Kelvinator KG7SD 108D-45D Use and Care Manual
Contents
1. B rner Finish Finish Assembly Flange Igniter Flange Roll Out Gas Blower Assembly Flame Switch Manifold behind blower panel Y Sensor E i J an Furnace NK g e Blower Door 5 aqe a iis aan Control Switch lo a BO Furnace w e Board behind blower panel p Control aE Board Inducer Jo Main Air a n Limit Switch EN Limit Switch 7 Transformer Inducer a i Condensate Vent Limit ale Assembly ip Pressure Switch Switch a inducer B C amp D cabinets only Inducer Assembly Pressure Switch 1 gt EA Y PA Transformer L IS SK j Inducer Blower Door ee ote tN ese Pressure Main Air P o em Switch Switch Limit Switch st 3 eat yl a Bi T Gas Valve t Igniter O Gas Manifold Blower Burner Roll Out Flame Assembly Assembly Switch Sensor SC 92 1 Upflow Horizontal Gas Furnace SL 92 1 Downflow Gas Furnace Finish Gas Finish Flange Manifold Flange Flame Roll Out Pact Blower Assembly Sensor Switch ssembly behind blower panel Main Air 5 H Furnace Limit Switch _ N Igniter elit om2. models should be controlled by a conventional single stage thermostat Two stage furnaces TA TK TC amp TL models will perform best with a conventional two stage thermostat NOTE It is possible to control two stage furnaces with a single stage thermostat Consult with your installer about which type is best for your installation Both thermostats are commonly available at your local building supply store Modulating MQ furnaces will not work with a conventional thermostat and must be controlled by an iQ thermostat available through your dealer FURNACE LOCATION If a furnace is installed in relatively small utility room or closet the installation needs openings in the walls or door to let combustion air in Make sure that these openings remain unobstructed Do not modify these openings in any way without consulting a licensed HVAC technician COMPONENT LOCATIONS FOR NON CONDENSING TYPE FURNACES Single Stage Models Main Air Limit Switch Furnace Control Board Inducer Assembly Gas Valve Pressure Transformer Switch Igniter Flame Sensor Gas Blower Manifold Door Switch Burner Assembly Roll Out Switch Blower Assembly SA 80 Upflow Horizontal Gas Furnace Blower Assembly behind blower panel Furnace 3 Control
3. safety inspections performed by a licensed technician Before occupancy the furnace shall be inspected and approved by applicable local authority even if this results in redundant inspections The duct work must be inspected and cleaned if found to contain any construction debris The filter must be replaced or cleaned and the furnace must be inspected by a licensed HVAC technician The furnace must be cleaned and or repaired if found to be dirty damaged or malfunctioning in any way FREQUENCY OF MAINTENANCE BEGINNING OF EACH END OF EACH HEATING SEASON HEATING sEason MONTHLY X aa ee feos Oo Oo ar as Ss E Table 1 Maintenance Table ENERGY STAR U DESIGNERS ASSEMBLED We Encourage Professionalism AMER at 4 S i amp ie CETE gt ENCE CERTIFIED g Tay EKVo amd lt 6 FRAT Residential Furnaces Oo YOUR ENVIRONMENT OUR EXPERTISE Through Technician one v MEMBER COMPANY Certification by NATE ve TC TL amp MQ Models Only NORDYNE D COMPLETE COMFORT GENUINE VALUE ld Specifications amp illustrations subject to change without notice or incurring obligations O Fallon MO Printed in U S A 09 11 708967A Replaces 7089670
4. tad Gas Valve 4 Pear IGUCET Amg Blower Door Switch Limit Switch pom fFurmace behind blower panel Lpe 4 Control Board Inducer Pressure Switch Gq Condensate Inducer s Pressure Limit Switch yo Inducer z Switch ATS Assembly z inducer Wet o Assembly Blower Transformer TY 5 Door Switch Ei Pr s Switch Gas Valve y t he Flame i Igniter Sensor Blower Burner Roll Out Gas Assembly Assembly Switch Manifold SD 95 0 Upflow Horizontal Gas Furnace SM 95 0 Downflow Gas Furnace Two Stage Models Finish Finish Burner Flange Flange Assembly Flame Roll Out Blower Assembly Furnace Sensor Switch Gas behind blower panel Control Manifold Inducer Sa y Board Pressure Igniter Motor Choke Switches C amp D cabinets only i Trea Gas Valve mall 7 A cond Main Air a Blower iT L0 1 Limit Switch g4 Furnace Door Switch as a Si Board Inducer zp RHI T Control Board behind blower panel gt ia Limit Switch His Transformer Condensate m g 8 Pressure Ind Pressure pd A yy Pre nducer itch wa Switches Assembly Switches HE Inducer Blower Door Transformer Inducer Limit77Fe PNA Assembly Switch Switch a ae Mot I eter N Main Air a b otor l pa imi PENS JE Conirol Gas Valve is Lim
5. E Board BI S ower 2 Door Switch D Transformer behind blower panel o Oo Pressure Switch Inducer 3 J S XN yA Assembly N 7 Gas Valve Main Air 3 l Limit Switch Y Gas s f Manifold Igniter Burner Roll Out Flame Assembly Switch Sensor SK 80 Downflow Gas Furnace 2 Stage Models Main Air Limit Switch Furnace Control Board Inducer Assembly Gas Valve Pressure 4 q Switch Igniter Blower Door Switch Motor Choke ap C amp D cabinets only gt doa lice Motor Control Box Blower Assembly Burner Assembly Motor Control Board TA 80 Upflow Horizontal Gas Furnace Blower Assembly behind blower panel Furnace Control F Board A e m A M Motor Choke mpl 5 ir otor C amp D cabinets only T m Control ESENS al T Board Blower 2 Door Switch 2 i Transformer behind blower panel Tl E Oo Pressure Inducer Switches Assembly Main Air Gas Valve Limit Switch Gas Manifold Igniter Burner Roll Out Flame Assembly Switch Sensor TK 80 Downflow Gas Furnace COMPONENT LOCATIONS FOR CONDENSING TYPE FURNACES Single Stage Models
6. GAS FURNACES Single Stage Two Stage amp Modulating Furnaces USER S MANUAL NON CONDENSING GAS FURNACES 80 AFUE SA Upflow Horizontal Furnaces SK Downflow Furnaces CONDENSING GAS FURNACES 92 1 AFUE SC Upflow Horizontal Furnaces lt e 7 SL Downflow Furnaces 95 97 AFUE SD TC MQ Upflow Horizontal Furnaces _ SM amp TL Downflow Furnaces WARNING FIRE OR EXPLOSION HAZARD e Failure to follow safety warnings exactly could result in serious injury or property damage e Installation and service must be performed by a qualified installer service agency or the gas supplier e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbors phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department DO NOT DESTROY THIS MANUAL KEEP IN A SAFE PLACE FOR FUTURE REFERENCE TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION Gas Supply amp Piping Venting System Clearances to Combustibles ABOUT THE FURNACE Introduction COMPONENT LOCATIONS FOR NON CONDENSING TYPE FURNACES Single Stage amp 2 Stage Models COMP
7. ONENT LOCATIONS FOR CONDENSING TYPE FURNACES Single Stage Models Two Stage Models STARTUP amp SHUTDOWN Starting the Furnace Shutting Down the Furnace Troubleshooting MAINTENANCE amp INSPECTION Furnace amp Air Ducts Venting System Blower amp Filter Burner Operation New Construction Maintenance Table IMPORTANT SAFETY INFORMATION IMPORTANT NOTE If the gas supply fails to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical supply A WARNING Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage A WARNING The safety information listed below must be followed during the installation service and operation of this furnace Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death A WARNING PROPOSITION 65 WARNING This product contains chemicals known to the state of Californiato cause cancer birth defects or other reproductive harm A WARNING This furnace is not approved for installation in mobile homes Installing this furnace ina mobile home could c
8. ause fire property damage and or personal injury GAS SUPPLY amp PIPING WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbors phone Follow the gas suppliers instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier The furnace was shipped from the factory equipped to operate on natural gas Conversion to LP propane gas must be performed by a licensed HVAC technician using a factory supplied conversion kit Failure to use the proper conversion kit can cause fire explosion property damage carbon monoxide poisoning personal injury or death A WARNING All gas piping and shutoff valves must be installed in compliance with local codes and utility regulations by licensed installers DO NOT attempt to modify or tap into existing gas lines yourself Fire or explosion may result causing property damage personal injury or loss of life Failure to follow the safety warnings exactly could result in serious injury death or property damage VENTING SYSTEM A WARNING It is imperative to maintain proper operation of the venting system including the masonry chimney if applicable Insufficient venting could create the prod
9. drain lines that drain to the outdoors If condensate freezes in the lines this will cause the condensate drain switch to shut down the furnace Only a licensed HVAC technician can reset this switch FILTER A WARNING Never operate the furnace without a filter in place Accumulating dust in the return air can build up on internal components resulting in loss of efficiency equipment damage and possible fire e Air filter s are not supplied with the furnace as shipped from the factory The installer must provide a high velocity filter and rack for a filter in the return air duct adjacent to the furnace or in a return air grill to the furnace The furnace should always have a clean filter located either at the air return on the furnace or in an air return register If the filter becomes dirty it should be cleaned or replaced e New or newly renovated homes may require more frequent changing until the construction dust has minimized Filters designed to remove smaller particles such as pollen may require additional maintenance Always reinstall the doors on the furnace after servicing or cleaning changing the filters Do not operate the furnace without all doors and covers in place THERMOSTAT This family of furnaces includes single stage two stage and modulating capabilities These different capabilities require different thermostats to reach their best performance e Single stage furnaces SA SK SC SL SD amp SM
10. e air openings or spacings around the furnace area or the room or closet the furnace is in Furniture and drapery should be arranged so that the supply air registers and return grilles are not obstructed If your furnace obtains its air through a pipe to the outdoors do not allow the inlet of the pipe to become blocked If the furnace is operated without adequate air for combustion the flame roll out switch will open turning off the gas supply to the burners This indicates that a serious problem with the burners has occurred and must be corrected immediately Only a licensed HVAC technician can reset this switch Before remodeling near the furnace consult with a local code official or the National Fuel Gas Code to make sure you will be in compliance with supplying adequate air for combustion By erecting new walls it is sometimes possible to inadvertently restrict the furnace s air supply You can find more information about supplying combustion air in the NFGC which is available at many libraries CLEARANCES TO COMBUSTIBLES A WARNING Donotplace combustible materials on or against the furnace cabinet or within 6 inches of the vent pipe Furnace area must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids A fire or explosion may result causing property damage personal injury or loss of life Failure to follow the safety warnings exactly could result in serious injury death or pro
11. furnace The component you need to familiarize yourself with is the gas valve You will use this to turn the furnace on and off There are no user serviceable parts All repairs must be performed by a licensed HVAC technician Category I Non Condensing Furnaces These furnaces typically have an AFUE rating of about 80 and may be vented through a properly designed metal vent or masonry chimney This venting system needs to be primarily vertical so that the hot combustion products will develop a natural upwards draft action Category IV Condensing Furnaces Category IV furnaces typically have an AFUE rating over 90 and are mainly vented through plastic PVC pipe These furnaces also produce liquid condensate which is slightly acidic The vent pipe must be sloped upwards away from the furnace to properly drain the condensate back to the condensate disposal system e Condensing type furnaces require condensate drain lines to be properly installed by the installer Depending on your configuration the drain lines may be routed out the left or right sides of the furnace These drain lines must maintain a downward slope to ensure proper condensate drainage Condensate must flow freely during furnace operation The homeowner must make sure the condensate drain lines do not become blocked pinched or crushed If the furnace is installed in an area where temperatures fall below freezing special precautions must be made for insulating condensate
12. it Switch otor oke Ch ba 5 L Board i ay D cabi l i i g 5 F ED ARDES any Igniter ye as Flame fa Y Sensor Blower Motor Burner Roll Out Gas Assembly Control Box Assembly Switch Manifold TC 95 1 Upflow Horizontal Gas Furnace TL 95 1 Downflow Gas Furnace Finish Burner Flange Assembly Roll Out Flame Switch Gas Manifold Sensor Pressure Switches Main Air Igniter Gas Valve Limit Switch Inducer C ji va d ontrol Boar Limit Switch Inducer Transformer Assembly Blower Door Switch E Motor 3 Control Te Board Motor Choke C amp D cabinets only Motor Control Blower Box Assembly MQ 97 1 Upflow Horizontal Gas Furnace STARTUP amp SHUTDOWN STARTING THE FURNACE 1 Make sure the filter is clean and in place 2 Make sure the vent system is properly installed 3 Set the thermostat to the lowest setting 4 Close the manual gas valve outside the furnace 5 Turn off all electric to the furnace 6 Remove the door from the burner compartment 7 Setthe gas valve switch or knob to the OFF position See Figure 1 for gas valve switch or knob location 8 Wait5 minutes If there is any smell of gas see WHAT TO DO IF YOU SMELL GAS on page 4 9 Set the gas valve switch or knob to the ON position 10 Turn on all electric to the furnace 11 Open the manual gas valve 12 Turn the thermostat back up to force igni
13. pected and relined if necessary by a licensed HVAC technician MAINTENANCE ITEMS x Verity combustion and ventilation aris notresticted x Verity no signs of physical deterioration ofthe furnace x Verity no obstructions or restrictions in vent orchimney x Verity no holes or cracks in ventppe x Verity no corrosion in ventpipe x Verity the horizontal vent pipes slope upwards away rom tumace x Very bumerfiame PS O Clean or repace ne ToS Clean biower compartment x FCleanburnerassemby T x BLOWER amp FILTER It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection Keep air filters cleaned It is recommended that the furnace air filter be checked at least once a month Clean or replace filter to maintain proper airflow and achieve maximum efficiency Furniture and drapery should be arranged so that the supply air registers and return grilles are not obstructed BURNER OPERATION Perform the startup instructions on page 10 The igniter should ignite the closest burner and the flames should quickly carryover to the other burners The flames should be bright blue with occasional yellow streaks NEW CONSTRUCTION The operation of gas furnaces inaconstruction environment can cause a variety of problems with the furnace Before occupying the residence homeowners should have these
14. perty damage The furnace is designed to have certain clearances to combustible items such as wood paper etc Some types of insulation are combustible If your furnace is installed in an attic near unfinished walls or in other insulated space keep area surrounding the furnace free of insulating material SOURCES OF CORROSION Itis known that certain common household chemicals can cause heat exchanger corrosion if the vapors are pulled into the furnace s burners The following is a list of chemicals that should not be used or stored near the furnace Do not store these chemicals near the furnace e Permanent wave solutions e Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners Masonry acid washing materials FILTER A WARNING Never operate the furnace without a filter in place Accumulating dust in the return air can build up on internal components resulting in loss of efficiency equipment damage and possible fire Keep air filters cleaned Clean or replace filter to maintain proper airflow and achieve maximum efficiency Refer to page 11 for Maintenance amp Inspection information FLOOD DAMAGE A WARNING Do not use this furnace if any pa
15. rt has been under water A flood damaged furnace is extremely dangerous Attempts to use the furnace 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 ABOUT THE FURNACE INTRODUCTION Congratulations on the purchase on your new furnace With our dedication to quality superior reliability and outstanding warranty we know you will be pleased with this new appliance This furnace has been designed and built to provide many years of safe and dependable home comfort providing it is properly installed and regular maintenance has been performed Improper use or insufficient maintenance can shorten the life of the furnace and result in serious personal injury or property damage Please read this manual thoroughly and familiarize yourself with the safety operation and maintenance procedures for this furnace DO NOT DESTROY THIS MANUAL KEEP IN A SAFE PLACE FOR FUTURE REFERENCE Your furnace is designed to fulfill the requirements of being classified as either a Category or Category IV furnace These classifications are related to the furnace s Annual Fuel Utilization Efficiency AFUE rating the percentage of fuel that is converted into usable heating energy The furnace components shown on pages 7 9 will help to identify and locate various parts of the
16. tion 13 Observe operation including burners If burners fail to ignite call a licensed HVAC technician 14 Replace the door on the burner compartment T ja D j NA Z gt SHUTTING DOWN THE FURNACE OA lq Jla IMPORTANT IF YOU NEED TO SHUT DOWN YOUR f aa FURNACE FOR SERVICE OR MAINTENANCE SHUT l OFF LIZ 1 FON OFF THE GAS VALVE TO THE FURNACE BEFORE A j TURNING OFF THE ELECTRICAL SERVICE NOTE Your furnace may be equipped with one of three types of gas valves Remove the door panel from the front of the furnace and determine which valve type matches your installation in Figure 1 Move the switch to the OFF Position N V LA A Mog S f X CO O An A If your installation has a manual gas shutoff valve on the gas supply pipe shut this off then shut off the electric to the furnace Set the thermostat to the lowest setting Close the manual gas valve outside the furnace Turn electric to the furnace off Open the door to the burner compartment Set the gas valve switch or knob to the OFF position Replace the door on the burner Compartment Ol CN MODULATING VALVE TROUBLESHOOTING Figure 1 Gas Valves If the furnace fails to operate check the following 1 Is the thermostat setting correct 2 Are the blower compartment door s in place 3 Has the circuit breaker tripped or the control board fuse burned open 4 ls the gas turned on at the manual sh
17. uction of excessive amounts of Carbon Monoxide CO acolorless odorless gas that is produced during incomplete combustion of any fuel It can cause death without warning Carbon monoxide poisoning can cause flu like symptoms and also dizziness fatigue headaches nausea and irregular breathing If you suspect that you are experiencing CO poisoning get fresh air immediately Leave the home and call for assistance from a neighbor s home This furnace does not have a pilot It is equipped with an ignition device which automatically lights the burner DO NOT light the burner by hand e TheU S Consumer Product Safety Commission CPSC recommends every home have a Carbon Monoxide IMPORTANT SAFETY INFORMATION detector in hallways near the bedrooms in each sleeping area CO detectors should be certified to the most recent requirements of the UL IAS OR CSA Standard and should be installed operated and maintained in accordance with the detector manufacturers instructions A CAUTION This furnace requires unrestricted airflow for combustion and ventilation For proper and safe operation it is extremely important that the furnace receives an unobstructed flow of clean fresh air to properly burn the fuel gas If this flow of air is restricted the partially burned combustion gases may create dangerous amounts of carbon monoxide that can cause personal injury or death e Do not block or obstruct air openings on the furnac
18. utoff 5 Is the filter dirty or clogged If the furnace still doesn t operate contact a licensed HVAC technician MAINTENANCE amp INSPECTION FURNACE amp AIR DUCTS The furnace should be inspected annually by alicensed HVAC technician Table 1 below contains suggested inspections and frequency of maintenance Homeowners should perform frequent visual inspections of the furnace for obvious signs of deterioration The furnace should be secure without sagging cracks gaps etc around the base The return air duct connection s is secured and sealed tothe furnace cabinet andterminates outside the area containing the furnace Any signs of damage or loose connections should be repaired by a qualified HVAC technician VENTING SYSTEM For proper and safe operation this furnace requires unrestricted airflow for combustion and ventilation Inspect for blocked or obstructed air openings on or around the furnace and the space around the furnace The furnace venting system shouldbe inspected annually by a licensed HVAC technician Vent pipe must slope upwards and be physically secured without holes or corrosion Any corroded section of vent pipe must be replaced and any obstruction or blockage must be removed by the technician Flue passageways the vent system and the burners should be inspected and cleaned if required by a licensed HVAC technician annually to ensure continued safe operation Existing masonry chimneys should be ins
Download Pdf Manuals
Related Search