Rheem Prestige Series: Up to 96% AFUE Modulating ECM Motor Use & Care Manual
Contents
1. ST A1123 01_01 ITEM ITEM NO PART NAME NO PART NAME 1 CONDENSATE TRAP 13 TOP PLATE 2 DOOR SWITCH 14 BURNER 3 JUNCTION BOX 15 IGNITER 4 TRANSFORMER 16 COMBUSTION AIR INLET 5 PRESSURE SWITCH ASSEMBLY 17 GAS VALVE 6 EXHAUST TRANSITION 18 INDUCED DRAFT BLOWER 7 CONNECTOR 19 POWER FACTOR CHOKE 8 MAIN LIMIT 20 INTEGRATED FURNACE CONTROL 9 EXHAUST AIR PIPE 21 BLOWER MOTOR 10 VENT CAP SHIPPING PLUG 22 BLOWER HOUSING 11 FLAME SENSOR N OVERTEMPERATURE SWITCH FIGURE 3 DOWNFLOW FURNACE WA 21 5 1123 01_02 NO PART 1 GAS VALVE 13 INTEGRATED FURNACE CONTROL 2 PRESSURE SWITCH ASSEMBLY 14 TRANSFORMER 3 BLOWER HOUSING 15 INDUCED DRAFT BLOWER 4 POWER FACTOR CHOKE 16 CONNECTOR 5 BLOWER MOTOR 17 EXHAUST TRANSITION 6 DOOR SWITCH 18 CONDENSATE TRAP 7 JUNCTION BOX 19 8 COMBUSTION AIR INLET 20 OVERTEMPERATURE SWITCH 9 21 BURNER 10 TOP PLATE 22 FLAME SENSOR 11 VENT CAP SHIPPING PLUG 12 OUTLET AIR PIPE gt FIGURE 3 HORIZONTAL FURNACE GJD 24 23 22 212. ITEM ITEM NO PART NAME NO PART NAME 1 GAS VALVE 14 OUTLET AIR PIPE 2 CAPACITOR FOR INDUCER 15 INTEGRATED FURNACE CONTROL 3 LOW PRESSURE SWITCH 16 TRANSFORMER 4 HIGH PRESSURE SWITCH 17 INDUCED DRAFT BLOWER 5 BLOWER HOUSING 18 CONNECTOR 6 POWER FACTOR CHOKE 19 EXHAUST TRANSITION 7 BLOWER MOTOR 20 CONDENSATE TRAP 8 DOOR SWITCH 21 IGNITER 9 JUNCTION BOX 22 OVERTEMPERATURE SWITCH 10 COMBUSTION AIR INLET 23 BURNER 11 24 FLAME SENSOR 12 TOP PLATE 25 FACTORY INSTALLED STREET ELBOW 95 VENT CAP PLUG ST A107801 S01 e Supply Air Sensors This thermister assembly is a field installed air probe communicate the furnace temperature rise to the integrated furnace control The integrated furnace control uses this information to calculate field conditions dur ing calibration to insure optimal efficiency and comfort during Please take the time to fill out the information below and read this manual to familiarize yourself with operation main tenance schedule and safety operation IMPORTANT READ THESE INSTRUCTIONS THOR OUGHLY BEFORE ATTEMPTING TO OPERATE THIS normal operation FURNACE This furnace has been designed to give you many years of efficient dependable home comfort With regular mainte nance this furnace will operate superbly year after year INSTALLATION INFORMATION Date Installed AC SYSTEM Dealer Name Model No Address Ser
3. 1407 Do not operate this furnace without provisions for an adequate combus tion air supply not allow snow or any other debris to accumulate in or around the exhaust and intake terminations of this furnace These are extended through the roof or horizontally through the sidewall of the structure See Figures 5 amp 6 Blockage of the intake and exhaust can result in inad equate combustion air as well as inadequate unit performance or nui sance tripping FIGURE 5 STANDARD VERTICAL DIRECT VENTING lax cel lll 1407 e Prevent flue gases from escaping into your residence Deterioration of the venting system or soot build up can cause leaks into the system Have a qualified installer service agency or the gas supplier replace damaged parts or repair obstructions in a deteriorated vent system immediately Do not use this furnace if any part 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 con trols control system parts electrical parts that have been wet or the furnace if deemed necessary To prevent carbon monoxid
4. INFORMATION MANUAL FOR COMMUNICATING MODULATING CONDENSING GAS FURNACES A Recognize this symbol as an indication of Important Safety Information WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLO SION MAY RESULT CAUSING PROPERTY DAM AGE PERSONAL INJURY OR DEATH FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instruc tions e If you cannot reach your gas supplier call the fire department Do not rely on smell alone to detect leaks Due to various factors you may not be able to smell fuel gases U L recognized fuel gas and CO detectors are recommended in all applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs Installation and service must be performed by a qualified installer service agency or the gas supplier NOTE TO INSTALLER REVIEW THIS MANUAL WITH THE USER AND LEAVE A WARNING IT WITH THE EQUIPMENT PROPOSITION 65 THIS PRODUCT CONTAINS CHEMICALS KNOWN T
5. Phase 3 After 12 minutes 100 of furnace capacity gas valve output and blower speed NOTE If the call for heat ends during any phase the furnace will terminate immediately at the firing rate of that phase Heating Cycle Termination W signal only refer to dip switch set SW2 on IFC When the heat call is removed the heat ing cycle will end and the furnace will shut down and return to the proper off cycle operation MAINTENANCE IMPORTANT IT 1S RECOMMENDED THAT AN ANNUAL INSPECTION OF YOUR FURNACE BE MADE BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER DURING THE ANNUAL INSPECTION IT IS RECOMMENDED THAT 120VAC POWER BE TURNED OFF THEN BACK TO THE ON POSITION REAPPLYING120VAC INITIATES A CALIBRATION CYCLE TO ENSURE OPTIMUM SYSTEM OPERATION A WARNING THIS FURNACE CONTAINS MOV ING ROTATING COMPONENTS AND USES HOUSEHOLD ELEC TRICAL CURRENT FOLLOW THE SAFETY RULES BELOW TO AVOID CUTS BURNS OR ELEC TRICAL SHOCK WHICH CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH POSSIBILITY OF BURNS OR ELECTRICAL INJURY Do not perform any service or mainte nance on the furnace while it is oper ating Read and follow the service instructions provided with this furnace before beginning any service or main tenance work Do not open the blower compartment disassemble or remove any compo nents while the furnace is operating This may expose sharp edges or points
6. and condenser are energized at the same time If not the order of dis play will be in the order that the compo nents are turned on When the system has found all neces sary components the text area of the communicating thermostat will go blank This is an indicator that the sys tem is operating properly Proceed by engaging a typical thermostat call to determine if operation is correct as described in the section of this book titled START UP PROCEDURES to test heating cooling and fan operation and to make necessary adjustments Heating Cycle Initiation The heating cycle is always initiated by a 24 volt signal on W of the thermostat When the controller senses a heat call or with a communicating signal from a com municating thermostat the following sequence occurs High low pressure switches are checked to insure contacts are open Inducer is powered on high speed for a thirty 80 second prepurge Pressure switches are monitored as the inducer creates the vacuum to close the contacts The gas valve servo or solenoid is energized at 100 No flow yet The controller generates a spark across the electrodes The main solenoid on the gas valve is energized allowing gas to flow to the burners When flame is proven the ignition con trol is de energized 8 second maxi mum trial time The gas valve maintains 100 rate through the warm up period 20 sec onds
7. equipped with a pressure switch which will shut off the main burners if the condensate drain line becomes blocked Be sure this condensate drain line does not become blocked or plugged Visual inspection of the condensate flow can eas ily be made while the furnace is in opera tion Use a flashlight to illuminate the dis charge end placed in the sewer opening See Figures 11 12 amp 13 Clean and flush the condensate tube to make sure condensate flows freely while the furnace is in operation IMPORTANT IT IS RECOMMENDED THAT AT THE BEGINNING OF THE HEATING SEASON THE CONDENSATE TRAP BE INSPECTED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER FOR DEBRIS OR BLOCKAGE A BLOCKED CONDENSATE TRAP CAN CAUSE WATER TO BACK UP INTO THE PRIMARY HEAT EXCHANGER AND LEAD TO NUISANCE TRIPPING OF THE OVER TEMPERATURE SWITCHES OR PRESSURE SWITCHES IMPORTANT IT IS RECOMMENDED THAT AT THE BEGINNING OF THE HEATING SEASON THE CONDENSATE NEUTRALIZER IF USED BE REPLACED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER MARKINGS It is recommended that an annual inspec tion and cleaning of all furnace markings be made to assure legibility Attach a replacement marking which can be obtained through the distributor if any are found to be illegible or missing FIGURE 9 DOWNFLOW FILTER INSTALLATION AIRFLOW A087001 S01 FI
8. proper balance and sealing FIGURE 1 MIGRATION OF DANGEROUS SUBSTANCES FUMES AND ODORS INTO LIVING SPACES Some building codes require extra cabinet insulation and gasketing when unit is installed in attic applica tions e If installed an unconditioned space apply caulking around the power wires control wires refriger ant tubing and condensate line where they enter the cabinet Seal the power wires on the inside where they exit conduit opening Caulking is required to prevent air leakage into and condensate from forming inside the unit control box and on electrical controls e Install the unit in such a way as to allow necessary access to the coil filter rack and blower control compartment Install the unit a level position to ensure proper condensate drainage Make sure unit is level in both direc tions within 1 8 e Install the unit in accordance with any local code which may apply and the national codes Latest editions Adapted from Residential Duct Diagnostics and Repair with permission of Air Conditioning Contractors of America ACCA RECEIVING Immediately upon receipt all cartons and contents should be inspected for transit damage Units with damaged car tons should be opened immediately If damage is found it should be noted on the delivery papers and a damage claim filed with the last carrier e After unit has been delivered to job site remove carto
9. ALLATION ADS 5422 01 1 Remove the blower compartment access door 2 Disengage the filter retaining rod and pull filter out 3 Clean filter and reinstall 4 Replace the blower compartment access door LUBRICATION The blower motor and induced draft motor are permanently lubricated by the manufacturer and do not require further attention IMPORTANT DO NOT ATTEMPT TO LUBRICATE THE BEARINGS ON THE BLOWER MOTOR OR THE INDUCED DRAFT BLOWER MOTOR ADDITION OF LUBRICANTS CAN REDUCE THE MOTOR LIFE AND VOID THE WAR RANTY The blower compartment and motor should be inspected and cleaned peri odically by your qualified installer ser vice agency or the gas supplier to pre vent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior And as suggested elsewhere in these instructions keep the air filters clean because dirty filters can restrict airflow and the motor depends on sufficient air flowing across and through it to keep it from overheating COMBUSTION AIR AND VENT SYSTEM 1 It is recommended that an annual inspection of your furnace s combus tion air and vent system be done by a qualified installer service agency or the gas supplier AWARNING IF DIRT RUST SOOT OR SCALE ACCUMULATIONS ARE PRESENT DO NOT OPERATE THE FURNACE INSPECT THE HEAT EXCHANGER FOR LEAKS LEAKS CAN CAUSE TOXIC FUMES TO ENTER THE HOME AND CAUSE CA
10. GURE 10 HORIZONTAL FILTER INSTALLATION GJD MODELS 4 087101 501 FIGURE 11 UPFLOW CONDENSATE DRAIN Ej amp SSeS e 4 9 AWD 7 INSTALLATION MANUAL OVERFLOW LINE REQUIRED ONLY WHEN OPTIONAL NEUTRALIZER CARTRIDGE IS USED CONDENSATE TRAP DRAIN LINE NEUTRALIZER CARTRIDGE OPTIONAL TO FLOOR DRAIN OR CONDENSATE PUMP A112001 S01 FIGURE 12 DOWNFLOW CONNECTION REFER INSTALLATION amp MANUAL 742 S085 A 10 OVERFLOW LINE Fi REQUIRED ONLY WHE 13 OPTIONAL NEUTRALIZER fi CARTRIDGE IS USED J 1 i f Iaa D l CONDENSATE TRAP DRAIN LINE NEUTRALIZER CARTRIDGE OPTIONAL TO FLOOR DRAIN OR CONDENSATE PUMP 112001 501 10 FIG
11. Heating Cycle Response The heating cycle is always initiated by a 24 volt signal on W1 or with a communi cating signal from a communicating ther mostat When the controller senses a heat call the following sequence occurs MODULATING FUNCTION W and V signal inputs refer to dip switch set SW2 on IFC After the warm up period the furnace will respond to the thermostat demand by adjusting the gas valve pressure and blower speed anywhere between 40 to 100 heating capacity gt TWO STAGE FUNCTION Two stage function only applies when both switches of SW2 are in the ON position and a two stage thermostat is installed 24V After the warm up period the furnace will respond to the thermostat demand by adjusting the gas valve pressure and blower heating speeds to the W signal values W only 40 gas valve pres sure and blower heating speed W2 65 gas valve pressure and blower heating speed for first five minutes and 100 thereafter Also if the call for heat ends the furnace terminates at the pre sent rate gt SINGLE STAGE FUNCTION W signal only After the warm up period the furnace will respond to the thermostat demand by altering the gas valve pressure and blower speed as follows Phase 1 0 to 5 minutes 40 of fur nace capacity gas valve output and blower speed Phase 2 5 to 12 minutes 65 of fur nace capacity gas valve output and blower speed
12. O THE STATE OF CALI FORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE 92 20802 98 00 GENERAL INFORMATION A WARNING DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT DUST FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAM AGE FUMES AND ODORS FROM TOXIC VOLATILE OR FLAMMABLE CHEMICALS AS WELL AS AUTO MOBILE EXHAUST AND CARBON MONOXIDE CO CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBAL ANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH SEE FIGURE 1 IF AIR MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN GARAGES OR OFF GARAGE STORAGE AREAS ALL JOINTS SEAMS AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRA TION OF TOXIC FUMES AND ODORS INCLUDING CARBON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE IF AIR MOVING EQUIPMENT DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS ALL JOINTS SEAMS AND OPEN INGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CAR BON MONOXIDE INTO THE LIVING SPACE A NOTICE IMPROPER INSTALLATION OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL CSA CERTIFICA TION OR THESE INSTRUCTIONS CAN RESULT IN UN
13. RBON MONOXIDE POISONING OR DEATH 2 Turn OFF the electrical supply to the furnace and remove the access doors 3 Inspect the gas burners for dirt rust or scale and clean as necessary 4 Inspect the flue connection area and vent pipe Be sure that the vent con nector is in place and slopes upward and is physically sound without holes or excessive corrosion 5 Be sure that the return air duct con nections are physically sound are sealed to the furnace casing and ter minate outside the space containing the furnace AWARNING CHECK THE VENT PIPE SECTIONS FOR DETERIORATION AND CHECK JOINT FITTINGS FOR THEIR INTEGRITY IF IT HAS BECOME DIS CONNECTED TOXIC FUMES CAN ENTER THE HOME AND CAUSE CARBON MONOXIDE POISONING OR DEATH DO NOT OPERATE THIS FURNACE APPROPRIATE SERVICE MUST BE APPLIED 6 Be sure the physical support of the fur nace is sound without sags cracks etc around the base so as to provide a seal between the support and the base 7 Look for the obvious signs of deteriora tion of the furnace 8 If the furnace is free of the above condi tions replace the access doors and restore electrical power to the furnace 9 Start the furnace and observe its opera tion Watch the burner flames to see if they are bright blue If a suspected mal function is observed or the burner flames are not bright blue call for appropriate service CONDENSATE This furnace is
14. SATISFACTORY OPERATION AND OR DANGEROUS CONDI TIONS AND ARE NOT COV ERED BY THE UNIT WARRANTY A NOTICE IN COMPLIANCE WITH RECOG NIZED CODES IT IS RECOMMEND ED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPO RATOR COILS OR UNITS CONTAIN ING EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CON TENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING SEE ACCESSORIES SEC TION OF THESE INSTRUCTIONS FOR AUXILIARY HORIZONTAL OVERFLOW PAN INFORMATION MODEL IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air To maintain efficiency comfort and good indoor air quality it is important to have the proper balance between the air being supplied to each room and the air returning to the cooling and heating equipment Proper balance and sealing of the duct system improves the efficiency of the heating and air conditioning system and improves the indoor air quality of the home by reducing the amount of air borne pollutants that enter homes from spaces where the ductwork and or equipment is located The manufacturer and the U S Environmental Protection Agency s Energy Star Program recom mend that central duct systems be checked by a qualified contractor for
15. URE 13 HORIZONTAL CONDENSATE DRAIN INSTALL A UNION BETWEEN THE MANUAL GAS STOP AND THE MAIN GAS VALVE Q H 57 Oo DRAIN VENT NEEDS TO BE ABOVE COLLECTOR BOX DRAIN SPOUT MINIMUM HEIGHT i OPEN TOP OVERFLOW LINE REQUIRED ONLY WHEN OPTIONAL NEUTRALIZER 5 6 CARTRIDGE IS USED _ l gt a T CONDENSATE TRAP DRAIN LINE NEUTRALIZER CARTRIDGE OPTIONAL 872 1 5 1 TO FLOOR DRAIN OR CONDENSATE PUMP 11 12 0409
16. ace the burner access door Turn on the electrical power 6 Set the room thermostat to a point above the room temperature to light the main burners After the burners are lit set the room thermostat to a desired temperature A WARNING BE SURE THAT THE MANUAL GAS CONTROL HAS BEEN IN THE OFF POSITION FOR AT LEAST FIVE MINUTES DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS FAILURE TO FOLLOW THIS WARNING CAN CAUSE A FIRE OR AN EXPLOSION RESULT ING IN PROPERTY DAMAGE PER SONAL INJURY OR DEATH 7 lf the appliance will not operate follow the instructions To Turn Off Gas To The Appliance and call your service technician or gas supplier TO TURN OFF GAS TO THE APPLIANCE A WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF SHUT OFF THE MANU AL GAS VALVE TO THE APPLI ANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY FAIL URE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING PROPERTY DAMAGE PERSON AL INJURY OR DEATH IMPORTANT SHUT OFF THE MANUAL GAS VALVE LOCATED IN THE GAS SUPPLY PIPING OUTSIDE THE FUR NACE CASING 1 Set the thermostat to the lowest set ting 2 Turn off all electric power to the appli ance on which service is to be per formed Remove the burner access door 4 Turn the gas control knob to the OFF position 5 Replace the burner access door 55 SEQUENCE OF OPERATION Startup For System
17. e poisoning all blower doors and compartment cov ers must be replaced after the furnace is serviced Do not operate the unit without all panels and doors securely in place SYSTEM OPERATION INFORMATION Keep the air filters clean Your heating system will operate more efficiently and provide better heating more economi cally Arrange your furniture and drapes so that the supply air registers and return air grilles are unobstructed Close doors and windows This will reduce the heating load on your sys tem Avoid excessive use of exhaust fans Do not permit the heat generated by television lamps or radios to influence the thermostat operation If you desire to operate your system with constant air circulation consult your thermostat manual or please ask advice from a qualified installer service agency or the gas supplier IMPORTANT FOR COMPLETE OPERATION AND SET UP OF YOUR THERMOSTAT REFER TO THE MAN UAL INCLUDED IN THE LITERATURE PACKET SHIPPED WITH THIS FUR NACE STARTING YOUR FURNACE LIGHTING INSTRUCTIONS This appliance is equipped with a direct spark ignition device This device lights the main burners each time the room thermostat calls for heat DO NOT try to light the burner by hand See lighting instructions on the furnace 1 Remove the burner access door 2 Set the thermostat to the lowest set ting 3 Turn the gas control knob counter clockwise to the ON position 4 Repl
18. g Keep any furnace installed in an attic or other insulated space free and clear of insulating material Examine the furnace area when installing the furnace or adding insulation Some materials may be combustible Any additions changes or conver sions required in order for the furnace to satisfactorily meet the application needs should be made by a qualified installer service agency or the gas supplier using factory specified or approved parts Read your Warranty Contact the WARRANTOR for con version information This furnace was equipped at the factory for use on NATURAL GAS ONLY Conversion to LP GAS requires a special kit sup plied by the WARRANTOR DANGER FROM ASPHYXIATION WARNING FIGURE 6 STANDARD HORIZONTAL DIRECT VENTING NNSS a 7 EA A Tay THIS FURNACE OPERATES BY BURNING GAS INSIDE YOUR HOME IMPROPER OR INCOM PLETE BURNING OF THIS GAS CAN RESULT IN THE FORMATION OF CARBON MONOXIDE IF INTRODUCED INTO THE LIVING SPACE THIS CAN CAUSE DIZZI NESS NAUSEA OR DEATH BY ASPHYXIATION YOU MUST READ AND OBSERVE THE SAFE TY RULES BELOW TO PREVENT OXYGEN DEPLETION OR UNBURNED GAS OR COMBUS TION FROM ESCAPING INTO THE LIVING SPACE OF YOUR RESI DENCE AALS OT
19. gas than the one listed on the rating plate e Follow the furnace lighting instruc tions carefully to be sure all gas fumes are cleared before lighting the furnace e Check carefully for gas before lighting a furnace Do not rely on smell alone to detect gas Use a UL recognized fuel gas detector and a soap and water solution on the pipes to check for gas leaks A damaged gas control knob can cause gas to leak Do not hit or dam age the knob Do not force the knob with tools Use only your hand to turn it to ON or OFF Call the a quali A WARNING fied installer service agency or the gas supplier immediately if you have problems turning the knob Should overheating occur or the gas valve fail to shut off the gas supply turn off the manual gas valve to the furnace before turning off the electri cal supply Soot buildup indicates a serious com bustion problem that requires immedi ate correction Turn the gas supply OFF until the furnace is repaired Contact a qualified installer service agency or the gas supplier immedi ately to inspect the furnace Do not place store or use gasoline or other flammable vapors and liquids on against or around the furnace jacket Do not store combustible materials near the furnace The furnace must have adequate clearances from all combustible materials such as cloth ing paper cardboard wood or clean ing materials to prevent them from ignitin
20. ial No City INDOOR COIL State Zip Model No Telephone No Serial No FURNACE Model No Serial No SAFETY PRECAUTIONS SIGNAL WORDS There are some safety precautions which must be understood and fol lowed by all users of equipment such as your furnace where flames gas electricity and rotating parts are pre sent To alert you to the above poten tial hazards we use the signal words WARNING and CAUTION through out this manual and safety labels attached to the furnace Read carefully and pay special atten tion to all warnings and cautions in this manual They are defined and designed as follows to help you recog nize and avoid the potential hazards of operating this furnace A WARNING Indicates a potentially hazardous situation which if not avoided could result in property damage serious injury or death A CAUTION Indicates a potentially hazardous situation which if not avoided could result in property damage or minor or moderate injury POSSIBILITY OF FIRE OR EXPLOSION THIS FURNACE OPERATES BY BURNING GAS INSIDE YOUR HOME THIS CREATES THE POS SIBILITY OF FIRE OR AN EXPLO SION WHICH CAN RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH YOU MUST READ AND FOLLOW ALL OF THESE SAFETY PRECAUTIONS TO HELP ENSURE SAFE OPERA TION OF YOUR FURNACE Do not test for gas leaks with a match or flame Do not use this furnace with any other
21. n taking care not to damage unit Check the unit rating plate for unit size electric heat coil voltage phase etc to be sure equipment matches what is required for the job specification e Read the entire instructions before starting the installation are available from National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 These publications are ANSI NFPA No 70 Latest Edition National Electrical Code e Installation of Air Conditioning and Ventilating Systems e NFPAQOB Installation of warm air heating and air conditioning sys tems The equipment has been evaluated in accordance with the Code of Federal Regulations Chapter XX Part 3280 INTRODUCTION YOUR FURNACE Thank you for the purchase of your new modulating gas fur nace This furnace is designed to be the ultimate in heating comfort and is the only true modulating gas furnace available on the market today The modulating gas furnace provides a superior level of comfort due to the interaction of seven basic components Variable Output Thermostat Whereas conventional ther mostats only send an On Off signal to the furnace the ther mostat for the modulating furnace system is specially designed to indicate the exact heating requirements of the conditioned space This is accomplished by a logic control routine that accurately senses the space load minimizes recovery times red
22. s Configured With Communications A WARNING INSTALLATION OF LINE VOLT AGE AND GAS MUST BE PER FORMED ACCORDING TO INSTRUCTIONS WRITTEN IN THIS MANUAL FAILURE TO DO SO COULD RESULT IN INJURY OR DEATH When the furnace is configured for communications the components on the network i e furnace thermostat and condenser must establish com munications before engaging a heat or other thermostat demand The proce dure for establishing communications is automatic and is described below Once the communicating wiring is properly installed and the furnace is connected to line voltage the system can be turned on The thermostat will display the following text SEARCHING is displayed several times for several seconds Next the text FURNACE FOUND and AIR CONDITIONER FOUND or HEAT PUMP FOUND depending on which is installed in the system will be displayed The process can take several minutes up to a maxi mum of 30 to complete If these mes sages are not displayed within 30 min utes after energizing the system com munications can not be established There are many reasons why commu nications may not be established including improper settings of the TERM and BIAS switches see BIAS TERMINATION and improper wiring The order in which these messages will be displayed will depend on which components are energized first The order listed here assumes that the fur nace
23. uces temperature swings and optimizes system efficiency and performance Fully Communicatiing Thermostat Modulating Gas Valve The gas valve has the conventional redundant solenoid valves for inherent safety but also has a third operator for capacity control This operator is actually a servo valve which varies the input rate of the furnace proportionally to the signal from the controller The modulating furnace can operate anywhere from 40 to 100 of the nameplate input of the furnace e Furnace Controller The furnace controller provides all of the ignition and safety functions of the typical IFC as well as interpreting the signals from the thermostat The furnace controller will optimize furnace performance by monitoring all thermostat and temperature inputs and insuring the stable operation of the inducer gas valve and indoor blower motor ECM Variable Speed Blower The airflow through the duct work is varied to meet the load demand Airflow as low as 300 CFM is achieved by the response of a brushless perma nent magnet variable speed blower motor e Two Speed Draft Inducer To insure clean combustion and peak efficiency the induced draft motor speed is adjust ed based on the gas valve setting to provide the proper amount of combustion air to the burners FIGURE 2 UPFLOW FURNACE
24. which could cause cuts hot surfaces which could cause burns and electrical circuits which could cause shocks Instruct children on the safety haz ards associated with furnaces Keep children away from the furnace at all times A CAUTION DO NOT OPERATE YOUR SYS TEM FOR EXTENDED PERIODS WITHOUT FILTERS A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AT THE SUPPLY REGISTERS ANY RECIRCULATED DUST WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER THIS RESIDUE WILL SOIL CEILINGS WALLS DRAPES CARPETS AND OTHER HOUSEHOLD ARTICLES FILTER MAINTENANCE Have your qualified installer service agency or the gas supplier instruct you on how to access your filters for regular maintenance Keep air filters clean at all times Vacuum dirt from filter wash with detergent and water air dry thorough ly and reinstall After filters are cleaned and returned to the furnace be sure doors are properly reinstalled If you are not totally sure of this procedure consult qualified installer service agency or the gas supplier REMOVING FILTERS FILTER IN BOTTOM OR SIDE LOCATION FIGURE 7 UPFLOW SIDE FILTER LOCATION ATTACH WITH SHEET METAL LJ 2 REQ D FILTER ROD FILTER SUPPORT ANGLE SEE ANGLE DETAIL 1332 FIGURE 8 JACKET ASSEMBLY FILTER UPFLOW BOTTOM FILTER INST
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