Amana GUI/GCI gas-fired warm air furnace Installation instructions
The Amana GUI/GCI gas-fired warm air furnace is a high-efficiency heating system designed to provide comfortable warmth to your home. It features a durable heat exchanger and a quiet, efficient blower motor that delivers consistent heat throughout your living space.
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GUI*/GCI*
GAS
-
FIRED WARM AIR FURNACE
I
NSTALLATION
I
NSTRUCTIONS
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·CSA-2.3 Gas
Fired Central Furnaces.
DESIGN
C ERTIFIED C E R T I F I E D
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.
Part No. 10759835 Rev. 1
Printed in USA
® is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved.
Goodman Company, L.P.
1810 Wilson Parkway • Fayetteville, Tennessee 37334 www.amana-hac.com
2004 Goodman Company, L.P.
Effective: March 2004
Table of Contents
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NY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL
............................................. 13
) .................................... 17
.................................................... 21
............................................................................. 21
2
Table of Contents
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) ........................................................................................ 23
................................................................................................ 26
............................................................................................ 29
3
WARNING
I
F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
–
D
O 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
:
D
O NOT TRY TO LIGHT ANY APPLIANCE.
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
PHONE IN YOUR BUILDING.
I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
F
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
I
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
DEPARTMENT.
–
I
NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
T
O
T
HE
O
WNER
It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date.
Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference.
If additional information or operating instructions are required, contact the dealer where the purchase was made.
Homeowner Notice:
If the residence is left unattended for an extended period of time (i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances beyond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.
T
O
T
HE
I
NSTALLER
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.
S
HOULD 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.
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.
CO can cause serious illness including permanent brain damage or death.
WARNING
4
T
O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,
THIS FURNACE MUST BE
C
ATEGORY
I
VENTED.
D
O NOT VENT USING
C
ATEGORY
III
VENTING.
T
RANSPORTATION
D
AMAGE
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.
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.
The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.
Keep this literature in a safe place for future reference.
I. CO MPO NENT ID ENTIFI C A TI O N
16
15
14
13
12
17
11 10
Upflow (GUI* Models)
1 Single Stage Gas Valve
2 Hot Surface Igniter
3 Burners
4 Gas Manifold
5 Blower Door Interlock Switch
6 Capacitor
7 PSC Multi-speed Circulator Blower
8 Single-Stage Integrated Control Module
(with diagnostic LED)
9 Control Mounting Bracket
10 Transformer (40 VA)
11 24 Volt Thermostat Connections
12 Auxiliary Limit
13 Flame Sensor
18
OFF ON
Y W R G C
BLOWER
HARNESS
19
20
21
22
1
2
5
4
3
6
7
8
9
10
11
18
9
12
8
G W
7
6
5
17
20
19
14
21
13
15
3
Counterflow (GCI* Models)
4
22
1
21
16
2
14 Gas Line Entrance
15 Rollout Limit
16 Electrical Connection Inlets (Alternate)
17 Single-Speed Induced Draft Blower
18 Flue Pipe Connection
19 Pressure Switch
20 Junction Box
21 Electrical Connection Inlets
22 Primary Limit Control
5
II. SAFET Y
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.
WARNING
T
O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS
MANUAL.
F
OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A
QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
T
HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH
MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE
S
TATE OF
C
ALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER
REPRODUCTIVE HARM.
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
T
O PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT
THE ELECTRICAL COMPONENTS FROM WATER.
WARNING
T
HIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER" DURING THE
FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE.
T
HIS TYPE OF
USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY
LOW RETURN AIR TERMPERATURES AND EXPOSURE TO CORROSIVE OR VERY
DIRTY ATMOSPHERES.
WARNING
III. PR O DUC T APPLI C A TI O N
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
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 installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.
H
EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE,
INSPECTION, MAINTENANCE AND SUPERVISION.
I
F THE BUILIDNG 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
A
DDITIONAL
S
AFETY
C
ONSIDERATIONS
• 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.
P
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON
MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,
OR MAINTENANCE OF THIS PRODUCT.
WARNING
E
LECTROSTATIC
D
ISCHARGE
(ESD) P
RECAUTIONS
NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components.
Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces.
T
O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL
VEHICLE.
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.
6
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:
American National Standards Institute
1430 Broadway
New York, NY 10018
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
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.
IV . LOC A TI
G
ENERAL
WARNING
P
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON
MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,
OR MAINTENANCE OF THIS PRODUCT.
WARNING
ERA TI O NS
T
O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED
WHEN INSTALLING THE 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.
• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.
•
•
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
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.
Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.
On 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 silicone 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 Product Data Bulletin for details). A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Refer to subbase instructions for installation details. Follow the instructions with the subbase for proper installation. 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.)
C
LEARANCES AND
A
CCESSIBILITY
Installations must adhere to the clearances to combustible materials which this furnace has been design certified to.
The minimum clearance information for this furnace is provided on the unit clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation’s
7
gas, electrical, and drain trap and drain line connections. The combustion and ventilating air openings in the front and top panels of the furnace must never be obstructed. Refer to the unit Product Data
Bulletin for minimum clearances to combustible surfaces.
F
URNACE
S
USPENSION
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.
PROVIDE 8" MINMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL
Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or
CAN/CSA B149 Installation Codes.
If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA
B149 Installation Codes.
3/8" DIAMETER
THREADED ROD
(6 PLACES)
HOLD DOWN
NUTS
SUPPORT
NUTS
2"x2"x3/8"
ANGLE IRON
(3 PLACES)
ASSURE FURNACE IS LEVEL FROM
END TO END AND HAS A SLIGHT
FORWARD TILT WITH THE FRONT
OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE FURNACE
POSITION AS CLOSE AS POSSIBLE
TO BLOWER DECK TO ALLOW FOR
CIRCULATOR BLOWER REMVOAL
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
REMOVAL
Figure 1 - Suspended Furnace
T
HERMOSTAT
L
OCATION
In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. Do not install the thermostat where it may be influenced by any of the following:
•
Drafts, or dead spots behind doors, in corners, or under cabinets.
•
Hot or cold air from registers.
•
Radiant heat from the sun.
•
Light fixtures or other appliances.
•
Radiant heat from a fireplace.
•
Concealed hot or cold water pipes, or chimneys.
•
Unconditioned areas behind the thermostat, such as an outside wall.
E
XISTING
F
URNACE
R
EMOVAL
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 Z21.47-1998, CSA-2.3-M98 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
-UNDER CABINETS
Figure 2 - Thermostat Influences
Consult the instructions packaged with the thermostat for mounting instructions and further precautions.
V . CO MBUSTI O N AND VENTIL A TI O N AIR REQUIREMENTS
WARNING
HOT
COLD
T
O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, SUFFICIENT
FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST
BE SUPPLIED.
M
OST 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 burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.
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.
If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances.
8
Refer to the latest edition of the National Fuel Gas Code NFPA 54/
ANSI Z223.1 (Section 5.3), or CAN/CSA B149 Installation Codes
(Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.
This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed combustion) furnace.
Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.
The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Sec- tion 5.3.
5.3.1 General:
(a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.
(b) Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.
(c) In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.
(d) In addition to air needed for combustion, air shall be supplied for ventilation, including all air required for comfort and proper working conditions for personnel.
(e) While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in
5.3.3 and 5.3.4.
(f) Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.
5.3.2 Equipment Located in Unconfined Spaces:
In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3-b or 5.3.4.
Space, Unconfined.
For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.
5.3.3 Equipment Located in Confined Spaces:
(a) All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.
The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.
Chimney or Gas Vent
NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not less than 100 square inches.
Furnace
Water
Heater
(b) All Air from Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000
BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Ventilation louvers
(each end of attic)
NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
Outlet Air
Alternate air inlet
Furnace
Water
Heater
Inlet Air
Opening
Opening
Equipment Located in Confined Spaces; All Air from Inside
Building. See 5.3.3-a.
Ventilation louvers for unheated crawl space
Equipment Located in Confined Spaces; All Air from Outdoors—
Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated
Attic. See 5.3.3-b
9
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Ventilation louvers
(each end of attic)
NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
Outlet Air
Furnace
Water
Heater
Inlet air duct
[ends 1 ft (300 mm) above floor]
Equipment Located in Confined Spaces; All Air from Outdoors
Through Ventilated Attic. See 5.3.3-b.
3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.
Chimney or Gas Vent
Furnace
Water
Heater
Outlet air duct
Inlet air duct
NOTE: The air duct openings must have a free area of not less than one square inch per
2000 BTU of the total input rating of all equipment in the enclosure*.
*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.
Equipment Located in Confined Spaces; All Air from Outdoors. See
5.3.3-b.
4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall not be less than 3 inches.
NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.
Chimney or Gas Vent
Furnace
Water
Heater
Opening
Alternate
Opening
Location
Equipment Located in Confined Spaces; All Air from Outdoors -
Single Air Opening. See 5.3.3-b.
5. One permanent opening may be permitted, provided the equipment has clearances of at least 1” from the sides and back and
6” from the front. The opening shall communicate directly with the outdoors and must be located within 12” of the top of the enclosure. The minimum free area of the opening shall be 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure. The minimum free area shall not be less than the sum of the areas of all vent connectors in the confined space.
5.3.4 Specially Engineered Installations:
The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.
5.3.5 Louvers and Grilles:
In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings.
Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:
Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.
VI. CA TEGO G ( VER TI C AL VENTIN G)
WARNING
10
T
O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,
THIS FURNACE MUST BE
C
ATEGORY
I
VENTED.
D
O NOT VENT USING
C
ATEGORY
III
VENTING.
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.
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
T
O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,
COMMON VENTING WITH OTHER MANUFACTURER'S INDUCED DRAFT APPLIANCS
IS NOT ALLOWED.
Common venting with specific Category I 80% furnaces is allowed with the addition of a common vent kit (CVK) for each appliance.
Contact the local installing dealer, distributor or us directly for more information.
The minimum vent diameter for the Category I venting system is as shown below:
MINIMUM VENT DIAMETER
MODEL GUI* GCI*
45
70
3 Inch
4 Inch
4 Inch
4 Inch
90
115
140
4 Inch
5 Inch
5 Inch
4 Inch
5 Inch
5 Inch
Under some conditions, larger vents than those shown above may be required or allowed.
When an existing furnace is removed from a venting system serv-
ing other appliances, the venting system may be too large to properly vent the remaining attached appliances.
The following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code
NFPA 54/ANSI Z223.1, or the CAN/CSA B149.1 and CAN/
CSA B149.2 Installation Codes and these instructions.
Determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
(c) Where practical, close all building doors, windows, and all doors between the space where the appliances remain connected to the common venting system are located and other spaces of the building. Turn on all gas appliances not connected to the common venting system and operate on high speed all exhaust fans (range hoods and bathroom), except summer exhaust fans. Close fireplace dampers.
(d) Following the lighting instructions, place the furnace being inspected in operation. Adjust thermostat so appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
(f) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.
(g) If improper venting is observed during any of the above tests, the common venting system must be corrected in accordance with the latest edition of the National Fuel Gas
Code NFPA 54/ANSI Z223.1.
When resizing any portion of the common venting system, use the appropriate table in Appendix G in the latest edition of the National
Fuel Gas Code NFPA 54/ANSI Z223.1.
Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated
90 degrees counterclockwise for Category I venting, with the airflow horizontal left to right (Figure 3). For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1
- latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments.
Figure 3 - Upflow Rotated Induced Draft Blower
Counterflow units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” as viewed for a counterflow installation.) The induced draft blower can be rotated 90 degrees counterclockwise for Category I venting, with the airflow horizontal right to left (Figure 4). For horizontal installations, a three inch B-vent pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1
- latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CSA B149.1 AND CAN/
CSA B149.2 - latest editions and amendments.
Supply
Air
Vent
Supply
Air
Return
Figure 4 - Counterflow Rotated Induced Draft Blower
Air
11
To rotate the induced draft blower counterclockwise proceed as follows:
1. Disconnect electrical power from furnace.
WARNING
T
O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,
DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR
MAINTENANCE.
2. Remove the round cutout from the side of the furnace.
NOTE: The assembly, starting from the outside, is induced draft blower, outer gasket, rotation plate, inner gasket, partition panel
(See Figure 5).
VII. MA SO NR Y CHIMNE YS
WARNING
P
OSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN A
SINGLE FAN ASSISTED
C
ATEGORY
I
APPLIANCE (80%
AFUE
FURNACE) IS
VENTED WITHOUT ADEQUATE DILUTION AIR.
D
O 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
T
YPE
B
METAL VENT.
A
LL INSTALLATIONS USING MASONRY
CHIMNEYS MUST BE SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING
TABLES.
I
F 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.
T
HE
RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING THE MASONRY
CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR
T
YPE
B
METAL VENT.
Crown
Clay Tile Size Generally
12" x 12" (24" Length)
Wash
Roof Line
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Attic Floor
1/2" to 1" Air Space
Figure 5 - Blower Assembly
3. Remove and save the four screws which hold the rotation plate on the partition panel. Note that one of the screws which hold the induced draft blower on the rotation plate needs to be removed.
4. Turn the rotation plate 90 degrees counterclockwise. The inner gasket must turn with the rotation plate.
5. Reinstall the rotation plate on the partition panel, using the four screws removed in step 3. Tighten screws to provide an airtight seal.
6. Make sure all wires are at least one inch from flue pipe.
Relocate junction box to right side of cabinet if necessary.
Refer to Section VIII, Electrical Connections for instructions.
WARNING
T
O PREVENT SERIOUS ILLNESS OR DEATH TO BUILDING OCCUPANTS DUE TO
FLUE PRODUCTS LEAKING INTO THE BUILDING, PROPER INSTALLATION OF
GASKETS AND SCREWS IS ESSENTIAL FOR PROVIDING A GAS TIGHT SEAL
BETWEEN THE PARTITION PANEL AND THE INDUCED DRAFT BLOWER.
Second Floor
Clean Out
Throat
Damper
Breech
First Floor
F.A.F. Vent
Connector
Fan Assisted
Forced Air
Furnace
Water Heater
Vent Connector
Natural Draft
Water Heater
Basement Floor
Figure 6 - Typical Multiple Flue Clay Tile Chimney
C
HECKLIST
S
UMMARY
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
Proper Chimney
Termination?
(Check 1)
Yes
No
Line, terminate with listed vent cap
(Fix 1)
Chimney channel free of solid and liquid fuel appliances?
(Check 2)
No
Yes
Change venting arrangements
(Fix 2)
Crown in good condition
(Check 3)
Yes
No
Cleanout free of debris?
(Check 4)
Yes
No
Liner in good condition?
(Check 5)
Yes
No
Rebuild crown
(Fix 3) and/or Reline
(Fix 4)
Reline
(Fix 4)
Reline
(Fix 4)
Figure 7
Termination 10 Feet Or Less From Ridge, Wall or Parapet
Dilution air available?
(Check 6)
Yes
No
Reline
(Fix 4)
Complete the installation.
(Check 7)
C
HECK
1 - P
ROPER CHIMNEY TERMINATION
.
A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it passes through the roof. It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet. In addition, the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet. The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar.
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.
C
Figure 8
Termination More Than 10 Feet From Ridge, Wall or Parapet
HECK
INTO
2 - A
THIS
NY SOLID
CHIMNEY
OR LIQUID
CHANNEL
FUEL APPLIANCES VENTED
13
Solid fuel appliances include fireplaces, wood stoves, coal furnaces, and incinerators.
Liquid fuel appliances include oil furnaces, oil-fired boilers and oilfired water heaters.
Appliances which burn propane (sometimes referred to as LP (liquefied petroleum)) gas are considered gas-fired appliances.
C
HECK
3 - C
HIMNEY
C
ROWN
C
ONDITION
.
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.)
For problems a, b, or c, see Fix 3. If problems d, e, or f are present, see Fix 4. IMPORTANT: It may be necessary to follow both Fix 3 and Fix 4.
C
HECK
4 - D
EBRIS IN
C
LEANOUT
A cleanout (dropleg) must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening.
A chimney without a cleanout could become partially blocked by debris. If no cleanout is present, the chimney must be refined (Fix
4).
Remove the cleanout cover, and examine the cleanout for debris. If significant amounts of any of the following are found:
• Fuel oil residue
•
Bricks
•
Mortar or sand
•
Pieces of the tile liner
• Rusted pieces of the metallic liner reline the chimney (Fix 4).
C
HECK
5 - L
INER CONDITION
.
If a metal liner is present, it must be checked. It cannot be assumed that all existing metal liners are correctly installed and in good condition.
Remove the lowest existing vent connector, and examine the inside of the elbow or tee at the base of the liner. A small amount of soot may be considered acceptable, provided the installer vacuums it away. If rusted pieces of the liner have collected here, the metal liner must be removed and replaced (Fix 4).
Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping does not sound like metal hitting metal, the liner must be removed 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.
Next, use a flashlight and small mirror to sight up the liner. B 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 rehung so as to be acceptable. A thimble or fire stop may be helpful here.
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.
14
If a metal liner is not present, a clay tile liner must be present, or the chimney must be lined (Fix 4).
Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner. If any of the following problems are present:
•
Tile sections misaligned
•
Tile sections missing
•
Gaps between tile sections
• Signs of condensate drainage at the cleanout or vent connectors
• Mortar protruding from between tile sections
•
Use of sewer pipe or drainage pipe rather than an approved fire clay tile reline the chimney (Fix 4).
Next, measure the size of the liner. It may be possible to do this from the cleanout. The liner must be at least as large as the minimum size established 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. If the liner is too small or too large, then the chimney must be relined (Fix 4).
C
HECK
6 - D
ILUTION
A
IR
.
If gas-fired appliances are to be vented into a clay tile liner, a source of dilution air is required.
Dilution air cannot be obtained through:
•
Induced draft appliances
•
Natural draft appliances with vent dampers
Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance’s vent connector does not include a vent damper.
If dilution air will not be available, the chimney must be relined (Fix
4).
C
HECK
7 - C
OMPLETE THE
I
NSTALLATION
.
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
•
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.)
If, in the judgment of the local gas utility, installer, and/or local codes; one or more of the above factors is likely to present a problem, the chimney must be relined (Fix 4).
F
IX
1 - L
INER TERMINATION
.
Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use. The liner and cap/roof assembly must then terminate above the roof in accordance with the manufacturer’s instructions.
In some cases, a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney.
For further information on relining, see Fix 4.
F
IX
2 -C
HANGE 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
Amana ® Air Command ® 80 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 Amana ® Air Command ®
80 may need to be vented vertically with a B Vent.
Under some conditions an Amana ® Air Command ® 90 or 95 could be installed rather than an Amana ® Air Command ® 80. The Amana ®
Air Command ® 90 or 95 can be vented horizontally or vertically through PVC pipe.
F
IX
3 - R
EBUILD THE CROWN
.
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.
F
IX
4 - R
ELINING
.
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 vent and the chimney walls must be covered at the top of the chimney by a weatherproof, corrosion resistant flashing.
The B vent should then be topped with a listed vent cap. The listed vent cap will, when installed per the manufacturer’s instructions, prevent problems due to rain, birds, or wind effects.
A B-vent installed as described in this section is considered to be an enclosed vent system, and the sizing 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 may be used.
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 AL294C 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).
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.
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.
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:
•
It is required by the liner manufacturer’s instructions.
•
The previous liner was properly sized and installed, and suffered from condensation damage.
•
It is required by your local building codes.
Even if none of those three conditions exist which require additional liner insulation, the installer may wish to consider it if:
• The local climate is very cold.
• The chimney is very tall.
• The vent connectors used are very long or have a large number of elbows.
• Local experience indicates that flexible liners installed without insulation are likely to have condensation problems.
Insulation must be selected and installed in accordance with the liner manufacturer’s instructions.
Finally, cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.
VIII. ELEC TRI C AL CO NNEC
WARNING
T
O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
POLARIZED AND GROUNDED.
WARNING
T
O AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
CAUTION
15
L
ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
W
IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
V
ERIFY PROPER OPERATION AFTER SERVICING.
W
IRING
H
ARNESS
The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color and number coded for identification purposes. Refer to the wiring diagram for wire routings. 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.
Any replacement wiring must be a copper conductor.
WARNING
T
O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
POLARIZED AND GROUNDED.
115 V
OLT
L
INE
C
ONNECTIONS
Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC
Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code,
ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.
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.
Line voltage wiring must enter into the junction box provided with the furnace.
NOTE: Line polarity must be observed when making field connections.
Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps.
WARNING rotation of the fan. Also confirm that wiring location will not interfere with filter removal or other maintenance.
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.
Low voltage wires may be connected to the terminal strip as shown in Figure 10.
IMPORTANT NOTE: To avoid possible equipment malfunction, route the low voltage wires to avoid interference with filter removal or other maintenance.
COOL-H
E16
E17
HEAT-H
PARK
E28
E18
EAC-H
PARK LINE-H
E27
E14
XFMR-H
E13
E20
HUM-H
LOW VOLTAGE
TERMINALS
RED
DIAGNOSTIC
LED
E4
E7
LINE-N
HIM-N
E8
EAC-N
E9
XFMR-N
E10
CIR-N
E11
Y W R G C
Y W R G C
RED
DIAGNOSTIC
LED
LOW VOLTAGE
TERMINALS
T
O PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,
DISCONNECT ELECTRICAL POWER.
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. Disconnect the hose from the pressure switch. Leave the other end attached to the induced draft blower.
4. Remove two wires entering junction box from blower deck.
5. Swap locations of the two bushings in the junction box.
6. Rotate the junction box 180 degrees so the access panel continues to face forward. The open snap bushing should now be at the bottom.
7. Insert the two wires through the open bushing in the bottom of the junction box.
8. Attach the junction box to the left side of the furnace, using the screws removed in step 2.
1
2
OFF ON
Y W R G C
RED
DIAGNOSTIC
LED
LOW VOLTAGE
TERMINALS
Figure 10 - Integrated Ignition Control
(Viewed in an Upflow Installation)
FUSE
WARNING
T
O 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
N
ATIONAL
E
LECTRIC
C
ODE.
Junction Box
(Right Side)
Figure 9 - Junction Box (Left Side)
9. Reconnect the hose to the pressure switch.
10. Check the location of the pressure hose and all wiring. Confirm that it will not be damaged by heat from the burners or by the
16
To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check.
1. Measure resistance between the neutral (white) connection and one of the burners.
2. Resistance should measure 10 ohms or less.
This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch.
24 V
OLT
T
HERMOSTAT
W
IRING
NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.
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”.
Heating
Room
Thermostat
Heating/Cooling
Room
Thermostat
W1
R
W1
G
C
Y
R
Y
R
C
G
W1
Furnace Control
Y
R
C
Y
C
G
W1
Remote
Condensing
Furnace Control
Unit
Figure 11 - Typical Field Wiring
(24 VAC Control Circuit)
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.
115 V
OLT
L
INE
C
ONNECTION OF
A
CCESSORIES
(H
UMIDIFIER
AND
E
LECTRONIC
A
IR
C
LEANER
)
OPTIONAL
ACCESSORIES
ELECTRONIC
AIR CLEANER
HUMIDIFIER
120 VAC
HOT AND
PARK
TERMINALS
12 PIN
CONNECTOR
HUM-N
EAC-N
120 VAC
NEUTRAL
TERMINALS
INTEGRATED
CONTROL
MODULE
Figure 12 - Accessories Wiring
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.
The integrated control module humidifier terminals (HUM) are energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.
IX. GA S SUPPL Y AND PIPIN G
G
ENERAL
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.
WARNING
CAUTION
T
O AVOID PERSONAL INJURY, ELECTRICAL SHOCK OR DEATH, 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 humidifier and/or electronic air cleaner.
The accessory load specifications are as follows:
Humidifier 1.0 Amp maximum at 120 VAC
Electronic Air Cleaner 1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any accessories.
Follow the humidifier or 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 humidifier and electronic air cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown in the following illustration.
17
T
O 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.
Inlet Gas Supply Pressure
Natural Gas Minimum: 5.0" w.c.
Maximum:10.0" w.c.
Propane Gas 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.
IMPORTANT NOTE: The furnace will naturally derate itself with altitude. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure. This can cause poor combustion and equipment failure.
At all altitudes, the manifold pressure must be within 0.3 inches
WC of that listed on the “Product Data bulletin” for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the furnace nameplate.
H
IGH
A
LTITUDE
D
ERATE
When this furnace is installed at high altitude, the appropriate High
Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.
High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/ or Pressure Switch) kits.
Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.
In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft 3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.
A different pressure switch may be required at high altitude regardless of the BTU/ft 3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.
P
ROPANE
G
AS
C
ONVERSION
WARNING
P
OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF
THE CORRECT CONVERSION KITS ARE NOT INSTALLED.
T
HE APPROPRIATE KITS
MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION.
A
LL
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.
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.
G
AS
P
IPING
C
ONNECTIONS
G
ENERAL
CAUTION
T
O 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 when sizing a trunk line.
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.
18
Length of
Pipe in Feet
10
20
30
40
50
60
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
1/2"
132
92
73
63
56
50
3/4"
Nominal Black Pipe Size
1" 1 1/4"
278
190
152
130
115
105
520
350
285
245
215
195
1050
730
590
500
440
400
70
80
46
43
96
90
180
170
370
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
CFH = BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
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. Refer to Figure 13 for typical gas line connections to the furnace.
•
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:
–
Rigid metallic pipe and fittings.
–
Semi-rigid metallic tubing and metallic fittings.
Aluminum alloy tubing must not be used in exterior locations.
–
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.
MANUAL
SHUT OFF VALVE
(UPSTREAM FROM
GROUND JOINT
PIPE UNION)
GAS VALVE
HEIGHT REQUIRED
BY LOCAL CODE
MANIFOLD
DRIP LEG
BURNERS
GROUND JOINT
PIPE UNION
Figure 13 - General Furnace Layout
U
PFLOW
I
NSTALLATIONS
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
(Figures 14 & 16).
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.
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 (Figures 15
& 17).
• 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.
Figure 15 - Gas Inlet Through Furnace Left Side
(Upflow)
Figure 16 - Gas Inlet Through Furnace Bottom Side
(Upflow)
Figure 17 - Gas Inlet Through Furnace Top Side
(Upflow)
C
OUNTERFLOW
I
NSTALLATIONS
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 (Figure 18).
Figure 14 - Gas Inlet Through Furnace Right Side
(Upflow)
19
Figure 18 - Gas Inlet Through Left Side
(Counterflow)
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.
When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting at the gas valve):
• 90 degree elbow.
• Close nipple.
• 90 degree elbow.
• Straight pipe to reach exterior of furnace (Figure 19).
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.
Figure 19 - Gas Inlet Through Right Side (Counterflow)
“Left side” and “right side” above are as viewed for a counterflow installation. Adaptation for horizontal airflow should be self explanatory.
G
AS
P
IPING
C
HECKS
Before placing unit in operation, leak test the unit and gas connections.
T
O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR
OPEN FLAME TO TEST FOR LEAKS.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.
WARNING
P
ROPANE
G
AS
T
ANKS AND
P
IPING
WARNING
I
F THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING
WARNING DEVICE IN CASE OF A GAS LEAK.
•
S
INCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
•
P
ROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Page 4 of this manual.
All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.
For satisfactory operation, propane gas pressure must be 11 inch
WC at the furnace manifold with all gas appliances in operation.
Maintaining proper gas pressure depends on three main factors:
1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.
2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).
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 appliances.
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.
Refer to the following illustration for typical propane gas installations and piping.
CAUTION
First Stage
Regulator
5 to 15 PSIG
(20 PSIG Max.)
Continuous
11" W.C.
T
O PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE
FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS
CONNECTIONS, PRESSURE TESTING, LOCATION OF SHUTOFF VALVE AND
INSTALLATION OF GAS PIPING.
200 PSIG
Maximum
Second Stage
Regulator
NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure.
Figure 20 - Propane Gas Installation (Typ.)
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).
D
UCTWORK
X. CIR CUL A TIN G AIR AND FIL TER S
- A
IR
F
LOW
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).
20
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.
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.
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. 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. A room, closet, or alcove must not be used as a return air chamber.
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.
When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.
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.
F
ILTERS
- R
EAD
T
HIS
S
ECTION
B
EFORE
I
NSTALLING
T
HE
R
ETURN
A
IR
D
UCTWORK
Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without filters, the warranty will be voided.
Guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut an opening to match the dimensions of these lines.
NOTE: An undersized opening will cause reduced airflow.
The bottom return is set up as a knock out.
For air delivery of less than 1800 CFM, use a one side or bottom return.
For air delivery of 1800 CFM or higher, use either two-sided returns or a one-sided return with a bottom return.
Refer to Minimum Filter Area tables at the end of this manual to determine filter area requirements.
U
PRIGHT
I
NSTALLATIONS
Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register, a side panel external filter rack kit (upflows), or the ductwork above a counterflow furnace. As an alternative, a media air filter or electronic air cleaner can be used as the requested filter. The following figures show possible filter locations.
CENTRAL
RETURN
GRILLE
SIDE RETURN
EXTERNAL FILTER
RACK KIT
(EITHER SIDE)
AIR FLOW
FILTER
ACCESS
DOOR
RETURN
DUCT
FILTER
SUPPORT
BRACKET
FIL
TE
R
FI
LT
ER
CENTRAL
RETURN
GRILLE
Upflow
Figure 21 - Possible Upright Filter Locations
AIR FLOW
Counterflow
H
ORIZONTAL
I
NSTALLATIONS
Filters must be installed in either the central return register or in the return air duct work.
XI. SEQUEN CE O F OPERA TI O N (INTEGRA TED
IGNITI O N CO NTR O L)
Refer to Timing Charts for sequencing.
N
ORMAL
H
EATING
S
EQUENCE
1. Thermostat calls for heat.
2. The induced draft blower is energized.
3. The igniter is energized and is allowed to preheat.
4. The gas valve is energized delivering gas to the burners and starting combustion.
5. The control checks for a signal from the flame sensor within seven seconds after the gas valve is energized. Gas will only continue to flow if a signal is present.
6. The control waits 30 seconds and turns on the air circulation blower to the speed that was selected for heating operation.
7. The thermostat is satisfied and opens.
8. The control de-energizes the gas valve.
9. After a 15 second delay while flue products are purged from the furnace heat exchanger, the induced draft blower motor is de-energized.
10. The air circulation blower has a delay-off timing of 90 seconds
(starting from the time the gas valve closes). This allows more heat from the furnace to be transferred to the conditioned space. After this time has elapsed, the blower will be deenergized. Some models include an optional adjustable delay off timing of 60, 90, 120, or 180 seconds.
N
ORMAL
C
OOLING
S
EQUENCE
- I
NTEGRATED
I
GNITION
C
ON
-
TROL
With the room thermostat in the FAN-AUTO position, the indoor air circulation blower and outdoor condensing unit will be energized when a call for cooling occurs. When the call for cooling ends, the outdoor condensing unit will be de-energized. The indoor air circulation blower will continue to run for 45 seconds.
C
ONSTANT
F
AN
During normal operation, the air circulation blower will continually run at “Cooling” speed as long as power is present at terminal G. If a call for heat occurs, the blower will run at heating speed throughout the heating cycle.
If a trip on high/auxiliary/rollout limit occurs, the air circulation blower will run at “Heating” speed. Even if power is present at terminal G, the blower will run at heating speed until the limit closes.
21
XII. ST AR T -UP PR OCEDURE AND AD JUST MENT
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.
This furnace is also equipped with a self-diagnosing electronic control module. In the event a furnace component is not operating properly, the control module LED will flash on and off in a factory-programmed sequence, depending on the problem encountered. This light can be viewed through the observation window in the blower access door. Refer to the Troubleshooting Chart for further explanation of the lighting codes.
On new installations, or if a functional part such as the gas valve, pressure switch, or limit control has been replaced, verify that the furnace is operating properly after servicing.
Check furnace operation as outlined in the following instructions. If any sparking, odors, or unusual noises are encountered, shut off electrical power and recheck for wiring errors, or obstructions in or near the blower motors. Various shipping materials must be removed before the blower motor is operated. In addition to the following start-up and adjustment items, refer to further information in Section
XIII, Operational Checks.
H
EAT
A
NTICIPATOR
S
ETTING
The heat anticipator in the room thermostat must be correctly adjusted to obtain the proper number of cycles per hour and to prevent
“overshooting” of the setting. Set the heat anticipator setting to 0.7
amps. Follow the thermostat manufacturer’s instructions on how to adjust the heat anticipator setting.
F
URNACE OPERATION
Purge gas lines of air prior to start-up. Do not purge lines into an enclosed burner compartment.
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.
F
URNACE
S
TART
-
UP
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. White-Rodgers Models 36E22/36F22/36G22: Push the switch to the OFF position.
6. Wait five minutes to clear out any gas. Then smell for gas, including near the floor.
7. If gas can be smelled following the five minute waiting period in Step 6, immediately follow the instructions on Page 4 of this manual. If you do not smell gas after five minutes:
White-Rodgers Models 36E22/36F22/36G22: Push the switch to the ON position.
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.
11. Set the room thermostat to the desired temperature.
NOTE: There is an approximate 20 second delay between thermostat energizing and burner firing.
F
URNACE
S
HUTDOWN
1. Set the thermostat to lowest setting.
2. Turn off the electrical power supply to the furnace.
3. White-Rodgers Models 36E22/36F22/36G22: Push switch to the OFF position.
4. Close manual gas shutoff valve external to the furnace.
5. Replace the door on the unit.
G
AS
S
Gas Valve
On/Off
Selector
Switch
INLET
INLET
2
Inlet Pressure Tap
(Side of Valve)
Pressure Regulator
Adjustment
(Under Cap Screw)
Figure 23 - White-Rodgers Model 36E22
Gas Valve
On/Off
Selector
Switch
INLET
UPPLY
Figure 25 - White-Rodgers Model 36G22
P
Outlet Pressure
Tap
Inlet Pressure
Tap
RESSURE
M
M
O
F
F
P
ON
C
1
3
OUTLET
Outlet (Manifold)
Pressure Tap
(Side of Valve)
OUTLET
Inlet Pressure Tap
(Side of Valve)
Pressure Regulator
Adjustment
(Under Cap Screw)
Outlet (Manifold)
Pressure Tap
Figure 24 - White-Rodgers Model 36F22
Pressure Regulator
Adjustment
(Under Cap Screw)
Gas Valve
On/Off
Selector
Switch
EASUREMENT
CAUTION
OUTLET
at
T
O 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.
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 burners operating. To measure the gas supply pressure, use the following procedure.
22
With Power and Gas Off:
1. Honeywell Model VR8205, or White-Rodgers Models 36E22,
or White-Rodgers Model 36F22: Connect a water manometer or adequate gauge to the “inlet pressure tap” of the gas valve.
As an alternative method, inlet gas pressure can also be measured by removing the cap from the drip leg and installing a predrilled cap with a hose fitting (Figure 26).
With Power and Gas On:
2. Put furnace into heating cycle and turn on all other gas consuming appliances.
If operating pressures differ from above, make necessary pressure regulator adjustments, check piping size, etc., and/or consult with local utility.
Gas Line
Gas
Shutoff
Valve
Drip Leg Cap
With Fitting
Gas Line
To Furnace
Manometer Hose
CAUTION
Open To
Atmosphere
Manometer
Figure 26 - Measuring Inlet Gas Pressure
(Alternate Method)
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 table below.
Inlet Gas Supply Pressure
Natural Gas Minimum: 5.0" w.c.
Maximum:10.0" w.c.
Propane Gas 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 started in step 3.
G
AS
M
ANIFOLD
P
RESSURE
M
EASUREMENT AND
A
DJUSTMENT
T
O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS
MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE.
O
NLY 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. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap (refer to gas valve figure in previous section).
3. Turn ON the gas supply and operate the furnace.
4. Measure gas manifold pressure with burners firing. Adjust manifold pressure according to the table below:
Manifold Gas Pressure
Gas
Natural
Propane
Range Nominal
3.2 to 3.8" w.c.
3.5" w.c.
9.7 to 10.3" w.c. 10.0" w.c.
G
AS
I
NPUT
R
ATE
M
EASUREMENT
(N
ATURAL
G
AS
O
NLY
)
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/ ft 3 ) 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 sum of the installation’s gas heating value and 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/ft 3
(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft 3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft 3 x 3600 sec/hr) ÷ 34 sec/ ft 3
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.
T
EMPERATURE
R
ISE
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.
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 Product Data Bulletin.
23
HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
P
ROPANE
G
AS
P
IPING
C
HARTS
SUPPLY
AIR
T
SUPPLY
RISE =
T
SUPPLY -
T
RETURN
T
RETURN
RETURN
AIR
Figure 27 - Temperature Rise Measurement
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.
C
IRCULATOR
B
LOWER
S
PEED
A
DJUSTMENT
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, 3/8"
Tubing Size, O.D. Type L
1/2" 5/8" 3/4" 7/8"
Nominal Pipe Size
Schedule 40
1/2" 3/4"
Feet
50
60
80
10
20
30
40
730
500
400
370
330
300
260
1,700
1,100
920
850
770
700
610
3,200
2,200
2,000
1,700
1,500
1,300
1,200
5,300
3,700
2,900
2,700
2,400
2,200
1,900
8,300
5,800
4,700
4,100
3,700
3,300
2,900
3,200
2,200
1,800
1,600
1,500
1,300
1,200
7,500
4,200
4,000
3,700
3,400
3,100
2,600
100
125
150
175
220
200
190
170
540
490
430
400
1,000
900
830
780
1,700
1,400
1,300
1,200
2,600
2,300
2,100
1,900
200 160 380 730 1,100 1,800
To convert to capacities at 15 psig settings - multiply by 1.130
To convert to capacities at 5 psig settings - multiply by 0.879
1,000
900
830
770
720
2,300
2,100
1,900
1,700
1,500
Sizing Between Single or Second Stage Regulator and Appliance*
Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length, 3/8"
Tubing Size, O.D. Type L
1/2" 5/8" 3/4" 7/8" 1-1/8" 1/2"
Feet
10
20
30
39
26
21
19
92
62
50
41
199
131
107
90
329
216
181
145
501
346
277
233
935
630
500
427
275
189
152
129 40
50
60
80
18
16
13
11
37
35
29
26
79
72
62
55
131
121
104
90
198
187
155
138
376
340
289
255
114
103
89
78 100
125
150
200
250
10
9
8
8
24
21
19
17
48
43
39
36
81
72
66
60
122
109
100
93
224
202
187
172
69
63
54
48
*Data in accordance with NFPA pamphlet NO. 54
Nominal Pipe Size
3/4"
Schedule 40
1" 1-1/4" 1-1/2"
567 1,071 2,205 3,307
393 732 1,496 2,299
315
267
237
217
185
162
146
132
112
100
590
504
448
409
346
307
275
252
209
185
1,212 1,858
1,039 1,559
913
834
724
630
567
511
439
390
1,417
1,275
1,066
976
866
787
665
590
WARNING
T
O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN
OFF
POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
(Terminals are identified as HEAT and COOL (hot)). If heating and cooling blower speeds 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.
This furnace is equipped with a PSC circulator blower motor. This blower provides ease in adjusting blower speeds. Refer to the Product Data Bulletin provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. The cooling blower speed is shipped set on HIGH, and the heating blower speed is set as indicated in the Product Data Bulletin. 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 Product
Data Bulletin.
3. Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module.
Circulator Blower Speeds
Low Red
Medium Low Orange
Medium Blue
High Black
Common/Neutral White
Figure 28
Wiring Designations
C
IRCULATOR
B
LOWER
F
AN
T
IMING
A
DJUSTMENT
NOTE: Items in this section refer to the air circulator blower fan,
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 (Figure 29). It is NOT adjustable in any other circumstances.
As shipped, the circulator blower fan will remain on for 90 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
37 seconds after the gas valve opens.
24
Style A Style B
60
Second
Delay
B1
B2
B3
B4
90
Second
Delay
B1
B2
B3
B4
120
Second
Delay
B1
B2
B3
B4
180
Second
Delay
B1
B2
B3
B4
Switches viewed in an upflow installation.
Figure 29 - Heating Fan Off Adjustments
XIII. OPERA TI O NAL CHECK S
WARNING
T
O AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL
COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT.
E
LECTRICAL
COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS.
C
ONTACT A
QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
SHOULD DEVELOP.
B
URNER
F
LAME
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.
WARNING
T
O AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL
COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT.
E
LECTRICAL
COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS.
C
ONTACT A
QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
FOLLOW THESE DIRECTIONS FOR THE AUXILIARY LIMIT CONTROL. IF THE
AUXILIARY LIMIT CONTROL OPENS, IT MAY BE RESET ONE TIME ONLY.
(SERVICER’S NOTE: If it becomes necessary to slide the blower assembly out of the furnace, the auxiliary limit control should be removed first. After the blower assembly is reinstalled, the auxiliary limit must be reinstalled.)
P
RIMARY
L
IMIT
The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger. If the primary limit control does not function during this test, the cause must be determined and corrected. Function of this control should be verified by gradually blocking the furnace return air after the furnace has been operating (burners firing) for approximately ten minutes. Check the control as follows:
1. Allow the furnace to operate with burners firing continuously for approximately ten minutes.
2. Gradually block the return air to furnace. Remove airflow blockage when limit control is activated and turns off burners.
Airflow blockage causes unit overheating and will produce the following reactions:
• The gas valve to close and extinguish flame,
• The induced draft blower to be de-energized after a fifteen second postpurge, and
• The circulator blower to remain energized continuously until limit control resets.
3. Remove the return air blockage to clear overheating condition.
After an acceptable temperature is reached during the cool down period, the limit control will reset and allow the furnace to resume normal operation.
WARNING
T
O PREVENT PREMATURE FAILURE OF HEAT EXCHANGER, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, DO NOT ADJUST THE LIMIT CONTROL (FACTORY
SET).
Primary Limit Control
Check the burner flames for:
1. Good adjustment
2. Stable, soft and blue
3. Not curling, floating, or lifting off.
Figure 30 - Burner Flame
A
UXILIARY
L
IMIT
C
ONTROL
A manual reset limits are located on or near the blower. To access this auxiliary limit, disconnect the electrical power and remove the blower door. If the limit control opens, the air circulation blower will run continuously. The diagnostic light will flash four times. These symptoms are identical to a trip of the primary limit control.
The auxiliary limit control is designed to prevent furnace operation in case of main blower failure on horizontal and counterflow 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.
25
Figure 31 - Primary Limit Control
IMPORTANT NOTE: This unit must not be used as a construction heater during the finishing phases of construction of a new structure. This type of use may result in premature failure due to extremely low return air temperatures and exposure to corrosive or very dirty atmospheres.
These checks establish that the primary limit control is functioning and will respond to a restriction in the return air, or a circulator blower failure. If the primary limit control does not function during this test, the cause must be determined and corrected.
XIV . SAFET Y CIR CUIT DESCRIPTI O N
G
ENERAL
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.
I
NTEGRATED
C
ONTROL
M
ODULE
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.
P
RIMARY
L
IMIT
The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor.
The limit guards against the overheating as a resulting of insufficient conditioned air passing over the heat exchanger.
A
UXILIARY
L
IMIT
The auxiliary limit control is located either on or near the circulator blower and monitors heat exchanger compartment temperatures.
The control is a normally-closed (electrically), manual-reset, temperature activated sensor. It guards against overheating resulting from insufficient conditioned air passing over the heat exchanger.
R
OLLOUT
L
IMITS
The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally-closed
(electrically), manual-reset, temperature-activated sensors. This limit guards against burner flames not being properly drawn into the heat exchanger.
P
RESSURE
S
WITCHES
The pressure switches are normally-open (closed during operation), single-pole single-throw, 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.
F
LAME
S
ENSOR
The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame.
1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the furnace away from 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.
D
IAGNOSTIC
C
HART
WARNING
T
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
Refer to the troubleshooting chart on the following pages 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.
R
ESETTING
F
ROM
L
OCKOUT
Furnace lockout results when a furnace is unable to achieve ignition after three attempts, or when it has lost flame five times during a single call for heat. 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 0 - 20 seconds.
3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat for 0 -20 seconds then reset to previous setting.
NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Diagnostic Chart for aid in determining the cause.
XVI. MAINTENAN CE
XV . TR OUBLESH TIN G
WARNING
E
LECTROSTATIC
D
ISCHARGE
(ESD) P
RECAUTIONS
NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components.
T
O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL
POWER BEFORE PERFORMING ANY MAINTENANCE. IF YOU MUST HANDLE THE
IGNITER, HANDLE WITH CARE.
T
OUCHING THE IGNITER ELEMENT WITH BARE
FINGERS, ROUGH HANDLING, OR VIBRATION COULD DAMAGE THE IGNITER
RESULTING IN PREMATURE FAILURE.
O
NLY A QUALIFIED SERVICER SHOULD
EVER HANDLE THE IGNITER.
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.
A
NNUAL INSPECTION
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
26
Timing Chart for Integrated Ignition Control Normal Heating Operation
Circulator
Blower
ON
OFF
Gas Valve
Igniter
OPEN
CLOSED
ON
OFF
Pressure Switch
Contacts
CLOSED
OPEN
Induced Draft
Blower
Thermostat
ON
OFF
ON
OFF
SECONDS 0 15 0
IGNITER
WARM UP PERIOD
(see note) t
ign
FIXED HEAT
ON DELAY:
30 SECONDS t
circ 60,90,
120 or
180
NOTE: CUSTOM CONTROLS, INC. INTEGRATED CONTROL MODULE HAS A FIXED
STANDARD SEVEN-SECOND IGNITER WARM UP PERIOD
(MINI IGNITER).
WHITE-RODGERS 50A55 or 50T55 INTEGRATED CONTROL MODULE HAS A
VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN
A 17-SECOND MAXIMUM AND A FIVE-SECOND MINIMUM.
WHITE-RODGERS 50A65 INTEGRATED CONTROL MODULE HAS A
20-SECOND IGNITER WARM UP PERIOD (SILICON NITRIDE).
Timing Chart for Integrated Ignition Control Normal Cooling Operation
Indoor Fan ON
OFF
Outdoor Fan and
Compressor
ON
OFF
Thermostat
ON
OFF
Seconds 0 5 0 45
27
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.
F
ILTERS
WARNING
T
O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT
ELECTRICAL POWER BEFORE REMOVING FILTERS.
N
EVER 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.
A return air filter is not supplied with this furnace; however, there must be a means of filtering all of the return air. The installer will supply filter(s) at the time of installation.
F
ILTER
M
AINTENANCE
Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned
(permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size.
WARNING
T
O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER TO THE FURNACE
BEFORE REMOVING THE FILTER OR PERFORMING ANY OTHER MAINTENANCE.
Become familiar with filter location and procedures for removal, cleaning and replacing them. If help is needed, contact the installer of the furnace or a qualified servicer.
F
ILTER
R
EMOVAL
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 to ensure proper unit performance.
To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. To remove internal filters see Internal Filter Removal section.
Internal filters are an accessory item and are not included with your furnace. For further details, see your distributor.
U
PRIGHT
F
ILTER
R
EMOVAL
To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit.
Clean, wash and dry a permanent filter. When using a metal filter, both sides should be sprayed with a dust adhesive as recommended on adhesive container. Spray adhesives for use with permanent metal filters can be found at some hardware stores. BE
SURE AIRFLOW DIRECTION ARROW POINTS TOWARDS THE
BLOWER.
C
OUNTERFLOW
F
ILTER
R
EMOVAL
A furnace mounted filter rack ordered from distributor.
NOTE: If using Media Air Cleaner or Electronic Air Cleaner, follow the instructions that came with the air cleaner for proper filter removal, cleaning, and replacement procedures.
The furnace-mounted filter rack is mounted on the top of the furnace. Two filters fit into the rack and rest against the sides of the return air plenum, forming a “V” above the furnace.
Inspect the filters frequently and clean or replace when necessary. In some installations, the filters can be inspected only after the electrical power is disconnected and the optional access door in the return air plenum removed. If the access door is not present, proceed as follows:
1. Disconnect the electrical power.
2. Remove the non-louvered door from the furnace.
3. Remove the left filter by reaching to the left side of the blower, pushing the filter up slightly to remove it from the filter rack, and pulling it down to the left of the blower and out the blower door. Repeat with the right filter.
4. Inspect filter. If your dirty filter is the disposable type, replace dirty with the same type and size filter. If your dirty filter is a permanent metal filter, clean as follows:
• Wash, rinse, and dry the permanent filters. Both sides should then be sprayed with a filter adhesive as is recommended on the adhesive container. Many hardware stores stock spray adhesives for use with permanent filters.
• If badly torn or uncleanable, these filters must be replaced by equal size permanent, high velocity filters.
Throwaway filters must not be used as replacement for permanent filters. Under normal use, permanent filters should last for several years.
5. To reinstall the filters, first MAKE CERTAIN THE AIRFLOW
DIRECTION ARROW POINTS TOWARDS THE
FURNACE. Then insert the filters from the left side of the blower. Starting with the right filter, push the filter into the plenum so that the bottom of the filter rests in the filter rack and the upper edge rests against the side of the plenum. Repeat with the left filter (Figure 33).
6. Replace the blower door, then reconnect the electrical power.
Figure 32 - Furnace Mounted Filter Rack (Counterflow)
28
I
NDUCED
D
RAFT AND
C
IRCULATOR
B
LOWER
M
OTORS
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.
F
LAME
S
ENSOR
(Q
UALIFIED
S
ERVICER
O
NLY
)
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 as indicated in the Specifications Sheet.
I
GNITER
(Q
UALIFIED
S
ERVICER
O
NLY
)
If the igniter and the surrounding air are at about 70°F and the igniter wires are not connected to any other electrical components, the resistance of the igniter should not exceed 200 ohms. If it does, the igniter should be replaced.
F
LUE
P
ASSAGES
(Q
UALIFIED
S
ERVICER
O
NLY
)
The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below.
1. Shut off electric power and gas supply to the furnace.
2. Remove burner assembly by disconnecting the gas line and removing the manifold brackets from the partition panel.
3. Remove the flue from the induced draft blower and the collector box from the partition panel.
4. The primary heat exchanger tubes can be cleaned using a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the spring cable.
Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Use a large cable for the large tube, and then repeat the operation with a small cable for the smaller tube. Repeat for each tube.
5. When all heat exchanger tubes have been cleaned, replace the parts in the reverse order in which they were removed.
6. To reduce the chances of repeated fouling of the heat exchanger, perform the steps listed in Section XII, Start-up
Procedure and Adjustment.
B
URNERS
WARNING
Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermostat. Wait a few minutes, since any dislodged dust will alter the normal flame appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.
C
LEANING
(Q
UALIFIED
S
ERVICER
O
NLY
)
1. Shut off electric power and gas supply to the furnace.
2. Remove screws securing manifold to burner bracket. Slightly pull manifold out and away from burner bracket. Burners will drop. Re-secure manifold to burner bracket.
3. Tilt burners to slotted side of burner bracket. Rotate burners clockwise to remove.
4. Use bottle brush to clean burner insert and inside of burner.
5. Replace burner (opposite of removal). Ensure burners are fully seated on burner bracket tabs and are properly aligned.
6. Turn on electric power and gas supply to the furnace.
7. Check furnace for proper operation. Refer to “Operational
Checks” section to verify burner flame characteristics.
XVII. BEFO RE LEA VIN G AN INST ALL A TI O N
•
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.
XVIII. REP AIR AND REPL ACEMENT PAR TS
•
When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers with the order.
•
Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description.
•
Parts are available from your Amana ® distributor.
Functional Parts List-
Single Stage Gas 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
Blower/Box Gasket
Rollout Limit Switch
Auxiliary Limit Switch
Heat Exchanger
Door Switch
Transformer
Blower Wheel
Blower Housing
Blower Cutoff
Blower Motor
Motor Mount Bracket
Capacitor
T
O PREVENT PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL
COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT.
E
LECTRICAL
COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS.
C
ONTACT A
QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
SHOULD DEVELOP.
29
30
Troubleshooting Chart
Symptoms of Abnormal
Operation
Associated
LED Code 2
Fault Description(s)
• Furnace fails to operate.
• Integrated control module diagnostic LED provides
no signal.
NONE
Possible Causes Corrective Action Cautions and Notes
• No 115 volt power to furnace, or no 24 volt power to integrated control module.
• Blown fuse or circuit breaker.
• Manual disconnect switch
OFF, door switch open, or 24 volt wires improperly connected or loose.
• Blown fuse or circuit breaker.
• No signal from thermostat.
• Improper thermostat connection or setting.
• Assure 115 and 24 volt power to furnace integrated control module.
• Turn power OFF prior to repair.
• Check integrated control module fuse (3A).
Replace if necessary.
• Check for possible shorts in 115 and 24 volt circuits.
Repair as necessary.
• Replace integrated control module fuse with 3A automotive fuse.
• Furnace fails to operate.
• Integrated control module diagnostic LED is lit
continuously.
ON
CONTINUOUS
ON
• Furnace fails to operate.
• Integrated control module diagnostic LED is flashing ONE (1) flash.
1
1 FLASH
• Integrated control module has an internal fault.
• Integrated control module has an internal fault.
• Furnace lockout due to an excessive number of ignition
“retries” (3 total) or
“recycles (5 total) 1 .
• 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.
• Replace bad integrated control module.
• Locate and correct gas interruption.
• Replace or realign igniter.
• 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.
• 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.
• Turn power OFF prior to repair.
• Read precautions in “Electrostatic
Discharge” section of manual.
• Turn power OFF prior to repair.
• Igniter is fragile, handle with care.
• Sand flame sensor with emery cloth.
• See “Combustion and Ventilation Air
Requirements” and
“Category I Venting
(Vertical Venting)” section for details.
• Furnace fails to operate.
• Integrated control module diagnostic LED is flashing TWO (2) flashes.
2
2 FLASHES
• Pressure switch circuit is closed.
• Induced draft blower
is not operating.
• Induced draft blower pressure switch contacts sticking.
• Shorts in pressure switch circuit.
• Induced draft blower runs continuously with no further furnace operation.
• Integrated control module diagnostic LED is flashing THREE (3) flashes.
3
3 FLASHES
• Pressure switch circuit not closed.
• Induced draft blower
is operating.
• Pressure switch hose blocked, pinched or connected improperly.
• Blocked flue or weak induced draft blower.
• Incorrect pressure switch setpoint or malfunctioning switch contacts.
• Loose or improperly connected wiring.
• Replace induced draft blower pressure switch.
• Repair short.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Inspect pressure switch hose. Repair, if necessary,
• Inspect flue for blockage, proper length, elbows, and termination.
• Correct pressure switch setpoint or contact motion.
• Tighten or correct wiring connection.
• Turn power OFF prior to repair.
• See “Combustion and Ventilation Air
Requirements” and “Category I
Venting (Vertical
Venting)” section for details.
• Replace pressure switch with proper replacement part.
1 Integrated control module will automatically attempt to reset from lockout after one hour.
31
Symptoms of Abnormal
Operation
• Circulator blower runs continuously. No furnace operation.
• Integrated control module diagnostic LED is flashing
FOUR (4) flashes.
Associated
LED Code 2
4
4 FLASHES
Fault Description(s)
• Primary or auxiliary limit circuit is open.
• Furnace fails to operate.
• Integrated control module diagnostic LED is flashing
SIX (6) flashes.
Troubleshooting Chart
• Rollout limit circuit is open.
6
6 FLASHES
• Polarity of 115 volt power is reversed.
Possible Causes Corrective Action Cautions and Notes
• Insufficient conditioned air over the heat exchanger.
Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.
• Flame rollout.
• Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.
• Loose or improperly connected wiring.
• Check filters and ductwork for blockage. Clean filters or remove obstruction.
• Check circulator blower speed and performance.
Correct speed or replace blower if necessary.
• Check burners for proper alignment.
• Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.
• Check induced draft blower for proper performance. Replace, if necessary.
• Tighten or correct wiring connection.
• Review wiring diagram to correct polarity.
• Turn power OFF prior to repair.
• See Product Data
Bulletin for allowable rise range and proper circulator speed.
• See “Vent/Flue
Pipe” section for piping details.
• Replace pressure switch with proper replacement part.
• Turn power OFF prior to repair.
• Polarity of 115 volt AC power to furnace or integrated control module is reversed.
• Poor unit ground.
• Verify proper ground.
Correct if necessary.
• Check and correct wiring.
• Induced draft blower runs continuously. No furnace operation.
• Integrated control module diagnostic LED is flashing
SEVEN (7) flashes.
7
7 FLASHES
• Flame sense microamp signal is low.
• Induced draft blower runs continuously. No furnace operation.
• Integrated control module diagnostic LED is flashing continuously.
C
CONTINUOUS
FLASHING
• Flame sensed with no call for heat.
• Flame sensor is coated/ oxidized.
• Flame sensor incorrectly positioned in burner flame.
• Lazy burner flame due to improper gas pressure or combustion air.
• Short to ground in flame sense circuit.
• Lingering burner flame.
• Slow closing gas valve
• Sand flame sensor is coated/oxidized.
• Inspect for proper sensor alignment.
• Check inlet air piping for blockage, proper length, elbows, and termination.
• Compare current gas pressure to rating plate info. Adjust as needed.
• Turn power OFF prior to repair.
• Sand flame sensor with emery clot.
• See “Vent/Flue
Pipe” section for piping details.
• See rating plate for proper gas pressure.
• Correct short at flame sensor or in flame sensor wiring.
• Check for lingering flame
• Verify proper operation of gas valve
• Turn power OFF prior to repair.
32
GCID WIRIN G DIAGRA M
OR-10
GY-8
24 VAC
24V THERMOSTAT
CONNECTIONS
Y W R
115 VAC
G C
BK-31
WH-32
40 VA
TRANSFORMER
DIAGNOSTIC
LED
INTEGRATED
CONTROL
MODULE
1
4
7
2
5
8
10 11 12
3
6
9
YL-20
OR-22
RD-11
GY-8
OR-10
XFMR-N
OR-10
BU-14
GY-8
BR-13
GY-12
GN
OR-15
BU-27
PK-30
LINE-N
WH-5
GND
BR
BR
115 VAC HOT AND PARK TERMINALS
COOL-H HEAT-H
SEE
NOTE 4
WH
RD (LOW)
OR (MED LOW)
BU (MED)
BK (HI)
CIRCULATOR
BLOWER
CAPACITOR
BLOWER COMPARTMENT
BURNER COMPARTMENT
BK
LINE-H
2
1
BK-4
CIRC-N
WH
33
BK
-3
RD
-2
MANUAL
RESET
AUXILIARY
LIMIT
PK
-30
VT
-28
BLOWER
COMPARTMENT
DOOR SWITCH
(OPEN WHEN
DOOR OPEN)
INTEGRATED CONTROL MODULE
TR (6)
GND (8)
C
G
Y
W
R
TO
MICRO
TH (3)
GND
MVC (9)
MV (12)
FRONT COVER
PRESSURE SWITCH
PS (10)
NO C
C
HLI (7)
HLO (1) MANUAL RESET
AUXILIARY
LIMIT CONTROL
GAS
VALVE
RO2 (11)
RO1 (5)
ID.BLOWER
PRESSURE
SWITCH
NO
AUTO RESET
PRIMARY
LIMIT
CONTROL
MANUAL RESET ROLLOUT
LIMIT CONTROL(S)
(SINGLE CONTROL ON 45 KBTU)
24 VAC
40 VA
TRANSFORMER
XFMR-H 115 VAC
FLAME SENSOR
XFMR-N
FP (2)
HOT SURFACE
IGNITER
IGN
HUM-H
HUMIDIFIER
HUM-N
ID
BLWR
IND
LINE-H
EAC-H
BLOWER
COMPARTMENT
DOOR
SWITCH
COOL-H
CO
OL
CIRCULATOR
BLOWER
HE
AT
HEAT-H
ELECTRONIC
AIR CLEANER
JUNCTION BOX
CIR-N
EAC-N
LINE-N
GND
WH
INDUCED
DRAFT
BLOWER
AUTO RESET PRIMARY
LIMIT CONTROL
VT-28
BU-27
MANUAL RESET ROLLOUT LIMIT CONTROL(S)
( SINGLE CONTROL ON 45 KBTU )
OR-15
PK-17 RD-11
WH-7
GND
WARNING:
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
MUST BE PROPERLY
POLARIZED AND
GROUNDED.
N
DISCONNECT
L GND
TO 115VAC/1Ø /60 HZ POWER SUPPLY WITH
OVERCURRENT PROTECTION DEVICE
RD
-2
WH-33
2 CIRCUIT
CONNECTOR
HOT
SURFACE
IGNITER
BU
-14
FRONT
COVER
PRESSURE
SWITCH NO
FLAME
SENSOR
GY-12
BR-13
C
GY-34
GAS VALVE
OR
-22
NO C
ID. BLOWER
PRESSURE SWITCH
JUCTION
BOX
WH
-5
BK
-1
WARNING:DISCONNECT POWER BEFORE
SERVICING.WIRING TO UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
DISCONNECT
GND
L
N
0 STEADY ON = REPLACE CONTROL
1
2
3
4
5
6
C
1 FLASH = SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED)
2 FLASHES = PRESSURE SWITCH STUCK CLOSED
3 FLASHES = PRESSURE SWITCH STUCK OPEN
4 FLASHES = OPEN PRIMARY OR AUXILIARY LIMIT
5 FLASHES = OPEN ROLLOUT LIMIT
6 FLASHES = 115V AC POWER REVERSED OR POOR UNIT GROUND
7
7 FLASHES = LOW FLAME SENSE SIGNAL
CONTINUOUS FLASHES = UNANTICIPATED FLAME PRESENT
COLOR CODES:
YL YELLOW
OR ORANGE
VT VIOLET
GN GREEN
BK BLACK
PK PINK
BR BROWN
WH WHITE
BU BLUE
GY GRAY
RD RED
20479301 REV.00
LOW VOLTAGE (24V)
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
JUNCTION
TERMINAL
INTERNAL TO
INTEGRATED CONTROL
PLUG CONNECTION
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. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER
BEFORE CONNECTING BLOWER LEADS. UNUSED BLOWER LEADS MUST BE PLACED ON
"PARK" TERMINALS OF INTEGRATED CONTROL OR TAPED.
5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
EQUIPMENT GND
FIELD GND
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
SWITCH (PRESS.)
OVERCURRENT
PROT. DEVICE
33
INDUCED DRAFT
BLOWER
BK WH
GND
BK
-3
WH
-7
GND
GUID/GUIE WIRIN G DIAGRA M
GAS VALVE
M1
P3
C2
FLAME
SENSOR
GN
BU-14
BR-13
GY-12
RD-11
PK-17
MANUAL RESET
ROLLOUT LIMIT
CONTROL(S)
(SINGLE CONTROL
ON 45K BTU)
PRESSURE
SWITCH
OR-15
HOT
SURFACE
IGNITER
C
NO
YL-20
OR-22
JUNCTION BOX
WH
-5
BK
-1
N
GND
L
WARNING: DISCONNECT
POWER BEFORE SERVICING.
WIRING TO UNITMUST BE
PROPERLY POLARIZED
AND GROUNDED.
TO 115VAC/ 1Ø /60 HZ
POWER SUPPLY WITH
OVERCURRENT PROTECTION
DEVICE
DISCONNECT
TO 115VAC/ 1Ø /60 HZ POWER SUPPLY WITH
OVERCURRENT PROTECTION DEVICE
L GND N
WARNING:
BEFORE SERVICING.
WIRING TO UNIT
MUST BE
PROPERLY
POLARIZED
AND GROUNDED.
DISCONNECT
AUTO RESET PRIMARY
LIMIT CONTROL
BURNER COMPARTMENT
VT-28
BU-27
DOOR
SWITCH
LINE-H
JUNCTION BOX
LINE-N
BLOWER COMPARTMENT
INDOOR
AIR
CIRCULATION
BLOWER
BR
BR
CAPACITOR
RD (LOW)
OR (MED LOW)
BU (MED)
BK (HI)
BK-4
GND
WH
SEE
NOTE 4
LINE -H COOL- H HEAT-H
115 VAC HOT AND PA RK TERMINALS
EAC-H
EAC-N
HUM-H
HUM-N
INTEGRATED
CONTROL
MODULE
OPTIONAL
BLOWER HEAT
OFF DELAY SELECTOR
(SECONDS)
DIP SWITCHES PIN JUMPER
ON
ON
60
180
OFF
ON
90
ON
OFF
120
OR 60
OFF
OFF
180
90
AS SHIPPED FROM FACTORY
120
DIAGNOSTIC
LED
24V THERMOSTAT
CONNECTIONS
MANUAL RESET
AUXILLARY LIMIT
PK-30
WH-7
WH-33
BK-4
WH-5
GY-8
OR-10
OR-10
WH-5
GY-8
WH-33
CIRC-N
XFMR-N
PK-30E
BU-27
GN
LINE-N
BK-3
RD-2
10
7
4
1
11
8
5
2
12
9
6
3
OR-22
(OPTIONAL)
FUS E
24VAC
3A
YL-20
OR-15
RD-11
GY-12
BR-13
GY-8
OR-10
BU-14
BK-31
115 VAC
24 VAC
40 VA
TRANSFORMER
WH-32
OR-10
GY-8
IND ID
BLWR
HUMIDIFIER
HUM-H
EAC-H
ELECTRONIC
AIR CLEANER
HEAT-H
HE
AT
CO
OL
COOL-H
INDOOR
AIR
CIRCULATION
BLOWER
IGN
HOT SURFACE
IGNITER
FP (2)
GND
XFMR-H
HUM-N
EAC-N
CIR-N
FLAME SENSOR
115 VAC XFMR-N
40 VA
TRANSFORMER
24 VAC
R
TH (3)
(OPTIONAL)
FUSE 3 A
RO1 (5)
RO2 (11)
MANUAL RESET ROLLOUT
LIMIT CONTROL
MANUAL RESET
AUXILIARY
LIMIT CONTROL
AUTO RESET
PRIMARY
LIMIT CONTROL
HLO (1)
W
HLI (7)
Y
TO
MICRO
G
C
PS (10)
MV (12)
MVC (9)
GND (8)
TR (6)
C
NO
PRESSURE
SWITCH
C2
P3
M1
GAS
VALVE
GND
INTEGRATED CONTROL MODULE
0
1
STEADY ON = REPLACE CONTROL
1 FLASH = SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED)
2 2 FLASHES = PRESSURE SWITCH STUCK CLOSED
3 3 FLASHES = PRESSURE SWITCH STUCK OPEN
4 4 FLASHES = OPEN PRIMARY OR AUXILIARY LIMIT
5 5 FLASHES = OPEN ROLLOUT LIMIT
6
LOW VOLTAGE (24V)
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
JUNCTION
TERMINAL
7 7 FLASHES = LOW FLAME SENSE SIGNAL
C CONTINUOUS FLASHES = UNANTICIPATED FLAME PRESENT
COLOR CODES:
YL YELLOW
OR ORANGE
VT VIOLET
GN GREEN
BK BLACK
PK PINK
BR BROWN
WH WHITE
BU BLUE
GY GRAY
RD RED
20302001 REV.01
INTERNAL TO
INTEGRATED CONTROL
PLUG CONNECTION
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
4. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER
BEFORE CONNECTING BLOWER LEADS. UNUSED BLOWER LEADS MUST BE PLACED ON
"PARK" TERMINALS OF INTEGRATED CONTROL OR TAPED.
5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
6. BLOWER HEAT OFF DELAY IS FIXED AT 90 SECONDS WITHOUT OPTIONAL BLOWER HEAT OFF
DELAY SELECTOR.
EQUIPMENT GND
FIELD GND
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
SWITCH (PRESS.)
OVERCURRENT
PROT. DEVICE
34
Minimum Filter Area (in
2
)
[Permanent based on 600 ft/min filter face velocity - Disposable based on 600 ft/min filter face velocity]
GUID Permanent Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
045__30
070__30
070__40
090__30
090__50
115__50
600 800 1000 1200 1400 1600 2000
168* 192 240 288 -------
251* 251* 251*
----251*
288 '--'--'---
288 336 384 ---
'305* '305* '305* '305*
------305*
'--'--'---
336 384 480
------419* 419* 419* 480
GCID Permanent Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
070__30
600 800 1000 1200 1400 1600 2000
210* 210* 240 288 '--'-----
090__50
140__50
---
---
---
---
---
---
288 336* 384 480
419* 419* 419* 480
GUIE Permanent Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
045__30
070__40
090__40
090__50
115__50
600 800 1000 1200 1400 1600 2000
168* 192 240 288 -------
---
---
---
---
---
---
---
---
251*
---
---
---
288 336 384 ---
305*
305*
381*
336 384 480
336 384 480
381* 384 480
GUID Disposable Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
045__30
070__30
070__40
090__30
090__50
115__50
600
335*
800 1000 1200 1400 1600 2000
384 480 576 -------
503* 503* 503*
----503*
576
576
'---
672
'---
768
'---
---
'610* '610* '610* '610*
------610*
-------
'---
672
838* 762*
'---
768
768
'---
960
960
GCID Disposable Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
070__30
600 800 1000 1200 1400 1600 2000
419* 419* 480 576 '--'-----
090__50
140__50
---
---
---
---
--576 672
699* 699* 699*
768
768
960
'---
GUIE Disposable Minimum Filter Area (in 2 )
COOLING AIRFLOW REQUIREMENT (CFM)
Model
045__30
070__40
090__40
090__50
115__50
600
335*
800 1000 1200 1400 1600 2000
384 480 576 -------
-----
610* 610*
-----
-----
503*
---
---
---
576
610*
610*
762*
672
672
672
762*
768
768
768
768
---
960
960
960
[Based on 600 ft/min filter face velocity] [Based on 300 ft/min filter face velocity]
*Minimum filter area dictated by heating airflow requirement.
35
36
2004 Goodman Company, L.P.
Effective: March 2004
advertisement
Key Features
- high-efficiency heating system
- durable heat exchanger
- quiet, efficient blower motor
- consistent heat delivery
- Category I venting
- integrated ignition control
- multiple safety features
- easy to install and operate