spaces open to the outdoors such as attics be rotated 90 degrees with the (0270F01119) chimney transior crawl spaces.
tion bottom kit for Category I venting. For horizontal installations, a four inch single wall pipe can be used to extend the
CATEGORY I VENTING (VERTICAL VENTING)
induced draft blower outlet 1/2” beyond the furnace cabinet.
THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCKWARNING
WISE INDUCED DRAFT BLOWER ROTATION.
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO Vent the furnace in accordance with the National Fuel Gas
ASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent
VENT USING CATEGORY III VENTING.
the furnace in accordance with the National Standard of Canada,
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.”
NOTE: Single stage gas furnaces with induced draft blowers
draw products of combustion through a heat exchanger allowing, in some instances, common venting with natural draft appliances (i.e. water heaters). All installations must be vented in
accordance with National Fuel Gas Code NFPA 54/ANSI Z223.1
- latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CSA
B149.1 and CAN/CSA B149.2 - latest editions and amendments.
CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and
amendments.
Venting - Furnace Installed in Horizontal Position
THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORIZONTALLY VENTED THROUGH AN EXTERIOR SIDE WALL.
The following describes an optional venting procedure when the
furnace is installed in the horizontal left discharge position.
To rotate the induced draft blower clockwise, you will need to
purchase one (0270F01119) chimney transition bottom kit.
NOTE: Masonry vent kit (MVK-01 and MVK-02) is to only be
used on interior masonry chimneys or qualifying exterior
masonry chimney applications identified in the MVK kit
installation instructions. To ensure safe and reliable operation,
use only the kit listed for your model.
NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the venting
system.
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER’S INDUCED DRAFT APPLIANCES IS NOT ALLOWED.
The minimum vent diameter for the Category I venting system
is as shown:
MODEL
40
60
80
100
120
140
MINIMUM VENT
UPFLOW
4 Inch
4 Inch
4 Inch
5 Inch
5 Inch
5 Inch
COUNTERFLOW
4 Inch
4 Inch
4 Inch
5 Inch
N/A
N/A
11
1. Disconnect electrical power from the furnace.
2. Disconnect the induced draft blower power leads, flue
pipe, and pressure switch tubing.
3. Remove the round cutout from the right side of the wrapper.
4. Remove and save the four screws that fasten the induced
draft blower to the flue collector box.
5. Remove and save the three screws that hold the chimney
assembly to the induced draft blower.
6. Remove and save the four screws that fasten the chimney
top to the chimney bottom.
7. Remove the chimney transition bottom from the transition
bottom kit.
8. Install the chimney top with the four screws retained
from step 6 onto the new chimney transition bottom from
the transition bottom kit.
9. Remove the induced draft blower and install the new
chimney assembly to it using the three screws retained
from step 5.
10. Rotate the induced draft blower 90 degrees to the right,
feed the flue pipe through the round cutout from the outside
of the wrapper, and fit onto the chimney top assembly.
Secure the pipe to the chimney top from the front, top,
and bottom using (3) screws and rotating the induced
EXTERIOR
MASONRY
CHIMNEYS - CATEGORY I FURNACES ONLY
draft blower to properly orient the assembly. NOTE: If
the pipe section is less than 18”, then attach it directly
to the chimney top on 3 sides and feed it through the
round cutout from the inside of the wrapper.
11. Reattach the induced draft blower using the (4) screws
retained from step 3. Ensure the gasket located between
the induced draft blower and collector box is rotated
accordingly.
12. Reconnect the induced draft blower power leads. NOTE:
If the wires are not long enough, pull extra wire from the
wire bundle in the blower compartment.
13. Reconnect the remaining flue pipe, and the pressure
switch tubing. Ensure that all wires and the pressure
switch tubing is at least one inch from the flue pipe, or
any other hot surface.
14. Restore power to furnace.
NOTE: In a horizontal installation the air conditioning coil
must be adequately supported by proper brackets and
supports. Inadequate coil support can result in furnace cabinet
distortion and air leakage.
WARNING
POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN A SINGLE FAN‐ASSISTED CATEGORY I APPLIANCE (80% AFUE FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR. DO NOT CONNECT AN 80% FURNACE TO A MASONRY CHIMNEY UNLESS THE FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE B METAL VENT. ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES. IF AN 80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS, EXTERIOR CHIMNEYS, OR ANY COMBINATION OF THESE CONDITIONS. THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR TYPE B METAL VENT.
Wash
Roof Line
Counterflow units are shipped with the induced draft blower
discharging from the top of the furnace. (“Top” as viewed for a
counterflow installation.)
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Attic Floor
Vent the furnace in accordance with the National Fuel Gas
Code NFPA54/ANSI Z223.1-latest edition. In Canada, vent the
furnace in accordance with the national standard of Canada,
CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and
amendments.
1/2" to 1" Air Space
Second Floor
WARNING
Throat
Damper
First Floor
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY.
Breech
Clean Out
EXTERIORMASONRYCHIMNEYS (CATEGORYIFURNACESONLY)
An exterior masonry chimney is defined as a “Masonry” chimney exposed to the outdoors on one or more sides below the
roof line.” The ability to use a clay lined masonry chimney
depends on a parameter not associated with interior chimneys.
This variable is the geographic location of the installation. Researchers have discovered that the winter design temperatures
have a direct impact on the suitability of this type of venting. In
most situations, the existing masonry chimneys will require a
properly sized metallic liner.
F.A.F. Vent
Connector
Fan Assisted
Forced Air
Furnace
Water Heater
Vent Connector
Natural Draft
Water Heater
Basement Floor
Typical Multiple Flue Clay Tile Chimney
CHECKLIST SUMMARY
This checklist serves as a summary of the items to be checked
before venting an 80+ furnace into a masonry chimney. In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system.
This checklist is only a summary. For detailed information on
each of the procedures mentioned, see the paragraph referenced with each item.
This inspection is based upon a draft topical report, “Masonry
Chimney Inspection and Relining”, issued by the Gas Research
Institute. While not yet finalized, we believe this report represents the best information on this subject which is currently
available.
12
EXTERIOR
MASONRY
CHIMNEYS - CATEGORY I FURNACES ONLY
If the chimney does not meet these termination requirements,
but all other requirements in the checklist can be met, it may
be possible for a mason to extend the chimney. If this will not
be practical, see Fix 1.
Proper Chimney
Termination?
(Check 1)
10' or Less
2' Min.
Chimney channel
free of solid and
liquid fuel
appliances?
(Check 2)
Change venting
arrangements
(Fix 2)
2' Min.
3' Min.
Wall or
Parapet
Chimney
Crown in good
condition
(Check 3)
10' or Less
Rebuild crown
(Fix 3)
and/or Reline
(Fix 4)
2' Min.
3' Min.
Cleanout free of
debris?
(Check 4)
Reline
(Fix 4)
Chimney
Termination 10 Feet Or Less From Ridge, Wall or Parapet
More than 10’
Liner in good
condition?
(Check 5)
Dilution air
available?
(Check 6)
Reline
(Fix 4)
3’ Min.
Wall or
Parapet
Reline
(Fix 4)
NOTE: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
More than 10’
Ridge
Complete the
installation.
(Check 7)
10’
Chimney
Height above any
roof surface within
10 feet horizontally.
2” Min.
3’ Min.
CHECK 1 - PROPER CHIMNEY TERMINATION.
Chimney
A masonry chimney used as a vent for gas fired equipment
must extend at least three feet above the highest point where it
Termination More Than 10 Feet From Ridge, Wall or Parapet
passes through the roof. It must extend at least two feet higher
than any portion of a building within a horizontal distance of 10 CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED
feet. In addition, the chimney must terminate at least 3 feet INTO THIS CHIMNEY CHANNEL
above any forced air inlet located within 10 feet. The chimney
must extend at least five feet above the highest connected equip- Solid fuel appliances include fireplaces, wood stoves, coal furnaces, and incinerators.
ment draft hood outlet or flue collar.
13
EXTERIOR
MASONRY
CHIMNEYS - CATEGORY I FURNACES ONLY
Liquid fuel appliances include oil furnaces, oil-fired boilers and Next, use a flashlight and small mirror to sight up the liner. B
oil-fired water heaters.
vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably be
Appliances which burn propane (sometimes referred to as LP rehung so as to be acceptable. A thimble or fire stop may be
(liquefied petroleum)) gas are considered gas-fired appliances. helpful here.
CHECK 3 - CHIMNEY CROWN CONDITION.
Damage from condensate usually shows up first in the crown.
If any of the following trouble signs are present, the condition of
the crown is not satisfactory:
a) Crown leaning
b) Bricks missing
c) Mortar missing
d) Tile liner cracked
e) No tile liner
f) Salt staining at mortar joints. (White stains, and mortar
becomes sandy and/or erodes.)
Flexible liners should be hung straight or nearly straight. If it is
spiraled in the chimney and in good condition, it should be
rehung. To do this, break the top seal; pull up and cut off the
excess liner length, and refit the top seal. Use caution when
doing this, as the cut edges of flexible liners may be sharp.
The surfaces of the liner must be physically sound. If gaps or
holes are present, the metal liner must be removed and replaced (Fix 4). Finally, confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA
tables and rules.
If a metal liner is not present, a clay tile liner must be present,
For problems a, b, or c, see Fix 3. If problems d, e, or f are or the chimney must be lined (Fix 4).
present, see Fix 4. IMPORTANT: It may be necessary to follow Use a flashlight and small mirror at the cleanout or vent conboth Fix 3 and Fix 4.
nector to inspect the clay tile liner. If any of the following problems are present:
CHECK 4 - DEBRIS IN CLEANOUT
•
Tile sections misaligned
A cleanout (dropleg) must be present such that the upper edge
•
Tile sections missing
of the cleanout cover is at least 12 inches below the lower edge
•
Gaps between tile sections
of the lowest chimney inlet opening.
•
Signs of condensate drainage at the cleanout or vent
A chimney without a cleanout could become partially blocked
connectors
by debris. If no cleanout is present, the chimney must be re•
Mortar protruding from between tile sections
lined (Fix 4). Remove the cleanout cover, and examine the
•
Use of sewer pipe or drainage pipe rather than an
cleanout for debris. If significant amounts of any of the following
approved fire clay tile reline the chimney (Fix 4).
are found:
•
Fuel oil residue
Next, measure the size of the liner. It may be possible to do
•
Bricks
this from the cleanout. The liner must be at least as large as
•
Mortar or sand
the minimum size established by the tables in National Fuel
•
Pieces of the tile liner
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
•
Rusted pieces of the metallic liner - reline the chimney
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
(Fix 4).
B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).
CHECK 5 - LINER CONDITION.
If a metal liner is present, it must be checked. It cannot be CHECK 6 - DILUTION AIR.
assumed that all existing metal liners are correctly installed
If gas-fired appliances are to be vented into a clay tile liner, a
and in good condition.
source of dilution air is required.
Remove the lowest existing vent connector, and examine the
Dilution air cannot be obtained through:
inside of the elbow or tee at the base of the liner. A small amount
•
Induced draft appliances
of soot may be considered acceptable, provided the installer
vacuums it away. If rusted pieces of the liner have collected
•
Natural draft appliances with vent dampers
here, the metal liner must be removed and replaced (Fix 4).
Sufficient dilution air can ordinarily be obtained through the draft
Next, gently tap the inside of the liner with a Phillips screw- hood of a natural draft appliance only if the appliance’s vent
driver. If the screwdriver perforates the liner, or if the tapping connector does not include a vent damper. If dilution air will not
does not sound like metal hitting metal, the liner must be re- be available, the chimney must be relined (Fix 4).
moved and replaced (Fix 4).
Remember that all appliances must be vented inside the liner.
Venting one appliance inside the liner and another appliance
outside the liner is not acceptable.
14
EXTERIOR
MASONRY
CHIMNEYS - CATEGORY I FURNACES ONLY
CHECK 7 - COMPLETE THE INSTALLATION.
FIX 3 - REBUILD THE CROWN
If Checks 1 through 6 have been satisfactory, and the liner is an
acceptable size as determined by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments, then the clay tile
liner can probably be used as a vent for the gas appliances.
However, the installer must keep in mind the following factors
which may render the tile liner unsuitable for use as a vent:
•
Extremely cold weather
If the chimney crown is damaged, a qualified mason must repair it in accordance with nationally recognized building codes
or standards. One such standard which may be referenced is
the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211.
•
Long vent connectors
•
Masonry chimneys with no air gap between the liner
and the bricks. (In practice, this can be difficult to
detect.)
•
Exterior chimneys (The tables in National Fuel Gas
Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments
assume interior chimneys.)
FIX 4 - RELINING
Relining options include B vent and flexible liners.
If the chimney has diagonal offsets, B vent probably cannot be
used.
If B vent is to be used, it must be supported adequately. Supports (such as fire stops or thimbles) must be used to prevent
the B vent from coming into direct contact with the tile liner or
chimney walls. Direct contact would result in higher heat loss,
with an increased possibility of poor venting system performance.
It is not acceptable to vent one appliance inside the B vent and
other appliances outside. The excess space between the B
If, in the judgment of the local gas utility, installer, and/or local vent and the chimney walls must be covered at the top of the
codes; one or more of the above factors is likely to present a chimney by a weatherproof, corrosion resistant flashing.
problem, the chimney must be relined (Fix 4).
The B vent should then be topped with a listed vent cap. The
FIX 1 - LINER TERMINATION
listed vent cap will, when installed per the manufacturer’s inAny cap or roof assembly used with a liner must be approved structions, prevent problems due to rain, birds, or wind effects.
by the liner manufacturer for such use. The liner and cap/roof A B-vent installed as described in this section is considered to
assembly must then terminate above the roof in accordance be an enclosed vent system, and the sizing tables in National
with the manufacturer’s instructions.
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in
In some cases, a shorter extension above the roof may be the National Standard of Canada, CAN/CSA B149.1 and CAN/
possible with a liner than would be required with a masonry CSA B149.2 - latest editions and amendments may be used.
chimney.
For further information on relining, see Fix 4.
FIX 2 -CHANGE VENTING ARRANGEMENTS
If the masonry chimney has more than one channel, it may be
possible to vent the gas appliances into one channel and vent
the solid or liquid fuel appliance(s) into another channel(s). Do
not vent an 80+ Furnace inside of a metal liner with other appliances vented outside the liner.
Alternatively, the homeowner may agree to discontinue use of
the fireplace (solid fuel appliance). If so, the tile liner must be
cleaned to remove creosote buildup. The fireplace opening must
then be permanently sealed.
If oil-fired appliance(s) are being replaced by gas-fired
appliance(s), the tile liner must first be cleaned to remove the
fuel oil residue.
If none of the above options is practical, the furnace may need
to be vented vertically with a B Vent.
If a flexible liner is to be used, it must be made of the proper
materials:
•
For most residential applications, an aluminum liner
should be acceptable.
•
If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
fluorine, a liner of AL 29-4C stainless steel should be
used. Common sources of chlorine and fluorine
compounds include indoor swimming pools and
chlorine bleaches, paint strippers, adhesives, paints,
varnishes, sealers, waxes (which are not yet dried)
and solvents used during construction and remodeling.
Various commercial and industrial processes may also
be sources of chlorine/fluorine compounds.
•
Heavier gauge 300 and 400 series stainless steel liners
were developed for use with oil or solid fuel appliances.
They are not suitable for use with gas-fired appliances.
Flexible liners specifically intended and tested for gas
applications are listed in the UL “Gas and Oil
Equipment Directory”. (UL Standard 1777).
Under some conditions, a 90%+ furnace could be installed rather
than an 80% furnace. The 90%+ furnace can be vented horizontally or vertically through PVC pipe.
15
ELECTRICAL CONNECTIONS
For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING .
To install the liner, read and follow the liner manufacturer’s instructions and your local codes. Excess liner length should be
pulled out of the chimney and cut off. Use caution when doing
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney. Support the liner as
recommended by the liner manufacturer.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE.
Some manufacturers of flexible liners offer an insulation sleeve
designed to be added to the liner before it is installed in the
chimney. (Poured insulation, either vermiculite or other materials, is no longer recommended.) Insulation will need to be added
to the flexible liner if:
WIRING HARNESS
•
It is required by the liner manufacturer’s instructions.
The wiring harness is an integral part of this furnace. Field
•
The previous liner was properly sized and installed,
alteration to comply with electrical codes should not be reand suffered from condensation damage.
quired. Wires are color coded for identification purposes. Re•
It is required by your local building codes.
fer to the wiring diagram for wire routings. If any of the original
Even if none of those three conditions exist which require addi- wire as supplied with the furnace must be replaced, it must be
tional liner insulation, the installer may wish to consider it if:
replaced with wiring material having a temperature rating of at
•
The local climate is very cold.
least 105° C. Any replacement wiring must be a copper con•
The chimney is very tall.
ductor.
•
The vent connectors used are very long or have a large
115 VOLT LINE CONNECTIONS
number of elbows.
•
Local experience indicates that flexible liners installed
Before proceeding with electrical connections, ensure that the
without insulation are likely to have condensation
supply voltage, frequency, and phase correspond to that speciproblems.
fied on the unit rating plate. Power supply to the furnace must
be NEC Class 1, and must comply with all applicable codes.
Insulation must be selected and installed in accordance with The furnace must be electrically grounded in accordance with
the liner manufacturer’s instructions.
local codes or, in their absence, with the latest edition of The
Finally, cap the chimney and terminate the liner in accordance National Electric Code, ANSI NFPA 70 and/or The Canadian
Electric Code CSA C22.1.
with the liner manufacturer’s instructions.
HIGH VOLTAGE !
Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit
breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED .
Line voltage wiring must enter into the junction box provided
with the furnace.
ELECTRICAL CONNECTIONS
WARNING
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
NOTE: Line polarity must be observed when making field
connections.
FOSSIL FUEL APPLICATIONS
This furnace can be used in conjunction with a heat pump in a
fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an
outdoor temperature sensor to determine the most cost efficient means of heating (heat pump, gas furnace, or both).
16
ELECTRICAL CONNECTIONS
A heat pump thermostat with two stages of heat is required to
properly use a furnace in conjunction with a heat pump. Refer
to the fossil fuel kit installation instructions for additional thermostat requirements.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE.
Strictly follow the wiring guidelines in the fossil fuel kit installation instructions. All furnace connections must be made to the
furnace integrated control module and the FURNACE terminal
strip on the fossil fuel control board.
JUNCTION BOX RELOCATION
To ensure proper unit grounding, the ground wire should run
from the furnace ground screw located inside the furnace juncWARNING
tion box all the way back to the electrical panel. NOTE: Do
not use gas piping as an electrical ground. To confirm proper
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A unit grounding, turn off the electrical power and perform the
PRECAUTION WHEN REMOVING HOLE PLUGS.
following check.
Line voltage connections can be made through either the right 1. Measure resistance between the neutral (white)
connection and one of the burners.
or left side panel. The furnace is shipped configured for a right
side electrical connection. To make electrical connections 2. Resistance should measure 10 ohms or less.
through the opposite side of the furnace, the junction box must
This furnace is equipped with a blower door interlock switch
be relocated to the left side prior to making electrical connecwhich interrupts unit voltage when the blower door is opened for
tions. To relocate the junction box, perform the following steps.
servicing. Do not defeat this switch.
24 VOLT THERMOSTAT WIRING
WARNING
NOTE: Wire routing must not interfere with circulator blower
operation, filter removal, or routine maintenance.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT.
Low voltage connections can be made through either the right
or left side panel. Thermostat wiring entrance holes are located
in the blower compartment. The following figure shows connections for a “heat only” system and “heat/cool system”.
1. Remove both doors from the furnace.
2. Remove and save the screws holding the junction box to
the right side of the furnace.
3. Models that have the junction box located in the burner
compartment will need to move the junction box directly
over.
4. Attach the junction box to the left side of the furnace,
using the screws removed in step 2.
5. Check the location of the wiring. Confirm that it will not
be damaged by heat from the burners or by the rotation
of the fan. Also confirm that wiring location will not
interfere with filter removal or other maintenance.
Heating
Room
Thermostat
W
Heating/Cooling
Room Thermostat
W
Furnace
Control
Remote
Condensing
Unit
Furnace
Control
Typical Field Wiring (24 VAC Control Circuit)
After the junction box is in the desired location, use washers to
connect field-supplied conduit to the junction box in accordance
with NEC and local codes. Connect hot, neutral, and ground
wires as shown in the furnace wiring diagram. The wires and
ground screw are located in the furnace junction box.
This furnace is equipped with a 40 VA transformer to facilitate
use with most cooling equipment. Consult the wiring diagram,
located on the blower compartment door, for further details of
115 Volt and 24 Volt wiring.
NOTE: In downflow applications the power leads should be A single-stage thermostat with only one heating stage can be
routed through the supplied wire tabs when rotating junction used to control this furnace.
box to the left side.
GME8 FURNACE WITH 2-STAGE CONDENSER FIELD WIRING
Low voltage wires may be connected to the terminal strip.
The GME8 model furnaces may be used with a 2-stage
IMPORTANT NOTE: To avoid possible equipment malfunction, outdoor air conditioner. A two stage cooling/single stage gas
route the low voltage wires to avoid interference with filter re- heat thermostat is required, in addition to a field supplied
relay. The relay must have a 24VAC coil and contacts rated
moval or other maintenance.
for up to 1 horse power at 125VAC.
17
GAS SUPPLY
AND
PIPING
1. Install the field supplied relay on the control mounting panel near the furnace ignition control. The relay
should be installed such that the motor leads will
reach the relay contact terminals.
2. Connect the “Y2” (high stage cool) thermostat
terminal to one coil terminal of the field supplied
relay. Connect the other field supplied relay coil
terminal to the “C” terminal on the furnace ignition
control. Typical 18AWG thermostat wire may be
used.
3. Connect the common terminal of the field supplied
relay to the “LINE-H” terminal on the furnace ignition
control. Use wiring having copper conductors only
and a temperature rating of at least 105°C.
4. Using the GME8 airflow tables in this manual,
determine the motor speed tap needed to deliver the
required high stage cooling airflow. Connect the
selected motor speed tap to the normally open
terminal on the field supplied relay. Use wiring
having copper conductors only and a temperature
rating of at least 105°C.
5. See the wiring schematic below.
•
•
•
Record the reading.
Divide this reading by 10.
Set the heat anticipator on the thermostat to match
this reading.
Example: If the reading on the ammeter is “4”, divide this by
10. The anticipator setting will be .4 amps.
115 VOLT LINE CONNECTION OF ACCESSORIES
(ELECTRONIC AIR CLEANER)
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
field-supplied electronic air cleaner.
The accessory load specifications are as follows:
ECO-TECH
MOTOR
1.0 Amp maximum at 120 VAC
Field
Supplied
Relay
Y
Y1
Y2
Y1
Y2
Heating/Cooling
Room Thermostat
Control Module
Hot 120 VAC
Remote Condensing Unit
EAC-H
Field Wiring for GME8 Furnace with 2-Stage Condenser
SETTING THE HEAT ANTICIPATOR
The following method should be used in measuring the amp
draw of the control circuit to assure proper adjustment of the
thermostat heat anticipator
Neutral 120 VAC
Optional
Accessories
EAC
Transformer
Line
Cool
Turn OFF power to the furnace before installing any accessories. Follow the air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be made through
the 1/4" quick connect terminals provided on the furnace integrated control module. The electronic air cleaner hot terminal
is identified as EAC-H and the neutral terminal is identified as
NEUTRAL. All field wiring must conform to applicable codes.
Connections should be made as shown in the following illustration.
Line
Transformer
T2
Line-H
T4
Hi-Heat
Lo-Heat
Furnace
Control
Electronic Air Cleaner
T5
T3
Air Cleaner
If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform
to all local codes, and have a minimum temperature rating of
105°C. All line voltage wire splices must be made inside the
furnace junction box.
•
•
Wrap the “R” leg around a clip-on ammeter 10 times.
Energize the furnace in the heat mode.
The integrated control module electronic air cleaner terminals
(EAC) are energized with 115 volts whenever the circulator blower
is energized.
18
GAS SUPPLY
24 VAC HUMIDIFIER
The yellow wire connected to the I.D. Blower pressure switch
is powered anytime the pressure switch is closed and
provides 24 VAC humidifier control. Remove the yellow wire
and connect the supplied brown jumper wire to the pressure
switch terminal. Reconnect the yellow wire to the “piggyback”
terminal on the brown jumper and then connect the 24 VAC
line of the humidifier to the stripped end of the brown wire.
Using a wire nut or a field-supplied quick connect terminal
can make this connection. The wiring must conform to all
local and national codes. Connect the COM side of the
humidifier to the B/C terminal on the furnace control board
(or to the COM side of the 24 VAC transformer). DO NOT
CONNECT 115V HUMIDIFIER TO THESE TERMINALS.
GAS SUPPLY AND PIPING
The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overfiring.
Natural Gas
Propane Gas
Inlet Gas Supply Pressure
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
NOTE: Adjusting the minimum supply pressure below the limits
in the above table could lead to unreliable ignition. Gas input to
the burners must not exceed the rated input shown on the
rating plate. Overfiring of the furnace can result in premature
heat exchanger failure. Gas pressures in excess of 13 inches
water column can also cause permanent damage to the gas
valve.
AND
PIPING
High altitude installations may require both a pressure switch
and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas
fuel and the combustion air at higher altitude.
For installations above 7000 feet, please refer to your distributor for required kit(s).
Contact the distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
PROPANE GAS CONVERSION
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED . THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION . ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied for
propane gas installations. Refer to the “Propane Gas and/or
High Altitude Installations” section for details.
Models using Single Stage Gas Valves
Altitude
Gas
Kit
Orifice
Manifo ld
Pressu re
Natural
None
#45
3.5" w.c.
0-7000
Pressure
Switch
None
Propane
#55
LPT-03
10.0" w.c.
NOTE: In Canada, gas furnaces are certified to 4500 feet.
NOTE: GMS81405DN** models utilize #43 orifices in Natural gas
applications.
At all altitudes, the manifold pressure must be within 0.3 inches Models using 2-Stage Gas Valves
w.c. of that listed in the Specification Sheet applicable to your
model for the fuel used. At all altitudes and with either fuel, the
Manifold Pressure Pressure
air temperature rise must be within the range listed on the furGas
Altitude
Kit
Orifice
Switch
High
Low
nace nameplate. Should this appliance be converted to LP,
Change
Stage
Stage
refer to the instructions included in the factory authorized LP
Natural
None
#45
3.5" w.c. 1.9" w.c.
None
conversion kit.
HIGH ALTITUDE DERATE
Propane
0-7000
LPM-06
#55
10.0" w.c. 6.0" w.c.
None
IMPORTANT NOTE: The furnace will naturally derate itself with NOTE: In Canada, gas furnaces are only certified to 4500 feet.
altitude. Do not attempt to increase the firing rate by changing NOTE: GMH81405DN** models utilize #43 orifices in Natural gas
orifices or increasing the manifold pressure. This can cause applications.
poor combustion and equipment failure.
19
GAS SUPPLY
AND
PIPING
•
Contact your distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
•
GAS PIPING CONNECTIONS
•
WARNING
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL /PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER/TANK TO THE FURNACE.
•
•
When sizing a trunk line, be sure to include all appliances
which will operate simultaneously.
The gas piping supplying the furnace must be properly sized
based on the gas flow required, specific gravity of the gas, and
length of the run. The gas line installation must comply with
local codes, or in their absence, with the latest edition of the
National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
Length of
Nominal Black Pipe Size
Pipe in Feet
1/2"
3/4"
1"
1 1/4"
10
132
278
520
1050
20
92
190
350
730
30
73
152
285
590
40
63
130
245
500
50
56
115
215
440
60
50
105
195
400
70
46
96
180
370
80
43
90
170
350
90
40
84
160
320
100
38
79
150
305
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
1 1/2"
1600
1100
980
760
670
610
560
530
490
460
–
–
Rigid metallic pipe and fittings.
–
Use listed gas appliance connectors in accordance
with their instructions. Connectors must be fully in
the same room as the furnace.
–
Protect connectors and semi-rigid tubing against
physical and thermal damage when installed.
Ensure aluminum-alloy tubing and connectors are
coated to protect against external corrosion when
in contact with masonry, plaster, or insulation, or
subjected to repeated wetting by liquids such as
water (except rain water), detergents, or sewage.
Semi-rigid metallic tubing and metallic fittings.
Aluminum alloy tubing must not be used in exterior
locations.
Location of Manual Valve
(Installed Ahead of
Ground Joint Pipe Union)
Height Required
By Local Code
CFH = BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
Ground Joint Pipe Union
To Be Installed Ahead of
Gas Valve
To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases,
the installer may also need to supply a transition piece from 1/
2" pipe to a larger pipe size.
The following stipulations apply when connecting gas piping.
•
Use black iron or steel pipe and fittings for the building
piping.
•
Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
•
Use ground joint unions.
•
Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.
Install a 1/8" NPT pipe plug fitting, accessible for test
gage connection, immediately upstream of the gas
supply connection to the furnace.
Use two pipe wrenches when making connection to
the gas valve to keep it from turning. The orientation
of the gas valve on the manifold must be maintained
as shipped from the factory.
Install a manual shutoff valve between the gas meter
and unit within six feet of the unit. If a union is installed,
the union must be downstream of the manual shutoff
valve, between the shutoff valve and the furnace.
Tighten all joints securely.
Connect the furnace to the building piping by one of
the following methods:
``
Drip Leg
Reducing Coupling
1/2” x 1/8” with 1/8”
Pipe Plug to Measure
Line Gas Pressure
General Furnace Layout
UPFLOW INSTALLATIONS
When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting
from the gas valve):
•
90 degree elbows (2).
•
Close nipple.
•
Straight pipe to reach the exterior of the furnace .
20
GAS SUPPLY
AND
PIPING
A ground joint union, drip leg, and manual shutoff valve must
also be supplied by the installer. In some cases, the installer
may also need to supply a transition piece from 1/2" to another
pipe size.
This unit must be isolated from the gas supply system by closing its manual shutoff valve before pressure testing of gas supply piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
When the gas piping enters through the left side of the furnace,
the installer must supply the following fittings (starting from the
gas valve):
•
Straight pipe to reach the exterior of the furnace.
•
A ground joint union, drip leg, and manual shutoff valve
must also be supplied by the installer. In some cases,
the installer may also need to supply a transition piece
from 1/2 inch to another pipe size.
PROPANE GAS TANKS AND PIPING
WARNING
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.
• SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
• PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
COUNTERFLOW INSTALLATIONS
When the gas piping enters through the left side of the furnace,
the installer must supply a straight pipe to reach the exterior of
the furnace.
A gas detecting warning system is the only reliable way to
detect a propane gas leak. Rust can reduce the level of odorant
A ground joint union, drip leg and manual shutoff valve must
in propane gas. Do not rely on your sense of smell. Contact a
also be supplied by the installer. In most cases, the installer
local propane gas supplier about installing a gas detecting
may also need to supply a transition piece from ½” to another
warning system. If the presence of gas is suspected, follow
pipe size. When the gas piping enters through the right side of
the instructions on Page 3 of this manual.
the furnace, the installer must supply the following fittings (starting at the gas valve):
All propane gas equipment must conform to the safety stan•
90 Degree Elbow
dards of the National Board of Fire Underwriters, NBFU Manual
•
Close Nipple
58.
•
90 Degree Elbow
For satisfactory operation, propane gas pressure must be 10
•
Straight Pipe to Reach Exterior of Furnace.
inch WC at the furnace manifold with all gas appliances in
operation. Maintaining proper gas pressure depends on three
main factors:
Before placing unit in operation, leak test the unit and gas con- 1. Vaporization rate, depending on temperature of the liquid,
nections.
and “wetted surface” area of the container or containers.
GAS PIPING CHECKS
2. Proper pressure regulation. (Two-stage regulation is
recommended for both cost and efficiency).
WARNING
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size will
depend on length of pipe run and total load of all
Check for leaks using an approved chloride-free soap and waappliances.
ter solution, an electronic combustible gas detector, or other
approved testing methods.
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.
Since propane gas will quickly dissolve white lead and most
standard commercial compounds, special pipe dope must be
used. Shellac-based compounds resistant to the actions of
liquefied petroleum gases such as Gasolac®, Stalactic ®,
Clyde’s® or John Crane® are satisfactory.
NOTE: Never exceed specified pressures for testing. Higher
Refer to the following illustration for typical propane gas instalpressure may damage the gas valve and cause subsequent
lations and piping.
overfiring, resulting in heat exchanger failure.
Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system
with pressures in excess of 1/2 psig (3.48 kPa).
21
CIRCULATING AIR
AND
FILTERS
5 to 15 PSIG
(20 PSIG Max.)
First Stage
Regulator
200 PSIG
Maximum
A duct system must be installed in accordance with Standards
of the National Board of Fire Underwriters for the Installation of
Air Conditioning, Warm Air Heating and Ventilating Systems.
Pamphlets No. 90A and 90B.
Continuous
11" W.C.
A closed return duct system must be used, with the return duct
connected to the furnace. NOTE: Ductwork must never be
attached to the back of the furnace. For installations requiring
more than 1800 CFM, use a bottom return or two sided return.
Supply and return connections to the furnace may be made
with flexible joints to reduce noise transmission. To prevent the
blower from interfering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Furnace is shipped
with the top flanges in the flat position. Before installing a coil
or ducts, the flanges must be bent 90°. A room, closet, or
alcove must not be used as a return air chamber.
Second Stage
Regulator
Propane Gas Installation (Typ.)
PROPANE GAS PIPING CHARTS
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length,
Feet
10
20
30
40
50
60
80
100
125
150
175
200
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
3/8"
1/2"
5/8"
3/4"
7/8"
1/2"
3/4"
730
500
400
370
330
300
260
220
200
190
170
160
1,700
1,100
920
850
770
700
610
540
490
430
400
380
3,200
2,200
2,000
1,700
1,500
1,300
1,200
1,000
900
830
780
730
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
830
770
720
7,500
4,200
4,000
3,700
3,400
310
2,600
2,300
2,100
1,900
1,700
1,500
When the furnace is used in connection with a cooling unit, the
furnace should be installed in parallel with or on the upstream
side of the cooling unit to avoid condensation in the heating
element. With a parallel flow arrangement, the dampers or other
means used to control the flow of air must be adequate to
prevent chilled air from entering the furnace and, if manually
operated, must be equipped with means to prevent operation of
either unit unless the damper is in the full heat or cool position.
When the furnace is installed without a cooling coil, it is recommended that a removable access panel be provided in the
outlet air duct. 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 visual light inspection or such that
a sampling probe can be inserted into the airstream. The access panel must be made to prevent air leaks when the furnace
is in operation.
Sizing Between Second Stage and Appliance Regulator*
Maxim um Propane Capacities lis ted are bas ed on 2 ps ig pres s ure drop at 10 ps ig s etting.
Capacities in 1,000 BTU /hour.
Pipe or
Tubing
Length,
Feet
10
20
30
40
50
60
80
100
125
150
200
250
Nominal Pipe Size
S chedule 40
Tubing Size, O.D. Type L
3/8"
1/2"
5/8"
3/4"
7/8"
1-1/8"
1/2"
3/4"
1"
39
26
21
19
18
16
13
11
10
9
8
8
92
62
50
41
37
35
29
26
24
21
19
17
199
131
107
90
79
72
62
55
48
43
39
36
329
216
181
145
131
121
104
90
81
72
66
60
501
346
277
233
198
187
155
138
122
109
100
93
935
630
500
427
376
340
289
255
224
202
187
172
275
189
152
129
114
103
89
78
69
63
54
48
567
393
315
267
237
217
185
162
146
132
112
100
1,071
732
590
504
448
409
346
307
275
252
209
185
1-1/4" 1-1/2"
2,205
1,496
1,212
1,039
913
834
724
630
567
511
439
390
3,307
2,299
1,858
1,559
1,417
1,275
1,066
976
866
787
665
590
NOTE: In a horizontal installation the air conditioning coil
must be adequately supported by proper brackets and
supports. Inadequate coil support can result in furnace cabinet
distortion and air leakage.
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.
CIRCULATING AIR AND FILTERS
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 a duct sealed
to the furnace casing and terminating outside the space containing the furnace.
DUCTWORK - AIR FLOW
WARNING
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY.
CHECKING DUCT STATIC
Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace.
Ductwork should be designed in accordance with the recommended methods of “Air Conditioning Contractors of America”
Manual D.
Refer to your furnace rating plate for the maximum ESP (external duct static) rating.
Total external static refers to everything external to the furnace
cabinet. Cooling coils, filters, ducts, grilles, registers must all
be considered when reading your total external static pressure. The supply duct pressure must be read between the fur-
22
START-UP PROCEDURE AND ADJUSTMENT
nace and the cooling coil. This reading is usually taken by FILTERS - READ THIS SECTION BEFORE INSTALLING THE
removing the “A” shaped block off plate from the end on the RETURN AIR DUCTWORK
coil; drilling a test hole in it and reinstalling the block off plate.
Take a duct static reading at the test hole. Tape up the test Filters must be used with this furnace. Discuss filter maintehole after your test is complete. The negative pressure must be nance with the building owner. Filters do not ship with this
read between the filter and the furnace blower.
furnace, but must be provided by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is
Too much external static pressure will result in insufficient air installed without filters, the warranty will be voided.
that can cause excessive temperature rise. This can cause
limit switch tripping and heat exchanger failure.
NOTE: An undersized opening will cause reduced airflow. The
bottom return is set up as a knock out.
To determine total external duct static pressure, proceed as
UPRIGHT INSTALLATIONS
follows;
1. With clean filters in the furnace, use a draft gauge
Depending on the installation and/or customer preference, dif(inclined manometer) to measure the static pressure of
fering filter arrangements can be applied. Filters can be inthe return duct at the inlet of the furnace. (Negative
stalled in the central return register or a side panel external
Pressure)
filter rack kit (upflows), or the ductwork above a downflow fur2. Measure the static pressure of the supply duct. (Positive
nace. As an alternative, a media air filter or electronic air cleaner
Pressure)
can be used as the primary filter.
3. The difference between the two numbers is .4” w.c.
CIRCULATION AIR FILTERS
Example:
static reading from return duct = -.1" w.c.
static reading from supply duct = .3" w.c.
total external static pressure on this system = .4" w.c.
One of the most common causes of a problem in a forced air
heating system is a blocked or dirty filter. Circulating air filters
must be inspected monthly for dirt accumulation and replaced
NOTE: Both readings may be taken simultaneously and read if necessary. Failure to maintain clean filters can cause premadirectly on the manometer if so desired. If an air conditioner ture heat exchanger failure.
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components, A new home may require more frequent replacement until all
construction dust and dirt is removed. Circulating air filters are
as shown in the following drawing.
to be installed in the return air duct external to the furnace
4. Consult proper tables for the quantity of air.
cabinet.
If the total external static pressure exceeds the maximum listed
on the furnace rating plate, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.
MINIMUM FILTER SIZES for DISPOSABLE FILTERS
FURNACE INPUT
FILTER SIZE
40M
320 in2
60M
483 in2
80M
640 in2
100M
800 in2
120M
738 in2
140M
738 in2
DISPOSABLE NOMINAL 300 F.M. FACE VELOCITY
HORIZONTAL INSTALLATIONS
Filters must be installed in either the central return register or
in the return air duct work.
SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL)
Refer to Timing Charts for sequencing.
NOTE: Dip switch positions referenced in this section applies
to *(M,D)H8 models only.
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
POWER UP
• 115 VAC power applied to furnace.
• Integrated ignition control performs internal checks.
• Integrated ignition LED will light.
23
START-UP PROCEDURE AND ADJUSTMENT
• Integrated ignition control monitors safety circuits
• Circulator blower is energized on low heat speed following
continuously.
a fixed thirty second blower on delay. Electronic air
cleaner terminals are energized with circulator blower.
• Furnace awaits call from thermostat.
• Furnace is now operating in low-stage heating mode.
• Furnace operates; integrated control module monitors
HEATING MODE
safety circuits continuously.
(MODE DIP SWITCH IS SET TO “1 STG” POSITION)
• If low-stage delay period expires, control will shift
The normal operational sequence in heating mode is as follows:
• R and W thermostat contacts close, initiating a call for
heat.
operation from low-stage heating mode operation to highstage heating mode operation. Control will energize
circulator blower high heat speed and high stage gas
valve.
Furnace is now operating in high-stage heating mode.
• Integrated control module performs safety circuit checks.
• Induced draft blower is energized for 15 second pre-purge
•
• R and W thermostat contacts open, completing the call
period causing pressure switch contacts to close.
Igniter warm up begins after 15 second prepurge expires.
for heat.
Induced draft blower is de-energized following a fifteen
second post purge.
Circulator blower is de-energized following a heat off delay
period (selectable 100 or 150 seconds; factory set at
150 seconds).
If the furnace is operating in the low-stage heating mode
when thermostat contacts open, circulator remains at
low heat speed for the selected delay off period.
If the furnace is operating in high-stage heating mode
when the thermostat contacts open, the circulator blower
remains at high heat speed for the selected heat off delay
period.
•
• Low and high-stage gas valves open at end of igniter
•
•
•
warm up period, delivering gas to burners and establishing
flame.
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
• Circulator blower is energized on high heat speed following
•
•
a fixed thirty second blower on delay. Electronic air
cleaner terminals are energized with circulator blower.
Furnace operates; integrated control module monitors
safety circuits continuously.
R and W thermostat contacts open, completing the call
for heat.
• Gas valve closes, extinguishing flame.
• Induced draft blower is de-energized following a fifteen
•
second post purge.
The circulator blower remains on high speed for the
selected heat off delay period.
• Furnace awaits the next call from thermostat.
• Furnace awaits the next call from thermostat.
COOLING MODE
The normal operational sequence in cooling mode is as follows:
• R and Y thermostat contacts close, initiating a call for
cool.
• Integrated control module performs safety circuit checks.
• Outdoor fan and compressor are energized.
• Circulator blower is energized on cool speed following a
(MODE DIP SWITCH IS SET TO “2 STG” POSITION)
The normal operational sequence in sequence is as follows:
• R and W thermostat contacts close, initiating a call for
heat.
fixed five second on delay. Electronic air cleaner
terminals are energized with circulator blower.
• Furnace circulator blower and outdoor cooling unit run,
• Integrated control module performs safety circuit checks.
• Induced draft blower is energized for 15 second prepurge
•
period causing pressure switch contacts to close.
Igniter warm up begins after 15 second prepurge expires.
•
• Low and high-stage gas valves open at end of igniter
•
•
integrated control module monitors safety circuits
continuously.
R and Y thermostat contacts open, completing the call
for cool.
Outdoor fan and compressor are de-energized.
•
• Circulator blower is de-energized following a fixed forty
warm up period, delivering gas to burners and establishing
flame.
High-stage gas valve closes after five seconds; low-stage
gas valve remains open.
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
•
24
five second cool off delay period. Electronic air cleaner
terminals are de-energized.
Furnace awaits the next call from thermostat.
START-UP PROCEDURE AND ADJUSTMENT
FAN ONLY MODE
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
The normal operational sequence in fan only mode is as follows:
NOTE: This furnace is equipped with an ignition device which
• R and G thermostat contacts close, initiating a call for
automatically lights the burner. Do not try to light the burner by
fan.
hand.
5. White-Rodgers Model 36G22 or 36G54: Push the switch
• Integrated control module performs safety circuit checks.
to the OFF position.
• Circulator blower is energized on low heat speed.
Honeywell VR8215 or VR9205: Slide the switch to the
Electronic air cleaner terminals are energized.
OFF position.
• Circulator blower runs, integrated control module
6. Wait five minutes to clear out any gas. Then smell for
monitors safety circuits continuously.
gas, including near the floor.
• R and G thermostat contacts open, completing the call
7. If gas can be smelled following the five minute waiting
for fan.
period in Step 6, immediately follow the instructions on
• Circulator blower is de-energized. Electronic air cleaner
Page 3 of this manual. If you do not smell gas after five
terminals are de-energized.
minutes:
• Furnace awaits the next call from thermostat.
White-Rodgers Model 36G22 or 36G54: Push the switch
to the ON position.
START-UP PROCEDURE AND ADJUSTMENT
Honeywell VR8215 or VR9205: Slide the switch to the
ON position.
Furnace must have a 115 VAC power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. An interlock switch prevents furnace operation if the
blower door is not in place. Keep the blower access door in
place except for inspection and maintenance.
8. Replace the door on the front of the furnace.
9. Open the manual gas valve external to the furnace.
10. Turn on the electrical power supply to the furnace.
This furnace is also equipped with a self-diagnosing electronic 11. Set the room thermostat to the desired temperature.
control module. In the event a furnace component is not operatNOTE: There is an approximate 30 second delay between thering properly, the control module LED will flash on and off in a
mostat energizing and burner firing.
factory-programmed sequence, depending on the problem encountered. This light can be viewed through the observation FURNACE SHUTDOWN
window in the blower access door. Refer to the Troubleshoot1. Set the thermostat to lowest setting.
ing Chart for further explanation of the lighting codes.
2. Turn off the electrical power supply to the furnace.
Follow the start-up and adjustment items, refer to further infor3. Set the room thermostat to the lowest possible setting.
mation in Section XIII, Operational Checks (see table of con4. Remove the burner compartment door.
tents, pages 2-3 for page number)..
5. White-Rodgers Model 36G54: Push switch to the OFF
position.
FURNACE OPERATION
Purge gas lines of air prior to start-up. Do not purge lines into
an enclosed burner compartment.
Honeywell VR8215 or VR9205: Slide the switch to the
OFF position.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other
approved method. Verify that all required kits (propane gas,
high altitude, etc.) have been appropriately installed.
6. Close manual gas shutoff valve external to the furnace.
7. Replace the door on the unit.
GAS SUPPLY PRESSURE MEASUREMENT
NOTE: An interlock switch prevents furnace operation if the
blower door is not in place. Keep the blower access doors in
place except for inspection and maintenance.
FURNACE START-UP
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
25
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
START-UP PROCEDURE AND ADJUSTMENT
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or inlet pressure boss (WhiteRodgers valve).
5. Turn ON the gas supply.
6. Turn On power and close thermostat “R” and “W” contacts
to provide a call for heat.
7. Using a leak detection solution or soap suds, check for
leaks at outlet pressure boss plug (Honeywell valve) or
screw (White-Rodgers valve). Bubbles forming indicate
a leak. SHUT OFF GAS AND REPAIR ALL LEAKS
IMMEDIATELY!
8. Measure the gas supply pressure with burners firing.
Adjust supply pressure using the Inlet Gas Supply
Pressure table shown below. If supply pressure reading
differs from the table, make necessary adjustments to
pressure regulator, gas piping size, etc., and/or consult
with local gas utility.
WARNING
HIGH VOLTAGE !
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH.
MODELS USING SINGLE STAGE GAS VALVES
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured
at the gas valve inlet pressure tap or at a hose fitting installed in
the gas piping drip leg. The supply pressure must be measured with the unit OFF. To measure inlet pressure, use the
following procedure.
Gas Valve
On/Off
Selector
Switch
Inlet Pressure
Tap
Natural Gas
Propane Gas
9. Turn OFF all electrical power and gas supply to the
system.
10. Remove the manometer hose from the hose barb fitting
or inlet pressure boss.
11. Replace inlet pressure tap:
a. Honeywell VR8215 valve:
Remove the 1/8” NPT hose barb fitting from the inlet
pressure tap. Replace the inlet pressure boss plug
and seal with a high quality thread sealer.
b. White-Rodgers 36G22 valve:
Turn inlet pressure test screw in to seal pressure port
(clockwise, 7 in-lb minimum).
12. Retest for leaks. If bubbles form, shut down gas and
repair leaks immediately.
13. Turn ON electrical power and gas supply to the system.
14. Turn valve switch ON.
INLET
OUTLET
Pressure Regulator
Adjustment
(Under Cap Screw)
Outlet Pressure
Tap
White-Rodgers Model 36G22
Pressure Regulator
(under cap screw)
Outlet
Pressure
Tap
Inlet
Pressure
Tap
Inlet Gas Supply Pressure
Minimum:5.0" W.C. Maximum :10.0" W.C.
Minimum:11.0" W.C. Maximum :13.0" W.C.
MODELS USING TWO STAGE GAS VALVES
CAUTION
Gas Valve On/Off
Selector Switch
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.
Honeywell Model VR8215 (Single-Stage)
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Turn OFF all electrical power to the system.
3. Inlet pressure tap connections:
a. Honeywell VR8215 Valve:
Remove the inlet pressure boss plug. Install an 1/8”
NPT hose barb fitting into the outlet pressure tap.
b. White-Rodgers 36G22 valve:
Back inlet pressure test screw (inlet pressure boss)
out one turn (counterclockwise, not more than one
turn).
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured
at the gas valve inlet pressure boss or at a hose fitting installed
in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply
pressure, use the following procedure.
26
START-UP PROCEDURE AND ADJUSTMENT
Manometer
Hose
Open to
Atmosphere
INLET
OUTLET
Common
Terminal(C)
High Fire Coil
Terminal (HI)
Low Fire Coil
Terminal (LO)
i
Gas Valve On/Off
Selector Switch
Inlet Pressure Tap
1/8 NPT
White-Rodgers Model 36G54 (Two-Stage)
Open to
Atmosphere
Manometer
Manometer
Hose
Outlet
Pressure Boss
High Fire Regulator
Adjust
Regulator
Vent
Outlet Pressure Tap
1/8 NPT
Honeywell Model VR9205 Connected to Manometer
Inlet
Pressure
Boss
Manometer
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
boss or the gas piping drip leg. See Honeywell VR9205
gas valve figure or White-Rodgers 36G54 gas valve figure
for location of inlet pressure boss.
Low Fire
Regulator
Adjust
High Fire Coil
Coaxial Coil
Terminal (HI)
Terminal (M)
Common
On/Off Switch
Terminal(C)
White-Rodgers Model 36G54 Connected to Manometer
Regulator
Vent
Gas Valve On/Off
Selector Switch
High Fire
Regulator
Adjust
NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205 gas valve, a field-supplied hose barb fitting must be
installed prior to making the hose connection. If using the inlet
pressure boss on the White-Rodgers 36G54 gas valve, then
use the 36G Valve Pressure Check Kit, Goodman Part No.
0151K00000S.
3. Turn ON the gas supply and operate the furnace and all
other gas consuming appliances on the same gas supply
line.
4. Measure furnace gas supply pressure with burners firing.
Supply pressure must be within the range specified in
the Inlet Gas Supply Pressure table.
Low Fire
Regulator
Adjust
Honeywell Model VR9205 (Two-Stage)
Natural Gas
Propane Gas
Inlet Gas Supply Pressure
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or
consult with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in
step 3.
27
START-UP PROCEDURE AND ADJUSTMENT
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
5. Turn ON the gas supply.
6. Turn ON power and close thermostat “R” and “W”
contacts to provide a call for heat.
7. Using a leak detection solution or soap suds, check for
leaks at outlet pressure boss plug (Honeywell valve) or
screw (White-Rodgers valve). Bubbles forming indicate
a leak. SHUT OFF GAS AND REPAIR ALL LEAKS
IMMEDIATELY!
8. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
Gas Line
Gas
Shutoff
Valve
Gas Line
To Furnace
Drip Leg Cap
With Fitting
Manometer Hose
Manifold Gas Pressure
Natural Gas
3.5" w.c.
Propane Gas
10.0" w.c.
Measuring Inlet Gas Pressure (Alt. Method)
9. Remove regulator cover screw from the outlet pressure
regulator and turn screw clockwise to increase pressure
or counterclockwise to decrease pressure. Replace
regulator cover screw.
10. Turn OFF all electrical power and gas supply to the
system.
11. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
12. Replace outlet pressure tap:
a. Honeywell VR8215 valve:
Remove the 1/8” NPT hose barb fitting from the outlet
pressure tap. Replace the outlet pressure boss plug
and seal with a high quality thread sealer.
b. White-Rodgers 36G22 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
13. Turn ON electrical power and gas supply to the system.
14. Close thermostat contacts to provide a call for heat.
15. Retest for leaks. If bubbles form, SHUT OFF GAS AND
REPAIR ALL LEAKS IMMEDIATELY!
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.
WARNING
HIGH VOLTAGE !
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH.
MODELS USING SINGLE STAGE GAS VALVES
This valve is shipped from the factory with the regulator preset
(see control label).
Consult the appliance rating plate to ensure burner manifold
pressure is as specified. If another outlet pressure is required,
follow these steps.
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Turn OFF all electrical power to the system.
3. Outlet pressure tap connections:
a. Honeywell VR8215 valve:
Remove the outlet pressure boss plug. Install an 1/8”
NPT hose barb fitting into the outlet pressure tap.
b. White-Rodgers 36G22 valve:
Back outlet pressure test screw (outlet pressure boss)
out one turn (counterclockwise, not more than one
turn).
MODELS USING TWO STAGE GAS VALVES
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.
Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure
must be measured with the burners operating. To measure
and adjust the manifold pressure, use the following procedure.
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Turn off all electrical power to the system.
28
START-UP PROCEDURE AND ADJUSTMENT
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)
3. Outlet pressure tap connections:
a. Honeywell VR9205 valve: Remove the outlet pressure
boss plug. Install an 1/8" NPT hose barb fitting into
the outlet pressure tap.
b. White-Rodgers 36G54 valve: Back outlet pressure test
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
7. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
8. Remove regulator cover screw from the low (LO) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
9. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.
10. Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
13. Replace outlet pressure tap:
a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
14. Turn on electrical power and gas supply to the system.
15. Close thermostat contacts “R” and “W1/W2” to energize
the valve.
The gas input rate to the furnace must never be greater than
that specified on the unit rating plate. To measure natural gas
input using the gas meter, use the following procedure.
1. Turn OFF the gas supply to all other gas-burning
appliances except the furnace.
2. While the furnace is operating, time and record one
complete revolution of the smallest gas meter dial.
3. Calculate the number of seconds per cubic foot (sec/ ft3)
of gas being delivered to the furnace. If the dial is a one
cubic foot dial, divide the number of seconds recorded in
step 2 by one. If the dial is a two cubic foot dial, divide
the number of seconds recorded in step 2 by two.
4. Calculate the furnace input in BTUs per hour (BTU/ hr).
Input equals the installation’s gas heating value multiplied
by a conversion factor (hours to seconds), divided by
the number of seconds per cubic foot. The measured
input must not be greater than the input indicated on the
unit rating plate.
EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3
Input = 106,000 BTU/hr
This measured input must not be greater than the input
indicated on the unit rating plate.
5. Turn ON gas and relight appliances turned off in step 1.
Ensure all the appliances are functioning properly and
that all pilot burners are operating.
TEMPERATURE RISE
Air temperature rise is the temperature difference between supply
and return air. The proper amount of temperature rise is usually obtained when the unit is operated at the rated input with
the “as shipped” blower speed. If the correct amount of temperature rise is not obtained, it may be necessary to change
the blower speed.
Using a leak detection solution or soap suds, check for leaks
at outlet pressure boss plug (Honeywell valve) or screw (WhiteRodgers valve). Bubbles forming indicate a leak. SHUT OFF
GAS AND REPAIR ALL LEAKS IMMEDIATELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriate conversion.
M anifold Gas Pressure
Gas
Range
Natural
Low Stage 1.6 - 2.2" w .c.
High Stage 3.2 - 3.8" w .c.
Propane
Low Stage 5.7 - 6.3" w .c.
High Stage 9.7 - 10.3" w .c.
Nom inal
1.9" w .c.
3.5" w .c.
6.0" w .c.
10.0" w .c.
An incorrect temperature rise can cause condensing in or overheating of the heat exchanger. Determine and adjust the temperature rise as follows. The temperature rise must be within
the range specified on the rating plate or Specification Sheet
applicable to your model. (Please contact your distributor or
our website for the applicable Specification Sheet referred to
in this manual.)
29
START-UP PROCEDURE AND ADJUSTMENT
3. Relocate desired motor leads to the circulator blower
heat and cool speed terminals on the integrated control
module. (Terminals are identified as LO HEAT, HI HEAT
and COOL (hot)) for *(M,D)H8 models and HEAT and
COOL for *(M,H,D)S8 models). If a heating speed and
the cooling speed are the same, a jumper wire must be
used between the heat and cool terminals.
4. Connect all unused blower motor leads to the “PARK”
terminals on the integrated control module. Any leads
not connected to the “PARK” terminals must be taped.
5. Turn ON power to furnace.
6. Verify proper temperature rise as outlined in Temperature
Rise section.
SUPPLY
AIR
RETURN
AIR
CIRCULATOR BLOWER FAN TIMING ADJUSTMENT
Temperature Rise Measurement
NOTE: Items in this section refer to the air circulator blower
fan in the *(M,D)H8 models, NOT to the induced draft blower.
The induced draft blower timing sequence is not adjustable.
The circulator blower fan timing is adjustable only on models
with optional “heating fan OFF delay” adjustment pins or
switches. It is NOT adjustable in any other circumstances.
1. Operate furnace with burners firing approximately 15
minutes. Ensure all registers are open and all duct
dampers are in their final (fully or partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must
not be influenced by radiant heat by being able to “see”
the heat exchanger.
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
Refer to the following section for speed changing details.
WARNING
OFF
ON
1
100
SECOND
DELAY
Switch viewed in an upflow installation.
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
Adjustment Switch
This furnace is equipped with a PSC circulator blower motor.
This blower provides ease in adjusting blower speeds. Refer to
the Blower Performance Data in the back of the manual for
proper selection of heating and cooling speeds. The cooling
blower speed is shipped set on HIGH. High heat ships on
MEDIUM and low heat is shipped on MEDIUM-LO. These blower
speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and the correct cooling CFM.
To adjust the circulator blower speed, proceed as follows:
1. Turn OFF power to the furnace.
2. Select the heating and cooling blower speeds that match
the installation requirements from the airflow table in the
Specification Sheet applicable to your model. (Please
contact your distributor or our website for the applicable
Specification Sheet referred to in this manual.)
OFF
CIRCULATOR BLOWER SPEED ADJUSTMENT
ON
150
SECOND
DELAY
1
As shipped, the circulator blower fan will remain on for 150
seconds after the gas valve closes. When a call for cooling
occurs, the circulator fan comes on and remains on for 45 seconds after the call for cooling ends. During normal heating operation, the circulator fan will come on approximately 34 seconds after the gas valve opens.
SETTING FURNACE OPERATING MODE (*DH8, *ME8, AND
*MH8 MODELS ONLY)
This furnace is designed to operate with either a single gas
input rate or with two discrete gas input rates. The Mode
DIP switch is used to select the single gas input rate or two
discrete input rates.
Setting the Mode switch to “1 STG” forces the furnace to
operate at the furnace’s highest input rate only. Operation is
as described under Sequence of Operation (Integrated
Ignition Control) – Mode DIP Switch is set to “1 STG”
position.
30
START-UP PROCEDURE AND ADJUSTMENT
AUXILIARY LIMIT CONTROL
Setting the Mode switch to “2 STG” allows the furnace to
operate at the furnace’s highest input AND at an input rate
that is 75% of the highest input rate. For this mode of
operation, the furnace operates at the low input rate for a
pre-determined time period then steps to the high input rate.
Operation is as described under Sequence of Operation
(Integrated Ignition Control) – Mode DIP Switch is set to “2
STG” position.
Auto reset limits are located on or near the blower. To access
this auxiliary limit, disconnect the electrical power and remove
the blower door. The auxiliary limit control is designed to prevent furnace operation in case of main blower failure on horizontal installations. It may also open if the power supply is
interrupted while the furnace is firing. The auxiliary limit control
is suitable for both horizontal right and horizontal left installations. Regardless of airflow direction, it does not need to be
relocated.
The time period is determined by the 2nd Stg Dly DIP switch.
Setting the 2nd Stg Dly DIP switch to 5 minutes fixes the
delay period at 5 minutes. Setting the 2nd Stg Dly DIP
switch to Auto enables an algorithm that calculates a delay
period based on the heating cycle time and the total cycle
time. The delay period can range from 1 minute to 12
minutes.
WARNING
TO AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP.
OFF ON
M
2 STG
5 MIN
2ND STG DLY
1 STG
SAFETY CIRCUIT DESCRIPTION
AUTO
GENERAL
OPERATIONAL CHECKS
A number of safety circuits are employed to ensure safe and
proper furnace operation. These circuits serve to control any
potential safety hazards and serve as inputs in the monitoring
and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated
control module.
WARNING
TO AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL
COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. ELECTRICAL
COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. CONTACT A
QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
INTEGRATED CONTROL MODULE
SHOULD DEVELOP.
BURNER FLAME
The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft,
and blue (dust may cause orange tips but they must not be
yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not
impinge on the sides of the heat exchanger firing tubes.
Check the burner flames for:
1. Good adjustment
2. Stable, soft and blue
3. Not curling, floating, or lifting off.
Burner Flame
The integrated control module is an electronic device which
controls all furnace operations. Responding to the thermostat,
the module initiates and controls normal furnace operation, and
monitors and addresses all safety circuits. If a potential safety
concern is detected, the module will take the necessary precautions and provide diagnostic information through an LED.
PRIMARY LIMIT
The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures. It is an
automatic reset, temperature sensor. The limit guards against
the overheating resulting from insufficient air passing over the
heat exchanger.
AUXILIARY LIMIT
The auxiliary limit control is located either on or near the circulator blower and monitors heat exchanger compartment temperatures. The control is an automatic reset, temperature
sensor. It guards against overheating resulting from insufficient
air passing over the heat exchanger.
31
OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
ROLLOUT LIMITS
DIAGNOSTIC CHART
The rollout limit controls are mounted on the burner/manifold
assembly and monitor the burner flame. They are manualreset, temperature sensors. This limit guards against burner
flames not being properly drawn into the heat exchanger.
Refer to the troubleshooting chart in the Appendix for assistance in determining the source of unit operational problems.
The red diagnostic LED blinks to assist in troubleshooting the
unit. The number of blinks refer to a specific code.
PRESSURE SWITCHES
NOTE: To clear all alarm codes, depress the push button for 6
seconds.
The pressure switches are normally-open, negative air pressure-activated switches. They monitor the airflow (combustion
air and flue products) through the heat exchanger via pressure
taps located on the induced draft blower. These switches guard
against insufficient airflow (combustion air and flue products)
through the heat exchanger.
FAULT RECALL
TROUBLESHOOTING
RESETTING FROM LOCKOUT
The ignition control is equipped with a momentary push button
switch that can be used to display on the diagnostic LED the
last five faults detected by the control. The control must be in
Standby Mode (no thermostat inputs) to use the feature. Depress the pushbutton switch for approximately 2 seconds. ReFLAME SENSOR
lease the switch when the LED is turned off. The diagnostic
The flame sensor is a probe mounted to the burner/manifold LED will then display the flash codes associated with the last
assembly which uses the principle of flame rectification to de- five detected faults. The order of display is the most recent fault
to the least recent fault.
termine the presence or absence of flame.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
Furnace lockout results when a furnace is unable to achieve
ignition after three attempts. It is characterized by a non-functioning furnace and a one flash diagnostic LED code from the
red LED. If the furnace is in “lockout”, it will (or can be) reset in
any of the following ways.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
2. Manual power interruption. Interrupt 115 volt power to
the furnace for 1 - 20 seconds.
3. Manual thermostat cycle. Lower the thermostat so that
there is no longer a call for heat for 1 - 20 seconds then
reset to previous setting.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and uninstalled
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
NOTE: If the condition which originally caused the lockout still
control prior to discharging your body’s electrostatic
exists, the control will return to lockout. Refer to the Diagnostic
charge to ground.
Chart for aid in determining the cause.
2. Firmly touch a clean, unpainted, metal surface of the
MAINTENANCE
furnace away from the control. Any tools held in a
person’s hand during grounding will be discharged.
WARNING
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT not to recharge your body with static electricity; (i.e., do
ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU not move or shuffle your feet, do not touch ungrounded
MUST HANDLE THE IGNITER , HANDLE WITH CARE. TOUCHING THE objects, etc.). If you come in contact with an ungrounded
IGNITER ELEMENT WITH BARE FINGERS, ROUGH HANDLING , OR object, repeat step 2 before touching control or wires.
VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE 4. Discharge your body to ground before removing a new
FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE control from its container. Follow steps 1 through 3 if
IGNITER.
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
32
TROUBLESHOOTING & MAINTENANCE
ANNUAL INSPECTION
FILTER REMOVAL
The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure
that all furnace components are in proper working order and
that the heating system functions appropriately. Pay particular
attention to the following items. Repair or service as necessary.
•
Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
•
Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
•
Burners. Check for proper ignition, burner flame, and
flame sense.
•
Wiring. Check electrical connections for tightness and/
or corrosion. Check wires for damage.
•
Filters.
Depending on the installation, differing filter arrangements can
be applied. Filters can be installed in either the central return
register or a side panel external filter rack (upflow only). A
media air filter or electronic air cleaner can be used as an alternate filter. Follow the filter sizes given in the Recommended
Minimum Filter size table or instruction provided by the media
or electronic air cleaner manufacturer to ensure proper unit
performance.
FILTERS
WARNING
To remove filters from an external filter rack in an upright upflow
installation, follow the directions provided with external filter
rack kit. For further details, see your distributor.
INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the flame sensor. This coating acts
as an insulator causing a drop in the flame sense signal. If the
flame sense signal drops too low the furnace will not sense
flame and will lock out. The flame sensor should be carefully
cleaned by a qualified servicer using emery cloth or steel wool.
Following cleaning, the flame sense signal should be 1 to 6
A return air filter is not supplied with this furnace; however,
microamps at 115 volts.
there must be a means of filtering all of the return air. The installer will supply filter(s) at the time of installation.
IGNITER (QUALIFIED SERVICER ONLY)
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE REMOVING FILTERS. NEVER OPERATE FURNACE WITHOUT A FILTER INSTALLED BECAUSE DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAGE AND POSSIBLE FIRE.
FILTER MAINTENANCE
If the igniter and the surrounding air are at about 70°F and the
igniter wires are not connected to any other electrical compoImproper filter maintenance is the most common cause of innents, the resistance of the igniter should not exceed 75 ohms.
adequate heating or cooling performance. Filters should be
If it does, the igniter should be replaced.
cleaned (permanent) or replaced (disposable) every two months
or as required. When replacing a filter, it must be replaced with BURNERS
a filter of the same type and size.
WARNING
WARNING
TO PREVENT PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY HIGH VOLTAGE!
INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. DEATH DUE TO ELECTRICAL SHOCK , DISCONNECT CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL ELECTRICAL POWER TO THE FURNACE BEFORE FLAME APPEARANCE SHOULD DEVELOP.
REMOVING THE FILTER OR PERFORMING ANY OTHER MAINTENANCE.
Periodically during the heating season, make a visual check of
the burner flames. Turn the furnace on at the thermostat. Wait
Become familiar with filter location and procedures for removal, a few minutes, since any dislodged dust will alter the normal
cleaning and replacing them. If help is needed, contact the flame appearance. Flames should be stable, quiet, soft and
blue with slightly orange tips. They should not be yellow. They
installer of the furnace or a qualified servicer.
should extend directly outward from the burner ports without
curling downward, floating or lifting off the ports.
33
TROUBLESHOOTING & MAINTENANCE
CLEANING (QUALIFIED SERVICER ONLY)
REPAIR AND REPLACEMENT PARTS
1. Shut off electric power and gas supply to the furnace.
• When ordering any of the listed functional parts, be sure
to provide the furnace model, manufacturing, and serial
numbers with the order.
2. Disconnect the rollout limit wires, flame sensor wire, and
disconnect the igniter plug.
• Although only functional parts are shown in the parts
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING .
3. Remove four (4) screws securing the burner box top.
CAUTION
THE IGNITER IS FRAGILE AND CAN BE EASILY DAMAGED. USE EXTREME CAUTION WHEN REMOVING THE BURNER BOX TOP.
4. Remove the screws securing the burners to the burner
bracket. Remove the burners.
5. Use bottle brush to clean burner insert and inside of
burner.
6. Replace burner (opposite of removal). Ensure burners
are fully seated on burner bracket and are properly
aligned. Replace burner box top. Reconnect wiring.
7. Turn on electric power and gas supply to the furnace.
list, all sheet metal parts, doors, etc. may be ordered by
description.
• Parts are available from your distributor.
Functional Parts ListGas Valve
Natural Gas Orifice
Propane Gas Orifice
Burner
Hot Surface Igniter
Flame Sensor
Gas Manifold
Ignition Control
Blower Mounting Bracket
Pressure Switch
Pressure Switch Hose
Induced Draft Blower
Collector Box
8. Check furnace for proper operation. Refer to “Operational
Checks” section to verify burner flame characteristics.
BEFORE LEAVING AN INSTALLATION
• Cycle the furnace with the thermostat at least three
times. Verify cooling and fan only operation.
• Review the Owner’s Manual with the homeowner and
discuss proper furnace operation and maintenance.
• Leave literature packet near furnace.
34
Blower/Collector Box Gasket
Primary Limit Switch
Rollout Limit Switch
Auxiliary Limit Switch
Heat Exchanger
Door Switch
Transformer
Blower Wheel
Blower Housing
Blower Cutoff
Blower Motor
Motor Mount Bracket
Capacitor
COMPONENT IDENTIFICATION
1 Tubular Heat Exchanger
2 Pressure Switch
3 Flue Pipe Connection
4 Induced Draft Blower
(Chimney Transition Top Shipped Loose)
躀
5 Gas Line
Entrance
6 Gas Valve
7 Rollout Limit
8 Junction Box
9 Wiring Harness
Grommet
Gas Manifold
Gas Line Entrance
(Alternate)
Inshot Burner
Transformer
Circulator Blower
Blower Door
Interlock Switch
Integrated Control Module
1
2
3
4
5
6
7
8
Tubular Heat Exchanger
Pressure Switch
Flue Pipe Connection
Induced Draft Blower
Gas Line Entrance
Gas Valve
Rollout Limit
Junction Box
9
10
11
12
13
14
15
16
Wiring Harness Grommet
Gas Manifold
Inshot Burner
Transformer
Integrated Control Module
Blower Door Interlock Switch
Circulator Blower
Gas Line Entrance (Alternate)
35
COMPONENT IDENTIFICATION
Inshot Burner
1 Tubular Heat Exchanger
7 Rollout Limit
Gas Manifold
4 Induced Draft Blower
6 Gas Valve
Gas Line Entrance
(Alternate)
8 Junction Box
9 Wiring Harness
Grommet
5 Gas Line
Entrance
2 Pressure Switch
3 Flue Pipe Connection
(Chimney Transition Top Shipped Loose)
Transformer
Integrated Control Module
Circulator Blower
Blower Door
Interlock Switch
1
2
3
4
5
6
7
8
Tubular Heat Exchanger
Pressure Switch
Flue Pipe Connection
Induced Draft Blower
Gas Line Entrance
Gas Valve
Rollout Limit
Junction Box
9
10
11
12
13
14
15
16
36
Wiring Harness Grommet
Gas Manifold
Inshot Burner
Transformer
Integrated Control Module
Blower Door Interlock Switch
Circulator Blower
Gas Line Entrance (Alternate)
TROUBLESHOOTING C HART
Symptoms of
Abnormal Operation
Associated
LED Code2
Fault
Description(s)
Possible
Causes
• Furnace fails to operate.
NONE
• No 115 volt power to
furnace, or no 24
volt power to
integrated control
module.
• Manual disconnect switch
OFF, door switch open, or
24 volt wires improperly
connected or loose.
• Assure 115 and 24 volt
power to furnace
integrated control
module.
• Blown fuse or circuit
breaker.
• Check integrated control
module fuse (3A).
Replace if necessary.
• Integrated control module
diagnostic LED provides
no signal.
• Blown fuse or circuit
breaker.
• Furnace fails to operate.
• Integrated control
module has an
internal fault.
• Furnace fails to operate.
• Integrated control module
diagnostic LED is
flashing ONE (1) flash.
1
1 FLASH
• Furnace lockout due
to an excessive
number of ignition
attempts. (3 total)1
• Auxiliary Limit Open
2
• Integrated control module
diagnostic LED is
flashing TWO (2)
2 FLASHES
flashes.
• Induced draft blower
runs continuously with
no further furnace
operation.
3
• Pressure switch
circuit is closed.
• Turn power OFF
prior to repair.
• Replace integrated
control module
fuse with 3A
automotive fuse.
• Turn power OFF
prior to repair.
• Integrated control module
has an internal fault.
• Replace bad integrated
control module.
• Read precautions
in “Electrostatic
Discharge” section
of manual.
• Failure to establish flame.
Cause may be no gas to
burners, bad igniter or
igniter alignment, improper
orifices, or coated/
oxidized or improperly
connected flame sensor.
• Locate and correct
gas interruption.
• Turn power OFF
prior to repair.
• Replace or realign
igniter.
• Check flame sense
signal. Sand sensor
if coated and/or
oxidized.
• Check flue piping for
blockage, proper
length, elbows, and
termination.
• Verify proper
induced draft blower
performance.
• Insufficient conditioned air
over the heat exchanger.
Blocked filters, restrictive
ductwork, improper
circulator blower speed,
or failed circulator blower.
• Check circulator
blower speed and
performance.
Correct speed or
replace blower if
necessary.
• Induced draft blower
pressure switch contacts
sticking.
• Replace induced
draft blower
pressure switch.
• Induced draft blower
is not operating.
• Shorts in pressure switch
circuit.
• Pressure switch
circuit not closed.
Cautions
& Notes
• Check for possible
shorts in 115 and 24 volt
circuits. Repair as
necessary.
• Loss of flame after
establishment. Cause may
be interrupted gas supply,
lazy burner flames
(improper gas pressure or
restriction in flue or
improper induced draft
blower performance.
• Furnace fails to operate.
Corrective
Action
• Pressure switch hose
blocked, pinched or
connected improperly.
• Induced draft blower
• Blocked flue or weak
is operating.
• Integrated control module 3 FLASHES
induced draft blower.
• If installed, manual
diagnostic LED is
• Incorrect pressure switch
reset limit switch is
flashing THREE (3)
setpoint or malfunctioning
open on Masonry
flashes.
switch contacts.
Vent Kit (MVK).
• Loose or improperly
connected wiring.
• Blockage in flue or
chimney.
• Repair short.
• Clean flame sensor
with steel wool.
• See “Combustion
and Ventilation Air
Requirements” and
“Category I Venting
(Vertical Venting)”
section for details.
• See Product Data
Bulletin for
allowable rise
range and proper
circulator speed.
• Turn power OFF
prior to repair.
• Replace pressure
switch with proper
replacement part.
• Inspect pressure switch • Turn power OFF
prior to repair.
hose. Repair, if necessary,
• See “Combustion
• Inspect flue for blockage, and Ventilation Air
Requirements” and
proper length, elbows,
“Category I Venting
and termination.
(Vertical Venting)”
• Correct pressure switch
section for details.
setpoint or contact
•
Replace
pressure
motion.
switch with proper
• Tighten or correct wiring
replacement part.
connection.
• Replace masonry
• Inspect masonry
vent kit limit switch
chimney and flue; remove with correct
replacement part.
blockage.
1
Integrated control module will automatically attempt to reset from lockout after one hour.
2
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
37
• Igniter is fragile,
handle with care.
TROUBLESHOOTING C HART
Symptoms of
Abnormal Operation
• Circulator blower runs
continuously. No furnace
operation.
• Integrated control module
diagnostic LED is flashing
FOUR (4) flashes.
Associated
Associated
LED Code22
LED Code
4
Fault
Description(s)
• Primary limit
circuit is open.
4 FLASHES
Possible Causes
• Integrated control module
diagnostic LED is flashing
FIVE (5) flashes.
5
• Check primary limit.
Replace if necessary.
• Turn power OFF
prior to repair.
• Check filters and
ductwork for blockage.
Clean filters or remove
obstruction.
• Replace primary
switch with proper
replacement part.
• Faulty primary limit switch.
• Check circulator blower
speed and performance.
Correct speed or replace
blower if necessary.
• Tighten or correct wiring
connection.
• Replace blower
with correct
replacement part.
• Short to ground in flame
sense circuit.
• Correct short at flame
sensor or in flame
sensor wiring.
• Turn power OFF
prior to repair.
• Flame rollout.
• Check burners for proper
alignment.
• See “Vent/Flue Pipe”
section for piping
details.
• Replace induced
draft blower with
proper replacement
part.
5 FLASHES
• Furnace fails to operate.
• Integrated control module
diagnostic LED is flashing
SIX (6) flashes.
• Flame sensed
with no call for
heat.
• Rollout limit open.
6
6 FLASHES
• Integrated control
module fuse is
blown.
• No furnace operation.
• Misaligned burners,
blocked flue and/or air
inlet pipe, or failed
induced draft blower.
• Loose or improperly
connected wiring.
• Short in 24 volt AC
control circuits or safety
circuits.
• Faulty rollout limit.
• Normal furnace
operation.
• Integrated control module
diagnostic LED is
flashing SEVEN (7)
flashes.
2
Cautions
& Notes
• Insufficient conditioned air
over the heat exchanger.
Blocked filters, restrictive
ductwork, improper
circulator blower speed, or
failed circulator blower.
• Loose or improperly
connected wiring.
• Induced draft blower and
circulator blower runs
continuously. No furnace
operation.
Corrective Action
7
7 FLASHES
• Flame sense
microamp signal is
low.
• Check flue and air inlet
piping for blockage,
proper length, elbows,
and termination. Correct
as necessary.
• Check rollout limit. Replace
• Replace integrated
if necessary.
control module fuse
• Check induced draft
with 3A automotive
blower for proper
fuse.
performance. Replace, if
• Read precautions in
necessary.
“Electrostatic
• Tighten or correct wiring
Discharge” section
connection.
of manual.
• Repair short in 24 volt AC
control/safety circuit(s).
• Replace rollout limit
• Replace integrated control
with correct
module fuse (3A).
replacement part.
• Flame sensor is coated/
oxidized.
• Sand flame sensor.
• Turn power OFF
prior to repair.
• Flame sensor incorrectly
positioned in burner
flame.
• Lazy burner flame due to
improper gas pressure or
combustion air.
• Inspect for proper sensor
alignment.
• Clean flame sensor
with steel wool.
• Compare current gas
pressure to rating plate
info. Adjust as needed.
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
38
• See “Vent/Flue
Pipe” section for
piping details.
• See rating plate for
proper gas
pressure.
TROUBLESHOOTING C HART
Symptoms of
Abnormal Operation
Associated
Associated
2
LED
LED Code
Code2
• Furnace not operating.
• Integrated control module
diagnostic LED is
flashing EIGHT (8)
flashes.
Fault
Description(s)
• Problem with
igniter circuit.
Possible Causes
C
• Integrated control module
diagnostic LED is flashing
continuously.
CONTINUOUS
FLASHING
• Polarity of 115
or 24 volt
power is
reversed.
• Check and correct wiring
from integrated control
module to igniter.
• Turn power OFF
prior to repair.
• Bad igniter.
• Replace bad igniter.
• Poor unit ground.
• Poor burner ground.
• Check and correct unit
ground wiring.
• Faulty integrated control
module.
• Replace bad integrated
control module.
• Replace igniter
with proper
replacement part.
• Read precautions
in “Electrostatic
Discharge”
section of manual.
• Polarity of 115 volt AC
power to furnace or
integrated control module
is reversed.
• Review wiring diagram to
correct polarity.
• Red and blue wires to
transformer are reversed.
• Reverse red and blue
wires connected to
transformer.
• Poor unit ground.
2
STEADY
Cautions
& Notes
• Improperly connected
igniter.
8 FLASHES
• Induced draft blower runs
continuously. No furnace
operation.
• LED is steady on
Corrective Action
• Verify proper ground.
Correct if necessary.
• Normal operation.
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
39
• Turn power OFF
prior to repair.
BLOWER PERFORMANCE DATA
*M(H/S)8
(CFM & Temperature Rise vs. External Static Pressure)
Heating Speed
As Shipped
EXTERNAL STATIC PR ESSURE (Inches Water Column)
Tons AC
Model
Motor
Speed
0.1
at 0.5"
0.2
0.3
0.4
0.5
0.6
0.7
0.8
ESP
CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
HIGH
3.0
1521
----
1466
----
1414
----
1373
----
1298
----
1243 1164 1075
*M(H/S)80403A***
MED
2.5
1160
26
1160
26
1132
26
1121
26
1082
27
1042
997
925
(MEDIUM)
MED-LO
2.0
961
31
955
31
948
31
932
32
913
33
882
821
803
LOW
1.5
781
38
785
38
781
38
773
38
761
32
745
716
668
HIGH
3.0
1422
31
1352
33
1307
34
1197
37
1157
38
1092 1075
983
*M(H/S)80603A***
MED
2.5
1098
40
1081
41
1051
42
1039
43
1021
44
983
924
868
(MEDIUM)
MED-LO
2.0
919
48
913
49
892
50
847
----
829
----
818
792
728
LOW
1.5
758
----
741
----
741
----
733
----
699
----
677
649
626
HIGH
4.0
2134
21
2100
21
2042
22
1975
23
1883
24
1786 1700 1601
*M(H/S)80604B***
MED
3.5
1668
27
1663
27
1656
27
1645
27
1616
28
1549 1492 1391
(MEDIUM)
MED-LO
3.0
1419
31
1426
31
1426
31
1432
31
1419
31
1378 1328 1261
LOW
2.5
1134
39
1145
39
1166
38
1171
38
1160
38
1144 1111 1071
HIGH
3.0
1607
37
1572
38
1547
39
1498
40
1448
41
1390 1302 1222
*M(H/S)80803B***
MED
2.5
1159
51
1156
51
1145
52
1127
53
1108
53
1075 1033
957
(MEDIUM)
MED-LO
2.0
938
63
916
65
916
65
900
----
889
----
865
829
785
LOW
1.5
785
----
766
----
743
----
730
----
709
----
683
666
604
HIGH
4.0
2051
----
1983
----
1895
----
1812
----
1725
----
1627 1530 1439
*M(H/S)80804B***
MED
3.5
1736
----
1708
35
1652
36
1611
37
1540
38
1475 1394 1307
(MEDIUM)
MED-LO
3.0
1693
35
1668
36
1459
41
1429
41
1389
43
1339 1274 1204
LOW
2.5
1200
49
1185
50
1180
50
1173
51
1158
51
1125 1125 1080
HIGH
5.0
2290
----
2229
----
2155
----
2047
----
1960
----
1837 1712 1584
*M(H/S)80805C***
MED
4.0
1852
----
1820
----
1777
----
1719
---
1641
36
1567 1469 1382
(MEDIUM)
MED-LO
3.5
1615
37
1592
37
1556
38
1516
39
1470
40
1405 1346 1235
LOW
3.0
1290
46
1285
46
1265
47
1235
48
1214
49
1174 1044
HIGH
5.0
2323
----
2225
----
2120
35
2040
36
1974
38
1801 1688 1577
*M(H/S)81005C***
MED
4.0
1858
40
1847
40
1799
41
1744
42
1674
44
1577 1493 1399
(MEDIUM)
MED-LO
3.5
1596
46
1587
47
1571
47
1552
48
1493
50
1397 1326 1217
LOW
3.0
1291
57
1272
58
1261
59
1257
59
1205
61
1168 1118 1060
HIGH
5.0
2469
----
2389
----
2300
----
2223
40
2131
42
2027 1902 1786
*M(H/S)81205D***
MED
4.0
1575
56
1558
57
1545
58
1513
59
1500
59
1419 1354 1271
(MEDIUM)
MED-LO
3.5
1402
63
1380
64
1343
66
1319
67
1296
69
1245 1183 1106
LOW
3.0
1200
----
1186
----
1161
----
1127
----
1082
----
1042
HIGH
5.0
2469
42
2389
43
2300
45
2223
47
2131
49
2027 1902 1786
*M(H/S)81405D***
MED
4.0
1575
66
1558
67
1545
67
1513
69
1500
69
1419 1354 1271
(MEDIUM)
MED-LO
3.5
1402
----
1380
----
1343
----
1319
----
1296
----
1245 1183 1106
LOW
3.0
1200
----
1186
----
1161
----
1127
----
1082
----
1042
40
995
995
904
926
926
BLOWER PERFORMANCE DATA
*(D/H)S8
(CFM & Temperature Rise vs. External Static Pressure)
Model
Motor
Speed
Heating Speed
As Shipped
EXTERNAL STATIC PRESSURE (Inches Water Column)
Tons AC
0.1
at 0.5"
ESP
0.2
0.3
0.4
0.5
0.6
0.7
0.8
CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
H IGH
3.0
1353
----
1290
----
1246
----
1199
25
1149
26
1116 1116 1099
GDS80403A***
MED
2.5
1183
25
1113
27
1098
27
1052
28
1039
29
1006 1012
969
(MEDIUM)
MED-LO
2.0
980
30
946
31
920
32
900
33
896
33
885
855
804
LOW
1.5
778
38
762
39
738
40
746
40
738
40
717
696
678
H IGH
3.0
1290
34
1236
36
1194
37
1166
38
1176
38
1166 1108 1029
GDS80603A***
MED
2.5
1139
39
1090
41
1035
43
1063
42
1063
42
1020
962
895
(MEDIUM)
MED-LO
2.0
962
46
927
48
925
48
941
47
909
49
877
834
779
LOW
1.5
787
56
776
57
763
58
744
60
723
----
690
641
581
H IGH
4.0
2128
----
2063
----
2001
----
1927
----
1824
----
1726 1628 1529
GDS80804B***
MED
3.5
1840
----
1788
----
1745
----
1689
35
1625
36
1550 1470 1364
(MEDIUM)
MED-LO
3.0
1602
37
1558
38
1543
38
1493
40
1455
41
1402 1328 1239
LOW
2.5
1277
46
1252
47
1244
48
1229
48
1214
49
1179 1141 1079
H IGH
5.0
2405
----
2361
----
2250
----
2161
-----
2037
36
1937 1808 1689
GDS81005C***
MED
4.0
1880
39
1838
40
1794
41
1734
43
1677
44
1568 1510 1401
(MEDIUM)
MED-LO
3.5
1659
45
1630
45
1587
47
1537
48
1492
50
1445 1368 1287
LOW
3.0
1472
50
1454
51
1404
53
1366
54
1326
56
1300 1228 1139
(CFM & Temperature Rise vs. External Static Pressure)
Model
Heating Speed
As Shipped
Motor
Speed
EXTERNAL STATIC PRESSURE (Inches Water Column)
Tons AC
at 0.5"
ESP
0.1
0.2
0.3
0.4
0.6
0.5
0.7
0.8
CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE
HIGH
3.0
1739
----
1656
----
1601
----
1551
----
1513
20
1460 22.8
1413 23.6 1353 24.6
GHS80403A***
MED
2.5
1422
21
1399
21
1378
22
1350
22
1305
23
1275 26.1
1220 27.3 1178 28.3
(MEDIUM)
MED-LO
2.0
1207
25
1213
24
1197
25
1169
25
1158
26
1131 29.5
1103 30.2 1068 31.2
LOW
1.5
991
30
980
30
958
31
950
31
937
32
924
HIGH
4.0
2097
21
2068
21
2012
22
1939
23
1869
24
1795 28.9
36.1
1718 30.2 1631 31.8
GHS80604B***
MED
3.5
1596
28
1566
28
1534
29
1492
30
1445
31
1401
1354 38.3 1288 40.3
(MEDIUM)
MED-LO
3.0
1380
32
1356
33
1328
33
1303
34
1274
35
1239 41.8
1192 43.5 1127
LOW
3.0
1239
36
1191
37
1165
37
1133
39
1104
40
1082 47.9
1040 49.9
37
910
36.6
874
996
38.1
46
52.1
HIGH
5.0
2382
----
2315
----
2234
----
2158
----
2078
----
1971 33.8
1866 35.7 1762 37.8
GHS80805C***
MED
4.0
1622
37
1603
37
1583
37
1556
38
1516
39
1482
1422 46.9 1359 49.1
(MEDIUM)
MED-LO
3.5
1436
41
1391
43
1387
41
1356
44
1325
45
1279 52.1
1239 53.8 1180 56.5
LOW
3.0
1240
48
1214
49
1191
50
1157
51
1120
53
1083 61.6
1052 63.4 1025
41
45
65
BLOWER PERFORMANCE DATA
GME8
(CFM & Temperature Rise vs. External Static Pressure)
Heating Speed
As Shipped
GME80603B***
GME80805C***
GME81005C***
EXTERNAL STATIC PRESSURE (Inches Water Column)
Tons AC
Model
Motor Speed
at 0.5"
ESP
0.1
0.2
0.3
0.4
0.5
0.6
0.8
CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
T1 - YELLOW
1.5
875
----
793
----
736
----
674
----
592
----
556
509
460
T2 - RED
2.0
1032
43
965
46
914
49
861
----
810
----
756
712
659
T3 - ORANGE
2.5
1217
37
1153
39
1098
40
1051
42
1009
44
964
918
877
T4 - BLUE
3.0
1365
33
1313
34
1268
35
1221
36
1172
38
1129 1086 1054
T5 - BLACK
3.5
1549
29
1505
30
1460
30
1420
31
1378
32
1350 1305 1268
T1 - YELLOW
2.5
1268
47
1198
49
1151
51
1092
54
1041
57
988
T2 - RED
3.0
1362
44
1305
45
1261
47
1212
49
1170
51
1121 1074 1021
T3 - ORANGE
3.5
1576
38
1519
39
1473
40
1426
42
1398
42
1341 1290 1252
T4 - BLUE
4.0
1755
----
1711
35
1657
36
1627
36
1579
38
1548 1502 1463
T5 - BLACK
5.0
2183
----
2128
----
2094
----
2060
----
2014
----
1992 1944 1847
T1 - YELLOW
3.0
1466
51
1415
52
1357
55
1306
57
1248
59
1202 1144 1088
T2 - RED
3.5
1642
45
1596
46
1552
48
1499
49
1449
51
1388 1352 1306
932
883
T3 - ORANGE
4.0
1750
42
1750
42
1707
43
1667
44
1610
46
1574 1531 1486
T4 - BLUE
4.0
1870
40
1805
41
1782
42
1737
43
1701
44
1656 1606 1571
T5 - BLACK
5.0
2297
----
2297
----
2224
----
2106
35
2014
37
1896 1813 1669
Notes:
• CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two
return filters, this chart assumes both filters are installed.
•
•
•
•
•
0.7
All furnaces ship as high-speed cooling and medium-speed heating. Installer must adjust blower cooling and heating speed as needed.
For most jobs, about 375 - 400 CFM per ton when cooling is desirable.
INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.
This chart is for information only. For satisfactory operation, external static pressure should not exceed value shown on the rating plate.
The above chart is for U.S. furnaces installed at 0-2000 feet. At higher altitudes, a properly derated unit will have approximately the same
temperature rise at a particular CFM, while ESP at the CFM will be lower.
• Factory Motor Speed Setting: T1 = 1st Stage Ht, T2 = 2nd Stage Ht, T5 = Cooling.
• Temperature rise data is based on 2nd-stage heat. First-stage heat is 75% of rise indicated above.
42
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
*(M, D, H)S8 WIRING DIAGRAM
BOX
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
43
GME8 WIRING DIAGRAM
WARNING:DISCONNECTPOWERBEFORE
SERVICING.WIRINGTOUNITMUST BE
PROPERLYPOLARIZEDANDGROUNDED.
INTEGRATED
CONTROLMODULE
HUMIDIFIER
XFMR(6)
GND
GND(8)
24VAC
HUMIDIFIER
C2
MVC(9)
HI
MVH(12)
MVL(2)
C
GAS
VALVE
M1
IDBLOWER
PRESSURE
SWITCH
AUXILIARY
LIMITCONTROLS
G
R
W
Y
TG
DS
5MIN
2N
2STG
MODE
100 SEC HTO
FF D
LY
AUTO
1STG
150SEC
10 11 12
8
9
5
6
1
2
3
WH
BL
DIAGNOSTIC
LED
7
4
FUSE
SEE NOTE6
BR
FS
PS(10)
RD
RD
W
HLO(1)
R
AUTORESET
PRIMARY
LIMIT
CONTROL
RO2(11)
RO1(5)
MANUALRESETROLLOUT
LIMITCONTROL(S)
(SINGLECONTROLONSOMEMODELS)
24VAC
XFMR(3)
40VA
TRANSFORMER
COOL-H LO HEAT-H
PU
OR
LINENEUTRAL
YL
YL
1
XFMR-H
XFMR-N
115VAC
FLAMESENSOR
FP
HOTSURFACE
IGNITER
XFMR-H LINE-H EAC-H
24V
BL
CIRCULATOR
BLOWER
BR
115V
WH
XFMR
WH
IGN-N
ID
BLWR
IND
COOL-H CIRCULATOR
BLWR
HI -H
AT
HE
BK
15PINPLUG
ONSOMEMODELS
GR
EAC-H
BLOWERCOMPARTMENT
WH
BK
RD
NO
LINE-N
JUNCTIONBOX
DOOR
SWITCH
C
WH
WH
PRESSURE
SWITCH
YL
PRIMARYLIMIT
EAC-N
LINE-H
24VAC
HUMIDIFIER
OR
RD
CIR-N
ELECTRONIC
AIRCLEANER
BURNERCOMPARTMENT
DOORSWITCH
SWITCHLOCATEDINBLOWER
COMPARTMENTONSOMEMODELS
IND-N
HE LO
AT
-H
YL
RD
YL
YL
WH
BK
WARNING:
DISCONNECTPOWER
BEFORE SERVICING.
WIRINGTOUNIT
MUSTBE
PROPERLY
POLARIZED
ANDGROUNDED.
DISCONNECT
L
GND
N
BR
BL
OVERCURRENTPROTECTIONDEVICE
WH
PM C
1
3
HOT
SURFACE
IGNITER
HI
2
BK
JUNCTION
BOX
WH
2STAGE
GASVALVE
(HONEYWELL)
LINE-N
GND
LINEH
PU
PU
INDUCEDDRAFT
BLOWER
PU
ROLLOUTLIMITS
(SINGLECONTROLONSOMEMODELS)
0
STEADYON=NORMALOPERATION
1
1FLASH =
2
2FLASHES=PRESSURESWITCHSTUCKCLOSED
3
3FLASHES=PRESSURESWITCHSTUCKOPEN
4
4FLASHES=OPENHIGHLIMIT
5
5FLASHES=FLAMESENSEWITHOUTGASVALVE
6
6FLASHES=
OFF
FLAME
SENSOR
LOW VOLTAGE (24V)
=CONTROLFAILURE
SYSTEMLOCKOUT(RETRIES/RECYCLESEXCEEDED)
7FLASHES=LOWFLAMESIGNAL
8
8FLASHES=CHECKIGNITEROR IMPROPER GROUND
C
RAPIDFLASHES=REVERSED115VACPOLARITY/VERIFYGND
PKPINK
BRBROWN
WH WHITE
BLBLUE
GYGRAY
RD RED
LOW VOLTAGEFIELD
HIVOLTAGE (115V)
HIVOLTAGEFIELD
JUNCTION
TERMINAL
OPENROLLOUTOROPENFUSE
7
COLORCODES:
YL YELLOW
OR ORANGE
PUPURPLE
GRGREEN
BKBLACK
TO115VAC/1/60HZ
POWERSUPPLYWITH
OVERCURRENTPROTECTION
DEVICE
INTERNALTO
INTEGRATEDCONTROL
PLUGCONNECTION
EQUIPMENTGND
FIELDGND
FIELDSPLICE
SWITCH(TEMP.)
IGNITER
SWITCH (PRESS.)
OVERCURRENT
PROT.DEVICE
NOTES:
1.SETHEATANTICIPATORONROOMTHERMOSTATAT0.7AMPS.
2.MANUFACTURER'SSPECIFIEDREPLACEMENT PARTS MUSTBEUSEDWHENSERVICING.
3.IFANYOFTHEORIGINALWIREASSUPPLIEDWITHTHE FURNACEMUSTBEREPLACED,ITMUSTBE REPLACEDWITH
WIRINGMATERIALHAVINGATEMPERATURE RATINGOFATLEAST105°C.USECOPPER
CONDUCTORS ONLY.
4.BLOWERSPEEDSSHOULDBEADJUSTEDBYINSTALLERTOMATCHTHEINSTALLATIONREQUIREMENTSSOAS TO
PROVIDE THECORRECTHEATINGTEMPERATURE RISEANDTHE CORRECTCOOLINGCFM.(SEESPECSHEETFORAIR
FLOWCHART)
5.UNITMUSTBE PERMANENTLYGROUNDEDANDCONFORMTON.E.C.ANDLOCALCODES.
6.TORECALLTHELAST5FAULTS,MOSTRECENTTOLEASTRECENT,DEPRESSSWITCHFORMORETHAN2SECONDS
WHILE INSTANDBY(NOTHERMOSTATINPUTS).
0140F00658 REV.A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
44
INTEGRATEDCONTROLMODULE
WH(N)
BK
INTEGRATEDCONTROLMODULE
BK(HI)
BL(MEDHI)
OR(MED)
RD(MEDLOW)
YL(LOW)
PU
WH
IGN
PARK
BK
NO
C
PSO(4)
TO
MICRO HLI(7)
Y
BR
BL
RD
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
AUXILIARY
LIMITS
G
HI HEAT-H
INTEGRATED
CONTROLMODULE
2
24VTHERMOSTATCONNECTIONS
C
Y
DL
*(M,D)H8 WIRING DIAGRAM
WARNING:DISCONNECT POWER BEFORE
SERVICING.WIRING TO UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
INTEGRATED
CONTROL MODULE
HUMIDIFIER
XFMR (6)
GND
GND (8)
24 VAC
HUMIDIFIER
C2
MVC (9)
HI
MVH (12)
G
R
W
Y
DL
TG
DS
5 MIN
2N
2 STG MODE
100 SEC HT
OF
FD
LY
Y
AUTO
1 STG
150 SEC
10 11
12
8
9
4
5
6
1
2
3
WH
FUSE
SEE NOTE 6
BR
FS
RD
RD
W
OR
LINENEUTRAL
YL
YL
1
R
AUTO RESET
PRIMARY
LIMIT
CONTROL
RO2 (11)
RO1 (5)
MANUAL RESET ROLLOUT
LIMIT CONTROL(S)
(SINGLE CONTROL ON SOME MODELS)
24 VAC
40 VA
TRANSFORMER
XFMR-H
XFMR-N
115 VAC
FLAME SENSOR
FP
HOT SURFACE
IGNITER
XFMR-H LINE-H EAC-H
24V
BL
ID
BLWR
IND
COOL-H CIRCULATOR
BLWR
HI -H
AT
HE
BK
15 PIN PLUG
ON SOME MODELS
GR
EAC-H
BLOWER COMPARTMENT
BK
WH
NO
LINE-N
JUNCTION BOX
DOOR
SWITCH
C
OR
WH
WH
YL
PRIMARY LIMIT
EAC-N
LINE-H
24 VAC
HUMIDIFIER
DOOR SWITCH
SWITCH LOCATED IN BLOWER
COMPARTMENT ON SOME MODELS
RD
CIR-N
ELECTRONIC
AIR CLEANER
BURNER COMPARTMENT
RD
IND-N
HE LO
AT
-H
CAP
WH
WH
BR
BR
CICULATOR
BLOWER
BR
115V
XFMR
IGN-N
PRESSURE
SWITCH
YL
RD
YL
YL
WH
BK
WARNING:
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
MUST BE
PROPERLY
POLARIZED
AND GROUNDED.
DISCONNECT
L
GND
N
BR
BL
OVERCURRENT PROTECTION DEVICE
WH
PM C
1
3
HOT
SURFACE
IGNITER
BK
HI
2
2 STAGE
GAS VALVE
(HONEY WELL)
LINE-N
GND
LINE H
PU
PU
INDUCED DRAFT
BLOWER
PU
ROLLOUT LIMITS
(SINGLE CONTROL ON SOME MODELS)
0
JUNCTION
BOX
WH
FLAME
SENSOR
STEADY ON = NORMAL OPERATION
OFF
LOW VOLTAGE (24V)
= CONTROL FAILURE
1
1 FLASH =
2
2 FLASHES = PRESSURE SWITCH STUCK CLOSED
3
3 FLASHES = PRESSURE SWITCH STUCK OPEN
4
4 FLASHES = OPEN HIGH LIMIT
5
5 FLASHES = FLAME SENSE WITHOUT GAS VALVE
6
6 FLASHES = OPEN ROLLOUT OR OPEN FUSE
SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED)
HI VOLTAGE FIELD
JUNCTION
TERMINAL
7 FLASHES = LOW FLAME SIGNAL
8
8 FLASHES = CHECK IGNITER OR IMPROPER GROUND
C
RAPID FLASHES = REVERSED 115 VAC POLARITY/VERIFY GND
PK PINK
BR BROWN
WH WHITE
BL BLUE
GY GRAY
RD RED
0140F00662 REV. A
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
7
COLOR CODES:
YL YELLOW
OR ORANGE
PU PURPLE
GR GREEN
BK BLACK
TO 115 VAC/ 1/60HZ
POWER SUPPLY WITH
OVERCURRENT PROTECTION
DEVICE
INTERNAL TO
INTEGRATED CONTROL
PLUG CONNECTION
EQUIPMENT GND
FIELD GND
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
SWITCH (PRESS.)
OVERCURRENT
PROT. DEVICE
NOTES:
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING.
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE
RATING OF AT LEAST 105 °C. USE COPPER CONDUCTORS ONLY.
4. BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION
REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE
CORRECT COOLING CFM. (SEE SPEC SHEET FOR AIR FLOW CHART)
5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
6. TO RECALL THE LAST 5 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH
FOR MORE THAN 2 SECONDS WHILE IN STANDBY(NO THERMOSTAT INPUTS).
45
INTEGRATEDCONTROLMODULE
BK
INTEGRATEDCONTROLMODULE
BK(HI)
BL(MED)
OR(MEDLOW)
RD(LOW)
WH(N)
PU
WH
IGN
PARK
BK
NO
C
HLO (1)
XFMR (3)
COOL-H LOHEAT-H
PU
2
PS (10)
PSO (4)
TO
MICRO HLI (7)
Y
BR
BL
RD
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
AUXILIARY
LIMITS
G
HIHEAT-H
INTEGRATED
CONTROL MODULE
BL
DIAGNOSTIC
LED
7
ID BLOWER
PRESSURE
SWITCH
AUXILIARY
LIMIT CONTROLS
24VTHERMOSTATCONNECTIONS
C
M1
MVL (2)
C
GAS
VALVE
THIS PAGE LEFT INTENTIONALLY BLANK
46
THIS PAGE LEFT INTENTIONALLY BLANK
47
Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
© 2009-2010 Goodman Manufacturing Company, L.P.
48
Download PDF

advertising