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Installation Operation & Service Manual

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1. 9 7 Te nn naines 10 1 General sasinen 10 2 Start Up Proc dures 10 3 Furnace Start Te oed ivit ica PE GU EG i 10 4 Sequence of Operation 10 5 Gas Manifold Pressure Measurement And Adjustment 25 06 ale Hate Mes Na 9 ELECTRICAL CONNECTIONS cnrs 10 START UP ADJUSTMENT AND SAFETY CHECK 16 17 18 18 19 20 20 20 21 21 21 21 21 23 23 23 33 24 14 SERVICE AND MAINTENANCE PROCEDURES 30 14 1 Annual Inspection icai actis DO 14 2 FET e Nis 14 3 INDUCED DRAFT AND CIRCULAING BLOWER MOTORS 30 14 4 FLAME SENSOR QUALIFIED SERVICER ONLY 30 L2 d c 1 14 6 Cleaning Heat Exchangel sccsscsscsscsscssesssssessssessssnessseneed 1 14 7 Before Leaving An Installation 32 14 8 Repair And Replacement 32 15 WIRING DIAGRAMS iiiter tita eto a rtv rl bores Rire EFFICIENCY RATING GERTIFIED SF CERTIFIED ISO 9001 2008 NOTE Read the entire instruction manual before starting the installation Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2006 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington
2. WH HOT GAS VALVE FLAME E SURFACE SENSOR L GND N TO 115VAC 1 60 HZ POWER SUPPLY WITH OVERGURRENT PROTECTION DEVICE a o o T 5 ov o x O CN a gt 5 a do 3 2 po _ 5a oo 00 E 20 5 c D gt p L o H Q o x Q L o o E to gt gt O o D o D A Lo 3 DO E ear EK E o o c gt JUNCTION BOX LINE N IGNITER SNP LINE H PU INDUCED DRAFT BLOWER TO 115V 1 60 HZ o PU POWER SUPPLY WHIT OVERCURRENT PROTECTION DEVICE gt bo ROLLOUT LIMIT SINGLE CONTROL ON SOME MODELS x STEADY ON INTERNAL CONTROL FAILURE Give OFF NORMAL OPERATION EQUIPMENT GND rh FLASH SYSTEM LOCKOUT RETRIES REGYGLES EXGEEDED FUR MALE FIELD FIELD GND FLASHES PRESSURE SWITCH STUCK CLOSED HI VOLTAGE 115V FLASHES PRESSURE SWITCH STUCK OPEN 1 ce HI VOLTAGE FIELD FIELD SPLICE 4 FLASHES OPEN HIGH LIMIT 5 6 7 SWITCH TEMP S JUNCTION IGNITER HN Wiring is subject to change Always refer to the wiring diogram on the unit for the most up to date schematic FLASHES FLAME ROLLOUT SENSED FLASHES 115VOLT AC POWER REVERSED IMPROPER GROUND FLASHES LOW FLAME SENSE SIGNAL RAPID FLASHES FLAME SENSED WITHOUT GAS VALVE WARNING TERMINAL SWITCH PRESS INTERNAL TO 55 INT
3. 27 5 in 178 cm 30 in 194 cm 35 in 226 cm o d 18 cm 15 cm m ma ez a d 18 cm 18 cm d 7 5 Air Supply Openings Ducts 1 Two permanent openings one within 12 in 305 mm of the top and one within 12 in 305 mm of bottom of the confined space Two permanent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces 2 One permanent openings commencing within 12 in 305 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 25 4 mm from the sides and back and 6 in 152 4 mm from the front of the appliance The opening shall communicate directly with the outdoors and shall have a min imum free area of a 1 square in per 3000 Btu per hour 734 mm2 kW of the total input rating of all equipment located in the enclosure b Not less than the sum of all vent connectors in the confined space 3 The dud shall be least the same Cross sectional area as the free area of the air supply inlet opening to which it connects 4 The blocking effects of louvers grilles and screens must be given consideration in calculating free area If the free area of a specific louver aor grille is not known Refer to Table Estimated Free Area to estimated free area Table 7 Estimated Free Area Wood or Metal Wood 20 25 Louvers or Grilles Metal 60 7096 1 4 0 635cm me
4. 42 o o v bu o gt 7 o 5 o 2 LL en 0 o i 2 gt bh E as I amp O manual 33 Models 50A3A WARNING DISCONNECT POWER BEFORE INTEGRATED SERVICING WIRING TO UNIT MUST BE CONTROL MODULE PROPERLY POLARIZED AND GROUNDED XFMR 6 GND 8 id GAS C G R W 2 ium uve 8 VALVE ID BLOWER PRESSURE SWITCH po 15 DIAGNOSTIC LED OR T as AUXILIARY AUTO GONTROLS LIMIT CONTROLS PRIMARY RE Bei 11 way LIMIT CONTROL SNOILOANNOD LVLSONYAHL Ave WW KE z MANUAL RESET ROLLOUT rd INTEGRATED gt LIMIT CONTROL S CONTROL MODULE 3 SINGLE CONTROL ON SOME MODELS e 40 VA mer 2 S Eu TRANSFORMER Ic SE XFMR H E EE XFMR N CS overs FLAME SENSOR wo 2 o HOT SURFACE o IGNITER c es a P i 8 z 8 I SEIT w 5o _ TT gt CG D D 3 III S IND BLWR IND N AUXILIARY LIMITS 31ndON 1O0NLNOD GQ31VV9531NI 31ndON TONLNOD Qq31V39531NI EAC N LJ BLOWER COMPARTMENT LINE H LINE N BURNER COMPARTMENT 15 DOOR SS de SWITCH O Yi WA DOOR SWITCH GR SWHITCH LOCATED IN BLOWER COMPARTMENT ON SOME MODELS i 18 RNING m DISCONNECT POWER PRESSURE DISCONNECT SWITCH BEFOR SERVICING WIRING TO UNIT MUST BE PROPERLY MEME BR EL YL m AND GROUNDED BR W BL Ld BK
5. FLASHES FLAME ROLLOUT SENSED FLASHES 115VOLT AC POWER REVERSED IMPROPER GROUND FLASHES LOW FLAME SENSE SIGNAL IGNI TER TERMINAL 2 3 4 FLASHES OPEN HIGH LIMIT 5 SWITCH PRESS 7 INTERNAL TO INTEGRATED CONTROL OVERGURRENT PROT DEVICE PLUG CONNECTION OHZHSHeSHSHeHNSH H RAPID FLASHES FLAME SENSED WITHOUT GAS VALVE YELLOW RED NOTE ORANGE 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS 2 MANUFACTURER SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING PURPLE 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT NUST BE REPLACED WI TH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST GREEN 105 C USE GOPPER CONDUCTORS ONLY 4 BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS 0 AS TO PROVIDE THE GORRECT COOLING CFM SEE SPEC SHEET FOR AIR FLOW CHART 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TON E C AND LOCAL CODES BLACK 202082290008 REV 01 EGT TO 115 1 60 HZ POWER SUPPLY WITH OVERCURRENT UR HN e RE Always refer to the wiring diogram on the unit for the most up to date schematic Wiring is subject to change High Voltage Multiplepower sources talling this uni Ins icing or Disconnecet all power before serv WARNING lt D 5 i o gt art 5 c o 0 i D I D gt
6. Ge ee p 205 4 1 71 sos rat 8 4 p axe as 808 234 64 187 189 88 so soso 739 15 m 20 95 98 204 72 ant 90 as e osol 15 200 s _ 80 c aa ea ter 1600 ar e 15 14 293 24 er sv 20 60 a 2 m 2 9 _ s2 s 258 200 o7 so es 2 m 2 _ toon 293 sv 234 2000 104 so 133 29 _ 200 352 96 281 200 101 so 35e5 1935 20 REES 306 05 fair 2000 100 4o10 z229 200 Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE Test procedures National Electrical Code NFPA 70 latest edition and all local code The furnace shall be installed so that the electrical components are protected from water I amp O manual 21 DIP SWITCH HEAT OFF DELAY FACTORY SET Option Switch Positions Neutral terminal T 2 zl 2 u ZU ol scil Fuse LINE N Thermostat Humidifier Input voltage 115V 60Hz Unused circulator blower terminal XFMR H HUM H EAC Unused circulator blower terminal Heat stage Cool stage HEAT H EACH PARK Option Switch LED OPERATION amp DIAGNOSTIC LIGHT Fig 26 Furnace Control F
7. N 0 5 16 516 9 3 4 503 427 Downflow Applications on Combustible Flooring with Manufacturer 19 11 16 500 19 3 16 487 Supplied Box 19 1 1 16 500 19 3 16 487 20 5 16 516 19 13 16 503 24 4 2 Downflow Applications on Noncombustible Flooring 23 3 16 589 19 11 16 500 23 13 16 605 20 5 16 516 Downflow Applications on Combustible Flooring Using special base 22 3 16 563 19 483 23 584 19 3 4 503 622 Downflow Applications on Combustible Flooring with Manufacturer 49 4 1 16 500 19 3 16 487 20 5 16 516 19 13 16 503 Supplied Coil Assembly or Coil Box Sr FURNACE APPROVED COIL ASSEMBLY OR COIL BOX FURNACE OR COIL CASING WHEN USED COMBUSTIBLE COMBUSTIBLE FLOORING DOWNFLO SUBBASE HEET META PLENUM FLOOR OPENING B Ref Fig 6 FLOOR OPENING D Ref Fig 6 Fig 8 Furnace Plenum and Coil Assembly or Fig 7 Furnace Plenum and Subbase Installed on a Coil Box Installed on a Combustible Floor Combustible Floor 4 1 4 6mm THREADED ROD 4 REQ 22 GAUGE er Wi K STRAPS TYPICAL FOR 4 STRAPS OUTER DOOR ASSEMBLY AIR OPENING E LL OUTER DOOR ASSEMBLY CC _ 203 e DOGY MIN 2 HEX NUTS 2 WASHERS d ER dia ES amp 2 LOCK WASHERS 1 SQUARE 1 4 X 1 4 X 1 8 TYPICA
8. Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 1800 apart 16 Replace blower access door only if it was removed 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling 19 Check for gas leaks 20 Replace outer access door WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never use a match or other open flame to check for gas leaks Use a soap and water solution 21 Turn on electric power and gas supply to the furnace 22 Check furnace for proper operation Refer to Operational Checks section to verify burner flame characteristics 14 7 Before Leaving An Installation Cycle the furnace with the thermostat at least three times Verify cooling and fan only operation Review the Owner s Manual with the homeowner and discuss proper furnace operation and maintenance Leave literature packet near furnace 14 8 Repair And Replacement Parts 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 ava
9. module diagnosic NONE control module or loose eCheck integrated control module fuse with 3A Blown fuse or circuit Blown fuse or circuit module fuse 3A Replace automotive fuse LED provides NO SIGNAL breaker breaker if necessary Read precautions in Integrated control Integrated control eCheck for possible shorts Electrostatic Discharge module has an module has an internal in 115 and 24 volt circuits Section of manual internal fault fault Repair as necessary Replace bad integrated control module Furnace fails to Furnace lockout due Failure to establish Turn power OFF operate to an excessive flame Cause may be locate and correct gas prior to repair Integrated control number of ignition no gas to burners interruption gniter is fragile module diagnostic FLASH attempts bad igniter or igniter Replace or realign igniter handle with care LED is flashing alignment improper e Check flame sense signal Clean flame ONE 1 flash orifices or coated Sand sensor if coated and sensor with steel wool oxidized or improperly lor oxidized connected flame sensor Check flue piping for loss of flame after blockage proper length establishment Cause elbows and termination may be interrupted gas Verify proper induced draft supply lazy burner blower performance flames improper gas pressure or restriction in flue LED is flashing operating switch circuit switch
10. repair No furnace operation Reverse flow switch Insufficient conditioned if necessary Replace primary limit with Integrated control is open air over the heat Check filters and ductwork proper replacement part module diagnostic 4 exchanger Blocked for blockage Clean filters Replace blower with LED is flashing FLASHES filters restrictive or remove obstruction correct replacement part FOUR 4 flashes ductwork improper e Check circulator blower e Replace reverse flow circulator blower speed Speed and performance switch with proper or failed circulator blower Correct speed or replace replacement part Loose or improperly blower if necessary connected wiring Tighten or correct wiring connection 1 Integrated control module will automatically attempt to reset from lockout after one hour 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch I amp O manual 28 TROUBLE SHOOTING CHART Symptoms of Associated ie Cauti autions and Notes Abonormal Operation Fault Description s Possible reason Corrective Action Furnace fails to operate Integrated control module diagnostic LED is flashing FIVE 5 flashes FLASHES eInduced draft blower runs continuously No furnace operation Integrated control 6 module diagnostic FLASHES LED is flashing SIX 6 flashes Normal furnace Integrated control module diagnostic LED is flashi
11. 6 Reinstall cover to J Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 25 and Fig 27 AX WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components 1 Select and remove a hole knockout in the casing where the electrical box is to be installed NOTE Check that duct on side of furnace will not interfere with installed electrical box I amp O manual 20 2 Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing 3 Fasten the electrical box to casing by driving two field supplied screws from inside electrical box into casing steel 4 Remove and save two screws holding J Box See Fig 25 5 Pull furnace power wires out of 1 2 13 mm diameter hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electri cal box and into electrical box Pull field power wires into electrical box Remove cover from furnace J Box N 9 Route field ground wire through holes in electrical box and casing and into furnace J Box 10 Reattach furnace J Box to furnace ca
12. 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 I amp O manual 18 The following stipulations apply when connecting gas piping e 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 e 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 e 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 e 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 e Tighten all joints securely Connect the furnace to the building piping by one of the following methods Rigid metallic pipe and fittings Semi rigid metal
13. can result in fire or explosion A qualified service agency should be contacted to inspect the furnace and to replace all gas controls control system parts electrical parts that have been wet or the furnace if deemed necessary AGD Midea Heating amp Ventilating Equipment Co Ltd Penglai Industry Road Beijiao Shunde Foshan Guangdong P R China Installation Start up Operating and Service and Maintenance Instructions CONTENTS PAGE 1 SAFETY CONSIDERATIONG c sssscosssscsssccssccssccsssssneconsessnsscssscesssesneesse2 3 CODES AND STANDARDS SE nn 10 7 Temperature Rise rennes 10 8 Circulator Blower Speed Adjustment 1T OPERATIONAL CHECKS meneur 12 SAFETY CIRCUIT DESCRIPTION terit enge 3 2 General Installation eme KK in itai Quit E RE aaa 3 3 Combustion and Ventilation Air nee 122 Integrated Control Module 27 3 4 Duct E EE 12 3 Primary LIM 27 3 5 Acoustical Lining and Fibrous Glass 6 12 4 Reverse Flow Swith eere 27 3 6 Gas Piping and Gas Pipe Pressure 6 12 5 Rollout E E 3 7 Electrical Connections usoaceac ncn minio nire cite et nian ai 12 6 Pressure SWIEChes aa coit troi eege 3 8 Electrical Power SUpDly ssscsscsscsscssccsecsscnsesscnsesscnsessensesscenceseeeO
14. could cause an unsafe condition Close all building doors and windows and all doors Turn on clothes dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace damper Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so the appliance shall operate continuously Test each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief opening after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels o each appliance Use a draft gauge to check for a downdraft or inadequate draft condition 6 After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their normal condition 7 If improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft
15. disconnecting Reconnect wires correctly Verify proper operation after servicing WARNING FIRE EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace with proper control could result in fire explosion or carbon monoxide poisoning This appliance uses a NEGATIVE PRESSURE REGULATED gas control Replace ONLY with the same model number or as specified by the manufacturer 14 1 Annual 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 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 a All flue gas carrying areas external to the furnace i e chimney vent connector are clear and free of obstructions b The vent connector is in place slopes upward and is physically sound without holes or excessive corrosion c The return air duct connection s is physically sound is sealed to the furnace casing and terminates outside the space containing the furnace d The physical support of the furnace is sound without sagging cracks gaps etc around the base so as to provide a seal between the support and the base e There are no obvious signs of deterioration of the furnace f The pilot and burner flames are in good adjust
16. may be combustible See Fig 2 for required clearances to combustible construction Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or local code for further require ments e These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installations factory accessory floor base MUST be used when installed on combustible materials and wood flooring Special base is not required when this furnace is installed on manufacturer s Coil Assembly I amp O manual 2 e See Fig Instruction of lighting shutdown operation Should the d The physical support of the furnace is sound without sagging gas supply fail to shut off or if overheating occurs shut off the cracks gaps etc around the base so as to provide a seal gas valve to the furnace before shutting of the electrical supply between the support and the base e There are no obvious sign of deterioration of the furnace Before heating season begins exame the furnace to determine f The burner flames are in good adjustment by comparison with that pictorial sketches of the main burner flame see Fig 31 a All flue gas carrying areas external to the furnace i e chimney vent connector are clear and free of obstructions e Furnace operation needs air for combustion and ventilation b Th
17. reading is not in excess of 0 1 in W W 25 kPa with all of the appliance s operating at the same time 8 Any corrections to the venting system and or to the supply outside air system must be in accordance with the National Fuel Gas Code Z223 1 or CAN CGA B149 1 Natural Gas and Propane Installation Code latest editions If the vent system must be resized follow the appropriate tables in Appendix G of the above codes or for this appliance 8 GAS SUPPLY AND PIPING AX WARNING AX WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage If local codes allow the use of a flexible gas appliance connec tor always use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace check all connections 8 1 General 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 conve
18. to prevent ESD damage 5 LOCATION 5 1 General This multipoise furnace is shipped in packaged configuration Some assembly and modifications are required when used in any of the four applications This furnace must e Be installed so the electrical components are protected from water e Not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS e Downflow installation and horizontal installation in atttic have additional requirements See Section 6 Installation Be located as close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section Be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures e Commercial buildings e Buildings with indoor pools e Laundry rooms e Hobby or craft rooms and e Chemical storage areas WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can c
19. to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces Improper installation adjustment alteration service Maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accesso ries when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these instruc tions thoroughly and follow all warnings or cautions include in literature and attached to the unit Consult local building codes the current editions of the National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the National Standards of Canada CAN CSA BI49 1 and 2 Natural Gas and Propane Installa tion Codes and Canadian Electrical Code CSA C22 1 Recogniz
20. with proper replacement part TWO 2 flashes Induced draft blower Pressure switch Pressure switch hose e Inspect pressure switch e Turn power OFF prior to runs continuously circuit not closed blocked pinched or hose Repair repair with no further Induced draft blower connected improperly if necessary furnace operation is operating Blocked flue or weak Inspect flue for blockage e See Combustion and Integrated control induced draft blower proper length elbows Ventilation Air Requirements 3 FLASHES Furnace fails to Pressure switch Induced draft blower Replace induced draft Turn power OFF operate circuit is closed pressure switch contacts blower pressure switch prior to repair Integrated control 5 Induced draft sticking Repair short module diagnostic Ej asHEs blower is not Shorts in pressure Replace pressure module diagnostic LED is flashing THREE 3 flashes Incorrect pressure switch and termination and Category Venting setpoint or malfun Correct pressure switch section for details ctioning switch contacts setpoint or contact motion loose or improperly Tighten or correct Replace pressure switch connected wiring wiring connection ith proper replacement part Circulator blower e Primary limit circuit Faulty primary or Check primary or reverse Turn power OFF prior to runs continuously is open reverse flow limit switch flow limit switch Replace
21. 12 7 Hame SENSOR 2428 1 e D 13 TROUBLES HOOTINGS nm 27 4 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 6 13 1 Electrostatic Discharge Eso Precautions 27 13 2 Diagnostic Chiat Esas quisi 2 7 13 3 Resetting From Lockout eee 2 7 5 1 Upflow installations tes lebten seit 6 2 Downflow Installations 6 3 Horizontal Installation 6 4 Filter Arrangement 7 1 Vent Connections os cst Rp PH SEE And e eas Ord PERTH PG OR NI EE 7 3 Venting Into An Existing Chimney nm 7 4 Air For Combustion and Ventilation 7 5 Air Supply Openings and Ducts eere 7 6 Ventilated Combustion Air eere eeeenenenen 7 7 Vent and Supply Outside Air Safety Check Procedure 15 8 GAS SUPPLY AND PIPING eege BT General a obest 82 High Altitude Defdate ss cuti nids 8 3 Propane Gas Conversion eee eser rere ense ento oous 8 4 Gas Piping Connections eere eere eren tennune 8 5 Gas Piping ChiBEKS custo e e SE nis tu E eH E te 9 2 Electrical Connection To J box mme 9 3 Power Cord Installation In Furnace J box 9 4 Cable Installation In Furnace 9 6 Accessories Field Supplied
22. 290006 18 inches front dearanre required for alcove HORIZONTAL INSTALLATION IN ATTIC ndicates supply or return sides when furnace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket and building joists studs or framing A special base is required refer to Horizontal Installation section in Manual D GAGEMENT MINIMUM EN POUCES AVEC L MENTS DE CONSTRUCTION COMBUSTIBLES T POUR LA POSITION COURANT DESCENDANT Pour l installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale Dans une alo ve on doit maintenir un d gagement l avant de 18 po 450mm La poistion indiqu e conceme le c t d entr e ou de retour quand la foumaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la cherrise de la foumaise et les solives montant sous cadre de charpente Fig 2 Clearances to Combustibles I amp O manual 5 3 CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed belo
23. 54 intitul e National Fuel Gas Code ou les code d installation CSAB 149 1 2 This fumace must be installed so there are provisions for combustion and ventilation air See manufacturer s installation information provided with this appliance Ce foumaise air chaud doit tre install de mani re ce qu ilyait ait suffisamment d air de ventilation et combustion Consulter les instructions d installation du fabricant foumies avec cet appareil OPERATION This fumace is equipped with manual reset limit swich es in bumer compartment to protect against overheat conditions that can result from inadequate combustion air supply or blocked vent conditions 1 Do not bypass limit switches 2 If a limit opens call a quallified serviceman to correct the condition and reset limit switch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES An accessory kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for some natural gas applications This fumace is for indoor installation in a building constructed on site This fumace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material This furnace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Utiliser une trousse de conversion foumie par le fabricant pour pass
24. DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety WARNING FIRE OR EXPLOSION HAZARD The furnace is designed and approved for use with Natural Gas and LP Propane Gas ONLY DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE Burning any unapproved fuel will result in damage to the furnace heat exchanger which could result in Fire Personal Injury and or Property Damage I amp O manual 1 1 SAFETY CONSIDERATIONS WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous opera tion serious injury death or property damage Improper installation adjustment alteration service maintenance or use could cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or accessories when modifying this product FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure Application of this furnace should be indoors with special attention given
25. ECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access panel door switch opens 115V power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 27 for field wiring diagram showing typical field 115V wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 35 C rise WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2008 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire conduit approved for electri cal ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground FURNACE MAY NOT OPERATE Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else control will lock out Control must remain grounded through green yellow wire routed to gas valve and manifold bracket screw 9 1 115V wiring Verify tha
26. EGRATED CONTROL OVERCURRENT PROT DEVICE EH RO HSHe Ho fa HeHsHe HHS PLUG CONNECTION YELLOW RED NOTE ORANGE 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 7 AMPS 2 MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING PURPLE 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 GREEN 105 C USE COPPER CONDUCTORS ONLY BLACK BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS SO AS TO PROVIDE THE CORRECT COOLING CFM SEE SPEC SHEET FOR AIR FLOW CHART 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES E 202082290027 REV 01 I amp O manual 34 GMSOS Series 7909 N W 54th Street Miami FL 33166 USA Phone 1 305 594 4972 Fax 1 305 675 2212 e mail sales klimaire com www klimaire com LIMA RE e
27. Gas Furnace Installation Operation amp Service Manual 80 AFUE P a 805 Series KLiMA RE THIS BOOKLET CONTAINS IMPORTANT INFORMATION INSTALLER USE THE INFORMATION IN THIS BOOKLET TO INSTALL THE APPLIANCE AND AFFIX THIS BOOKLET ADJACENT TO THE APPLIANCE AFTER INSTALLATION USER KEEP THIS BOOKLET OF INFORMATION FOR FUTURE REFERENCE SERVICER USE THE INFORMATION IN THIS BOOKLET TO SERVICE THE APPLIANCE AND AFFIX THE BOOKLET ADJACENT TO THE APPLI ANCE AFTER SERVICING NOTE Please read all instruction in the manual and retain all manuals for futrue reference A WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS s De nattry to light any appliance s Oo nattoueh any electrical switch de not use any phone in your building Leave the building immediately s Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions fyoucannat reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier NOTE Do not use this furnace if any part has been under water A flood damaged furnace is extremely dangerous Attempts to use the furnace
28. IELD 24V WIRING FIELD 115V 208 230V WIRING FACTORY 24V WIRING FACTORY 115V WIRING NOTE 2 THERMOSTAT FIVE WIRE Di 09 CO FIELD SUPPLIED THREE WIRE DISCONNECT HEATING ONLY _ BLOWER DOOR 208 230V THREE SWITCH f PHASE 208 230V V SINGLE PHASE 115V FIELD SUPPLIED DISCONNECT SH CONDENSING UNIT TWO WIRE FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire Fig 27 Heating and Cooling Application Wiring Diagram with I Stage Thermostat I amp O manual 22 10 START UP ADJUSTMENT AND SAFETY CHECK 10 1 General WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switches Correct inadequate combustion air supply problem before resetting the switches CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety g
29. L FOR 2 SUPPORTS REQ PER ROD Fig 9 Horizontal Unit Suspension Fig 10 Horizontal Suspension with Straps I amp O manual 9 LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF VENT Maintain required clearances to combustibles THE TOP AND TWO SIDES OF THE FURNACE gt lt JACKET AND BUILDING JOISTS STUDS OR FRAMING NT LEE iras ew x AT Supply Air r K Return Air Filter rack must be a minimun distance of 18 45 7mm from the furnace 30 IN 762 mm WORK AREA Sheet metal in front of furnace combustion air Openings is Recommended Fig 11 Typical Attic Installation 6 3 Horizontal Installation WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace The furnace can be installed horizontally in an attic or crawl space on bottom or either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or p
30. PRIMARY MIT Bei 11 l a gt Y CONTROL JINGOW 1081409 GALWYDSLN tn x CONTROL MODULE 7 XFHR G SINGLE CONTROL ON SONE MODELS 924 VACO D Te 40 VA gt TRANSFORMER mz X o L XFMR H XFMR N 2ggrcr ee 1 FLAMF SENSOR a of o HOT SURFACE IGNITER D D D z z S w Fd z HUM N m 2 9 2 x m IND N AUXILIARY 2 LINITS z 0 o C i d 9 S c E M ELECTRONIC AIR CLEANER LEO BLOWER COMPARTMENT EECH WH AND GROUNDED L ND N PROTEGTION DEVIGE BURNER COMPARTMENT LL DOOR SWITCH SWHITCH LOCATED IN BLOWER YL COMPARTMENT ON SOME MODELS 1 d i WARNING DISCONNECT POWER PRESSURE DISCONN SWITCH BEFOR SERVICING BR F WIRING TO UNIT MUST BE PROPERLY POLARIZED a BK WH HOT GAS VALVE FLAME E SURFAGE SENSOR JUNCTION BOX LINE N IGNITER LINE H PU INDUCED DRAFT BLOWER TO 115V 1 60 HZ PU PU POWER SUPPLY WHIT DVERGURRENT PROTECTION DEVICE ROLLOUT LINITS SINGLE GONTROL ON SOME MODELS STEADY ON INTERNAL CONTROL FAILURE LOW VOLTAGE 24V OFF NORMAL OPERATION EQUIPMENT GND 1 FLASH SYSTEN LOCKOUT RETRIES RECYCLES EXCEEDED FLASHES PRESSURE SWITCH STUCK CLOSED FLASHES PRESSURE SWITCH STUCK OPEN LOW VOLTAGE FIELD FIELD GND HI VOLTAGE 115V FIELD SPLICE HI VOLTAGE FIELD SWITCH TEMP JUNGT I ON
31. THERMOSTAT WIRE ENTRY 7 8 22mm 28 1 2 724mm Table 1 Dimensions FURNACE SIZE 100C5A 100D5A 110C5A 120D5A 135D5A A CABINET WIDTH IN MM 24 13 16 630mm 3 1 8 79mm DIA LEFT VENT OUTLE 4 3 4 120 7mm DIA THERMOSTAT WIRE ENTRY 7 8 22mm Fig 1 Dimensional Drawing D E SUPPLY RETURN AIR WIDTH AIR WIDTH IN MM IN MM 12 27 32 326 12 27 32 326 15 27 32 402 SHIP WT Ibs I amp O manual 4 2 INTRODUCTION This series 4 way multipoise Category fan assisted furnace is CSA design certified A Category fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger The furnace is factory shipped for use with natural gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum continuous return air temperature of 60 F 16 C db or intermittent operation down to 55 F 13 C db such as when used with A WARNING a night setback thermostat Return air temperature must not exceed 85 F 29 C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipp
32. ad Suspended Furnace Support The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 9 and 10 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the furnace from each bottom corner To prevent screws from pulling out use 2 8 x 3 4 in screws into the side and 2 8 x 3 4 in screws in the bottom of the furnace casing for each strap See Fig 9 and 10 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment screws are not In tension are loaded in shear for reliable support Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Fig 2 and 11 For furnaces with 1 in clearance requirement on side set furnace on noncombustible blocks bricks or angle iron For crawl space installations if the furnace is not suspended from the floor joists the ground underneath furnace must be level and the furnace set on blocks or bricks Roll Out Protection Provide a piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 in 305 mm above the combustible deck or suspended furnaces closer than 12 in 305 mm to joists The sheet metal MUST extend underneath the furnac
33. aft blowe for proper performance Replace if necessary Tighten or correct wiring connection Review wiring diagram to correct polarity Verify proper ground Correct if necessary Reverse red and blue wires connected to transformer Turn power OFF prior to repair Sand flame sensor Inspect for proper sensor alignment Compare current gas pressure to rating plate info Adjust as needed Turn power OFF prior to repair Clean flame sensor with steel wool See VenVFlue Pipe section for piping details See rating plate for proper gas pressure Correct short at flame sensor or in flame sensor wiring Turn power OFF prior to repair Check electric power frequency Change control board Turn power OFF prior to repair 1 Integrated control module will automatically attempt to reset from lockout after one hour 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch I amp O manual 29 14 SERVICE AND MAINTENANCE PROCEDURES WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to
34. ain casing NOTE For horizontal applications the top most flange may be bent past 90 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed Downflow Furnaces Connect supply air duct to supply air outlet on furnace Bend flange inward past 90 with wide duct pliers The supply air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase or a factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace casing I amp O manual 12 Table 3 Air Delivery CFM Without Filter xx EXTERNAL STATIC PRESSURE IN WC 0 5 0 6 0 7 0 8 FURNACE RETURN AIR SIZE 50A Bottom or Sides EN St lt Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides Bottom or Sides lt r A filter is required for each return air Inlet Airflow performance Included 3 4 In 19 mm washable filter media such as contained In factory authorized accessory filter rack To determine airflow performance with this filter assume an additional 0 1 in wc available ex
35. all your gas supplier from a STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand SWITCH SHOWN IN THE OFF POSITION Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Remove control access panel Wait five 5 minutes to clear out any gas if you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 7 Push gas control switch to ON NOTE Do not force 8 Replace control access panel 9 Turn on all electric power to the appliance 10 Set thermostat to desired setting 11 If the appliance will not operate follow instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 Push gas control to OFF Do not force 5 Replace control access panel I amp O manual 3 24 13 16 630mm be 24 1 2 6 22mm gt 2 1 8 54mm EN Im 19 1 2 495mm DIA
36. and Ventilation of the National Fuel Gas Code Z223 1 NFPA 54 latest edition or Sections 7 2 7 3 or 7 4 of CSA B149 1 National Gas and Propane Codes latest edition or applicable provisions of the local building code and these instructions The furnace shall be connected to a type B vent connector The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel Single wall vent pipe is not allowed It is recommended that the appliance is installed in a location where the space temperature is 32 F 0 C or higher If the appliance is installed in a location where the temperature is below 32 F 0 C the combustion byproducts could condense causing damage to the appliance heat exchanger This appliance may be common vented with another gas appliance for residential installations as allowed by the codes and standards listed in these instructions 7 2 Venting Category venting consists of vertically venting one or more appliances in B vent or B vent connectors Type B vent system extends in a gen eral vertical direction and does not contain offsets exceeding 45 A vent system having not more than one 60 offset is permitted Gable Vent PEN Z Ventilated Attic Top Above Insulation Ventilated Attic Top Above Insulation Optional Inlet a Furnace Ventilated Crawl Space 7 3 Venting Into An Existing Chimney This furnace may not be connected to any mas
37. ber of seconds recorded in step 2 by two 4 Calculate the furnace input in BTUs per hour BTU hr Input equals the installation s gas heating value multiplied by a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating HTG value 1 000 BTU ft3 Obtained from gas supplier Installation s seconds per cubic foot 34 sec ft3 Conversion Factor hours to seconds 3600 sec hr Input Htg value x 3600 seconds per cubic foot Input 1 000 BTU ft3 x 3600 sec hr 34 sec ft3 Input 106 000 BTU hr This measured input must not be greater than the input indicated on the unit rating plate 5 Turn ON gas and relight appliances turned off in step 1 Ensure all the appliances are functioning properly and that all pilot burners are operating 10 7 Temperature Rise Adjustment 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 withi
38. closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used See 6 1 and Fig 5 for bottom closure removal Gg ST 2 PLENUM OPENING g g 7 g Fig 6 Floor Plenum Opening Dimensions I amp O manual 8 TABLE 2 OPENING DIMENSIONS IN MM CASING PLENUMOPENNG CASING APPLICATION PLENUM OPENING FLOOR OPENING WIDTH E Downflow Applications on Noncombustible Flooring 13 3 16 9 11 16 500 13 13 16 350 20 5 16 516 14 1 2 368 N Downflow Applications on Combustible Flooring Using special base 12 3 16 311 9 483 13 331 9 3 4 503 335 311 19 3 Downflow Applications on Combustible Flooring with Manufacturer Co lA can bV Ge Cell Bax 13 3 16 335 19 3 16 487 13 13 16 351 19 13 16 503 Downflow Applications on Noncombustible Flooring 16 3 16 411 19 11 16 500 16 13 16 427 20 5 16 516 17 12 Downflow Applications on Combustible Flooring Using special base 15 3 16 385 19 483 16 406 19 3 4 503 445 Downflow Applications on Combustible Flooring with Manufacturer 16 3 16 411 19 3 16 487 16 13 16 19 13 16 503 Supplied Coil Assembly or Coil Box 2 Downflow Applications on Noncombustible Flooring 19 11 16 500 19 11 16 500 20 5 16 516 1 553 487 9 516 Downflow Applications on Combustible Flooring Using special base 18 11 16 474 9 483 19 1 2 495 516 9
39. container Spray adhesives for use with permanent filters can be found at some hardware stores BE SURE AIRFLOW DIRECTION ARROW POINTS TOWARDS THE BLOWER Inspect filter If your dirty filter is the disposable type replace dirty filter with the same type and size filter If your dirty filter is a permanent 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 14 3 INDUCED DRAFT AND CIRCULAING BLOWER MOTORS The bearings in the induced draft blower and ciretdator 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 14 4 FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will lock out The flame sensor should be carefully clea
40. djustment screw and adjust the outlet pressure to manufacturer s specified outlet pressure Refer to Fig 28 and Section 10 5 and 10 6 for outlet pressure tap location and pressure measure ment 6 Replace the regulator cover screw 7 Attach the WARNING label provided in the kit to the gas valve attach small round LP label to the top of regulator cover screw 8 Fill required blanks in provided conversion label and attach it to appropriate location on furnace case 8 4 Gas Piping Connections To avoid possible unsatisfactory operation or equipment damage due to underfiring of equipment use the proper size of naturaupropane 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 See Table 11 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 Refer to the latest version of NFPA54 ANSI Z223 1 for US and the latest version of CSA B149 1 for Canada Table 11 NaturalGas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH 1 2 12 7 0 622 15 8 3 4 19 0 2 0 380 35 0 1400 950 EE 610 40 9 1460 1180 Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific GravityGas CFH BTUH Furnace input Heating Value of Gas BT U
41. ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 M of main duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts Supply Air Connections For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the airstream The cover attachment shall prevent leaks Upflow and Horizontal Furnaces Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace m
42. e casing by 1 in 25 mm with the door removed The bottom closure panel on furnaces of widths 12in 305 mm and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 11 for proper orientation of roll out shield I amp O manual 10 Vent the furnace with the appropriate connector as shown in Fig 12 18 AL I Fig 14 Horizontal Left Application Vent Elbow Up Fig 15 Horizontal Right Application Vent Elbow Up Fig 16 Upflow Application Vent Fig 17 Upflow Application Vent Fig 18 Upflow Application Vent Elbow Left Elbow Up Elbow Right I amp O manual 11 6 4 Filter Arrangement WARNING CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in personal injury or death Never operate a furnace without a filter or with filter access door removed FILTER SIZE See recommended filter size and type in Table 4 One of the most common causes of a problem in furnace is a blocked or dirty filter The filter must be inspected monthy for dirt accumulation and replace it if neccessarily FILTER TYPE Air velocity through throwaway filters may not exceed 300 feet per minute 91 4m min All velocities over this require the use of hight velocity filters If a normal speed desposable filter is used and air speed exceeds 300 feet per minute FPM two side returns or one side return and the bottom return may be need
43. e by putting the furnace the control and the person at the same electrostatic potential e Disconnect all power to the furnace Multiple disconnects maybe required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND e Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged e After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity for example DO NOT move or shuffle your feet do not touch ungrounded objects etc f you touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control or wires Use this procedure for installed and un installed ungrounded furnaces I amp O manual 6 e Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the furnace Put all used and new controls into containers before touching ungrounded objects e An ESD service kit available from commercial sources may also be used
44. e safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced Installation reliability or operation Use only with type of gas approved for this furnace Refer to the furnace rating plate nstall this furnace only in a location and position as specified in the Location section of these instructions e Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and ventilation section Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in the Venting section of these instructions Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Suppy and Piping section e Always install furnace to operate within the furnace s inte
45. e vent connector is in place slopes upward and is Do not block or obstruct air openings on furnace or spacing physically sound without holes or exccessive corrosion arroud furnace required for supplying sufficient combustion air c The return air duct connection s is physically cound is and ventilation sealed to the furnace casing and terminates outside the space containing the furnace Cover old lighting instructions with this label Note Rating plate must be left visible for future reference FOR YOUR SAFETY READ BEFORE OPERATING This appliance does not have a pilot it is equipped with an neighbors phone Follow the gas suppliers ignition device which automatically lights the burner Instructions Do not try to light the burner by hand f you cannot reach your gas supplier call the BEFORE OPERATING smell all around the appliance fire department area for gas Be sure to smell next to the floor because Use only your hand to turn the gas control switch Never use some gas Is heavier than air and will settle on the floor tools If the switch will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair FOR YOUR SAFETY may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately c
46. ed For airflow refer to Table 3 If disposable filters are used air throw away passage through filters should be increased to twice the size of original air opening by using a transition duct or using two filters in V shap in normal duct size SIDE RETURN Locate the 4 cutout locations These indicate the size of the cut out to be made in the furnace side panel Refer to Fig 19 Side Return Cutout Markings Front of Furnace Corner Markings Fig 19 Side Return Cutout Markings Install the side filter rack following the instructions provided with that accessory If a filter s is provided at another location in the return air system the ductwork may be directly attached to the furnace side panel IMPORTANT Some accessories such as electronic air cleaners and pleated media may require a larger side opening Follow the instruc tions supplied with that accessory for side opening requirements Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Filter s may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of straps and or supports is required to support the weight of the exte
47. en the vent pipe is routed within the casing 1 Remove and save two screws holding J Box See Fig 24 NOTE The J Box cover need not be removed from the J Box in order to move the J Box Do NOT remove green ground screw inside J Box The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J Box outboard of the casing 2 Cut wire tie on loop in furnace wires attached to J box 3 Move J Box to desired location 4 Fasten J Box to casing with two screws removed in Step 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces J box cover GND screw Door switch Fig 25 J box 9 2 Electrical Connection To J box Field Supplied Electrical Box on Furnace J Box Bracket See Fig 25 1 Remove cover from furnace J Box 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will not pierce wire insulation 3 Route furnace power wires through holes in electrical box and J Box bracket and make field wire connections in electrical box Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 4 Route and secure field ground wire to green ground screw on J Box bracket OR FURNACE FAIL TO OPERATE 5 Connect line voltage leads as shown in Fig 27
48. ent 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 Follow the start up and adjustment items refer to further information in Operational Checks 10 3 Furnace Start 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 36J22 214 Push the switch to the OFF position 6 Wait five minutes to clear out any gas Then smell for gas including near the floor T If gas can be smelled following the five minute waiting period in Step 6 If you do not smell gas after five minutes Push the switch to the ON position WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detection of leaks to check all connections 8 Replace the door on the front of the fu
49. er au gaz propane ou pour certaines installations au gaz naturel Cette foumaise est pr vue pour tre install e dans un b timent construit sur place Cette foumaise peut tre install e sur un planctler combustible dans une ald ve ou dans un garde robe en respedant le minimum d espace libre des mat riaux combustibles tel qu indiqu sur le diagramme Cette foumaise peut tre utilis e avec un oondutt d vacuation de Type B 1 ou connect e au conduit ommun d autres appareils gaz This fumace is approved for UPFLOW DOWNFLOW and HORIZONTAL installations Cette foumaise est approuv e pour l installation HORIZONTALE et la circulation d air VERS LE HAUT et VERS LE BAS Clearance arrows do not change with fumace orientation Les fl ches de d gag ement ne change pas avec orientation de la foumaise N e E 3 3 TOPIPLENUM DESSUSI CHAMBRE D AIR Clearance in inches D gagement po Vent Clearance to combustibles For Single Wall vents 6 inches 6 po For Type B 1 vent type 1 inch 1 po D gagement de l vent avec combustibles Pour oondurt d vacuation paroi simple 6 po 6 inches Pour oonduit d vacuation de Type B 1 1 PO 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS T Installation on non combustible floors only For Installation on combustible flooring only when installed on sub base provided by installer or manufacturer s Part number 202882
50. erate 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 The gas supply shall be shut off prior to disconnecting the electrical power before proceeding with conversion 1 Make sure all utilities gas and electricity are turned off 2 Remove the furnace front panel 3 Disconnect the gas line from the gas valve 4 Disconnect the wires at gas control To Replace Orifices with LP Orifices From Gas Manifold See Fig 23 1 Disconnect all control wires 2 Remove 4 screws holding gas manifold to supporting burner assembly bracket 3 Slide the manifold with valve and orifices out of burners Be careful not to damage the assembly 4 Replace the natural gas orifices with the LP orifices or appropriate high altitude orifices refer to Section High Altitude Installation 5 Re assemble the gas manifold and re connect all wires Inlet Burner Box Gas Valve Gas Manifold Burner Orifices Fig 23 To Convert From Natural to LP Gas on Gas Valve 1 Remove regulator gas valve cover screw 2 Remove regulator adjustment screw beneath the cover screw 3 Remove natural gas spring from regulator sleeve 4 Insert the LP spring included in the conversion kit into sleeve 5 Replace the a
51. ergized and the ignitor is powered within one second the pressureswitch contacts PRS close to begin a 15 second prepurge period b Igniter Warm Up At the end of the prepurge period the Hot Surface igniter HSI is energized for a 10 second igniter warm up period This controller has an adaptive algorithm that adjusts the duration of the ignitor warm up to extend ignitor life Upon initial application of power the warm up time is 10 seconds The ignitor on time will then be increased or decreased depending on whether or not flame is achieved The warm up time is limited to a maximum of 14 seconds During the first 64 warm up periods following power up the warm up time may not be less than 10 seconds Upon a call for heat if the warm up time has not been locked it will be decreased by one second This reduction of the ignitor ontime will continue until flame fails to be achieved resulting in a retry In the event of a retry the warm up time will be increased by two seconds and locked in at that duration Once the warm up time is locked it remains fixed until another call for heat results in a retry in which case the warm up time is again increased by two seconds and remains locked In the event of two successive retry attempts the warm up time will be unlocked and set to 14 seconds If flame is then achieved the warm up time will begin adapting again with the next call for heat If however this third attempt fails to achie
52. fter the call for cooling ends During normal heating operation the circulator fan will come on approximately 30 seconds after the gas valve opens DIP SWITCH HEAT OFF DELAY FACTORY SET Fig 30 Adjustment Switches Not present on all models 11 OPERATIONAL CHECKS WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD To avoid personal injury or death Do not remove any interal compartment covers or attempt any adjustment Electrical compartments are contained in both compartments Contact a qualified service agent at once if an abnormal flame appearance should develop Burner Flame The burner flames should be inspected with the burner compartment door installed Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow Flames should extend directly outward from the burners without curling floating or lifting off and should enter heat exchanger tube Flames must not impinge on the sides of the heat exchanger firing tubes Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Fig 31 Burner Flame 1 amp O manual 26 12 SAFETY CIRCUIT DESCRIPTION 12 1 General 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 diagnos
53. going procedures until each cell in fur nace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor with fine steel wool 9 Reinstall burner assembly Center burners in cell openings 10 Remove old sealant from cell panel and collector box flange 11 Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use con nection diagram on wiring label if wires were not marked for reconnection locations a Draft safeguard switch b Inducer motor c Pressure switch es d Limit over temperature switch e Gas valve f Hot surface igniter g Flame sensing electrode h Flame rollout switches 14 Reinstall internal vent pipe if applicable Fig 34 Cleaning Heat Exchanger Cell I amp O manual 31 15
54. grated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch aclean 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 donot 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 The primary limit control is located on the partition panel and 13 2 Diagnostic Chart 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 See Table 16 13 3 Resetting From Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts It is characterized by a non functioning furnace and a one flash diagnostic LED code from the red LED If the furnace is in lockout it
55. he R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y circuits start the furnace blower motor BLWM on COOL H speed The cool delay to fan on period begins After the delay period ends the optional electronic air cleaner is energized and the circulator fan is energized at cool speed After the thermostat is satisfied the compressor is de energized and the cool mode delay to fan off period begins After the delay to fan off period ends the circulator fan and electronic air cleaner optional are de energized 3 FAN Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on COOL H speed If the thermostat fan switch is moved to the ON position the circulator fan cool speed and optional electronic air cleaner are energized When the fan switch is returned to the AUTO posi tion the circulator fan and electronic air cleaner optional are de energized I amp O manual 24 10 5 Gas Manifold Pressure Measurement And Adjustment Measure gas manifold pressure with burners firing Adjust CAUTION To prevent unreliable operation or equipment damage the gas manifold pressure must be as specified on the unit rating palte Only minor adjustments should be made by adjusting the gas valve pressure regulator This valve is shipped from the factory with the regulator preset Consult the appliance rating plate to ensure burner manifold pressure is as specif
56. ied If another outlet pressure is required follow these steps See Table 13 and Fig 28 Turn OFF all electrical power to the system Using a 3 32 inch hex wrench loosen outlet pressure tap boss screw one turn Do not remove screw 3 Attach a hose and manometer to the potlet pressure boss of valve to over lap at least 3 8 4 Turn ON system power and set thermostat to a call for heat 5 Using a leak detection solution or non chlorine soap suds check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY 6 Remove regulator screw cover Turn regulator screw either clockwis to increase pressure or counter clockwise to decrease Always adjust regulator to provide the correct pressure according to the original equipment manufacturer specifications listed on the appliance rating plate 7 Replace regulator screw cover and finger tighten securely 8 Turn OFF all electrical power to the system 9 Remove manometer and hose from outlet pressure tap 10 Tighten outlet pressure tap clockwise 7 in lbs minimum to seal port 11 Turn ON system power and set thermostat to call for heat 12 Using a leak detection solution or non chlorine soap suds 1 check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY Outlet Pressure Vent Port Port Inlet gt lt Outlet Wrench Boss Inlet eem Sw
57. ifold 8 Remove the 5 screws that attach the burner assembly to the cell panel The gas valve and individual burners need not be removed from support assembly NOTE Be very careful when removing burner assembly to avoid breaking igniter See Fig 32 and Fig 33 for correct igniter location 9 Using field provided 25 caliber rifle cleaning brush 36 in 914 mm long 1 4 diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows a Remove metal screw fitting from wire brush to allow in sertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT Fig 33 Igniter Position 2 NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush 2 Insert brush end of cable into the outlet opening of cell and slowly rotate with drill DO NOT force cable Gradually insert cable into upper pass of cell See Fig 34 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of cell and proceed to clean 2 lower passes of cell in same manner as upper pass 5 Repeat fore
58. ilable from your distributor See Fig 35 amp e 600 COMPONENT IDENTIFICATION 1 Single Stage Gas Valve 12 Transformer 2 Gas Manifold 13 Rollout Limit Switch 3 Mini Igniter 14 Primary Limit Switch 4 Natural Propane Gas Orifice 15 Junction Box 5 Burner 16 Induced Draft Blower 6 Door Switch 17 Flue Collector Box 7 Integrated Contol Module 18 Heat Exchanger 8 24 Volt Thermostat Connections 19 Blower Wheel 9 Circulator Blower 20 Pressure Switch 10 Capacitor 21 Pressure Switch Hose 11 Reverse flow switch 22 Flame Sensor Please contact your local installer or dealer for replacement parts I amp O manual 32 15 WIRING DIAGRAMS Models 70A3A 80B4A 80C4A 90B4A 100C5A 100D5A 110C5A 12005 135D5A WARNING DISCONNECT POWER BEFORE INTEGRATED SERVICING WIRING TO UNIT MUST BE CONTROL MODULE PROPERLY POLARIZED AND GROUNDED XFMR 6 GND 8 C G R W Y TWIN MVC 9 VALVE Dp 9 ID BLOWER PRESSURE OR SWITCH LIMIT CONTROLS SNOILO3NNOO LVISOWYAHL Ab INTEGRATED RR CJ ACA MANUAL RESET ROLLOUT LIMIT CONTROL S AUXILIARY AUTO CONTROLS
59. ing brackets and materials before operating the furnace INSTALLATION A AVERTISSEMENT FIRE EXPLOSION ASPHYXIATION HAZARD RISQUE D INCENDIE D EXPLOSION ET ASPHYXIE Improper adjustment alteration service maintenance or installation can cause serious injury or death Read and follow instructions and precautions in User s Information Manual provided with this furnace Installation and service must be performed by a qualified service agency or the gas supplier Une r glage une modification un reparation un enretien ou une installation incorrect puet entrainer des blessures graves ou la mort Suivre les instructions et les consignes qui figurent dans la notice d utilisation qui accompagne ce g n rateur d air chaud L installation et l entretien doivent tre effectur s par un r parateur qualifi ou par le foumisseur de gaz CAUTION A MISE EN GARDE Check entire gas assembly for leaks after lighting this appliance V rifier tous les l ments a gaz pour rechercher les fuites apr s avoir allum cet appareil INSTALLATION 1 This fumace must be installed in accordance with the manufacturer s instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 NFPA54 or CSA B 149 1 Gas Installation Code Ce foumaise a air chaud doit tre install conforrn ment aux instructions du fabricant et aux codes locaux En l absence de ces demiers la norme ANSI Z223 1 NFPA
60. ing directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria 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 000BTU per hour of the total input rating of all gas utilization equipment in the confined sp ace One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure See Table 5 Table 5 Minimum Area in Square Inch Required for Each Opening Minimum Free Area in Square Inch Required for Each Opening 120 in 742 cm 135 in2 871 cm b All air from outdoors BTUH Input Rating Table 6 Minimum Free Area Required for Each Opening Minimum Free Area Required for Each Opening Vertical Duct or Round Duct Opening to Outside j de BTUH LUE 5 13 5 13 in 2 2 BTUH Input Rating Horizontal Duct 2 000 BTUH 25 in 129 cm 35 in 226 cm 40 in 258 cm 45 in 290 cm 50 in 323 cm 55 in 355 cm 60 in 387 cm 135 000 70 in 452 cm EXAMPLE Determining Free Area Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 4 000 32 5 Sq In Vertical Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 2 000 65 Sq In Horizontal a Qt a gat
61. is energized and remains energized as long as the blower motor BLWM is energized Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners The inducer motor IDM will remain energized for a 5 second post purge period humidifier is de energized The blower motor BLWM and air cleaner terminal EAC will remain energized for 60 90 120 or 180 seconds depending on the HEAT OFF delay selection The furnace control CPU is factory set for a 180 second HEAT OFF delay TIMING SPECIFICATIONS All times are in seconds unless noted otherwise These times will vary depending on option switch position The control is factory set at 30 seconds heat delay to fan on 120 seconds heat delay to fan off and 40 seconds cool delay to fan off See OPERATION section for further information 50A55 443 01 h PRE PURGE INITIAL IGNITOR WARM UP 1st 64 attempts MINIMUM IGNITOR WARM NM MAXIMUM IGNITOR WARM IGNITION ACTIVATION PERIOD TRIAL FOR IGNITION PERIOD RETRIES VALVE SEQUENCE PERIOD 15 10 14 4 INTERPURGE POST PURGE HEAT DELAY TO FAN ON 60 90 HEAT DELAY TO FAN OFF cen an HUMIDIFIER ELECTRONIC AIR CLEANER COOL DELAY TO FAN ON COOL DELAY TO FAN OFF AUTO RESET C E U U 2 Cooling Mode The thermostat calls for cooling See Fig 27 for thermostat connections The thermostat closes t
62. is of abnormal function These circuits are continuously monitored during furnace operation by the integrated control module 12 2 Integrated Control Module 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 12 3 Primary Limit The primary limit control is located on the partition panel and monitors heat exchanger compartment temperature It is an automatic reset temperature sensor The limit guards against the overheating resulting from insufficient air passing over the heat exchanger 12 4 Reverse Flow Swith The reverse flow switch is located on the air circulating blower housing It is an automatic reset temperature sensor Reverse flow switch shuts off the furnace when air circulating blower fails on downflow or horizontal installations to prevent air filter or other parts from overhating by hot air 12 5 Rollout Limits The rollout limit controls are mounted on the burner manifold assembly and monitor the burner flame They are manual reset temperature sensors This limit guards against burner flames not being properly drawn into the heat exchanger 12 6 Pressure Switches The pressure switches are normally o
63. itch Adjustment E Shown in ON position Regulator Plastic cd N Regulator OIEA Adjustment 47 Screw iat d S rin zh pring Regulator Sleeve Fig 28 Gas Valve and Regulator Adjustment manifold pressure per the Manifold Gas Pressure table Table 13 Manifold Gas Pressure Manifold Gas Pressure Input Rating Range KBTU H Propane Gas 50 9 7 10 3 W C 70 9 3 9 9 W C 9 7 10 3 W C 3 6 4 0 W C 9 7 10 3 W C 100 4 0 4 4 W C 9 7 10 3 W C 110 3 6 4 0 W C 9 1 9 7 W C 120 4 3 4 7 W C 9 7 10 3 W C 4 3 4 7 W C 9 7 10 3 W C The final manifold pressure must not vary more than 0 3 w c from specified manifold pressure Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice 10 6 Gas Input Rate Measurement Natural Gas Only The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas burning appliances except the furnace 2 While the furnace is operating time and record one complete revolution of the smallest gas meter dial 3 Calculate the number of seconds per cubic foot sec ft3 of gas being delivered to the furnace If the dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one If the dial is a two cubic foot dial divide the num
64. lasses and gloves when handling parts and servicing furnaces 1 Maintain 115V wiring and ground Improper polarity will result in rapid flashing LED and no furnace operation See Fig 27 2 Make thermostat wire connections at the 24 V terminal block on the furnace control Failure to make proper connections will result in improper operation See Fig 27 3 Gas supply pressure to the furnace must be greater than 4 5 in wc 0 16 psig but not exceed 14 in we 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Replace outer door 10 2 Start up Procedures WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detection of leaks to check all connections 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115V power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 3 This furnace is also equipped with a self diagnosing electronic control module In the ev
65. lic 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 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 Location of Manual value Installed Ahead of Ground Joint Pipe Union Height Required By Local Code Ground Joint Pipe Union To Be Installed Ahead of Gas Valve Drip Leg Reducing Coupling _ 1 2 x 1 8 with 1 8 Pipe Plug To Measure Line Gas Pressure Fig 24 Typical Gas Pipe Arrangement 8 5 Gas Piping Checks Before placing unit in operation leak test the unit and gas conn tions WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage Never test for gas leaks with an open flame Use a commer cially available soap solutio
66. lt in personal injury death and or property damage When the furnace is installed in a residential garage the burners and ignition sources must be located at least 18 inches 457 mm above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the NFGC or CAN CSA B149 1 05 See Fig 4 I amp O manual 7 CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause prema ture furnace component failure This gas furnace may be used for heating buildings under construction provided that The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installa tion instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other const
67. ment by comparison with pictorial sketches or drawings of the main burner flame and if applicable the pilot burner flame 14 2 Filters 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 FILTER MAINTENANCE Improper filter maintenance is the most common cause of inadequate heating or cooling performance Filters should be cleaned permanent or replaced disposable every one month or as required When replacing a filter it must be replaced with a filter of the same type and size 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 FILTER REMOVAL Depending on the installation differing filter arrangements can be applied 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 For further details see your distributor UPRIGHT FILTER REMOVAL 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 permanent filter both sides should be sprayed with a dust adhesive as recommended on the adhesive
68. n the range specified on the rating plate I amp O manual 25 HEAT EXCHANGER RADIATIO LINE OF SIGHT i Supply Air Return Air Fig 29 Temperature Rise Measurement Temperature Rise Adjustment 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 10 8 Circulator Blower Speed Adjustment WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn OFF power to the furnace before changing speed taps This furnace is equipped with a PSC circulator blower motor This blower provides ease in adjusting blower speeds The cooling blower speed is shipped set on HIGH High heat ships on MEDIUM and low heat is shipped on MEDIUM La These blowe
69. n made specifically for the detection of leaks to check all connections Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector methods NOTE Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa 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 or other approved testing 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 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 I amp O manual 19 9 ELECTRICAL CONNECTIONS WARNING EL
70. nded temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate e When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section e The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions These multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawispaces and garages The furnace is factory shipped for use with natural gas A CSA listed accessory gas conversion kit is required to convert furnace for use with propane gas The furnaces must be kept free and clear of insulating materials Inspect surrounding area to ensure insulation material is in safe distance when installing furnaces or adding insulation materials Insulation materials
71. ned by a qualified servicer using emery cloth or steel wool Following cleaning the flame Sense signal should be 1 to 6 microamps at 115 volts IGNITER QUALIFIED SERVICER ONLY 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 14 5 Burners WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD To avoid personal injury or death Do not remove any interal compartment covers or attempt any adjustment Electrical compartments are contained in both compartments Contact a qualified service agent at once if an abnormal flame appearance should develop 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 See Fig 30 NOTE Only a qualified contractor installer or service agency should clean the burners if the burners get a heavy accumul ation of soot and carbon I amp O manual 30 Flame sensor 14 6 Cleaning Heat Exchanger The following steps sho
72. ng 7 SEVEN 7 flashes FLASHES Induced draft blower and circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing continuously Continuous FLASHES Constant ON Internal control failure Rollout limit open Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct Flame rollout Misaligned burners blocked flue or failed induced draft blower Loose or improperly See Vent Flue Pipe section for piping details Replace induced draft blower with proper replacement part Replace rollout limit with Flame sense Flame sensed with connected wiring Faulty rollout limit Polarity of 115 Volt AC power to furnace or integrated control module is reversed Red and blue wires to transformer are reversed Poor unit ground Polarity of 115 Volt power is reversed Improper grounding Flame sensor is coated loxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to Improper gas pressure or combustion air microamp signal is low Short to ground in flame no call for heat sense circuit Internal control failure Wrong electric power frequency Internal control failure as necessary correct replacement part Check rollout limit Replace if necessary Check induced dr
73. o not pinch wires between cover and bracket 9 5 24 V Wiring Make field 24V connections at the 24V terminal strip See Fig 26 Connect terminal Y Y2 as shown in Fig 25 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24V circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is 9 6 Accessories Field Supplied 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using l 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC H and EAC M The terminals are rated for 115V AC 1 0 amps maximum and are energized during blower motor operation See Fig 26 2 Humidifier HUM Connect an accessory 115V AC 0 5 amp maximum humidifier if used to the 1 4 male quick connect HUM H terminal and HUM N terminal on the control board The HUM terminal is energized when gas valve relay GVR is energized See Fig 26 9 7 Grounding The furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code CSA C22 1 Part 1 if an external electrical source is utilized Max Outlet Min Wire Size Air Temp awg 75 ft F c Protection Amps
74. onry chimney However an existing masonry chimney may be used on as a chase through which the metal vent pipe passes 7 4 Air For Combustion and Ventilation 7 4 1 Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance This may be from within the space in a non confined location or it may be brought into the furnace area rom outdoors through permanent openings or ducts A single roperly sized pipe from the furnace vent connector to the outdoors must be provided For upflow models combustion air is brought into the furnace through the unit top panel opening Fig 21 Combustion Airflow Path Through The Furnace Casing to the Burner Box A WARNING This type of installation requires that the supply air to the applian ce s be of a sufficient amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an exhaust fan kitchen ventilation system clothes dryer or fireplace may cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supp ly air will result in a hazardous condition which can cause the ap pliance to soot and generate dangerous levels of CARBON MINO XIDE which can lead to serious injury property damage and or death An unconfined space is not les
75. orrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products Do not install furnace in a corrosive or contaminated atmosphere Make sure all combustion and circulating air requirements are met in addition to all local codes and ordinances If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion e Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals ge De icing salts or chemicals e Carbon tetrachloride e Halogen type refrigerants e Cleaning solvents such as perchloroethylene e Printing inks paint removers varnishes etc e Hydrochloric acid e Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials All fuel burning equipment must be supplied with air for fuel combustion Sufficient air must be provided to avoid negative pressure in the equipment room or space A positive seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and from draft safeguard opening Also see Section 6 4 18 IN 457 2 mm MINIMUM TO BURNERS Fig 4 Installation in a Garage WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could resu
76. pen 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 12 7 Flame Sensor 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 WARNING FIRE EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace with proper control could result in fire explosion or carbon monoxide poisoning This appliance uses a NEGATIVE PRESSURE REGULATED gas control Replace ONLY with the same model number or as specified by the manufacturer 13 TROUBLESHOOTING 13 1 Electrostatic Discharge Eso Precautions 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 uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the inte
77. r 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 Refer to Table 2 Air Delivery CFM Without Filter 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 Table 5 Air Delivery CFM Without Filter Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module 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 LA 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 CIRCULATOR BLOWER FAN TIMING ADJUSTMENT 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 As shipped the circulator blower fan will remain on for 120 seconds after the gas valve closes When a call for cooling occurs the circulator fan comes on and remains on for 40 seconds a
78. re permitted and must be installed in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the CSA B 149 1 Natural Gas and Propane Installation Codes and the manufacture s instructions Vent connectors serving Category furnaces shall not be connected into any portion of mechanical draft systems operating under positive pressure I amp O manual 15 Horizontal portions of the venting system shall be supported to prevent sagging using hangers or perforated straps and must slope upwards not less than 1 4 per foot 0 635 cm m from the furnace to the vent terminal It is recommended that you follow the venting safety procedure below This procedure is designed to detect an inadequate ventilation system that can cause the appliances in the area to operate improperly causing unsafe levels of Carbon Monoxide or an unsafe condition to occur WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into oper ation while all other appliances connected to the venting system are not in operation Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which
79. remove the screw holding bottom filler panel See Fig 5 2 Remove bottom closure panel BOTTOM FILLER PANEL BOTTOM CLOSURE PANEL Fig 5 Removing Bottom Closure Panel Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration 6 2 Downflow Installation NOTE For downflow applications this furnace is approved for use on combustible flooring when anyone of the following 3 accessories are used e Special Base e Cased Coil Assembly Coil Box Determine application being installed from Table 2 Construct hole in floor per Table 2 and Fig 6 Construct plenum to dimensions specified in Table 2 and Fig 6 If down flow subbase is used install as shown in Fig 7 If Coil Assembly or Coil Box is used install as shown in Fig 8 pep NOTE It is recommended that the supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange Be careful of sharp edges Bottom Return Air Inlet Do not use side return openings in downflow configuration These furnaces are shipped with bottom
80. rigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16 3 5 Acoustical Lining and Fibrous Glass Duct e US and CANADA current edition of SMACNA NFPA 90B as tested by UL Standard 181 for Class Rigid Air Ducts 3 6 Gas Piping and Gas Pipe Pressure Testing e US NFPA 54 ANSI Z223 1 2006 Chapters 5 6 7 and 8 and National Plumbing Codes CANADA CAN CSA B149 1 05 Parts 4 5 and 6 and Appendices A B E and H 3 7 Electrical Connections e US National Electrical Code NEC ANSI NFPA 70 2008 e CANADA Canadian Electrical Code CSA C22 l 3 8 Electrical power supply Voltage ANSI C84 1 2006 104 127 volt 3 9 Venting e US NFGC NFPA 54 ANSI 2223 1 2006 chapters 12 and 13 e CANADA CAN CSA B149 1 05 Part 8 and Appendix C 4 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE caution FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause prema ture furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electro static discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharg
81. rnace 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 48 second delay between thermostat energizing and burner firing FURNACE SHUTDOWN 1 Set the thermostat to lowest setting 2 Turn off the electrical power supply to the furnace 3 White Rodgers Models 36J22 214 Push switch to the OFF position 4 Close manual gas shutoff valve external to the furnace 5 Replace the door on the unit I amp O manual 23 10 4 Sequence of Operation NOTE Furnace control must be grounded for proper operation or control will lock out Control is grounded through green wire routed to gas valve and manifold bracket screw follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU transformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV 1 Heating mode See Fig 27 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period The inducer blower and optional humidifier are en
82. rnal filter box 6 5 Air Ducts General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guidelines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design external static pressure The furnace airflow rates are provided in Table 6 AIR DELIVERY CFM Without Filter When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a l in 25 mm clearance from combustible materials to supply air
83. rsion kits required for alternate fuels and or high altitude WARNING FIRE OR EXPLOSION HAZARD Inlet gas supply pressures must be maintained within the ranges specified in Table 8 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 Failure to follow this warning could result in personal injury death and or property damage Use proper length of pipe to avoid stress on gas control manifold and a gas leak Table 8 Inlet Gas Supply Pressure Inlet Gas Supply Pressure CAUTION Natural Gas Minimum 5 0 W C Maximum 10 5 W C Minimum 11 0 W C Maximum 13 0 W C FURNACE OVERHEAT HAZARD Failure to follow this caution may result in property damage Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment I amp O manual 16 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 At all altitudes and with either fuel the air temperature rise mus
84. ruction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 60 F 16 C and 85 F 29 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the gas input rate has been set to the nameplate value The filters used to clean the circulating air during the construc tion process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions 6 INSTALLATION This furnace can be installed for upflow downflow and horizonal positions see Fig 12 18 6 1 Upflow Installation Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and
85. s US Installation 120 7 49 57 so 58 51 so 52 et ss 62 9 135 8 57 50 LP orifice based on 10 inWC manifold pressure The input to the furnace must be checked AFTER reorificing Table 10 High Altitude Derate Orifice Size Chart Natural and LP Gas Canada Installation Elevation Ft 6000 8000 Na o tP Na 1 Nat Na Nat LP 70 3 48 se 49 sz so 58 s eo 52 61 90 5 5 i Inout Rate 5s ss 4 s so ss s oo s2 1 6 a sr so sa si so s2 ss 62 s s 49 s s ss s oo gt 1 120 s7 50 ss so s2 1 s3 62 9 of o0 58 51 59 5 La 4 LP orifice based on 10 inWC manifold pressure The input to the furnace must be checked AFTER reorificing I amp O manual 17 8 3 Propane Gas Conversion Possible property damage personal injury or death may occur if the correct conversion kits are not installed the appropriate kits must be applied to insure safe and proper furnace operation all conversions must be performed by a qualified installer or service agency This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit PRT NO 202082290028 must be applied for propane gas installations High Altitude Installations refer to the High Altitude D
86. s than 50 cu ft 1 42m per 1 000Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appliances through openings not furnished with doors are considered a part of the unconfined space 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 An confined space section An confined space is an area with less than 50 cu ft 1 42m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combus tion and ventilation in confined spaces Outlet Fig 22 Outside and Ambient Combustion Air 1 amp O manual 14 WARNING When a Category furnace is removed or replaced the original venting system may no longer be correctly sized to properly vent the attached appliances An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury and or death Equipment Located in Confined Spaces a All air from inside the building The confined space shall be provided with two permanent openings communicat
87. sh or larger 10096 Screens 5 An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction The opening shall be located within 12 30 5 cm horizontally from the burner level of the appli ance Refer to COMBUSTION AIR SOURCE FROM OUTDOORS and VENT AND SUPPLY AIR SAFETY CHECK in these instruc tions for additional information and safety check procedure 7 6 Ventilated Combustion Air The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in Combustion Air Source from Outdoors in this instruction or in Section 7 4 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition This type installation requires two properly sized pipes One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection top right of unit to the exterior of the building 7 7 Vent and Supply Outside Air Safety Check Procedure For Category furnaces vent installations shall be in accordance with Parts 7 and 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Section 7 and Appendix B of the CAS B 149 1 Natural Gas and Propane Installation Codes the local building codes furnace and vent manufacture s instructions Multi story or common venting systems a
88. sing with screws removed in Step 4 11 Secure field ground wire to J Box green ground screw 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Fig 27 Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket 9 3 Power Cord Installation In Furnace J box NOTE Power cords must be able to handle the electrical requirements listed in Table 12 Refer to power cord manufacturer s 1 Remove cover from J Box 2 Route listed power cord through 7 8 in 22 mm diameter hole in J Box 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 27 6 Reinstall cover to J Box Do not pinch wires between cover and bracket Table 12 Ratings amp Physical Electrical Data Nominal Air Temp Rise Max Over Current oe Di xe 9 4 Bx Cable Installation In Furnace J box 1 Remove cover from J Box 2 Route BX cable into 7 8 in 22 mm diameter hole in J Box 3 Secure BX cable to J Box bracket with connectors approved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 27 6 Reinstall cover to J Box D
89. t be within the range listed on the furnace nameplate Should this appliance be converted to LP refer to the instructions included in the factory authorized LP conversion kit 8 2 High Altitude Derate Alternately standard derate for altitude from National Fuel Gas Code ANSI 2223 1 of 4 per 1000 may be taken Refer to the most recent version of ASNI Z223 1 for correct gas orifice The orifices must be selected using the table below The furnace derate is 4 for each 1 000 feet above sea level This table is based upon a heating value of approximately 1 000 Btu ft3 In Canada input rating must be derated by 10 percent for altitudes of 2 000 ft 610m to 4 500 feet 1370m above sea level by an authorized Gas Conversion Station or Dealer When an appliance is installed at elevations above 4500ft 1350m the certified high altitude input rating shall be reduces at the rate of 4 for each additional 1000ft 300m 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 ft3 content of the derated gas and the altitude Refer to the latest version of NFPA54 ANSI 2223 1 for US and the latest version of CSA B149 1 for Canada and information provided by the gas supplier to determine the proper orifice size Table 9 High Altitude Derate Orifice Size Chart Natural and LP Ga
90. t the voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or Table 8 for equipment electrical specifications U S installations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2008 and any local codes or ordinances that might apply Canadian installations Make all electrical connections in accordance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Use a separate fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 12 for wire size and fuse specifications A readily accessible means of electrical discon nect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115V wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace will NOT operate JUNCTION BOX RELOCATION NOTE If factory location of J Box is acceptable go to next section ELECTRICAL CONNECTION TO J BOX NOTE On 14 wide casing models the J Box shall not be relocated to other side of furnace casing wh
91. ternal static pressure Manufacturer default speed tap for heating CSAtested at Max external static pressure 0 5 in W C Table 4 Filter Size Information In mm FILTER SIZE FURNACE CASING WIDTH FILTER TYPE SIDE RETURN BOTTOM RETURN 16X25 14X25 14 1 2 368 406X635 356X635 16X25 16X25 406X635 406X635 16X25 20X25 406X635 508X635 16X25 24X25 24 5 622 406X635 610X635 High Velocity 600 FPM High Velocity 600 FPM 17 1 2 445 High Velocity 600 FPM 21 533 High Velocity 600 FPM I amp O manual 13 7 VENT SYSTEM 7 1 Vent Connections Fig 20 Combustion Air Inducer shows the furnace as it is shipped from the factory To convert to a horizontal or downflow position remove the four screws that secure the inducer assembly and rotate 90 being careful not to damage the gasket Reinstall screws Remove cap from appropriate vent outlet location on the cabinet cut insulation in cabinet to same size as the hole provided and reinstall cap in the hole in the top panel IMPORTANT In downflow applications do not block the combustion air inlet The furnace must be installed on a coil cabinet or subbase to allow combustionair to enter the burner compartment Flue Transition Do Not Remove Mounting Screw Remove Fig 20 Combustion Air Inducer CATEGORY 1 450 F MAX VENT TEMP The venting system must be installed in accordance with Section 5 3 Air for combustion
92. uld be performed by a qualified service agency NOTE If the heat exchangers get a heavy accumulation of soot and carbon they should be replaced rather than trying to clean them thoroughly A heavy build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjust ment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when disconnecting wires from switches because damage may occur a Draft safeguard switch b Inducer motor c Pressure switch es d Limit overtemperature switch e Gas valve f Hot surface igniter g Flame sensing electrode h Flame rollout switches 6 Remove screws that fasten the collector box assembly to the cell panel Be careful not to damage the collector box Inducer assembly and elbow need not be removed from collector box 7 Disconnect gas line from gas man
93. ve flame the control will go into system lockout Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens 7 second The gas valve GV permits gas flow to the burners where it is ignited by the HSI a 7 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If flame is not detected the gas valves is de energized the ignitor is turned off and the furnace control goes into the retry sequence The retry sequence provides a 15 second wait following an unsuccess ful ignition attempt flame not detected After this wait the ignition sequence is restarted with an additional 2 seconds of ignitor warm up time If this ignition attempt is unsuccessful one more retry will be made before the control goes into system lockout If flame is detected then lost the furnace control will repeat the initial ignition sequence for a total of four recycles After four unsuccessful recycle attempts the control will go into system lockout e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT H speed 30 seconds after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC
94. w and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following 3 1 Safety e USA National Fuel Gas Code NFGC NFPA 54 2006 ANSI Z223 1 2006 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B e CANADA CSA B149 1 05 National Standard of Canada Natural Gas and Propane Installation Codes CAN CSA B149 1 05 OUTLET AIR FRONT Max 85 F 29 C RETURN AIR Min 60 F 16 C 0 d Fig 3 Return Air Temperature 3 2 General Installation e US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 www NFPA org or for only the NFGC contact the American Gas Association 400 N Capitol Street N W Washington DC 20001 www AGA org CANADA CAN CSA B149 1 05 For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada 3 3 Combustion and Ventilation Air e US Section 9 3 of the NFGC NFPA 54 ANSI Z223 1 2006 Air for Combustion and Ventilation e CANADA Part 8 of CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances 3 4 Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Ref
95. will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace for 1 20 seconds 3 Manual thermostat cycle Lower the thermostat so that there is no longer a call for heat for 1 20 sec 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 WARNING FIRE EXPLOSION AND ASPHYXIATION HAZARD Improper adjustment alteration service maintenance or installation can cause serious injury or death Read and follow instructions and precaution in User s information Manual provided with this furnace Installation and service must be performed by a qualified service agency or the gas supplier I amp O manual 27 Table 14 Troubleshooting Chart TROUBLE SHOOTING CHART Symptoms of Associated i i Cautions and Notes Abnormal Operation Fault Description s Possible reason Corrective Action cho 115 volt power to Door switch open Assure 115 and 24 volt Turn power OFF furnace or no 24 volt or 24 volt wires power to furnace integrated Prior to repair power to integrated improperly connected control module Replace integrated control Furnace fails to operate eIntegrated control

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