LG 395CAV User's Manual
Contents
1. b Check gas input rate by clocking gas meter 1 Obtain average yearly heat value for local gas supply 2 Check and verify orifice size in furnace NEVER ASSUME THE ORIFICE SIZE ALWAYS CHECK AND VERIFY CAUTION DO NOT redrill burner orifices Improper drilling burrs out of round etc can cause excessive burner operating noise and misdirection of burner flames This could result in flame impingement on burners and heat exchanger surfaces leading to potential failures 3 Turn off all other gas appliances and pilots 4 Start furnace and let run for 3 minutes 5 Measure time in sec for gas meter to complete 1 revolution 6 Refer to Table 7 for cu ft of gas per hr 7 Multiply gas rate cu ft hr by heating value Btu cu ft EXAMPLE Btu heating input Btu cu ft X cu ft hr Heating value of gas 1070 Btu cu ft Time for 1 revolution of 2 cu ft dial 72 sec Gas rate 100 X 1070 107 000 Btuh 8 Measured gas input should not exceed gas input on unit rating plate 9 Proceed to item c to adjust manifold pressure c Adjust gas input 1 Remove regulator adjustment seal cap See Fig 12 2 Turn adjusting screw counterclockwise to decrease input Turn screw clockwise to increase input DO NOT set manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas Make any major adjustments by changing2. SHUTOFF VALVE REQUIRED SEDIMENT TRAP UNION 89417 Fig 7 Typical Gas Pipe Arrangement WARNING Use the proper length of pipes to avoid stress on the gas control manifold Failure to follow this A warning can result in a gas leak causing fire explosion personal injury or death A CAUTION Connect the gas pipe to the furnace using a backup wrench to avoid damaging gas controls WARNING Never purge a line into a combustion chamber Never use matches candles flame or other A Sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage Failure to follow this warning can cause a fire explosion personal injury or death VI ELECTRICAL CONNECTIONS A 115 v Wiring Refer to the unit rating plate or Table 5 for equipment electrical requirements The control system requires an earth ground for proper operation A CAUTION Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Make all electrical connections in accordance with the National Electrical Code NEC ANSI NFPA 70 1996 and local codes or ordinances that might apply For Canadian installations all elec trical connections must be made in accordance with CSA C22 1 Canadian Electrical Code or authorities having jurisdictio
3. 115 VAC L1 p EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 5 AMP MAX EAC 2 WHITE POWER 115 VAC L2 NEUTRAL SUPPLY CONNECTION HOT SURFACE INDUCER MOTOR IGNITOR CONNECTOR CONNECTOR A93052 Fig 9 Control Board A93053 ig 10 EAC Terminals on Control Board 1 Heating mode When the wall thermostat calls for heat the R W circuit closes The furnace control performs a self check verifies the pressure switch contacts are open and starts inducer motor a Prepurge period As the inducer motor comes up to speed the pressure switch contacts close to begin a 15 sec prepurge period b Ignitor warm up At the end of the prepurge period the ignitor is energized for a 17 sec ignitor warm up period c Ignition sequence When the ignitor warm up period is completed the gas valve opens permitting gas flow to the burners where it is ignited After 5 sec the ignitor is de energized and a 2 sec flame sensing period begins d HUM terminal is energized with the gas valve See accessories in the Electrical Connections section e Flame sensing When burner flame is sensed the con trol begins the blower on delay period and continues holding the gas valve open If burner flame is not sensed the control closes the gas valve and repeats ignition cycle NOTE Ignition sequence will repeat 3 additional time before a lockout occurs Lockout automatically resets after 3 hrs o
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6. te Back Set Temperature Rise Plenum Top Set Thermostat Heat Single Wall Vent Check Safety Controls rettet e periret 14 Type B 1 Double Wall Vent e Pete 14 Single Wall Vent Type B 1 Double Wall Vent SAFETY CONSIDERATIONS Service a 5 7 NOTES Installing and servicing heating equipment can be hazardous due to 1 Provide 30 in front clearance for servicing An open door in front of the unit gas and electrical components Only trained and qualified person can meet this requirement M 1 should i ll ice heat 2 A minimum clearance of 3 in must be provided in front of the unit for nel should install repair or service heating equipment combustion air and proper operation Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes In the United States follow all safety codes including the National Fuel Gas Code NFGC NFPA No 54 1992 ANSI Z223 1 1992 In Canada refer to the current edition of the National Standard of Canada CAN CGA B149 1 I 28 1 _ 2 e FLU
7. 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touch ing control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge 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 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage INTRODUCTION 9 The Model 395CAV Series G Furnace is available in sizes 45 000 through 155 000 Btuh input capacities The design of the upflow gas fired furnace is A G A C G A certified for natural and propane gas and for installation on combustible flooring in alcoves attics basements closets or utility rooms The design of this furnace line is not A G A C G A certified for installation in mobile homes recreation vehicles or outdoors Before installing the furnace refer to the current edition of the NFGC Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction For further information the NFGC is available from National Fire Protection Association Inc Batterymarch Park Quincy MA 02
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9. a If combustion air is taken from outdoors through vertical ducts the openings and ducts MUST have at least 1 sq in of free area per 4000 Btuh of the total input for all equipment within the confined space See Fig 3 b If combustion air is taken from the outdoors through horizontal ducts the openings and ducts MUST have at least 1 sq in of free area per 2000 Btuh of the total input for all equipment within the confined space For Example 395CAV FURNACE INPUT BTUH 110 000 132 000 FREE AREA PER OPENING SQ IN ROUND PIPE 154 000 7 For Example 395CAV FURNACE INPUT BTUH 110 000 132 000 154 000 FREE AREA PER OPENING SQ IN ROUND PIPE IN DIA c When ducts are used they must be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular ducts must not be less than 3 in See Fig 3 1SQIN PER 4000 DUCTS A TO ase BTUH OUTDOORS SUPPLY AIR A DUCTS T O OUTDOORS RETURN AIR EM Minimum dimensions of 3 In NOTE Use any of the following CONFINED SPACE HH AN TO OUTDOORS combinations of openings A amp B C amp D D amp E F amp G 1 SQIN PER 4000 BTUH A89013 Fig 3 Air For Combustion and Ventilation Outside Air m A WARNING Do not install the furnace on its back safety control operation wil
10. High Medium High present Blue Red White Medium Low Low Common 3 Set thermostat heat anticipator The thermostat heat anticipator must be set to match the amp draw of the electrical components in the R W circuit Accurate amp draw readings can be obtained at thermostat subbase terminals R and W Fig 14 illustrates an easy method of obtaining the actual amp draw The amp reading should be taken after the blower motor has started See the thermostat manufacturer s instructions for adjusting the heat anticipator and for varying the heating cycle length NOTE When using an electronic thermostat set the cycle rate for 3 cycles per hr THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED HOOK AROUND VOLT AMMETER EN FROM UNIT 24 VOLT TERMINAL BLOCK 5 0 AMPS ON 0 5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS EXAMPLI A80201 Fig 14 Amp Draw Check With Ammeter E Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up Procedures section as part of normal operation 1 Check primary limit control This control shuts off the combustion control system and energizes the circulating air blower motor if the furnace overheats 14 The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes As soo
11. When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace the return air must also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace Provide ample space for servicing and cleaning Always comply with the minimum fire protection clearances shown on the unit rating plate B Location Relative to Cooling Equipment The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with a furnace dampers or other means used to control the flow of air must prevent chilled air from entering the unit If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position C Hazardous Locations When the furnace is installed in a residential garage it must be installed so that the burners and ignition source are located at least 18 in above the floor The furnace should be protected from physical damage by vehicles When a furnace is installed in public garages airplane hangars or other buildings having hazardous atmospheres the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association Inc Il AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion and ve
12. cycle is completed f Bl t t heati d for 10 sec th When the thermostat calls for cooling the blower oper T EA M dis stops ates on cooling speed When the thermostat is satisfied the P blower operates an additional 90 sec before reverting back 3 operate furnace follow procedures on operating instruc to continuous operation on heating speed tions label attached to furnace 4 Heat pump mode 4 With furnace operating set thermostat below room tem perature and observe that furnace goes off Set thermostat When installed with a heat pump the furnace control above room temperature and observe that furnace restarts automatically changes the timing sequence to avoid long blower off time during demand defrost cycles When the D Adjustments W Y or W Y G thermostat inputs are received at the same time the control changes the blower to heating speed or t Sebgas Tate starts the blower if it was off and begins a heating cycle There are 2 methods of adjusting the gas input rate The The blower remains on until the end of the prepurge period preferred method is by using Table 6 and following the then shuts off until the end of the ignition warm up and trial instructions in item a The second method is by clocking the for ignition periods a total of 24 sec The blower then gas meter and using the instructions in item b comes back on at heating speed The gas valve regulator has been nominally
13. dryer water heaters etc in the space For Example 395CAV FURNACE INPUT BTUH 44 000 66 000 MINIMUM SQ FT WITH 7 1 2 FT CEILING 88 000 110 000 132 000 154 000 If the unconfined space is constructed unusually tight air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors Combustion and ventilation openings must be sized the same as for a confined space A minimum opening with a total of at least 1 sq in per 5000 Btuh of total input rating for all equipment must be provided Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room B Confined Space A confined space has volume less than 50 cu ft per 1000 Btuh of the total input rating for all appliances installed in that space A confined space MUST have 2 permanent openings 1 within 12 in of the ceiling and the other within 12 in of the floor See Fig 2 NOTE In determining the free area of an opening the blocking effect of the louvers grilles and screens must be considered If the free area of a louver or grille design is unknown it may be assumed that wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area Screens when used must not be smaller than 1 4 in mesh Louvers and grilles must be constructed so they cannot be closed The size of the openings depends upon whether the air comes
14. function properly and correct condition e Turn off 115 v power to furnace f Reconnect inducer motor wires replace control door and turn on 115 v power F Checklist Put away tools instruments and clean up debris 2 Verify manual reset switches have continuity 3 Ensure blower and control access doors are properly in stalled 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Manual with owner 7 Leave literature packet near furnace SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 15 1996 BDP Co P O Box 70 Indianapolis IN 46206 Printed in U S A 16 395c4010 Catalog No BDP 3339 518
15. X 25 X 1f 1 16 X 25 X1 Cleanable 21 1 16 X 25 X 1 1 20 X 25 X 1f Cleanable 24 1 2 2 16 X 25 X 1f 1 24 X 25 X 1 Cleanable Filters can be field modified by cutting the frame as marked and folding to the desired size Alternate sizes can be ordered from your distributor or dealer T Factory provided with the furnace 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement V GAS PIPING Gas piping must be installed in accordance with national and local codes Refer to the current edition of the NFGC Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction Refer to Table 4 for the recommended gas pipe size Risers must be used to connect to the furnace and the meter PESE A89014 Fig 6 Leveling Leg Installation TABLE 4 MAXIMUM CAPACITY OF PIPE NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE SIZE DIAMETER IN IN 10 20 30 40 50 Cubic ft of gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 10 2 NFPA 54 1992 CAUTION If a flexible connector is required or al lowed by the authority having jurisdiction black iron pipe shall be installed at the gas valve and extend a minimum of 2 in outside the furnace casing A gt
16. from inside or outside of the structure 1 air from inside the structure a Each opening MUST have at least 1 sq in of free area per 1000 Btuh of the total input for all equipment within the confined space but not less than 100 sq in per opening See Fig 2 SUPPLY AIR VENT THROUGH ROOF Lose cu I 4 E 12 MAX 1 SQIN PER 1000 BTUH IN DOOR OR WALL irr JE UNCONFINED INTERIOR SPAGE HEATED SPACE CONFINED SPACE 6 MIN FRONT t 1 SQIN PER 1000 BTUH IN DOOR OR WALL l E MAX RETURN AIR Minimum opening size is 100 square in with minimum dimensions of 3 In t Minimum of 3 In when type B1 vent is used IL 3 89012 Fig 2 Air For Combustion and Ventilation Inside Air For Example FREE AREA PER OPENING SQ IN 395CAV FURNACE INPUT BTUH 110 000 132 000 154 000 b If the building is constructed unusually tight a perma nent opening directly communicating with the outdoors should be provided This opening shall have a minimum free area of 1 sq in per 5000 Btuh of total input rating for all equipment in the enclosure c If the furnace is installed on a raised platform to provide a return air plenum and return air is taken directly from the hallway or space adjacent to the furnace all air for combustion must come from outdoors 2 All air from outside the structure
17. set at 3 5 in wc When the W input signal disappears the control begins the for natural gas When adjusting input rate do not set normal inducer post purge period and the blower changes to manifold pressure above 3 8 in wc or below 3 2 in wc cooling speed after a 1 sec delay If the W Y G signals a Check gas input rate using Table 6 disappear at the same time the blower remains on for the selected heating blower off delay period and the inducer 1 Obtain average yearly heat value for local gas goes through its normal post purge period If the W Y supply inputs should disappear leaving the G signal input the 2 Obtain average yearly specific gravity for local gas control goes into continuous blower and the inducer re supply mains on for the normal post purge period 3 Verify furnace model Table 6 can only be used for Anytime the control senses false flame the control locks model 395CAV Furnaces out of the heating mode This occurs because the control mH cannot sense the W input due to the false flame signal and 4 Check and verify orifice size in furnace NEVER ASSUME THE ORIFICE SIZE ALWAYS as a result sees only the Y input and goes into cooling CHECK AND VERIFY mode blower off delay All other control functions remain in standard format 5 Find natural gas heat value and specific gravity in NOTE EAC 1 terminal is energized whenever blower operates Table 6 HUM terminal is only energized when gas
18. valve is energized 6 Follow heat value and specific gravity lines to point C Start up Procedures of intersection Find orifice size and manifold pres sure settings for proper operation at given natural 1 Purge gas lines After all connections have been made KS gas conditions purge the lines and check for leaks EXAMPLE Heat value 1070 Btu cu ft specific gravity 0 58 Therefore Orifice No 44 WARNING Never purge a line into a combustion chamber Never use matches candles flame or other sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage Failure to follow this warning can cause fire explosion personal injury or death Manifold pressure 3 3 in wc The furnace is shipped with No 43 orifices Therefore in this example all main burner orifices must be changed and manifold pressure must be adjusted 2 Component test The furnace control board allows all components except gas valve to be run for a short period of time 7 Proceed to item c to adjust manifold pressure TABLE 6 MODEL 395CAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT RATE Tabulated Data Based on Altitude Up to 2000 Ft and 22 000 Btuh Per Burner GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE BTU CU FT 860
19. 2 9 16 12 11 16 042091 17 1 2 15 7 8 16 048091 21 19 3 8 19 1 2 036110 17 1 2 15 7 8 16 048111 21 19 3 8 19 1 2 060111 24 1 2 22 7 8 23 048135 21 19 3 8 19 1 2 060135 24 1 2 22 7 8 23 060155 24 1 2 22 7 8 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electro static potential 23 OOo 45 45 45 5 Disconnect all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND Firmly touch a 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 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch un grounded objects etc
20. 269 Ameri can Gas Association 1515 Wilson Boulevard Arlington VA 22209 or from Literature Distribution Installation must conform to the regulations of the serving gas supplier and the local building heating and plumbing codes in effect in the area in which the installation is made or in the absence of local codes with the requirements of the NFGC CAUTION Application of this furnace should be in doors with special attention given to vent sizing and A material gas input rate air temperature rise and unit sizing Improper installation or misapplication of the furnace can require excessive servicing or cause prema ture component failure This furnace is designed for a minimum continuous return air temperature of 60 F db or an intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed a maximum of 85 F db WARNING Improper installation adjustment alter ation service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service A agency local gas supplier or your distributor or branch for information or assistance The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product Failure to follow this warning can cause electrical shock fire
21. E COLLAR b 1 gt fs 76 IN DIA HOLE TA POWER ENTRY 76 IN DIA TERS ACCESSORY 5 1346 3 4 39 7 1 3 4 IN DIA HOLE GAS ENTRY 7 R Ve IN DIA HOLE 238 THERMOSTAT WIRE ENTRY SIDE INLET 4 1146 AIR INLET a 24 5A 11467 E AIRFLOW 2146 19 1346 iy OUTLET 1346 76 IN DIA 536 POWER ENTRY 1 Y IN DIA 5 Tw EM ulli R H GAS ENTRY 2938 76 IN DIA ACCESSORY DIA THERMOSTAT WIRE ENTRY SIDE INLET Gain TYP 1 E 134 1146 i 1 58 2314 TYP d xt SIDE RETURN DUCT LOCATION NOTES 1 Two additional 76 in dia knockouts are located in the top plate 2 Minimum return air opening at furnace For 800 CFM 16 in round 141 x 12 in rectangle For 1200 CFM 20 in round or 1412 x 19 2 rectangle For 1600 CFM 22 in round 1412 x 2314 rectangle For airflow requirements above 1800 CFM use both side inlets a combination of 1 side inlet and the bottom or the bottom only A88367 Fig 1 Dimensional Drawing TABLE 2 DIMENSIONS IN UNIT SIZE A D E 12 11 16 VENT CONN SHIP WT LB 4 122 024045 14 3 16 12 9 16 036045 14 3 16 12 9 16 024070 14 3 16 12 9 16 12 11 16 12 11 16 124 036070 14 3 16 1
22. Piping should be pressure tested in accordance with local and national plumbing and gas codes before the furnace has been attached If the pressure exceeds 0 5 psig 14 in wc the gas supply pipe must be disconnected from the furnace and capped before the pressure test If the test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on the gas valve before the test It is recommended that the ground joint union be loosened before pressure testing After all connections have been made purge the lines and check for leakage with regulated gas supply pressure Install a sediment trap in the riser leading to the furnace The trap can be installed by connecting a tee to the riser leading from the furnace Connect a capped nipple into the lower end of the tee The capped nipple should extend below the level of the gas controls See Fig 7 Apply joint compound pipe dope sparingly and only to the male threads of each joint The compound must be resistant to the action of propane gas An accessible manual shutoff valve MUST be installed upstream of the furnace gas controls and within 72 in of the furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shutoff valve Place ground joint union between the gas control manifold and the manual shutoff valve GAS SUPPLY
23. UNIT AMPS MINIMUM WIRE GAGE MAXIMUM WIRE LENGTH FT MAXIMUM FUSE OR HACR TYPE CKT AMPSt 024045 036045 024070 036070 042091 048091 036110 048111 060111 048135 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 060135 115 60 1 060155 115 60 1 Permissible limits of the voltage range at which the unit operates satisfactorily T Time delay fuse is recommended t Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop 127 127 127 127 127 127 127 104 104 104 104 104 104 104 6 0 14 47 15 8 3 14 34 15 5 9 14 47 15 8 7 14 32 15 9 0 14 31 15 10 4 14 27 15 8 0 14 35 15 The furnace must have a 115 v power supply properly connected and grounded Proper polarity must be maintained for correct operation Thermostat wire connections at R W C and Y must be made at the 24 v terminal block on the control board The gas service pressure must not exceed 0 5 psig 14 in wc but must be no less than 0 16 psig 4 5 in wc The blower compartment door must be in place to complete the 115 v circuit to the furnace B Sequence of Operation CAUTION Furnace control must be grounded for proper operation or control will lockout Control is grounded through green wire routed to gas valve and bu
24. e replacement is required use ONLY a 3 amp fuse of identical size C Accessories 1 Electronic Air Cleaner EAC Two spring clamp terminals for 12 gage maximum solid or stranded wire marked EAC 1 and EAC 2 are provided for EAC connection See Fig 9 These terminals are energized with 115 v 1 maximum during blower motor operation To connect EAC power leads to furnace control center strip approximately 1 8 in of insulation from wire Open terminal by depressing switch arm with a screwdriver or finger and insert wire as shown in Fig 10 2 Humidifier HUM Screw terminals HUM and Com are provided for 24 v humidifier connection The terminals are energized with 24 v 0 5 amp maximum after inducer motor prepurge period NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation Vil VENTING Refer to the National Local Installation Code such as National Fuel Gas Code Z223 1 1992 or the Canadian Installation Code CAN B149 1 and 2 M95 for proper vent sizing and installation requirements Use the enclosed Venting Tables for Category I Fan Assisted Furnaces for a quick easy reference The horizontal portion of the venting system shall maintain a minimum of 1 4 in upward slope per linear ft and it shall be rigidly supported every 5 ft or less with hangers or straps to ensure that there will be no movement after ins
25. feature helps diagnose a system problem in case of a furnace blower motor on cooling speed The EAC 1 termi component failure To initiate component test procedure nal is energized with 115v when the blower is operating on short jumper the TEST 1 4 in quick connect terminal on cooling speed control board adjacent to diagnostic light and the Com When the thermostat is satisfied R G and R Y circuits are terminal on thermostat connection block for approximately broken The furnace blower and EAC continue operating on cooling speed for an additional 90 sec NOTE Component test feature will not operate if any thermostat signal is present at control board 3 Continuous blower mode NOTE EAC 1 terminal is energized with 115v whenever blower operates a Momentarily jumper TEST and Com terminals until When the R G circuit is made the blower motor operates on heating speed During a call for heat the blower stops b LED will display previous fault 4 times allowing the furnace heat exchangers to heat up more c Inducer motor operates for 10 sec then stops quickly then restarts at the end of the 40 sec blower on delay period If jumper is on pin 6 and pin 9 the blower on delay is 60 sec Component test sequence is as follows d Hot surface ignitor is energized for 15 sec then de energized e Blower motor operates on cooling speed for 10 sec then The blower reverts to continuous operation after the heating stops
26. from supply air temperature to determine ADJUSTMENT temperature rise c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise De crease blower speed to increase temperature rise WARNING Disconnect the electrical power before AN changing the speed tap A failure to follow this warning can cause personal injury INLET PRESSURE TAP MANIFOLD PRESSURE TAP d To change blower motor speed selections for heating mode remove blower motor lead from control board A95618 HEAT terminal See Fig 11 Select desired blower Fig 12 Redundant Automatic Gas Control Valve motor speed lead from 1 of the other terminals and relocate it to HEAT terminal See Table 9 for lead color identification Reconnect original lead on SPARE termi nal d High altitude In the United States gas input on rating plate is for altitudes up to 2000 ft Ratings for altitudes over 2000 ft must be 4 percent less for each 1000 ft above sea level To obtain the adjusted altitude rating adjust the manifold pressure see item c and replace the main burner orifices as needed Refer to National Fuel Gas Code Appendix F Table F 4 for proper orifice sizing at high altitudes CAUTION Recheck temperature rise It must be within limits specified on unit rating plate Recommended op eration is at midpoint of rise or above 3 TABLE 9 SPEED SELECTOR FACTORY ATTACHED TO Black Yellow When
27. ing side and into the filler strip to secure it in place Filter should rest on the top of the filler strip when installed WARNING Never operate unit without a filter or with A filter access door removed Failure to follow this warning can cause fire personal injury or death IV LEVELING LEGS IF REQUIRED When the furnace is used with side inlet s and leveling legs are required refer to Fig 6 and install field supplied corrosion resistant 5 16 in machine bolts and nuts NOTE The maximum length of the bolt should not exceed 1 1 2 in 1 Lay furnace on its back Locate and drill 5 16 in diameter hole in each bottom corner of furnace as shown in Fig 6 2 Install nut on bolt and install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 247 1 WIDE CASINGS ONLY CUT AND FOLD FACTORY PROVIDED FILTERS AS SHOWN TO DESIRED SIZE 17 IN WIDE CASINGS ONLY INSTALL FIELD SUPPLIED FILTER FILLER STRIP UNDER FILTER WASHABLE FILTER FILTER RETAINER FILTER SUPPORT A96030 Fig 5 Bottom Filter Arrangement Control Removed for Clarity TABLE 3 FILTER INFORMATION IN FURNACE FILTER SIZE FILTER TYPE CASING WIDTH Side Return Bottom Return 14 3 16 1 16 X 25 X 1f 1 14 X25 X 1 Cleanable 17 1 2 1 16
28. installation instructions 395CAV operating instructions Series G UPFLOW GAS FIRED INDUCED COMBUSTION FURNACES Cancels 11 395C 40 9 395C 40 10 1 96 NOTE Read the entire instruction manual before starting the installation Y E EFFICIENCY This symbol indicates a change since the last issue eal eee K JA Index Page ama SAFETY CONSIDERATIONS 1 Ner Clearances From Combustible Materials sss 1 m Dimensional Drawing eese 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS and 2 M95 Natural Gas and Propane Installation Codes NSC PROCEDURE deu 2 3 Wear safety glasses and work gloves Have fire extin INTRODUCTION irte arr eger eer e tens 3 guisher available during start up and adjustment procedures and 3 service Calls eccl 3 Recognize safety information This is the safety alert symbol Location Relative to Cooling 3 When you see this symbol on the furnace and in instructions or Hazardous Locations ccccccccescsesesessssessesssseeees is manuals be alert to the potential for personal injury AIR FOR COMBUSTION AND VENTILATION 3 5 Understand the signal words DANGER WARNING and CAU Unconfined SPACE C L EEE TION These words are used with the safety alert symbol DAN Confined Space GER identifies
29. l be adversely affected Never connect return air ducts to the back of the furnace A failure to follow this warning can cause a fire personal injury or death FILTER ARRANGEMENT The factory supplied filter s is shipped in the blower compart ment Determine location for the filter and relocate filter retaining wire if necessary See Fig 4 for side return application and Fig 5 for bottom return application See Table 3 to determine correct filter size for desired filter location Table 3 indicates filter size location and quantity shipped with the furnace WASHABLE FILTER Sm FILTER RETAINER A93045 Fig 4 Side Filter Arrangement Control Removed for Clarity For bottom air return applications filter may need to be cut to fit some furnace casing widths A bottom closure panel is factory installed in the bottom of the furnace When bottom return inlet is desired remove and discard the bottom closure panel Remove side clip s and install in hole Two sets of hardware are needed for furnaces in 24 1 2 in wide casings using 2 filters for bottom return hardware is provided for filter installation NOTE Furnaces with a 17 1 2 in wide casing require an addi tional procedure when locating the filter for bottom return air application Field fabricate a sheet metal filler strip 1 X 3 X 24 1 2 in and install it along side of the filter as shown in Fig 5 Drive 2 screws through the cas
30. main burner ori fices TABLE 7 GAS RATE CU FT HR BURNER FLAME SIZE OF SECONDS FOR 1 TEST DIAL FOR 1 REVOLUTION REVOLUTION 10 50 11 51 12 52 13 53 14 54 15 55 16 56 17 57 18 19 20 21 22 23 24 A 25 MANIFOLD 26 27 A89020 28 Fig 13 Burner Flame SIZE OF BURNER SECONDS TEST DIAL e Canadian installations only The Canadian ratings are approved for altitudes up to 2000 ft for natural and propane gases High altitude ratings are from 2000 ft to 4500 ft above sea level See Table 8 for nominal burner orifice size High altitude rating includes a 10 percent derate as required by Canadian standards TABLE 8 CANADIAN ORIFICE SIZE SEA LEVEL HIGH ALTITUDE F FT M FT EL URS ap NEN 2 Set temperature rise Furnace must operate within range of temperature rise 3 When correct input is obtained replace regulator specified on the unit rating plate Determine the air tem seal cap Main burner flame should be clear blue perature rise as follows almost transparent See Fig 13 a Place duct thermometers in return and supply ducts as near furnace as possible Be sure thermometers do not ON AND see heat exchangers so that radiant heat will not affect OFF SWITCH thermometer readings This is particularly important with straight run ducts GAS PRESSURE b When thermometer readings stabilize subtract return air REGULATOR temperature
31. n mI M WARNING The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 1996 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 or conduit approved for electrical ground when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning could result in electrical shock fire or death The auxiliary junction box J box can be moved to the left hand side of the furnace when a left side power supply is desired Remove the 2 screws holding the auxiliary J box Mount the J box on the left hand side of the furnace holes have been pre drilled in casing When moved tuck the wiring harness behind the clip provided to keep extra wire lengths out of the way NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control board fault code indicator light will flash rapidly and the furnace will not operate B 24 v Wiring Make field 24 v connections at the 24 v terminal strip See Fig 9 Connect terminal Y as shown in Fig 8 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the main control board Any direct shorts during installation service or maintenance could cause this fuse to blow If fus
32. n as the limit has shut off the burners the return air opening should be unblocked By using this method to check the limit control it can be established that the limit is functioning properly and operates if there is a motor failure 2 Check draft safeguard switch The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions a Disconnect power to furnace and remove vent connector from furnace outlet collar Be sure to allow time for vent pipe to cool down before removing b Restore power to furnace and set room thermostat above room temperature c After normal start up allow furnace to operate for 2 minutes then block flue outlet 100 percent Furnace should cycle off within 2 minutes d Remove blockage and reconnect vent pipe to furnace outlet collar e Wait 5 minutes and then reset draft safeguard switch 3 Check pressure switch This control proves operation of draft inducer blower a Turn off 115 v power to furnace b Remove control door and disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface ignitor should NOT glow and control center diagnostic light flashes a 31 fault If hot surface ignitor glows when inducer motor is disconnected shut down furnace im mediately Determine reason pressure switch did not
33. ntilation air must be provided in accordance with Section 5 3 of the NFGC Air for Combustion and Ventilation or applicable provisions of the local building codes Canadian installations must be installed in accordance with NSC NGPIC and all authorities having jurisdiction CAUTION Air for combustion must not be contami nated by halogen compounds which include fluoride chloride bromide and iodide These elements are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products fuel burning equipment must be supplied with air for combus tion of the fuel Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space In addition a positive seal MUST be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and draft safeguard opening CAUTION The operation of exhaust fans kitchen ven tilation fans clothes dryers or fireplaces could create a A NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST BE PROVIDED for the ventilation devices in addition to that required by the furnace The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space A Unconfined Space An unconfined space must have at least 50 cubic ft for each 1000 Btuh of input for all the appliances such as furnaces clothes
34. personal injury or death For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before operating the furnace l LOCATION A General CAUTION 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 CAUTION Do not use this furnace during construction when adhesives sealers and or new carpets are being installed If the furnace is required during construction use clean outside air for combustion and ventilation Compounds of chlorine and fluorine when burned with combustion air form acids which cause corrosion of the A heat exchangers and metal vent system Some of these compounds are found in paneling and dry wall adhesives paints thinners masonry cleaning materials and many other solvents commonly used in the construction pro cess Excessive exposure to contaminated combustion air will result in safety and performance related problems This furnace must be installed so the electrical components are protected from water This furnace shall not be installed directly on carpeting tile or any combustible material other than wood flooring Locate furnace as close to the chimney vent and as near the center of the air distribution system as possible The furnace should be installed as level as possible
35. r can be manually reset by turning 115v off not at thermostat for 3 sec minimum then on again f Blower on delay Forty sec after burner flame is proven the blower motor is energized on heating speed Simul taneously the humidifier and electronic air cleaner terminals HUM and Com for humidifier EAC 1 and 2 for electronic air cleaner are energized If jumper is on pin 6 and pin 9 blower on delay is 60 sec g Blower off delay When the thermostat is satisfied the circuit between R W is broken de energizing the gas valve stopping gas flow to the burners The blower motor and EAC remain energized 90 135 180 or 225 sec depending on the blower off time selection The furnace is factory set for a 135 sec blower off delay h Post purge The inducer motor remains energized 5 sec after the burners are extinguished If jumper is on pin 6 and pin 9 the post purge period is 15 sec N Cooling mode When the thermostat calls for cooling R G and R Y circuits close The R Y circuit starts the outdoor condensing 9 S 6S6V Dij lt O A3u 101 6982c 12euuoo xoinb epeds eulos Z uo si 74 pesn ueuM Ajuo
36. rner bracket screw CAUTION This furnace is equipped with a manual reset limit switch or fuse link in the gas control area The switch or fuse link opens and shuts off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switch Correct inadequate combustion air supply problem and reset the switch or replace the fuse link Using the schematic diagram shown in Fig 11 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If there is a power interruption and any thermostat call the control initiates a 90 sec blower only on period before starting Before operating the furnace check each manual reset switch for another cycle continuity If necessary press the button to reset the switch Dg BLOWER OFF DELAY ADJUSTMENT SWITCH 0 E TET G 24V THERMOSTAT LSL TERMINALS ___ IBIR SY Sw TEST TWIN TST Com HUMIDIFIER TERMINAL 1241 24 VAC 0 5 AMP HUM J LED OPERATION amp Sa DIAGNOSTIC LIGHT HARNESS CONNECTOR SEC 1 24V TRANSFORMER SEC 2 DOO A rne rane HEAT oe SELECTION TERMINALS 5 SPARE 2 E xA Lt EAC 1 BLACK
37. tallation Vill START UP ADJUSTMENT AND SAFETY CHECK A General NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control board fault indicator light will flash rapidly and furnace will not operate FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING NOTE 2 THERMOSTAT FIVE 9O TERMINALS FIELD SUPPLIED WIRE eed FUSED DISCONNECT THREE WIRE ae HEATING E 208 230 OR ONLY T 460 VOLT e THREE W 1 0 0 ___ PHASE i OY ep eee i ips SINGLE 115 VOLT FIELD AUXILIARY A alata ter J PHASE SUPPLIED J BOX s GND FUSED CONTROL L NOTE1 j CONDENSING DISCONNECT iem UNIT 24 VOLT TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal as shown for proper 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 A95241 Fig 8 Heating and Cooling Application Wiring Diagram TABLE 5 ELECTRICAL DATA UNIT SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE Maximum Minimum MAXIMUM
38. the most serious hazards which will result in severe FILTER ARRANGEMENT seen personal injury or death WARNING signifies a hazard which LEVELING LEGS IF REQUIRED z could result in personal injury or death CAUTION is used to GAS PIPING e IMBRE UU EE identify unsafe practices which would result in minor personal ELECTRICAL CONNECTIONS eee injury or product and property damage 11557 WATS eese imm BS sodden ERE ANT These instructions cover minimum requirements and conform to DAV WITIDE 4 reir GERNE EE REESE Ms existing national standards and safety codes In some instances Accessories these instructions exceed certain local codes and ordinances VENTING vrer aeria ERU SEC R especially those that may not have kept up with changing residen ia bd BEST MEN ANDSAFE HE Rat e tial construction practices We require these instructions as a A n ro vemm tora s fe Heating ony re ee Dien order 9 TABLE 1 MINIMUM CLEARANCES FROM Cooling Mode ens 9 11 COMBUSTIBLE MATERIALS IN Continuous Blower Mode ccccscccccsssscccesssseccesssceeeeesseees UNIT SIZE 045 AND 070 091 155 Heat Pump ener eei ener Sid Sindle Wall V Start Up Procedures essent Iges Inge vent Adjustments e Type B 1 Double Wall Vent Set Gas Input Rate
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