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AMS95 IO MANUAL

1. MANUAL SHUT OFF VALVE GAS VALVE UPSTREAMFROM ALTERNATE MANIFOLD BURNERS MANUAL GROUND JOINT GAS LINE SHUT OFF VALVE m PIPE UNION LOCATION UPSTREAM FROM ALTERNATE GROUND JOINT 4 GAS LINE PIPE UNION LOCATION i A gt l La 1 gt PLUG IN y PLUG IN ALTERNATE 27 N sZ HEIGHT REQUIRED ALTERNATE GAS LINE __ ce HEIGHT REQUIRED BY LOCAL CODE GAS LINE HOLE aS BY LOCAL CODE HOLE 7 4 1 SS td AW H GROMMET i 22 tk IN STANDARD Mm j GAS LINE HOLE GROUND JOINT 7 4 GAS VALVE PIPE UNION GROMMET IN STANDARD GAS LINE HOLE 7 MANIFOLD DRIP LEG gt j DRIP LEG BURNERS GROUND JOINT PIPE UNION gt MANUAL SHUT OFF VALVE UPSTREAM FROM GROUND _ MANUAL SHUT OFF VALVE JOINT PIPE UNION 2 UPSTREAMFROM GROUND 1 GROUND JOINT Pa JOINT PIPE UNION GROUND JOINT A PIPE UNION PIPE UNION N 2 ORIPLEG _ gt DRPLEG 22 H 5 2 GAS VALVE GROMMET IN STANDARD GAS VALVE __ GROMMET IN STANDARD GAS LINE HOLE ue ON GAS LINE HOLE BURNERS BURNERS ae 1
2. RAE naredna raina 22 GENERAL 22 GAS PIPING CONNECTIONS 23 PROPANE GAS TANKS AND PIPING csceccssececeseceneececuseeeneseueseseeuseeenausecugeeenaueeeseeeeuseeenaueesseuenaueeeseueausesensuseaesens 24 XIII Circulating Air amp Fitters ic ccccesccsssccccevsscccsec cases sstctescveesssecceccesessscctenccevenssecten ceeded stceedvecessaeeeeeeesscceecsveedeescceeeseeesssuaieeeeed 25 DUCTWORK AIR ANNA 25 READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK 25 UPRIGHT INSTALLATIONS five sntxcstvacawuvinccdacestdaasesssacusivcettacenstdscadudcisbacendeaseuvaucdbudenavidssaisucdiivept sascatdsesivdebsdsashvvanaetia 26 HORIZONTAL INSTALLATIONS 26 Table of Contents
3. 11 PEEVE USING 11 ALTERNATE VENT FLUE AND COMBUSTION AIR CONNECTIONS 11 ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ccsccecueececeseeeeeeneueeeuueseeuueeeuauseeuuseuaueeeuuuseauueseuauseeuuusenaueeenes 12 DD RAIN 12 FREEZE PROTECTION AINES EPA NEKEAREN ASA ANNAA NKI RAEE AAS PEA 12 FURNACE 6 amp A NSAN 12 VIII Propane Gas High Altitude 12 Vent Flue Pipe amp Combustion 12 GENERAL A ETA E A A EAA downs OE EAE E A AAA E E AA A se 12 DUAL CERTIFICATION NON DIRECT DIRECT VENT 12 MATERIALS AND JOINING METHODS
4. 30 POWER 30 HEATING MODE sacen 30 COOLING MODE E 30 FAN MODE 30 Operational CHECKS 5 0 cs sacncwstennnesexnnenstaannadnss ennnsdaganandennnndeasaannannanscasisahasud esas EEE ae a ANEA aaaea EEEa 30 BURNER FLAME Sicccsshucenisninnnticnsnnenn pense ashacnnasdensavelssiaunnsacenasacsnnsannniaasntacsen densa ttasdncenteniacsntiesonsdcsariausndeaucnbvsanentansens 30 PRIMARY LIMIT 30 Safety Circuit sessirnir EEE 31 GENERAL E A 31 INTEGRATED CONTROL MODULE 31 PRIMARY
5. s _HOSEB A eS SIDE PANEL 5 GROMMET A BS at REDHOSE HOSEA DRAIN TRAP CLAMP TUBE S 2 Upright Alternate Connections Right Side Only Upflow Shown Counterflow Similar Remove grommet from front right side panel drain hole Seal hole in grommet with large end of plug Reinstall grommet and plug into side panel drain hole Cut 1 4 inch from the end of the drain port on the externally mounted rubber elbow Discard cut portion Insert Tube 1 into rubber elbow drain port and secure with ared hose clamp Angle tube outward toward front of furnace Cut 17 7 8 inches from the long end of Hose B and discard Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose toward right side panel grommet holes Insert short end of one Tube 2 through rear right side panel grommet drain hole Secure tube to Hose A with a green hose clamp Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding lowing section UPRIGHT Drain TRAP LEFT oR Sipe PANEL 1 Insert drain tubes into drain trap and position the drain trap against the side panel NOTE Drain tubes must reach the bottom of the drain trap 2 Secure drain trap to side panel at
6. face cca tae see seca dn EE coins 36 A warninc IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE 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 IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS 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 Ay WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY DANGER PELIGRO Se CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas Carbon monoxide producing devices such as an automobile space heater gas water heater etc should not be operated in enclosed areas such as unventilated garages utility rooms or parking areas because of the danger of
7. Startup Procedure ACjuStMe it sic 26 HEAT ANTICIPATOR SETTING csseccceseccunececuseceeesecueeenaueeeuuseeuueeeuaueeeuueseuaueeeuuuseeueseuausueuueseuaueseuauseensesenauseaugessnaess 26 DRAIN TRAP PRIMING Ses sivsusasssonkvsesvivesasaawn sdansaudadontansnasanuasaais viacuasaaneavanvaudalandaasinatanesiaavondatwnbiabonvsatsbianwaisawnaniaawnds 26 FURNACE OPERATION seus titcasicensdeveceticwedh conoansas vadwauniadaeacGeavadacsaiicuivacoedunseudtawdavindanaslasvalaeesaicacatestvaiaudvauaativdesdaaiaaain 26 Gas SuPPLY PRESSURE MEASUREMENT cccccecceeeceneeeccnecseneceeeneeseneeeeeuueeussseususeeuseeeeaseeuseseeaueeeuaseeneesennesseneesenas 27 Gas MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT cseccceececeseccneceeceseseceeeeeeseneeeauaeeeeuseeeceuuenneusesesseaneuees 28 Gas INPUT RATE MEASUREMENT NATURAL GAS ONLY 29 TEMPERATURE RISE cssecccsceccesececcseeeeeececusesensceeeeeeenaceeeususesseeeusueaesseaenssuaeuseaeaueeeuuseeaueeauaueeaunssauaueeeuuueeesueseenes 29 CIRCULATOR BLOWER SPEEDS ssscceececcceeseceseeeneceeeseueeuseeeneeeecuseeeneseeeueeeeuseeenausesuueuensueeeueeeesuueeenauseeeseseneueseuseees 29 XV Normal Sequence OF
8. ccccceececeseseceseeecseeeneseueueeeeeuseeeuuuseeuueeeeuuseeueeeeuaseeeuuseeeuseseuausenuuesensuseeusesenesens 12 PROPER VENT FLUE AND COMBUSTION AIR PIPING PRACTICES ssceeseceeeeceesececcseeeueeeeeuseeeeuseseuseeeeusesenuseeseseueeeseusens 13 TERMINATION LOCATIONS 13 CANADIAN VENTING REQUIREMENTS 13 STANDARD FURNACE CONNECTIONS wiscucsisusisducdidsccdvccnsacdudacuenduswaueddenaavdeidvussedussusccudaunsuduuvouasaen iveusducedvivacnvadaniinaau 13 ALTERNATE FURNACE CONNECTIONS ccccsececcseccneeseccseeenaesenueeenaueueuueseeuueeanausenuueeanauseauueeenaueseuuseeeuseeeuuseauuesanausesages 14 NON DIREGT VENT SINGLE PIPE 16 Direct VENT DUAL PIPE PIPING seeseesseesneeeeeenees 17 VENT INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES 18 CONCENTRIC VENT TERMINATION cicsaxccusaccacacceteeieausaveanss cbdevvnauawacuecs castvacdevssuauv bales dunassuncdvebuase dun 18 X Condensate Drain Lin
9. BLOWER COMPARTMENT BURNER COMPARTMENT MANUAL RESET AUXILARY LIMITS 1 UPFLOW BLOWER DECK 102 IN C FLOw BLOWER HOUSING WH INDUCED DRAFT BLOWER WH RESET PRIMARY LIMIT BU YL RD OR fo aR cA 6 a 9 9 PK WH Ke _ BLOWER RET SINGLE CONTROL ON 45K BTU Y SWITCH HUMIDIFIER FRONT COVER PRESSURE SWITCH 2 CIRCUIT 1 GY GY CONNECTOR P3 GND 2 HOT SURFACE c2 BR Lr IGNITER FLAME SENSOR GAS VALVE 7 HUMIDIFIER INTEGRATED N CONTROL MODULE LTR 6 8 GND 1 9 12 ID BLOWER PRESSURE FRONT COVER PRESSURE SWITCH Ps 10 ro 0 1 LVLSOWYSHL Ap R Ro2 11 o 1 5 MANUAL RESET ROLLOUT LIMIT CONTROL 5 SINGLE CONTROL ON 45K BTU 2 24 vac 40 va SS TRANSFORMER 4 XFMR H 115 vac XFMR N FLAME SENSOR 0 0 HOT SURFACE IGNITER o Orns FP 2 22 HUMIDIFIER K IND TOYLNOD TOYLNOD CIRCULATOR BLWR lt N ELECTRONIC CLEANER EAC H LINE H JUNC
10. 5 9 5 Heating amp Air Conditioning GAS FIRED WARM AIR FURNACE ana INSTALLATION INSTRUCTIONS LASTS AND LASTS AND LASTS Installer Affix all manuals adjacent to the unit Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace These furnaces comply with requirements embodied in the American National Standard National Standard of Canada ANSI Z21 47 CSA 2 3 Gas Fired Central Fur US naces Ligte A RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual are intended as supplemental to existing practices However if there is a direct conflict between existing practices and the content of this manual the precautions
11. T T N i Ge Ee Q Ie e a 2 lol 1 com 7 A Ao eae nee af ee a DRAIN TRAP 9 MANIFOLD PLUG IN ALTERNATE ALTERNATE GAS LINE HOLE ij MANIFOLD PLUG IN ALTERNATE GAS LINE LOCATION ALTERNATE GAS SDN yen LINE LOCATION HORIZONTAL UPFLOW MODEL NOTES 1 WHEN GAS LINE IS IN THE ALTERNATE LOCATION SWAP THE POSITION OF THE PLUG AND GROMMET HORIZONTAL COUNTERFLOW MODEL 2 DRIP LEG MAY TERMINATE WITH A 1 2 X 1 8 PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT Gas Piping Connections 24 A caution EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS DiREcCT STANDARD INLET PIPING When gas piping enters directly to the gas valve through the stan dard inlet hole the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration A semi rigid connector to the gas piping can be used outside the cabinet per local codes InDIRECT ALTERNATE INLET PIPING When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the following fittings starting from the gas valve to reach the outside of the cabinet must be supplied e Coupling 90 degree elbow e 2 inch close nipple 90 degree elbow e Straight pipe
12. Chimney or Gas Vent 4 lt Opening Alternate Opening Location ee Equipment Located in Confined Spaces All Air from Outdoors Single Air Opening See 5 3 3 b 10 5 When directly communicating with the outdoors single open ing shall have a minimum free area of 1 square inch per 3 000 BTU per hour of total input rating of all equipment in the enclo sure 5 3 4 Specially Engineered Installations The requirements of 5 3 3 shall not necessarily govern when special engineering approved by the authority having jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue gases 5 3 5 Louvers and Grilles In calculating free area in 5 3 3 consideration shall be given to the block ing effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch mesh If the area through a design of louver or grille is known it should be used in calculating the size of opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 5
13. Troubleshooting Diagnostic Chart for aid in determining the cause XIX MAINTENANCE To AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE IF YOU MUST HANDLE THE IGNITER HANDLE WITH CARE TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER ANNUAL INSPECTION The furnace should be inspected by a qualified installer or service agency at least once per year This check should be performed at the beginning of the heating season This will ensure that all fur nace components are in proper working order and that the heating system functions appropriately Pay particular attention to the fol lowing items Repair or service as necessary e Flue pipe system Check for blockage and or leakage Check the outside termination and the connections at and internal to the furnace Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways Burners Check for proper ignition burner flame and flame sense Drainage system Check for blockage and or leakage Check hose connections at and internal to furnace Wiring Check electrical connections for tightness and or corrosion Check wires for damage e Filters FILTERS To ENSURE PROPER UNIT PERFORMANCE ADHERE TO THE FILTER SIZES GIVEN IN THE DATA
14. V VENT FLUE PIPE AIR PIPE DIRECT VENT ONLY 9 909 RUBBER at RUBBER COUPLING ELBOW COUPLINGS NON DIRECT VENT WITH WORM NON DIRECT VENT WITH WORM UPFLOW STANDARD CONNECTIONS COUNTERFLOW ALTERNATE FURNACE CONNECTIONS If the standard locations are undesirable for a specific installation alternate side panel locations are available for both combustion air inlet and vent flue pipe connections These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil or to upright counterflow installations requiring additional access to a filter or electronic air cleaner or to horizontal installations desiring vent flue and combustion air intake piping run vertically from the side of the cabinet NOTE Standard and alternate locations can be combined i e an installation may use the standard combustion air intake location but use the alternate vent flue location or vice versa if needed Ay warnine 14 EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS A PRE CAUTION WHEN REMOVING HOLE PLUGS ALTERNATE VENT FLUE LOCATION The alternate vent flue location is the large hole directly in line with the induced draft blower outlet To use the alternate vent flue loca tion refer to the following steps the Vent Flue Pipe Cuts figure and the Alternate Vent Flue Location figure NOTE Counterflow instructions follow th
15. TEMPERATURES AND WILL BE VACANT ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED Non direct vent single pipe central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or Direct vent dual pipe central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions To ensure proper installation and operation thoroughly read this manual for specifics pertaining to the installation and application of this product ELectrostatic DiscHARGE ESD PRECAUTIONS NOTE Discharge static electricity accumulated in the body before touching the unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and ser vicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electro static potential these steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is appli cable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground A warninc POSSIBLE PRO
16. e Check circulator blower speed and performance Correct speed or replace blower if necessary Tighten or correct wiring connection Correct short at flame sensor or in flame sensor wiring e Check burners for proper alignment e Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary e Check induced draft blower for proper performance Replace if necessary e Tighten or correct wiring connection e Sand flame sensor is coated oxidized Inspect for proper sensor alignment Check inlet air piping for blockage proper length elbows and termination Compare current gas pressure to rating plate info Adjust as e Check and correct wiring from integrated control module to igniter e Replace bad igniter e Check and correct unit ground wiring e Review wiring diagram to correct polarity Reverse orange and gray wires connected to transformer e Verify proper ground Correct if necessary Cautions and Notes Turn power OFF prior to repair e Replace primary auxiliary limit switch with proper replacement part e Replace blower with correct replacement part Turn power OFF prior to repair e Turn power OFF prior to repair See Vent Flue Pipe section for piping details Replace rollout limit with correct replacement part Replace induced draft blower with correct replace ment par
17. etc This joint is the equivalent of one 90 deg elbow when considering elbow count 45 DEGREE LONG SWEEP Increased Clearance Configuration NOTE Do not use other commercially available no hub connec tors due to possible material conflicts The vent flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue see Section IX Materials and Joining Methods NOTE For non direct vent installations a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage ComBusTION AIR PIPE Direct VENT INSTALLATIONS On upflow units secure the combustion air intake pipe directly to the air intake coupling On counterflow units secure the combus tion air intake pipe to the air intake coupling using the rubber cou pling and worm gear hose clamps provided with the unit The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment NOTE Be cause of probable material conflicts do not use other commer cially available no hub connectors The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling Now DiRECT VENT INSTALLATIONS A minimum of one 90 elbow should be installed on the combus tion air intake coupling to guard against inadvertent blockage COMBUSTION VENT FLUE PIPE COMBUSTION AIR PIPE DIRECT VENT ONLY
18. low 7 FLASHES Furnace not operating Integrated control module diagnostic LED is flashing EIGHT 8 flashes e Problem with igniter circuit 8 FLASHES Furnace fails to operate Integrated control module diagnostic LED is flashing continuously Polarity of 115 or 24 volt power is reversed CONTINUOUS RAPID FLASH Possible Causes Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower Faulty primary or auxiliary limit switch Loose or improperly connected wiring Short to ground in flame sense circuit Flame rollout Misaligned burners blocked flue and or air inlet pipe or failed induced draft blower Loose or improperly connected wiring Faulty rollout limit Flame sensor is coated oxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to improper gas pressure or combustion air Improperly connected igniter Bad igniter Poor unit ground Polarity of 115 volt AC power to furnace or integrated control module is reversed Orange and gray wires to transformer are reversed Poor unit ground 35 Corrective Action Check auxiliary limit Replace if necessary e Check filters and ductwork for block age Clean filters or remove obstruction
19. required by the National Fuel Gas Code ANSI Z223 1 or the CSA B149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficien cies which could cause an unsafe condition c In so far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the venting sys tem Turn on any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continu ously e Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above re turn doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g If improper venting is observed during any of the above tests the common venting system must be corrected Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54
20. showing the relationship between airflow CFM and external static pressure E S P for the proper selection of heating and cooling speeds The cooling blower speed is shipped set on HIGH and the heating blower speed is set as indicated in the Product Data Book applicable to your model These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cool ing CFM To adjust the circulator blower speed proceed as follows 1 OFF power to the furnace 2 Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Product Data Book 3 Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module Terminals are identified as HEAT and COOL hot If heating and cooling blower speeds are the same a jumper wire must be used between the heat and cool terminals 4 Connect all unused blower motor leads to the PARK terminals on the integrated control module Any leads not connected to the PARK terminals must be taped 5 Turn ON power to furnace 29 6 Verify proper temperature rise as outlined in Section XIV Startup Procedure and Adjustment Temperature Rise Circulator Blower Speeds low Ra Common Neutral XV NORMAL SEQUENCE OF OPERATION Power Up The normal power up seq
21. 3 6 Special Conditions Created by Mechanical Exhausting or Fire places Operation of exhaust fans ventilation systems clothes dryers or fire places may create conditions requiring special attention to avoid unsat isfactory operation of installed gas utilization equipment Air from Inside Building See 5 3 3 VI INSTALLATION POSITIONS This furnace may be installed in an upright position or horizontal on either the left or right side panel Do not install this furnace on its back For upright upflow furnaces return air ductwork may be attached to the side panel s and or basepan For horizontal upflow furnaces return air ductwork must be attached to the basepan For both upright or horizontal counterflow furnaces return ductwork must be attached to the basepan top end of the blower compartment NOTE Ductwork must never be attached to the back of the furnace Contact your distributor for proper airflow requirements and number of required ductwork connections Refer to Recommended Instal lation Positions figure for appropriate installation positions duct work connections and resulting airflow arrangements HORIZONTAL APPLICATIONS amp CONSIDERATIONS GENERAL Horizontal applications in particular may dictate many of the installation s specifics such as airflow direction ductwork connec tions flue and combustion air pipe connections etc The basic ap plication of this furnace as a horizontal furnace differs
22. Book APPLICABLE TO YOUR MODEL MAINTENANCE Improper filter maintenance is the most common cause of inad equate heating or cooling performance Filters should be cleaned permanent or replaced disposable every two months or as re quired When replacing a filter it must be replaced with a filter of the same type and size REMOVAL Depending on the installation differing filter arrangements be applied Filters can be installed in either the central return register or a side panel external filter rack upflow only A media air filter or electronic air cleaner can be used as an alternate filter Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance To remove filters from an external filter rack in an upright upflow installation follow the directions provided with external filter rack kit To remove internal filters see Internal Filter Removal section Internal filters are an accessory item and are not included with your furnace For further details see your distributor HorizonTAat Unit FILTER REMOVAL Filters in horizontal installations are located in the central return register or the ductwork near the furnace Toremove 1 Turn OFF electrical power to furnace 2 Remove filter s from the central return register or ductwork 3 Replace filter s by reversing the procedure for removal 4 Turn ON electrical power to furnace Air Fit TER oR ELEC
23. COMBUSTION MEDIUM RADIUS AIR INTAKE ELBOWS 12 MIN Vertical Terminations Dual Pipe 17 Horizontal terminations should be as shown in the following fig ure Refer to Section IX Vent Flue Pipe and Combustion Pipe Termination Location for location restrictions A 2 3 8 inch diameter wall penetration is required for 2 diameter pipe while a 3 1 2 inch diameter hole is required for 3 diameter pipe To secure the pipe passing through the wall and prohibit damage to piping connec tions a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetration should be sealed with silicone caulking ma terial 12 Min Above Highest Anticipated wal Snow Level 12 Min Above 2 Highest Anticipated Snow Level Standard Horizontal Terminations Dual Pipe 12 Mi AIR INTAKE Ep SCREEN pam 2 Min Above Highest Anticipated Snow Level gt lt Alternate Horizontal Vent Termination Dual Pipe ae VENT FLUE SUPPORT TEE STRAPS 12 MIN ABOVE HIGHEST ANTICIPATED SNOW LEVEL COMBUSTION AIR INTAKE 12 MIN ABOVE HIGHEST ANTICIPATED SNOW LEVEL N 90 MEDIUM 7 RADIUS ELBOWS gt Standard Horizontal Terminations
24. DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified below The supply pressure must be constant and avail able with all other household gas fired appliances operating The minimum gas supply pressure must be maintained to prevent unre liable ignition The maximum must not be exceeded to prevent unit overfiring Inlet Gas Supply Pressure Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C Natural Gas HIGH ALTITUDE DERATE When this furnace is installed at high altitude the appropriate High Altitude orifice kit must be applied This is required due to the natural reduction in the density of both the gas fuel and combus tion air as altitude increases The kit will provide the proper design certified input rate within the specified altitude range High altitude kits are purchased according to the installation alti tude and usage of either natural or propane gas Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer s high altitude Natural Propane Gas and or Pressure Switch kits Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate The combination of the lower air density and a lower manifold pressure will prohibit the
25. DEVICE A gas detecting warning system is the only reliable way to detect a propane gas leak Rust can reduce the level of odorant in propane gas Do not rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence of gas is suspected follow the instructions on Page 4 of this manual All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 11 inch w c at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended for both cost and efficiency 3 Pressure drop in lines between regulators and between second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization rec ommended regulator settings and pipe sizing is available from most regulator manufacturers and propane gas suppliers Since propane gas will quickly dissolve white lead and most stan dard commercial compounds special pipe dope must be used Shellac based compounds resistant to the actions of liquefied petroleu
26. FURNACE FURNACE REMOTE COOLING ROOM CONDENSING THERMOSTAT SAMOS TAT UNIT Thermostat Diagram This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 115 Volt and 24 Volt wiring 115 Voit Line CONNECTION Accessories HUMIDIFIER AND ELECTRONIC AIR CLEANER To AVOID INJURY ELECTRICAL SHOCK OR DEATH DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING The furnace s integrated control module is equipped with line volt age accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows 1 0 Amp maximum at 120 VAC Electronic Air Cleaner 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any accessories Follow the humidifier or air cleaner manufacturers instructions for locating mounting grounding and controlling these accessories Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the furnace integrated control mod ule The humidifier and electronic air cleaner hot and neutral termi nals are identified as HUM and EAC All field wiring must conform to applicable codes Connections should be made as shown below OPTIONAL ACCESSORIES ELECTRONIC AIR CLEANER TERMINALS
27. FURNACE MUST BE VT VIOLET BU BLUE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE N RATING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY 4 IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BK BLACK BEFORE CONNECTING BLOWER LEADS UNUSED BLOWER LEADS MUST BE PLACED ON PARK TERMINALS OF INTEGRATED CONTROL OR TAPED 22314901 REV O1 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES Wiring is subject to change always refer to the wiring diagram on the unit for the most up to date wiring 36 Amana is a trademark of Maytag Corporation and is used under license to Goodman Company L P All rights reserved 1810 Wilson Parkway Fayetteville TN 37334 www amana hac com 2005 Goodman Company L P 37
28. INTEGRATED CONTROL MODULE 120 VAC NEUTRAL TERMINALS 12 PIN CONNECTOR Accessories Wiring If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace the wiring must conform to all local codes and have a minimum temperature rating of 105 C All line voltage wire splices must be made inside the furnace junction box The integrated control module humidifier terminals HUM are en ergized with 115 volts whenever the induced draft blower is ener gized The integrated control module electronic air cleaner termi nals EAC are energized with 115 volts whenever the circulator blower is energized 24 HUMIDIFIER 1 4 piggy back quick connect terminal on the pressure switch provides 24VAC humidifier control This terminal is powered any time the pressure switch closes To connect 24VAC HUM connect the 24VAC line of the humidifier to the piggyback on the pressure switch and the COM line of the humidifier to C on the control board terminal strip or to the COM side of the 24VAC transformer Do not connect 115V humidifier to these terminals XII GAS SUPPLY AND PIPING GENERAL The furnace rating plate includes the approved furnace gas input rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any conversion kits required for alternate fuels and or high altitude 22 To PREVENT UNRELIABLE OPERATION OR EQUIPMENT
29. The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather tight corrosion resistant flashing STANDARD FURNACE CONNECTIONS It is the responsibility of the installer to ensure that the piping con nections to the furnace are secure airtight and adequately sup ported As shipped attachment couplings for vent flue and combustion air intake pipe connections are provided on the furnace s top cover upflow or basepan counterflow To use the standard connec tions field supplied vent flue pipe and combustion air intake pipe when applicable should be secured directly to the furnace at these locations VeENT FLUE PIPE Vent flue pipe can be secured to the vent flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace see Standard Connections figure The rubber coupling allows separation of the vent flue pipe from the furnace during servicing Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines metering devices condensate drain lines etc If necessary clearances may be increased by utilizing two 45 deg Long Sweep Elbows and creat ing an S joint to provide additional space at connection loca tions This joint can be rotated on the fitting to establish maxi mum clearance between refrigerant lines metering devices and condensate drain lines
30. as shown in the wiring diagram located on the unit s blower door For direct vent applica tions the cabinet opening to the junction box must be sealed air tight using either a UL approved bushing such as Heyco Liquid Tight or by applying a UL approved non reactive sealant to bush ing Line polarity must be observed when making field connections Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a left side right side for counterflows electrical connection with the junction box located in side the burner compartment To make electrical connections through the opposite side of the furnace the junction box must be relocated to the other side of the burner compartment prior to mak ing electrical connections To relocate the junction box follow the steps shown below NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS 1 Remove the burner compartment door 2 Remove and save two screws securing junction box to the side panel 3 Relocate junction box and associated plugs and grommets to opposite side panel Secure with screws removed in step 2 STANDARD ALTERNATE JUNCTION BOX JUNCTION BOX LOCATION LOCATION a Ju
31. assure proper air supply 6 Upflow and Counterflow units For direct vent installations secure field supplied combustion air intake pipe directly to the air intake coupling NOTE APVC coupling or elbow is required on counterflow units pe 2 2 CLEARANCE 4 SCREWS NC REMOVE 4 SCREWS 2 NON DIRECT REMOVE __ VENT AND CUT N REMOVE REMOVE 3 SCREWS AND _ RELOCATE 3 ADDITIONAL PLUG FROM DRAIN KIT REMOVE AND RELOCATE UPFLOW COUNTERFLOW SECURE gt A lt 5 UPFLOW HORIZONTAL SHOWN COUNTERFLOW SIMILAR Alternate Combustion Air Intake Location Non Direct SINGLE PIPE PIPING Non direct vent installations require only a vent flue pipe The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building The vent can also be run through an existing unused chimney however it must extend a minimum of 12 inches above the top of the chimney The space between the vent pipe and the chimney must be closed with a weather tight corrosion resistant flashing For details concerning connection of the vent flue pipe to the furnace refer to Section IX Vent Flue Pipe and Combustion Air Standard Furnace Connections or Alternate Fu
32. burner orifice from drawing the proper amount of air into the burner This may cause incomplete combustion flash back and possible yellow tipping In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If the gas is artifi cially derated the appropriate orifice size must be determined based upon the BTU ft content of the derated gas and the altitude Refer to the National Fuel Gas Code NFPA 54 ANSI 2223 1 and information provided by the gas supplier to determine the proper orifice size A different pressure switch may be required at high altitude regard less of the BTU ft content of the fuel used Contact your distributor for a tabular listing of appropriate altitude ranges and correspond ing manufacturer s pressure switch kits PROPANE GAS CONVERSION POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit must be applied for propane gas installations Refer to the Section VIII Propane Gas High Altitude Installations section for details Gas VALVE This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrate
33. container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object DIAGNosTIC CHART To AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems The red diagnostic LED blinks to assist in troubleshooting the unit The number of blinks refers to a specific fault code RESETTING FROM Lockout Furnace lockout results when a furnace is unable to achieve igni tion after three attempts during a single call for heat It is character ized by a non functioning furnace and a one flash diagnostic LED code If the furnace is in lockout it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace for 1 20 seconds 3 Manual thermostat cycle Lower the thermostat so that there is no longer a call for heat then reset to previous setting Interrupt thermostat signal to the furnace for 1 20 seconds NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to Section XVIII
34. entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recom mended that a removable access panel be provided in the outlet air duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream The access panel must be made to prevent air leaks when the furnace is in operation When the furnace is heating the temperature of the return air en tering the furnace must be between 55 F and 100 F Fitters READ THis SECTION BEFORE INSTALLING THE Return AiR Ductwork Filters must be used with this furnace Discuss filter maintenance with the building owner Filters do not ship with this furnace but must be provided by the installer Filters must comply with UL900 or CAN ULCS111 standards If the furnace is installed without fil ters the warranty will be voided On upflow units guide dimples locate the side return cutout locations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines NOTE An undersized opening will cause reduced airflow Refer to Minimum Filter Area tables to determine filter area require ments COOLING AIRFLOW REQUIREMENT CFM 600
35. listed here take precedence NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual Amana is a trademark of Maytag Corporation and is used under license to Goodman Company L P All rights reserved 10 276A 2005 Goodman Company L P 10 05 Table of Contents Component Shun ews sins in VG nanan aa diei 5 11 SAT a T EE 6 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 6 Product Application 6 IV Location Requirements amp 7 GENERAL 7 CLEA
36. only slightly from an upright installation When installing a furnace horizontally additional consideration must be given to the following 11 FURNACE MUST BE LEVEL FROM END TO END ALTERNATE VENT FLUE ye xt AND COMBUSTION AIR at INTAKE LOCATIONS FURNACE MUST LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0 3 4 BELOW THE BACK PANEL 4 3 4 MINIMUM DRAIN TRAP L CLEARANCE N GAS LINE WITH DRIP LEG 3 MINIMUM N ae DRAIN LINE WITH 1 4 PER FOOT DRAIN PAN DOWNWARD SLOPE 36 MINIMUM SERVICE CLEARANCE REQUIRED FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE Horizontal Furnace DRAIN TRAP AND LINES In horizontal applications the condensate drain trap is secured to the furnace side panel suspending it below the furnace A mini mum clearance of 4 3 4 inches below the furnace must be pro vided for the drain trap Additionally the appropriate downward piping slope must be maintained from the drain trap to the drain location Refer to Section X Condensate Drain Trap and Lines for further details If the drain trap and drain line will be exposed to temperatures near or below freezing adequate measures must be taken to prevent condensate from freezing LEVELING Leveling ensures proper condensate drainage from the heat ex changer and induced draft blower For proper flue pipe drainage the furnace must be level lengthwise from end to end The furnace should also be le
37. the thermostat to the lowest setting The integrated control will close the gas valve and extinguish flame Following a 15 second delay the induced draft blower will be de energized After a 90 120 150 or 180 second delay period field selectable the circulator blower will be de energized 2 Remove the burner compartment door and move the furnace gas valve manual control to the OFF position 3 Close the manual gas shutoff valve external to the furnace 4 Replace the burner compartment door Gas PRESSURE MEASUREMENT To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING 36 22 Gas VALVE The line pressure supplied to the gas valve must be within the range specified below Inlet Gas Supply Pressure Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C Natural Gas Propane Gas The supply pressure can be measured at the gas valve inlet pres sure tap or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following procedure Gas Valve On Off Selector Switch 59 6 Ww Inlet Pressure Tap Side of Valve A Outlet Manifold Pressure Regula
38. through which flue gases may enter a building door window or gravity air inlet The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line or the anticipated snow level and be at least 12 inches from any vertical wall including any anticipated snow build up A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty Non Direct Vent amp Direct Vent Vent Flue Terminations Non Direct Vent Vent Flue Termination No Terminations Above Walkway Grade or Highest Anticipated Snow Level j L Vent Vent Flue Termination Forced Air Inlet Direct Vent Vent Flue Termination Vent Termination Clearances NOTE In Canada the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions CANADIAN VENTING REQUIREMENTS In Canada venting must conform to the requirements of the cur rent CAN CSA B149 Installation Code Use only CSA listed two or three inch diameter PVC or ABS pipe solvent cement and fittings throughout Carefully follow the pipe manufacturers instructions for cutting cleaning and solvent cementing PVC and or ABS
39. to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws tion Air Intake Location figure A warnine NOTE Counterflow unit instructions follow the upflow instructions 1 THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT FLUE PIPING AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE 8 Upflow and Counterflow units For upright installations externally mount the rubber elbow to the vent flue coupling using a worm gear hose clamp Secure field supplied vent flue piping to the rubber elbow using a worm gear hose clamp NOTE Use of the alternate vent flue location for upright installations requires the drain trap be installed on the same side of the unit as the flue pipe 9 Upflow and Counterflow units For horizontal installations externally secure the field supplied vent flue pipe directly to the vent flue coupling using a PVC or ABS coupling or elbow 15 Remove and save the four screws securing the combustion air intake coupling to the furnace s top panel upflow Counterflow units Remove and save the four screws securing the combustion air intake coupling to the basepan Remove an additional three screws securing the furnace s internal combustion air intake pip
40. 2 by two 4 Calculate the furnace input in BTUs per hour BTU hr Input equals the installation s gas heating value multiplied with a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating value 1 000 BTU Sft Obtained from gas supplier Installation s seconds per cubic foot 34 3 Conversion Factor hours to seconds 3600 sec hr Input value x 3600 seconds per cubic foot Input 1 000 x 3600 sec hr 34 3 Input 106 000 BTU hr Minor changes to the input rate may be accomplished through manifold pressure adjustments at the gas valve Refer to Section XIV Startup Procedure and Adjustment Gas Manifold Pressure Measurement and Adjustment for details NOTE The final mani fold pressure cannot vary by more than 0 3 w c from the speci fied setting Consult your local gas supplier if additional input rate adjustment is required 5 Turn ON gas to and relight all other appliances turned off in step 1 Be certain that all appliances are functioning properly and that all pilot burners are operating TEMPERATURE RISE Temperature rise must be within the range specified on the unit rating plate An incorrect temperature rise may result in condens ing in or overheating of the heat exchanger An airflow and tem perature
41. 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas BTUH Furnace Input Heating Value of Gas BTU Cubic Foot CFH To connect the furnace to the building s gas piping the installer must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size The following stipulations apply when connecting gas piping Re fer to Gas Piping Connections figure for typical gas line connec tions to the furnace e Use black iron or steel pipe and fittings for building piping Where possible use new pipe that is properly chamfered reamed and free of burrs and chips If old pipe is used be sure it is clean and free of rust scale burrs chips and old pipe joint compound e Use pipe joint compound on male threads ONLY Always use pipe joint compound pipe dope that is APPROVED FORALL GASSES DO NOT apply compound to the first two threads e Use ground joint unions 23 Install a drip leg to trap dirt and moisture before it can enter the gas valve The drip leg must be a minimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace Always use a back up wrench when making the connection to the gas valve to keep it from turning The orientati
42. 8 590 Data in accordance with NFPA pamphlet NO 54 Propane Gas Piping Chart Il 25 XIII CIRCULATING AIR 8 FILTERS Ductwork FLow Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace Ductwork should be designed in accordance with the recommended meth ods of Air Conditioning Contractors of America Manual D A duct system must be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning Warm Air Heating and Ventilating Systems Pam phlets No 90A and 90B A closed return duct system must be used with the return duct connected to the furnace NOTE Ductwork must never be attached to the back of the furnace Supply and return connections to the furnace may be made with flexible joints to reduce noise transmis sion To prevent the blower from interfering with combustion air or draft when a central return is used a connecting duct must be installed between the unit and the utility room wall A room closet or alcove must not be used as a return air chamber When the furnace is used in connection with a cooling unit the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from
43. 800 1000 1200 1400 1600 2000 0453BXA 194 194 240 288 0703BXA 324 324 324 336 0704CXA 291 291 336 384 0904CXA 432 432 432 432 0905DXA 388 388 388 480 1155DXA 486 486 486 486 Minimum filter area dictated by heating airflow requirement Permanent Minimum Filter Area sq in Based on a 600 ft min filter face velocity COOLING AIRFLOW REQUIREMENT CFM 600 800 1000 1200 1400 1600 2000 0453B XA 388 388 480 576 0703BXA 647 647 647 672 0704 583 583 672 768 0904 863 863 863 863 0905DXA 777 777 777 960 1155DXA 971 971 971 971 Minimum filter area dictated by heating airflow requirement Disposable Minimum Filter area sq in Based on 300 ft min filter face velocity UPRIGHT INSTALLATIONS Depending on the installation and or customer preference differ ing filter arrangements can be applied Filters can be installed in the central return register or a side panel external filter rack kit upflows As an alternative a media air filter or electronic air cleaner can be used as the requested filter The following figure shows possible filter locations FILTER ACCESS DOOR CENTRAL RETURN GRILLE AIR FLOW RETURN CENTRAL DUCT RETURN GRILLE FILTER _ SUPP
44. A A N E E EAA A EA E 31 PAUTAT E A E T A EEE E A E E 31 31 PRESSURE 31 FAME SENSOR E E E 31 XVIIL Troubleshooting 31 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS icasicnstatiseccnencanadsanadscnecassasnsnancensaetnsenindeanisninisniatanteaiidannicnsaetnutnien 31 DIAGNOSTIC CHART 31 RESETTING FROM LOCKOUT 31 NAINGO vgcceucccacrcessssassceceonanctsssunesnestavasncesacetssaccecsaaatevsaixetscaestanunetussatinnseasasnstuasiaetasneesantesnestseituredssaiasiesdarsaeteseaivers 32 NNUAL INSPECTION ssis
45. ANSI 2223 1 and or CSA 149 Installation Codes If resizing is required on any portion of the venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI 2223 1 and or CSA B149 Installation Codes THERMOSTAT LOCATION The thermostst should be placed approximately five feet from the floor on a vibration free inside wall in an area having good air circulation Do not install the thermostat where it may be influ enced by any of the following e Drafts or dead spots behind doors in corners or under cabinets e Hot or cold air from registers e Radiant heat from the sun e Light fixtures or other appliances e Radiant heat from a fireplace e Concealed hot or cold water pipes or chimneys e Unconditioned areas behind the thermostat such as an outside wall NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual DRAFTS OR DEAD sPoTs BEHIND DOORS IN CORNERS N UNDER CABINETS Thermostat Influences Consult the instructions packaged with the thermostat for mounting instructions and further precautions V COMBUSTION amp VENTILATION AIR REQUIREMENTS POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA Impro
46. Above Anticipated Snow Level Dual Pipe 12 Min Above Highest Anticipated pee Level LA L Alternate Vent Termination Above Anticipated Snow Level Dual Pipe In a basement installation the pipes may be run between the joist spaces If the pipes must go below the joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows VENT INTAKE TERMINATIONS FoR INSTALLATION OF MULTIPLE Direct VENT FURNACES If more than one direct vent furnace is to be installed vertically through a common roof top maintain the same minimum clear ances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit If more than one direct vent furnace is to be installed horizontally through a common side wall maintain the clearances as in the following figure Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation gt ae 1 12 Min Above ww 2 Highest Anticipated Snow Level Me Horizontal Venting Of Multiple Units 2 pe a L J CONCENTRIC VENT TERMINATION Refer to the directions provided with the Concentric Vent Kit DCVK for installation specifications X CONDENSATE DRAIN LINES amp DRAIN TRAP GENERAL A condensing gas furnace achieves its high
47. Hose B with a green hose clamps NOTE Tube must reach bottom of trap Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting HorizonTaL Drain TRAP Mountine or Sipe PANEL 1 Position the drain trap against side panel with drain tubes inserted into trap Note that the trap may be orientated with the outlet facing either the furnace s top cover or base pan 2 Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes 3 Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding 4 Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling XI ELECTRICAL CONNECTIONS To AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION To AVOID INJURY ELECTRICAL SHOCK OR DEATH DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING 21 VERIFY PROPER OPERATION AFTER SERVICING Wirinc HARNESS The wiring harness is an integral part of this furnace Field alteration to comply with electrical codes should n
48. MMET N 0 ELBOW HOLES Lr T gt I L Ls Lp S RIGHT SIDE TUBES 2 N PANEL 4 RUBBER ELBOW DRAIN PORT HOSE 1 DRAIN TRAP CLAMP rs tag 3 PLACES Horizontal Connections Right Side Down Upflow Shown Counterflow Similar Cut 1 4 inch from the end of the drain port on the rubber elbow and discard Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp Angle tube outward toward front of furnace Cut 17 3 4 inches from the long end of Hose B and discard Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose to front right down side panel grommet holes Cut 5 1 2 inches straight length from the long end of each Tube 2 Insert approximately one inch of each Tube 2 through the right down side panel grommet holes Secure tubes to Hose A and Hose B using green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound Mounting Lert Sip E Down Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow 1 2 20 Remove the rubber plug from the coil front cover left down side drain port Relocate the front cover pressure switch hose connection from the right side as shipped pressure tap to the left down side t
49. ORT BRACKET PROVIDED 1 SIDE RETURN EXTERNAL FILTER RACK KIT EITHER SIDE AIR FLOW Possible Upright Upflow Possible Upright Counterflow Filter Locations NOTE Internal filter retention is not provided on this furnace If an internal installation is desired an internal filter retention kit is avail able as an accessory Please see your distributor for details 26 HORIZONTAL INSTALLATIONS Filters must be installed in either the central return register or in the return air duct work XIV STARTUP PROCEDURE amp ADJUSTMENT Furnace must have a 115 VAC power supply properly connected and grounded Proper polarity must be maintained for correct op eration In addition to the following start up and adjustment items refer to further information in Section XVI Operational Checks HEAT ANTICIPATOR SETTING The heat anticipator in the room thermostat must be correctly ad justed to obtain the proper number of cycles per hour and to pre vent overshooting of the setting Set the heat anticipator setting to 0 7 amps Follow the thermostat manufacturer s instructions on how to adjust the heat anticipator setting DRAIN TRAP PRIMING The drain trap must be primed prior to furnace startup To prime fill the drain trap with water This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping thro
50. PERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSTAION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE FIRE DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE To ensure proper furnace operation install operate and maintain the furnace in accordance with these installation and operation instructions all local building codes and ordinances In their ab sence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes of the National Fuel Gas Code NFPA 54 ANSI 2223 1 can be obtained from any of the following American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 A copy of the CAN CSA B149 Installation Codes can also be ob tained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated The total heat loss should be calculated by an approved method or in accordance with ASHRAE Guide o
51. R DISCHARGE Le gt ar DISCHARGE AIR DISCHARGE UPFLOW HORIZONTAL LEFT AIR DISCHARGE AIR AIR DISCHARGE DISCHARGE COUNTERFLOW HORIZONTAL UPFLOW HORIZONTAL RIGHT AIR DISCHARGE LEFT AIR DISCHARGE Recommended Installation Positions NOTE Alternate vertical piping connections can not be used when an upflow furnace is installed with supply air discharging to the right or when counterflow furnace is installed with supply air discharging to the left In either case use the standard flue and combustion air piping connections ALTERNATE ELECTRICAL AND Gas LINE CONNECTIONS This furnace has provisions allowing for electrical and gas line connections through either side panel In horizontal applications the connections can be made either through the top or bottom of the furnace Drain PAN A drain pan must be provided if the furnace is installed above a conditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if applicable FREEZE PROTECTION Refer to Section VII Horizontal Applications and Conditions Drain Trap and Lines FURNACE SUSPENSION If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad Never install the fur nace on the ground or allow it to be exposed to water Refer to Section IV Location Requirements and Considerations Furnace Suspension for furthe
52. RANCES AND 8 FURNACE SUSPENSION 8 EXISTING FURNACE sstancecscnuiei nntusaucudauusudensiuansvuautiudansdwawudwaacvuweculutausnlsacduvewebddauuewasvevsd deundausncausdvasnuawesuas 8 THERMOSTAT LOCATION sssecssececesecenseeeeseeenauseeuueseuaueueuueeeuueeeuauseeuuuseuaueeeuuusenuueeauauseeuuusauaueseususeenseeanauseeunusenausesenas 8 V Combustion Ventilation Air 9 Vie Installation POS IRONS csr a ea cvansubeaisancednssssnccanscvansuaueasasabensasavcautweiiineessassentueareantens 11 Horizontal Applications amp Considerations sean eee eeeeeee 11 ENA E A E A E O A A 11 DRAIN AND LINES
53. TION DOOR SWITCH L AN WARNING DISCONNECT POWER 7 DISCONNECT BEFORE SERVICING b WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED L GND N 115 1 0 60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE A WARNING DISCONNECT POWER BEFORE SERVICING WIRING TO UNIT MUST BE JUNCTION PROPERLY POLARIZED AND GROUNDED BOX Od AOL DA po 30 STEADY ON NORMAL OPERATION LOW VOLTAGE 24 EQUIPMENT GND OFF CONTROL FATLURE 19 1 FLASH SYSTEM LOCKOUT RETRIES RECYCLES EXCEEDED LOW VOLTAGE FIELD FIELD GND 27 2 FLASHES PRESSURE SWITCH STUCK CLOSED HI VOLTAGE 115V 33 FLASHES PRESSURE SWITCH STUCK OPEN HI VOLTAGE FIELD 1474 FLASHES OPEN HIGH LIMIT SWITCH TEMP ope 5 5 FLASHES FLAME SENSE WIT gt HOUT GAS VALVE IGNITER int te FLASHES OPEN ROLLOUT TERMINAL 317 FLASHES LOW FLAME SIGNAL INTERNAL TO SWITCH PRESS 8 8 FLASHES CHECK IGNITER OR IMPROPER GROUNDING INTEGRATED CONTROL SVERCURRENT ie PROT DEVICE XC CONTINUOUS RAPID FLASHES REVERSED 115 VAC POLARITY CONNECTION NOTES COLOR CODES PK PINK 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS YL YELLOW BR BROWN 2 MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING OR ORANGE WH WHITE 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
54. TRONIC AIR CLEANER REMOVAL Follow the manufacturer s directions for service BURNERS Visually inspect the burner flames periodically during the heating season Turn on the furnace at the thermostat and allow several minutes for flames to stabilize since any dislodged dust will alter the flames normal appearance Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow They should extend directly outward from the burners with out curling floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes INDUCED DRAFT AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer No further lubrication is required Check motor windings for accumulation of dust which may cause overheating Clean as necessary CONDENSATE TRAP AND DRAIN SYSTEM QUALIFIED SERVICER Annually inspect the drain tubes drain trap field supplied drain line for proper condensate drainage Check drain system for hose connection tightness blockage and leaks Clean or repair as necessary FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will loc
55. X VENT FLUE PIPE amp COMBUSTION AIR PIPE GENERAL FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION UPON COMPLETION OF THE FURNACE INSTALLATION CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS INCLUDING CARBON MONOXIDE A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place Be cause of the relatively low flue gas temperature and water conden sation requirements PVC pipe is used as venting material This furnace must not be connected to Type B BW or L vent or vent connector and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance Do not use commercially available no hub connectors other than those shipped with this product is the responsibility of the installer to follow the manufacturers recommendations and to verify that all vent flue piping and connec tors are compatible with furnace flue products Additionally it is the re
56. all plug before turning on gas to furnace Seal pressure port Tighten inlet pressure tap screw clockwise 7 in lbs minimum Retest for leaks If bubbles form shut down gas and fix leaks immediately Outlet Pressure Tap 10 Turn valve switch ON Gas MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR 36F22 GAs VALVE Only small variations in gas pressure should be made by adjust ing the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer or appropriate gas pressure gauge at the gas valve outlet pressure tap refer to gas valve figure in previous section Turn ON the gas supply and operate the furnace 4 Measure gas manifold pressure with burners firing Adjust manifold pressure using the Manifold Gas Pressure table shown wo Manifold Gas Pressure Natural Gas The final manifold pressure must not vary more than 0 3 w c from the above specified pressures Any necessary major changes in gas flow rate should be made by changing the si
57. ap The pressure switch hose must be connected to the down side to guard against blocked drain conditions Cut hose to appropriate length to minimize sagging Plug right unused pressure tap with plug removed from left side Secure Hose A to front cover drain port with a red hose clamp Route hose to rear left down side panel grommet holes NOTE For left side drainage grommets must be relocated to left side panel _ INDUCED DRAFT BLOWER DRAIN PORT _ HOSEB N FRONT COVER HOSE A PRESSURE GREEN HOSE 15 4 3 PLACES LEFT SIDE_ 444 TUBE S 2 PANEL FRONT COVER a DRAINPORT gt RED HOSE CLAMP DRAIN TRAP SIDE PANEL GROMMET HOLES Horizontal Connections Left Side Down Upflow Shown Counterflow Similar Remove the rubber cap from the side drain port on the rubber elbow Secure the short end of Hose B to rubber elbow side drain port using a green hose clamp NOTE For left side drainage route hose to far left down side panel grommet holes NOTE Horizontal left side connections when using new side port drain elbow does not require connecting a hose to the induced draft blower housing Cut 5 1 2 inches straight length from the long end of each Tube 2 Insert approximately one inch of each Tube 2 through left side panel grommet hole Secure tubes to Hose A and
58. ating and will produce the following reactions The gas valve to close and extinguish flame The induced draft blower to deenergized after a fifteen second postpurge and The circulator blower to remain energized continuously until limit control resets Remove the return air blockage to clear overheating condition After an acceptable temperature is reached during the cool down period the limit control will reset and allow the furnace to resume normal operation These checks establish that the primary limit control is functioning and will respond to a restriction in the return air or a circulator blower failure If the primary limit control does not function during this test the cause must be determined and corrected XVII SAFETY CIRCUIT DESCRIPTION GENERAL number of safety circuits are employed to ensure safe and proper furnace operation These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagno sis of abnormal function These circuits are continuously moni tored during furnace operation by the integrated control module INTEGRATED CONTROL The integrated control module is an electronic device which if a potential safety concern is detected the module will take the nec essary precautions and provide diagnostic information through an LED PRIMARY The primary limit control is located on the partition panel and moni tors heat exchanger compa
59. carbon monoxide CO poisoning resulting from the exhaust emissions If a furnace or air handler is installed in an enclosed area such as a garage utility room or parking area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 To THE OWNER It is important that you fill out the owner s registration card and mail it today This will assist us in contacting you should any service or warranty information change in the future When filling in the regis tration card be sure to include the model manufacturing and serial numbers plus the installation date Your warranty certificate is also supplied with the unit Read the warranty carefully and note what is covered Keep the warranty cer tificate in a safe location for future reference If additional information or operating instructions are required con tact the dealer where the purchase was made Homeowner Notice If the residence is left unattended for an extended period of time i e 4 hours or greater have your heating system periodically chec
60. d control module As shipped the valve is configured for natural gas The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer s propane gas conversion kit Taps for measuring the gas supply pressure and manifold pressure are provided on the valve The gas valve has a manual ON OFF control located on the valve itself This control may be set only to the ON or OFF position Refer to the lighting instructions label or Section XIV Startup Pro cedure amp Adjustment for use of this control during start up and shut down periods Gas PIPING CONNECTIONS GENERAL To AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT USE THE PROPER SIZE OF NATURAL PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER TANK TO THE FURNACE When sizing a trunk line be sure to include all appliances which will operate simultaneously when sizing a trunk line The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of the run The gas line installation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH Length of Pipe in Feet 10 20 350 30 40 50 60 70 80 90 100 Pressure 0
61. d copy of the Bill of Lading or indemnity bond e Original paid freight bill or indemnity in lieu thereof e Original or certified copy of the invoice showing trade and other discounts or reductions Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage Keep this literature in a safe place for future reference BLOWER COMPARTMENT BURNER COMPARTMENT gt NNa O OOANODOAKRWNH O 1 COMPONENT 7 N Upflow Horizontal Gas Valve Gas Line Entrance Alternate Pressure Switch Gas Manifold Combustion Air Intake Connection Coupling Hot Surface Igniter Rollout Limit Burners Flame Sensor Flue Pipe Connection Coupling Flue Pipe Internal Combustion Air Intake Alternate Primary Limit Gas Line Entrance Flue Pipe Connection Alternate Rubber Elbow Induced Draft Blower Electrical Connection Inlets Alternate Coil Front Cover Pressure Tap Coil Front Cover Drain Por
62. d to the gas valve must be within the range specified in the Inlet Gas Supply Pressure Table The sup ply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the unit OFF To measure inlet pressure use the following procedure Gas Valve On Off Selector Switch Inlet Pressure INET Pressure Regulator Adjustment Under Cap Screw White Rodgers Model 36G22 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace Using 3 32 hex wrench loosen inlet pressure tap screw one turn Connect a 5 16 inch hose and calibrated water manometer to the gas valve inlet pressure tap The hose should overlap the tap by 3 8 inch Turn ON the gas supply and operate the furnace Leak test Using a leak detection solution or non chlorine soap suds check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY BEFORE PROCEEDING TO NEXT STEP Measure furnace gas supply pressure Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table If supply pressure reading differs from the table make necessary adjustments to pressure regulator gas piping size etc and or consult with local gas utility Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer and hose Reinst
63. e to the blower deck Remove the combustion air intake coupling and gasket from the top panel Counterflow units Remove the combustion air intake pipe from the furnace and cut the pipe at the basepan coupling Save the basepan coupling and gasket from the blower deck coupling for use in the alternate location Discard the remaining pipe Remove plastic plug from alternate combustion air intake location Relocate and install plug in standard air intake location top cover Counterflow units Remove plastic plug from alternate combustion air intake location Relocate and install plug in standard air intake location basepan Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag Upflow and Counterflow units With the gasket facing the cabinet side panel and the flange s flat spot facing forward secure the combustion air intake coupling to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS 5 Upflow and Counterflow units For non direct vent installations installed horizontally a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage No elbow is required on the alternate combustion air intake of upright installations however a minimum clearance of 2 inches is required to
64. e upflow instructions 1 Remove and save the four screws securing the vent flue coupling to the furnace top panel Counterflow units Remove and save the four screws securing the vent flue coupling to the furnace basepan Also remove the three screws securing the furnace s internal vent flue piping to the blower deck gt D 3 Upflow Counterflow units 3 a 6 3 Loosen the worm gear hose clamps on the rubber elbow 4 REMOVE N 1 REMOVE and detach it from both the induced draft blower and the 4 SCREWS ae ove vent flue pipe or 3 SCREWS 4 Upflow and Counterflow units AG Remove the vent flue pipe from the furnace ee ce REMOVE 5 Cut the vent flue pipe 3 75 inches from the flanged end of ox the pipe See Vent Flue Pipe Cuts figure The section of 2 DETACH RUBBER DETATCH RUBBER pipe attached to the coupling will reach through the side ELBOW FROM ELBOW FROM ID BLOWER AND panel to the induced draft blower Discard remaining pipe and elbows RIFE Counterflow units UPFLOW COUNTERFLOW Cut the vent flue pipe 3 75 inches from the blower deck coupling See Vent Flue Pipe Cuts figure Save vent flue pipe _ ADDITIONAL PLUG attached to blower deck coupling for use in the alt
65. ee 5 3 3 b 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent NOTE The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure TTT Outlet air duct 1 J Water Furnace Heater 4 Inlet air duct i Fo T the appliance room is located against outside wall and the air openings communicate directly with the outdoors each opening shall have a free area of not less than one square inch per 4 000 BTU per hour of the total input rating of all appliances in the enclosure Equipment Located in Confined Spaces All Air from Outdoors See 5 3 3 b 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 inches NOTE The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equip ment in the enclosure but not less than the sum of the areas of all vent connectors confined space lt
66. ee times Verify cooling and fan only operation e Review Owners Manual with the homeowner and discuss proper furnace operation and maintenance e Leave literature packet near furnace XXII REPAIR amp REPLACEMENT PARTS e When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and serial numbers with the order e Although only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description e Parts are available from your distributor Functional Parts List Gas Valve Gas Manifold Natural Gas Orifice Propane Gas Orifice Igniter Flame Sensor Rollout Limit Switch Primary Limit Switch Auxiliary Limit Switch Pressure Switch Induced Draft Blower Door Switch Blower Motor Blower Wheel Blower Mounting Bracket Blower Cutoff Blower Housing Capacitor Heat Exchanger Recuperator Coil Coil Front Cover Integrated Control Module Transformer Troubleshooting Chart Associated LED Code Symptoms of Abnormal Cautions and Operation Fault Description s Possible Causes Corrective Action NONE e No 115 volt power to Manual disconnect switch furnace or no 24 volt OFF door switch open or power to integrated 24 volt wires improperly control module connected or loose Blown fuse or circuit Blown fuse or circuit breaker breaker Assure 115 and 24 volt Turn power OFF power to furnace pri
67. elay period selectable 90 120 150 180 factory set at 150 Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat Coo Linc The normal operational sequence in cooling mode is as follows Rand Y thermostat contacts close initiating a call for cool e Integrated control module performs safety circuit checks e Outdoor fan and compressor are energized e Circulator blower is energized on cool speed following a fixed five second on delay Electronic air cleaner terminals are energized with circulator blower e Furnace circulator blower and outdoor cooling unit run integrated control module monitors safety circuits continuously Rand Y thermostat contacts open completing the call for cool e Outdoor fan and compressor are de energized e Circulator blower is de energized following a fixed forty five second cool off delay period Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat Fan OnLy The normal operational sequence in fan only mode is as follows e Rand G thermostat contacts close initiating call for fan e Integrated control module performs safety circuit checks e Circulator blower is energized on heat speed Electronic air cleaner terminals are energized e Circulator blower runs integrated control module monitors safety circuits continuously e Rand G thermostat contacts open completing the call f
68. ent improper orifices or coated oxidized or improperly connected flame sensor Loss of flame after establish ment Cause may be interrupted gas supply lazy burner flames improper gas pressure or restriction in flue and or combustion air piping front cover pressure switch opening or improper induced draft blower performance Induced draft blower pressure switch contacts sticking Shorts in pressure switch circuit e Pressure switch hose blocked pinched or connected improperly e Blocked flue and or inlet air pipe blocked drain system or weak induced draft blower e Incorrect pressure switch setpoint or malfunctioning switch contacts Loose or improperly connected wiring Integrated control module will automatically attempt to reset from lockout after one hour e Normal operation e Turn power OFF prior to repair Locate and correct gas interruption Check front cover pressure switch operation hose wiring contact operation Correct if necessary Replace or realign igniter Check flame sense signal Sand sensor if coated and or oxidized Check flue piping for blockage proper length elbows and termination Verify proper induced draft blower perfor mance e Igniter is fragile handle with care Sand flame sensor with emery cloth See Vent Flue Pipe section for piping details Replace induced draft blower pressure s
69. ernate location Discard remaining pipe and elbows T D A EXTERNALLY 55 MOUNT FLANGE y il RUBBER ELBOW SECURE TO ID BLOWER WITH CUT RUBBER COUPLING e AND HOSE m CLAMPS COUNTERFLOW UPRIGHT 6 Remove plastic plug from alternate vent flue location Relocate and install plug in standard vent flue location top cover Counterflow units Remove plastic plug from alternate vent flue location Relocate and install plug in standard vent flue location basepan Plug remaining hole in blower deck with plastic plug included in the drain kit bag 7 Upflow and Counterflow units Insert cut section of vent flue pipe and coupling into alternate vent flue location Using a rubber coupling and worm gear hose clamps from the drain kit bag attach the vent flue pipe and coupling to the induced draft blower Secure the UPFLOW SIMILAR SECURE TO ID BLOWER WITH RUBBER COUPLING SECURE TO AND HOSE CABINET WITH CLAMPS SCREWS 1 UPFLOW HORIZONTAL COUNTERFLOW SIMILAR Alternate Vent Flue Location ALTERNATE COMBUSTION AIR INTAKE LOCATION The alternate combustion air intake location consists of a large unobstructed hole alternate vent connection is aligned with the Induced Draft Blower To use the alternate combustion air intake location refer to the following steps and the Alternate Combus coupling
70. es amp Drain 18 GENERAL O 18 UPRIGHT INSTALLATIONS 19 HORIZONTAL INSTALLATIONS 20 Al EleCtriGal CONMEGCHONS siirsin n a a a e aa a aE 21 WIRING 21 115 LINE CONNECTIONS c cccececccseseeceeeeneusecseeeuaususuueeanaueeeuuueeeuueeeauusenaueeanauseaaussanaueseuussanaueeauussenaueeanaueesages 21 24 VOLT THERMOSTAT WIRING ccccecsseccceseeeunsseeuseeeuueseeuueeeuaueeeuuusauaueeeuussenaueuauauseeuueeeuauseeuuuseuauseenuuseuaueseugusssuuesenas 22 115 Line CONNECTION OF Accessories HUMIDIFIER AND ELECTRONIC AIR CLEANER 1 22 24 VOLT HUMIDIFIER cadducndsuantyelecuducedaserdsausdaovecneuwaucsucauaduadvesvavuawenesdyatearacusaxedvancedswticausan 22 Rll Gas Supply
71. k out The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool Following clean ing the flame sense signal should be 1 to 4 microamps at 115 volts FLue Passaces QUALIFIED SERVICER ONLY The heat exchanger flue passageways should be inspected at the beginning of each heating season If necessary clean the pas sageways as outlined below 1 Turn OFF the electrical power and gas supply to the furnace Disconnect the gas line and remove the burner manifold assembly by removing the screws securing the assembly to the partition panel 3 Disconnect the flue pipe system from the induced draft blower 4 Remove the induced draft blower and drain and pressure tap hoses from the recuperator coil front cover 5 Remove the recuperator coil front cover to expose the coil tubes and turbulators 6 Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly 7 Clean the recuperator coil tubes using a long handle wire brush such as a gun cleaning brush 8 Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable such as drain cleanout cable Attach variable speed reversible drill to the other end of the cable Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes While reversing the drill work the cable in and out several times to obtain sufficient clea
72. ked to ensure proper operation Potential circumstances be yond our control such as power outages gas service interruptions product installation or component failures could result in heating system operational problems To THE INSTALLER Before installing this unit please read this manual thoroughly to fa miliarize yourself with specific items which must be adhered to in cluding but not limited to unit maximum external static pressure gas pressures BTU input rating proper electrical connections cir culating air temperature rise minimum or maximum CFM and mo tor speed connections TRANSPORTATION DAMAGE All units are securely packed in shipping containers tested accord ing to International Safe Transit Association specifications The car ton must be checked upon arrival for external damage If damage is found a request for inspection by carrier s agent must be made in writing immediately The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit In the event of damage the consignee should 1 a notation on delivery receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 With concealed damage carrier must be notified as soon as possible preferably within five days 4 File the claim with the following support documents within a nine month statute of limitations e Original or certifie
73. level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place The condensate which is generated must be piped to an appropri ate drain location 18 In upright installations the furnace s drain hoses may exit either the right or left side of the furnace NOTE If the alternate vent flue outlet is utilized in an upright installation the drain trap and drain connections must be located on the same side as the alternate vent flue outlet In horizontal installations the drain hoses will exit through the bottom down side of the unit with the drain trap suspended be neath the furnace The field supplied drain system must be in accordance with all local codes and the instructions in the follow ing sections Follow the bullets below when installing the drain system Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups The drain trap supplied with the furnace must be used The drain line between furnace and drain location must be constructed of 3 4 PVC or CPVC The drain line between furnace and drain location must maintain a 1 4 inch per foot downward slope toward the drain Do not trap the drain line in any other location than at the drain trap supplied with the furnace Do not route the drain line outside where it may freeze If the drain line is routed through an area which may see
74. m gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory Refer to the following illustration for typical propane gas installa tions 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C 200 PSIG Second Stage Regulato Propane Gas Installation Typ Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Pipe or Nominal Pipe Size Tubing Tubing Size O D Type L Schedule 40 Feet 10 1 700 3200 7 500 20 1 100 2 200 4 200 30 920 2 000 4 000 40 850 1 700 3 700 50 770 1 500 3 400 60 3 100 80 610 1 200 2 600 100 540 1 000 2 300 125 490 900 2 100 150 430 1 900 175 400 780 1 700 200 380 730 1 500 To convert to capacities at 15 psig settings multiply by 1 130 To convert to capacities at 5 psig settings multiply by 0 879 Propane Gas Piping Chart Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Based on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour Pipe or Nominal Pipe Size Tubing Schedule 40 Length 3 8 m 4 1 8 1 1 1 4 1 1 2 Feet 10 39 2 205 3 307 20 26 1 496 2 299 30 21 1 212 1 858 40 19 1 039 1 559 50 18 131 1 417 60 16 121 1 275 80 13 1 066 100 11 976 125 10 866 150 9 787 200 8 665 250
75. may be used Two or three inch ABS Schedule 40 pipe must meet ASTM D1527 and if used in Canada must be CSA listed Solvent cement for ABS to ABS joints must meet ASTM D2235 and if used in Canada must be CSA listed The solvent cement for the PVC to ABS transition joint must meet ASTM D3138 Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and if used in Canada must be CSA listed Carefully follow the manufacturers instructions for cutting cleaning and solvent cementing PVC and or ABS All 90 elbows must be medium radius 1 4 bend DWV or long radius Long sweep 1 4 bend DWV types conforming to ASTM D3311 A medium radius 1 4 bend DWV elbow measures 1 16 minimum from the plane of one opening to the centerline of the other opening for 2 diameter pipe and 4 9 16 minimum for 3 pipe PROPER VENT FLUE AND ComBusTION AIR PIPING PRACTICES Adhere to these instructions to ensure safe and proper furnace performance The length diameter and number of elbows of the vent flue pipe and combustion air pipe when applicable affects the performance of the furnace and must be carefully sized All piping must be installed in accordance with local codes and these instructions Piping must be adequately secured and supported to prohibit sag ging joint separation and or detachment from the furnace Hori zontal runs of vent flue piping must be supported every three feet and must maintain a 1 4 inch per foot do
76. mbustion air intake and a vent flue pipe The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building The pipes may be run through an existing unused chimney however they must extend a minimum of 12 inches above the top of the chimney The space between the pipes and the chimney must be closed with a weather tight corrosion resis tant flashing Both the combustion air intake and a vent flue pipe terminations must be in the same atmospheric pressure zone For details concerning connection of pipes to the furnace refer to the Section IX Vent Flue Pipe and Combustion Pipe Standard Furnace Connections or Alternate Furnace Connections VenT FLUE AND AIR PIPE LENGTHS AND DIAMETERS Refer to the following table for applicable length elbows and pipe diameter for construction of the vent flue and combustion air intake pipe systems of a direct vent dual pipe installation The number of elbows tabulated represents the number of elbows and or tees in each Vent Flue amp Combustion Air Intake pipe Elbows and or tees used in the terminations must be included when determining the number of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objection able insulation of the combustion air pipe may be required Use 1 2 thick closed cell foam in
77. n safety exhaust odor control and air for compressors d In addition to air needed for combustion air shall be supplied for ventilation including all air required for comfort and proper work ing conditions for personnel e While all forms of building construction cannot be covered in detail air for combustion ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be ob tained by application of one of the methods covered in 5 3 3 and 5 3 4 f Air requirements for the operation of exhaust fans kitchen ventila tion systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air re quirements 5 3 2 Equipment Located in Unconfined Spaces In unconfined spaces see definition below in buildings infiltration may be adequate to provide air for combustion ventilation and dilu tion of flue gases However in buildings of tight construction for example weather stripping heavily insulated caulked vapor bar rier etc additional air may need to be provided using the methods described in 5 3 3 b or 5 3 4 Space Unconfined For purposes of this Code a space whose volume is not less than 50 cubic feet per 1 000 BTU per hour of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through open ings not furnished wi
78. nction Box Relocation To AVOID THE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC Cope To ensure proper unit grounding the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel NOTE Do not use gas piping as an electrical ground To confirm proper unit grounding turn off the electrical power and perform the following check 1 Measure resistance between the neutral white connection and one of the burners 2 Resistance should measure 10 ohms or less This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servic ing Do not defeat this switch 24 THERMOSTAT WIRING NOTE Wire routing must not interfere with circulator blower operation filter removal or routine maintenance Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located in the blower compartment Wire routing must not to interfere with circu lator blower operation filter removal or routine maintenance Re fer to the following figure for thermostat connections to the inte grated control module terminal strip A gt HEATING HEATING AND ROOM
79. ning Repeat for each tube 32 11 12 Clean residue from furnace using a vacuum cleaner Replace the parts removed in the previous steps in reverse order Turn on electrical power and gas to furnace Check for leaks and proper unit operation Severe heat exchanger fouling is an indication of an operational problem Perform the checks listed in Section Startup Procedure and Adjustments to reduce the chances of repeated fouling XX INTERNAL FILTER REMOVAL Internal filters are an accessory item and are not included with your furnace For further details see your distributor Bottom RETURN REMOVAL 1 2 3 4 5 Turn OFF electrical power to furnace Remove blower compartment door Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan Slide filter forward and out Replace filter by reversing the procedure BLOWER COMPARTMENT REMOVAL 1 2 3 Turn OFF electrical power to furnace Remove blower compartment door Grasp lower portion of filter and lift up Front of Furnace Front of Furnace Blower Blower Grab Here And Lift 4 Angle filter toward the blower until filter clears bottom rail 5 Lower filter down and pull outward Front of Furnace Front of Furnace Blower 6 Replace filter by reversing procedure 33 XXI BEFORE LEAVING AN INSTALLATION e Cycle the furnace with the thermostat at least thr
80. nnecting the two couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetra tion should be sealed with silicone caulking material In a basement installation the vent flue pipe can be run between joist spaces If the vent pipe must go below a joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows 12 Min To Roof Or Highest Anticipated Snow Level Vertical Termination Single Pipe 90 MEDIUM RADIUS ELBOWS Alternate Vertical Termination Single Pipe _WALL INSIDE OUTSIDE 90 ELBOW TURNED DOWN ELBOW OR COUPLING HIGHEST ANTICIPATED SNOW LEVEL Horizontal Termination Single Pipe 12 MIN ees 12 MIN ABOVE pay HIGHEST ANTICIPATED SNOW LEVEL 7 Horizontal Termination Single Pipe Above Highest Anticipated Snow Level Direct Vent DUAL PIPING The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe Installation of screens while strongly recommended is not required and will not affect performance of the unit Direct vent installations require both a co
81. o the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces The following information on air for combustion and ventilation is repro duced from the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 5 3 1 a The provisions of 5 3 apply to gas utilization equipment installed in buildings and which require air for combustion ventilation and dilu tion of flue gases from within the building They do not apply to 1 direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere or 2 enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases b Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use Equipment shall be located so as not to interfere with proper circulation of air When normal infiltration does not provide the necessary air outside air shall be introduced c In addition to air needed for combustion process air shall be pro vided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilutio
82. ols held person s hand during grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object PRODUCT APPLICATION This furnace is primarily designed for residential home heating ap plications It is NOT designed or certified for use in mobile homes trailers or recreational vehicles This unit is NOT designed or certified for outdoor applications The furnace must be installed indoors i e attic space crawl space or garage area provided the garage area is enclosed with an operating door This furnace can be used in the following non industrial commercial applications Schools Office buildings Churches Retail stores Nursing homes Hotels motels Common or office areas In such applications the furnace must be installed with the following stipulations It must be installed per the installation instructions provided and per local and national codes It must be installed indoo
83. on of the gas valve on the manifold must be maintained as shipped from the factory Maximum torque for the gas valve connection is 375 in lbs excessive over tightening may damage the gas valve Install a manual shutoff valve between the gas meter and unit within six feet of the unit If a union is installed the union must be downstream of the manual shutoff valve between the shutoff valve and the furnace Tighten all joints securely Connect the furnace to the building piping by one of the following methods Rigid metallic pipe and fittings Semi rigid metallic tubing and metallic fittings Aluminum alloy tubing must not be used in exterior locations In order to seal the grommet cabinet penetration rigid pipe must be used to reach the outside of the cabinet A semi rigid connector to the gas piping may be used from there Use listed gas appliance connectors in accordance with their instructions Connectors must be fully in the same room as the furnace Protect connectors and semirigid tubing against physical and thermal damage when installed Ensure aluminum alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry plaster or insulation or subjected to repeated wetting by liquids such as water except rain water detergents or sewage
84. ons listed on the appliance rating plate 28 Replace regulator screw cover and finger tighten securely Turn OFF all electrical power to the system Remove manometer and hose from outlet pressure tap 0 Tighten outlet pressure tap clockwise 7 in lbs minimum to seal port 11 Turn ON system power and set thermostat to call for heat 12 Using a leak detection solution or non chlorine soap suds check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY Measure gas manifold pressure with burners firing Adjust mani fold pressure per the Manifold Gas Pressure table Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice ON Gas Input NATURAL Gas OnLy The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas burning appliances except the furnace 2 While the furnace is operating time and record one complete revolution of the smallest gas meter dial 3 Calculate the number of seconds per cubic foot sec ft of gas being delivered to the furnace If the dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one If the dial is a two cubic foot dial divide the number of seconds recorded in step
85. or fan e Circulator blower is de energized Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat XVI OPERATIONAL CHECKS BuRNER FLAME The burner flames should be inspected with the burner compart ment door installed A sight glass is provided for inspection pur poses Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow Flames should extend directly outward from the burners without curling floating or lifting off Flames must not impinge on the sides of the heat ex changer firing tubes Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Burner Flame PRIMARY The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger If the primary limit control does not function during this test the cause must be determined and corrected Function of this control should be verified by gradually blocking the furnace return air after the furnace has been operating burners firing for approximately ten minutes Check the control as follows 1 Allow the furnace to operate with burners firing continuously for approximately ten minutes 30 2 Gradually block the return air to furnace Remove airflow blockage when limit control is activated and turns off burners Airflow blockage causes unit overhe
86. or to repair integrated control module Replace integrated Check integrated control control module module fuse 3A fuse with 3A Replace if necessary automotive fuse Check for possible shorts Read precautions 115 and 24 volt circuits in Electrostatic Repair as necessary Discharge section Replace bad integrated Of manual control module e Furnace fails to operate Integrated control module diagnostic LED provides no signal Integrated control module has an internal fault Integrated control module has an internal fault e LED is Steady On vw CON DA CONTINUOUS Furnace fails to operate Integrated control module diagnostic LED is flashing ONE 1 flash 1 FLASH e Furnace fails to operate Integrated control module diagnostic LED is flashing TWO 2 flashes Induced draft blower runs continuously with no further furnace operation e Integrated control module diagnostic LED is flashing THREE 3 flashes 3 FLASHES e Normal Operation Furnace lockout due to an excessive number of ignition retries 3 total Pressure switch circuit is closed Induced draft blower is not operating Pressure switch circuit not closed Induced draft blower is operating Normal operation Failure to establish flame Cause may be no gas to burners front cover pressure switch stuck open bad igniter or igniter alignm
87. ot be required Wires are color coded for identification purposes Refer to the wiring dia gram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring ma terial having a temperature rating of at least 105 C Any replace ment wiring must be copper conductor 115 LINE CONNECTIONS Before proceeding with electrical connections ensure that the sup ply voltage frequency and phase correspond to that specified on the unit rating plate Power supply to the furnace must be N E C Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA 22 1 Use a separate fused branch electrical circuit containing properly sized wire and fuse or circuit breaker The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protec tion specified on the unit rating plate An electrical disconnect must be provided at the furnace location NOTE Line polarity must be observed when making field connections IN UPRIGHT UPFLOW INSTALLATIONS THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION Connect hot neutral and ground wires
88. oute hose to rear side panel grommet hole NOTE For left side drainage grommets will have to be relocated to left side panel 19 RIGHT SIDE x PANEL RUBBER a ELBOW RUBBER ELBOW DRAIN PORT HOSE CLAMP TUBE 1 HOSE SIDE PANEL 7 GROMMET HOLES Peg a TUBE S 2 7 P27 2 z HOSE _ FRONT COVER RED HOSE A GREEN f ine DRAIN PORT HOSE CLAMPS 3 PLACES Upright Standard Connections Right Side Upflow Shown Counterflow Similar LEFT SIDE PANEL 4 NI PO Cro FRONT COVER CO RUBBER DRAIN PORT ELBOW RED HOSE RUBBER CLAMP ELBOW HOSEA DRAIN PORT SIDE PANEL Je RED HOSE DRAIN CLAMP HOLES TUBE 1 TUBE S 2 GREEN HOSE CLAMPS DRAN 7 3 PLACES TRAP Upright Standard Connections Left Side Upflow Shown Counterflow Similar 3 Cut and remove 1 4 inch from the end of the drain port on the rubber elbow 4 Insert Tube 1 into rubber elbow drain port and secure with red hose clamp Angle tube outward toward front of furnace 5 Right side drains Cut 17 3 4 inches from the long end of Hose B and discard Secure the remaining hose to Tube 1 with a green hose clamp Route the other end of Hose B to front right side panel grommet hole Left side drains Cut X inches from the long end of Hose discard Refer to table for a
89. ppropriate length to cut Secure remaining hose to Tube 1 with a green hose clamp Route other end of Hose B to front left side panel grommet hole Cabinet Width Models X Length to Cut From Long 045 30 17 1 2 7 inches 070 30 21 3 1 2 inches 090 40 24 1 2 090 90 115 50 Insert short end of each Tube 2 through side panel grommet holes Secure tubes to Hose A and Hose with green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting ALTERNATE VENT FLUE DRAIN HosE CONNECTIONS Upright installations using the alternate vent flue outlet will require right side only drain hoses to be connected as follows Refer to Section IX Vent Flue Pipe and Combustion Air Pipe for details on alternate vent flue pipe connection 1 2 For details concerning mounting of the drain trap refer to the fol Remove the rubber plug from the front cover right side drain port Save for use in step 3 Secure Hose Ato front cover drain port with red hose clamp Route hose to rear right side panel grommet hole SRUBBER ELBOW O RUBBER EXTERNALLY ELBOW FRONT COVER MOUNTED DRAIN PORT pj N TECER RED HOSE CLAMP wha FL ruse 1 GREEN HOSE 4 lt lt CLAMPS 3 PLACES
90. r Manual J Load Calculations published by the Air Conditioning Contractors of America IV LOCATION REQUIREMENTS 8 CONSIDERATIONS GENERAL To PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT Follow the instructions listed below when selecting a furnace loca tion Refer also to the guidelines provided in Section V Combustion and Ventilation Air Requirements Centrally locate the furnace with respect to the proposed or existing air distribution system Ensure the temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating Provide provisions for venting combustion products outdoors through a proper venting system Special consideration should be given to vent flue pipe routing and combustion air intake pipe when applicable Refer to Section IX Vent Flue Pipe and Combustion Air Pipe Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given NOTE The length of flue and or combustion air piping can be a limiting factor in the location of the furnace Locate the furnace so condensate flows downwards to the drain Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection Refer
91. r details VIII PROPANE GAS HIGH ALTITUDE INSTALLATIONS POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This furnace is shipped from the factory configured for natural gas at standard altitude Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas High altitude installations may require both a pressure switch and an orifice change These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the com bustion air at higher altitude For installations above 7000 feet please refer to your distributor for required kit s HIGH ALTITUDE GAS ORIFICE CHART Manifold Gas Kit Orifice Pressure Switch Natural None 43 0 7000 Pressure Altitude 3 5 w c None 10 0 w c Propane LPT 00A 55 NOTE In Canada gas furnaces are certified to 4500 feet Contact the distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude installa tions The indicated kits must be used to insure safe and proper furnace operation All conversions must be performed by a quali fied installer or service agency I
92. re to the clearances to combustible mate rials to which this furnace has been design certified The mini mum clearance information for this furnace is provided on the 5 clearance label These clearances must be permanently main tained Clearances must also accommodate an installation s gas electrical and drain trap and drain line connections If the alternate combustion air intake or vent flue connections are used additional clearance must be provided to accommodate these connections Refer to Section IX Vent Flue Pipe and Combustion Air Pipe for details NOTE In addition to the required clearances to combus tible materials a minimum of 24 inches service clearance must be available in front of the unit TOP BOTTOM BOTTOM Counterflow Horizontal Upflow A furnace installed in a confined space 1 a closet or utility room must have two ventilation openings with a total minimum free area of 0 25 square inches per 1 000 BTU hr of furnace input rating Refer to the Product Data Book applicable to your model for minimum clearances to combustible surfaces One of the ventilation open ings must be within 12 inches of the top the other opening must be within 12 inches of the bottom of the confined space In a typical construction the clearance between the door and door frame is usu ally adequate to satisfy this ventilation requirement FURNACE SUSPENSION If suspending the furnace from rafters or joists use 3 8
93. rise table is provided in the Product Data Book applicable to your model Determine and adjust temperature rise as fol lows 1 Operate furnace with burners firing for approximately ten minutes Ensure all registers are open and all duct dampers are in their final fully or partially open position 2 Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger HEAT EXCHANGER RADIATION LINE OF SIGHT SUPPLY gt AIR RISE Tsuppty TRETURN Mi TRETURN RETURN AIR Temperature Rise Measurement 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 4 Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Refer to Section XIV Startup Procedure and Adjustment Circulator Blower Speeds for speed changing details CIRCULATOR BLOWER SPEEDS TO PREVENT PREMATURE FAILURE OF HEAT EXCHANGER PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT ADJUST THE LIMIT CONTROL FACTORY SET This furnace is equipped with a multi speed circulator blower This blower provides ease in adjusting blower speeds The Product Data Book applicable to your model provides an airflow table
94. rnace Con nections for specific details Refer to the following Non Direct 16 Vent Single Pipe Piping Vent Flue Pipe Terminations for spe cific details on termination construction Although non direct vent installations do not require a combus tion air intake pipe a minimum of one 90 elbow should be at tached to the furnace s combustion air intake if an upright instal lation uses the standard intake location or a horizontal installa tion uses the alternate air intake location This elbow will guard against inadvertent blockage of the air intake Vent Fiue PIPE LENGTHS AND DIAMETERS Refer to the following table for applicable length elbows and pipe diameter for construction of the vent flue pipe system of a non direct vent installation In addition to the vent flue pipe a single 90 elbow should be secured to the combustion air intake to prevent inadvertent blockage The tee used in the vent flue termination must be included when determining the number of elbows in the piping system Non Direct Vent Single Pipe Maximum Allowable Length of Vent Flue Pipe ft 3 5 Models Number of Elbows inc 2 3 4 7 oes 2 55 62 o 2 68 65 62 59 56 5 50 Lome fepe EE 16 13 10 16 13 10 65 62 so 56 5 60 090_5 MEAE mss 3 6 62 56 5 5 1 One 90 elbow should be secured to the combu
95. rs in a building constructed on site must be part of a ducted system and not used in a free air delivery application must not be used as a make up air unit must be installed with two pipe systems for combustion air especially if VOC s or other contaminants are present in the conditioned space All other warranty exclusions and restrictions apply This furnace is an ETL dual certified appliance and is appropriate for use with natural or propane gas NOTE If using propane a propane conversion kit is required Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a THIS UNIT MUST NOT BE USED AS A CONSTRUCTION HEATER DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE THIS TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TERMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES HEATING UNIT SHOULD UTILIZED WITHOUT REASONABLE ROUTINE INSPECTION MAINTENANCE AND SUPERVISION IF THE BUILIDNG IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED MAINTAINED AND MONITORED IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT ALL WATER BEARING PIPES SHOULD BE DRAINED THE BUILDING SHOULD BE PROPERLY WINTERIZED AND THE WATER SOURCE CLOSED IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING
96. rs or spaces crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet Air Alternate air inlet Ventilation louvers for unheated crawl space Equipment Located in Confined Spaces All Air from Outdoors Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet air duct ends 1 ft 300 mm above floor eS eS Equipment Located in Confined Spaces All Air from Outdoors Through Ventilated Attic S
97. rtment temperatures It is a normally closed electrically automatic reset temperature activated sen sor The limit guards against the overheating as a result of insuffi cient conditioned air passing over the heat exchanger AUXILIARY The auxiliary limit control s are located on or near the circulator blower and monitors heat exchanger compartment temperatures They are a normally closed electrically manual reset tempera ture activated sensors These limits guard against overheating as a result of insufficient conditioned air passing over the heat ex changer Limit The rollout limit controls are mounted on the burner manifold as sembly and monitor the burner flame They are normally closed electrically manual reset temperature activated sensors These limits guard against burner flames not being properly drawn into the heat exchanger PRESSURE SWITCHES The pressure switches are normally open closed during opera tion single pole single throw negative air pressure activated switches They monitor the airflow combustion air and flue prod ucts through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover These switches guard against insufficient airflow combustion air and flue products through the heat exchanger and or blocked condensate drain con ditions 31 FLAME SENSOR The flame sensor is a probe mounted to the burner manifold as sembl
98. sponsibility of the installer to ensure that all piping and connec tions possess adequate structural integrity and support to prevent flue pipe separation shifting or sagging during furnace operation 12 DuaL CERTIFICATION 1 VENT This furnace is dual certified and may be installed as a non direct vent single pipe or direct vent dual pipe appliance A non direct vent installation requires only a vent flue pipe while a direct vent installation requires both a vent flue pipe and a combustion air intake pipe Refer to the appropriate section for details concerning piping size length number of elbows furnace connections and terminations MATERIALS AND JOINING METHODS To AVOID BODILY INJURY FIRE OR EXPLOSION SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES I E SPARKS OPEN FLAMES AND EXCESSIVE HEAT AS THEY ARE COMBUSTIBLE LIQUIDS AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND OR EYES Two or three inch nominal diameter PVC Schedule 40 pipe meet ing ASTM D1785 PVC primer meeting ASTM F656 and PVC sol vent cement meeting ASTM D2564 specifications must be used Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311 Carefully follow the manufacturer s instructions for cutting cleaning and solvent cementing of PVC As an alternative to PVC pipe primer solvent cement and fittings ABS materials which are in compliance with the following specifi cations
99. ssteatsnssiwasheuusssnusndauwndeawnasinvandauundaausadanbandavandaabnadannsuaatendanbnadawandaavess 32 PA A AEN A SE AAE E AI A E EAA ATE T ANDON S 32 32 INDUCED DRAFT AND CIRCULATOR BLOWERS 32 CONDENSATE TRAP AND DRAIN SYSTEM QUALIFIED SERVICER 32 FLAME SENSOR QUALIFIED SERVICER ONLY senssescserennanssuctasnncsutenmsanncsareivenonaasdvitesvenennnin es cenenduansinnnciervaentnnssaneriee 32 FLUE PASSAGES QUALIFIED SERVICER ONLY jseisssecsescssnnsanssanendaunsansnnseedsnantannasnssasaacanainanasnssadannaanbednsieseacinasanianiins 32 Internal Filter REMOVAl vi 33 Leaving am Installation ccs cccccctssccedccccssssccncecepsastenseceeeseasqpececechsssnantecerssstancecdeceeassapecdetestuaneceetestacnaceecesssssaeeeed 33 AAI amp Replacement Parts cis aa NEE 33 595 Wiring
100. stion air intake nection Minimum requirement for each vent pipe is five 5 feet in length and one elbow tee Tees and or elbows used in the vent flue termination must be included when determining the number of elbows in the piping system 3 diameter pipe can be used in place of 2 diameter pipe Increased Clearance Configurations using 2 45 deg Long Sweep elbows should be considered equivalent to one 90 deg elbow Vent FLuE PIPE TERMINATIONS The vent flue pipe may terminate vertically as through a roof or horizontally as through an outside wall Vertical vent flue pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe and Com bustion Air Pipe Termination Locations for details concerning location restrictions The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent Horizontal vent flue pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe and Combus tion Air Pipe Termination Locations for details concerning loca tion restrictions A 2 3 8 diameter wall penetration is required for 2 diameter pipe while a 3 1 2 diameter hole is required for 3 diameter pipe To secure the pipe passing through the wall and prohibit damage to piping connections a coupling should be in stalled on either side of the wall and solvent cemented to a length of pipe co
101. sulation such as Armaflex or Insultube where required Direct Vent Dual Pipe Maximum Allowable Length of Vent Flue amp Combustion Air Intake Pipe ft Unit Input 0 Number of Elbows Btu ntake Termination stats 7 iss 65 62 53 50 52_ 49 40 37 070 3 65 62 53 50 52 49 40 37 070 4 Not Recommended 65 62 53 50 090_4 52 49 40 37 65 62 53 50 52 49 40 37 65 62 53 50 115_5 ternate 52 49 40 37 1 Minimum requirement for each vent pipe is five 5 feet in length and one elbow tee 2 Tees and or elbows used in the vent flue termination must be included when determining the number of elbows in the piping system 3 diameter pipe can be used in place of 2 diameter pipe Increased Clearance Configurations using 2 45 deg Long Sweep elbows should be considered equivalent to one 90 deg elbow VeNT FLUE AND ComBusTION AIR TERMINATIONS The vent flue and combustion air pipes may terminate vertically as through a roof or horizontally as through an outside wall Vertical pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe and Combustion Pipe Termina tion Locations for details concerning location restrictions The pen etrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent TEE VENT FLUE
102. t e Turn power OFF prior to repair Sand flame sensor with emery clot e See Vent Flue Pipe section for piping details See rating plate for proper gas pressure Turn power OFF prior to repair e Replace igniter with proper silicon nitride replacement part Turn power OFF prior to repair AMS95 WIRING DIAGRAM BLOWER oR 40 VA COMPARTMENT TRANSFORMER GY book OPEN WHEN 9 DOOR OPEN 24 Y 24 HUMIDIFIER 24 THERMOSTAT Q 9 115 vac CONNECTIONS ae DIAGNOSTIC LED ruse 24vac oR SHIPPED i FROM FACTORY gog PK Ei 5 oR OFF Oo OW anf Ata 000 BU a on oFF s BLOWER HEAT GY i OFF DELAY SELECTOR SECONDS BR L DIP SWITCHES 2 2 om eee cy ce n INTEGRATED 25 wm CONTROL 2 MODULE x 1 caren 98 z on acu bo dias male w 33 WEAT H SEE LINE H L GND NOTE 4 WH Ltt J L 2 S 0 HI RD PK BU MED lt OR MED LOW RD LOW BK lt CRUAKR CAPACITOR
103. t Drain Line Penetrations IDENTIFICATION 22 23 24 25 26 27 28 29 30 31 32 Counterflow Horizontal Drain Trap Blower Door Interlock Switch Capacitor Integrated Control Module with fuse and diagnostic LED 24 Volt Thermostat Connections Transformer 40 VA Circulator Blower Auxiliary Limit Junction Box Electrical Connection Inlets Coil Front Cover BLOWER COMPARTMENT BURNER COMPARTMENT ll SAFETY 2 Please adhere to the following warnings and cautions when in stalling adjusting altering servicing or operating the furnace To PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FoR ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM To PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER Firmly touch a clean unpainted metal surface of the furnaces near the control Any to
104. temperatures near or below freezing precautions must be taken to prevent condensate from freezing within the drain line If an air conditioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressure from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap UPRIGHT INSTALLATIONS In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet NOTE Refer to Section X Condensate Drain Lines and Drain Trap Alternate Vent Flue Hose Connections for upright installations using an alternate vent flue outlet STANDARD RIGHT or Lert Drain HosE CONNECTIONS Upright installations using the standard vent flue outlet require drain hoses to be connected as follows The following quantity of hoses tubes and hose clamps are provided with the unit OOII RRRS has HOSE A Q GREEN RED HOSE CLAMPS HOSE CLAMPS arty QTY 2 Hose and Tube Identification 1 Remove the rubber plug from the front cover drain port right or left side depending on the intended drain trap mounting 2 Secure Hose A to front cover drain port with a red hose clamp R
105. th doors are considered a part of the uncon fined space 5 3 3 Equipment Located in Confined Spaces a All Air from Inside the Building The confined space shall be pro vided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the com bined space shall be considered in making this determination Each opening shall have a minimum free area of 1 square inch per 1 000 BTU per hour of the total input rating of all gas utilization equip ment in the confined space but not less than 100 square inches One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure lt Chimney or Gas Vent NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equip ment in the enclosure but not less than 100 square inches 1 lt Opening 1 lt Opening SS Equipment Located in Confined Spaces All Air from Inside Building See 5 3 3 a b All Air from Outdoors The confined space shall be provided with two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoo
106. the mounting holes dimples or crosshairs on counterflow models located below the grommet drain holes 3 Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling HORIZONTAL INSTALLATIONS Sip E Down Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port NOTE Oncounterflow models relocation of the front cover pressure switch hose is required Make connections as follows 1 For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Remove the rubber plug from the coil front cover drain port Counterflow furnaces Relocate the front cover pressure switch hose connection from the left side pressure tap to the right down side tap The pressure switch hose must be connected to the down side to guard against blocked drain conditions Cut hose to appropriate length to minimize sagging Plug left unused pressure tap with plug removed from right side Secure Hose A to front cover drain tap with red hose clamp Route hose to rear right down side panel grommet holes r H FRONT COVER DRAIN PORT LA RED HOSE CLAMP HOSE A N a 4 4 FRONT Z 5 COVER SIDE PANEL fig PRESSURE A RUBBER CA TAP ad GRO
107. threaded rod and 2 x2 x1 8 angle iron as shown below The length of rod will depend on the application and the clearances necessary PROVIDE 8 MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL 3 8 DIAMETER THREADED ROD 7 ASSURE FURNACE IS LEVEL FROM PLACES m TO END AND HAS A SLIGHT f FORWARD TILT WITH THE FRONT V if OF THE FURNACE 0 3 4 BELOW THE BACK OF THE FURNACE HOLD DOWN NUTS SUPPORT NUTS e 2 2 1 8 ANGLE IRON PLAGES POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMVOAL Suspended Furnace TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL EXISTING FURNACE REMOVAL OTE When an existing furnace is removed from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appliances The following vent testing procedure is reproduced from the American National Standard National Standard of Canada for Gas Fired Cen tral Furnaces ANSI Z21 47b 2002 CSA 2 3b 2002 Section 1 23 1 The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances con nected to the venting system are not in operation Seal any unused openings in the venting system b Inspect the venting system for proper size and horizontal pitch as
108. to Section X Condensate Drain Lines and Trap for further details Ensure adequate combustion air is available for the furnace Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide Refer to Section V Combustion and Ventilation Air Requirements Set the furnace on a level floor to enable proper condensate drainage If the floor becomes wet or damp at times place the furnace above the floor on a concrete base sized approximately 1 1 2 larger than the base of the furnace Refer to the Section VII Horizontal Applications and Considerations for leveling of horizontal furnaces Ensure upflow or horizontal furnaces are not installed directly on carpeting or any other combustible material The only combustible material allowed is wood A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood Refer to subbase instructions for installation details NOTE A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is exposed to the following substances chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing sal
109. tor Pressure Tap Adjustment Under Cap Screw White Rodgers Model 36F22 1 OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pressure tap or the gas piping drip leg Gas Line Gas Shutoff Valve Gas Line To Furnace Open To mosphere Drip Leg Cap With Fitting 1 Manometer Hose f Manometer Measuring Inlet Gas Pressure Alt Method NOTE At either location a hose fitting must be installed prior to making the hose connection 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 27 4 Inlet Gas Supply Pressure Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table Natural Gas Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C If supply pressure differs from above make necessary adjustments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace Turn OFF any unnecessary gas appliances started in step 3 36G22 Gas VALVE The line pressure supplie
110. ts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials Seal off a non direct vent furnace if it is installed near an area frequently contaminated by any of the above substances This protects the non direct vent furnace from airborne contaminants To ensure that the enclosed non direct vent furnace has an adequate supply of combustion air vent from a nearby uncontaminated room or from outdoors Refer to the Section V Combustion and Ventilation Air Requirements for details If the furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling unit Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace If the furnace is installed in a residential garage position the furnace so that the burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the furnace from physical damage by vehicles If the furnace is installed horizontally the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger Do not install the unit with the access doors the up top or down bottom side of the furnace CLEARANCES AND ACCESSIBILITY Installations must adhe
111. uence is as follows e 115 VAC power applied to furnace e Integrated control module performs internal checks e Integrated control module flashes LED one time e Integrated control module monitors safety circuits continuously e Furnace awaits call from thermostat HEATING The normal operational sequence in heating mode is as follows Rand W thermostat contacts close initiating a call for heat e Integrated control module performs safety circuit checks e Induced draft blower is energized for 15 second prepurge period causing pressure switch contacts to close Humidifier terminals are energized with induced draft blower e Igniter warm up begins after 15 second prepurge expires e Gas valve opens at end of igniter warm up period delivering gas to burners and establishing flame e Integrated control module monitors flame presence Gas valve will remain open only if flame is sensed e Circulator blower is energized on heat speed following a fixed thirty second blower on delay Electronic air cleaner terminals are energized with circulator blower e Furnace runs integrated control module monitors safety circuits continuously Rand W thermostat contacts open completing the call for heat e Gas valve closes extinguishing flame e Induced draft blower is de energized following a fifteen second post purge Humidifier terminals are de energized e Circulator blower is de energized following the heat off d
112. ugh the drain system FURNACE OPERATION Purge gas lines of air prior to startup Be sure not purge lines into an enclosed burner compartment Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved method Verify that all required kits propane gas high altitude etc have been appropriately installed FurRnAcE STARTUP 1 Close the manual gas shutoff valve external to the furnace 2 Turn off the electrical power to the furnace 3 Set the room thermostat to the lowest possible setting 4 Remove the burner compartment door NOTE This furnace is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Move the furnace gas valve manual control to the OFF position 6 Wait five minutes then smell for gas Be sure to check near the floor as some types of gas are heavier than air 7 If you smell gas after five minutes immediately follow the instructions on page 4 of this manual If you do not smell gas after five minutes move the furnace gas valve manual control to the ON position 8 Replace the burner compartment door 9 Open the manual gas shutoff valve external to the furnace 10 Turn on the electrical power to the furnace 11 Adjust the thermostat to a setting above room temperature 12 After the burners are lit set the thermostat to desired temperature FuRNACE SHUTDOWN 1 Set
113. ved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows These changes have helped in reducing heating cooling costs but have created a problem supplying com bustion and ventilation air for gas fired and other fuel burning appli ances Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air House depressurization can cause back drafting or improper com bustion of gas fired appliances thereby exposing building occupants to gas combustion products that could include carbon monoxide 1 Headaches Nausea Dizziness Flu Like Symptoms 2 Excessive humidity heavily frosted windows or a moist clammy feeling in the home 3 Smoke from a fireplace will draw up the chimney 4 Flue gases that will not draw up the appliance vent pipe If this furnace is to be installed in the same space with other gas appliances such as a water heater ensure there is an adequate supply of combustion and ventilation air for the other appliances Refer to the latest edition of the National Fuel Gas Code NFPA 54 02 Section 5 3 or CAN CSA B149 2 05 Installation Codes Sec tions 7 2 7 3 or 7 4 or applicable provisions of the local building codes for determining the combustion air requirements for the appliances Most homes will require outside air be supplied t
114. vel from back to front or have a slight tilt with the access doors downhill approximately 3 4 inches from the back panel The slight tilt allows the heat exchanger condensate generated in the recuperator coil to flow forward to the recuperator coil front cover ALTERNATE VENT FLUE AND ComBusTION AIR CONNECTIONS In horizontal installations provisions for alternate flue and combus tion air piping are available for upflow furnaces with left air dis charge and counterflow furnaces with right air discharge This configuration allows the flue and combustion air piping to be run vertically through the side of the furnace Refer to the Recom mended Installation Positions figure for further detail The stan dard piping connections may also be used in these positions Refer to Section IX Vent Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent flue and combustion air connections ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS LY DISCHARGE 2 lt Duet Connection ff Side L Connection UPFLOW UPRIGHT ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS AIR DISCHARGE COUNTERFLOW UPRIGHT ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS Bottom 4 Return Duct Connection 2 COUNTERFLOW HORIZONTAL RIGHT AI
115. witch Turn power OFF prior to repair e Replace pressure switch with proper e Repair short replacement part Inspect pressure switch hose Repair if necessary Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Turn power OFF prior to repair e Replace pressure switch with proper replacement part Flash code will cease if power to the control module is interrupted through the disconnect door switch 34 Troubleshooting Chart Associated LED Code Symptoms of Abnormal Operation Fault Description s Circulator blower runs continuously No furnace operation Integrated control module 4 FLASHES diagnostic LED is flashing FOUR 4 flashes Primary or auxiliary limit circuit is open Induced draft blower and circulation blower run continuously No furnace operation e Flame sensed with no call for heat diagnostic LED is flashing FIVE 5 flashes e Circulator blower runs continuously No furnace operation e Integrated control module 6 FLASHES diagnostic LED is flashing SIX 6 flashes e Rollout limit circuit is open e Normal furnace operation Integrated control module diagnostic LED is flashing SEVEN 7 flashes Flame sense microamp signal is
116. with a ground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration Asemi rigid connector to the gas piping can be used outside the cabinet per local codes Gas PIPING CHECKS Before placing unit in operation leak test the unit and gas connec tions Ay warninc AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved testing methods NOTE Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE Gas TANKS AND PIPING A warnine PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK INSTALL A GAS DETECTION WARNING
117. wnward slope back to wards the furnace to properly return condensate to the furnace s drain system Allowances should be made for minor expansion and contraction due to temperature variations For this reason particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches 13 TERMINATION LOCATIONS NOTES Refer to Section IV Location Requirements and Considerations for combustion air contaminant restrictions The following bullets and diagram describe the restrictions con cerning the appropriate location of vent flue pipe and combustion air intake pipe when applicable terminations Refer to Non Di rect Vent Single Pipe Piping and Direct Vent Dual Pipe Piping located in this section for specific details on termination construc tion All terminations flue and or intake must located at least 12 inches above ground level or the anticipated snow level Vent terminations non direct and direct vent must terminate at least 3 feet above any forced air inlet located within 10 feet NOTE This provision does not apply to the combustion air intake termination of a direct vent application The vent termination of a non direct vent application must terminate at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building The vent termination of a direct vent application must terminate at least 12 inches from any opening
118. y which uses the principle of flame rectification to determine the presence or absence of flame XVIII TROUBLESHOOTING DiscHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and ser vicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electro static potential these steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is appli cable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground Firmly touch a clean unpainted metal surface of the furnaces near the control Any tools held person s hand during grounding will be discharged Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires Discharge your body to ground before removing a new control from its
119. ze of the burner orifice 5 To adjust the gas valve pressure regulator remove the regulator cap 6 Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure 7 Securely replace the regulator cap 8 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer 9 Reinstall gas valve outlet pressure tap plug before turning on gas to furnace 36G22 Gas VALVE This valve is shipped from the factory with the regulator preset see control label Consult the appliance rating plate to ensure burner manifold pres sure is as specified If another outlet pressure is required follow these steps 1 Turn OFF all electrical power to the system 2 Using a 3 32 inch hex wrench loosen outlet pressure tap screw one turn Do not remove screw 3 Connect a calibrated water manometer and 5 16 inch hose to the gas valve outlet pressure tap Hose should overlap tap by 3 8 inch 4 Turn ON system power and set thermostat to a call for heat 5 Using a leak detection solution or non chlorine soap suds check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY 6 Remove regulator screw cover Turn regulator screw either clockwise to increase pressure or counterclockwise to decrease Always adjust regulator to provide the correct pressure according to the original equipment manufacturer specificati

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