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92-24161-24 Revision 07 GPL, GLL Installation Instructions

1. AIR FLOW The importance of proper air flow over the heat exchanger cannot be over emphasized One of the most common causes of heat exchanger failure is overheating due to low air flow An air flow table is located inside the blower door and on the following pages NOTE The installation of the duct system is under the control of the installing contractor If the duct system is not correctly sized and installed the homeowner may experience air noise low or no airflow out of some vents component failures or high utility bills Other miscellaneous problems are also possible TEMPERATURE RISE CHECK To determine if the air flow is correct make a temperature rise check 1 Insert a thermometer in the supply air duct as close to the furnace as possible yet out of a direct line from the heat exchanger See Figure 25 2 Insert a thermometer in the return air duct as close to the furnace as possible 3 Operate the furnace 4 When the thermometer in the supply air duct stops rising approximately five minutes subtract the return air temperature from the supply air temperature The difference is the temperature rise 5 Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate See Figure
2. N I d H0LJ3NNOJ 4 L d Nid 91 7051409 WOHA N O O 97 9 N cO O O N O cO SV9 z HOLJINNOD 0132 oto 22 l ad Mass 59 1 511 OL 6 d 8 EA 83 80 3510 1 233 3 Nid 2 d N 02 PE N d z m Q lt lt gt u a lt o z mA a e l gt u FIGURE 33 41 42 43 44 CM 0604
3. GAS VALVE _ ST A0763 01 IMPORTANT When making gas pipe connections use a back up wrench to prevent any twisting of the control assembly and gas valve Any strains on the gas valve can change the position of the gas orifices in the burners This can cause erratic furnace operation IMPORTANT ENSURE that the furnace gas control valve not be subjected to high gas line supply pressures DISCONNECT the furnace and its individual shut off valve from the gas supply piping during any pressure testing that exceeds 1 2 PSIG 3 48 kPa GAS PRESSURE IMPORTANT The maximum gas supply pressure to the furnace should be 10 5 w c for natural gas and 13 w c for LP gas Natural gas supply pressure should operate between 5 to 10 5 w c LP gas supply pressure should be 11 to 13 w c This pressure must be maintained with all other gas fired appliances in operation NOTE Do not exceed a gas pressure of 13 w c ACAUTION ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJ USTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY OR MAY NOT NEED TO BE CHANGED SEE THE SECTION TITLED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS A WARNING NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER NEVER USE MATCHES FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAKAGE FAILURE TO FOL
4. Do not return to your home until authorized by the gas supplier or fire department DO NOT RELY ON SMELLALONE TO DETECT LEAKS DUE TO VARIOUS FACTORS YOU MAY NOT BE ABLE TO SMELL FUEL GASES ULL recognized fuel gas and CO detectors are recommended in all applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs Improper installation adjustment alteration service or maintenance can cause injury property damage or death Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier In the commonwealth of Massachusetts installation must be performed by a licensed plumber or gas fitter for appropriate fuel CERTIFIED ANSI RAB 7 Cation 2 QMS ga A Bg BA001 02 y o c a ee Q 0311103833 Accredited by the RvA KA me DO NOT DESTROY THIS MANUAL PLEASE READ CAREFULLY AND KEEP ISO 9002 Certificate Number 30164 IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN 92 24161 24 07 SUPERSEDES 92 24161 24 06 Before beginning any troubleshooting procedure complete the following installation checklist furnace malfunction is sometimes caused by an improper installation By completing this checklist the problem may be found and corrected Make copies of the ch
5. O b s KEN 59107 9 541051 9 511911 9 56901 9 9105 1 043 dol NI 39NVHV319 33 038 ST3IGON MO T3NMOG 5 TVIYUILVN AT8LLSNAWOD OL ADNVHV41D JGLL DOWNFLOW DIMENSIONS FIGURE 3 CLEARANCE ACCESSIBILITY The design of forced air furnaces with input ratings as listed in the tables on the following pages are certified by CSA for the clearances to combustible materials shown in inches See name rating plate and clearance label for specific model number and clearance information Service clearance of at least 24 inches is recommended in front of all furnaces ACCESSIBILITY CLEARANCES WHERE GREATER MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES A WARNING UPFLOW AND HORIZONTAL FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE CAUSING PROPERTY DAMAGE SEVERE PERSONAL INJ URY OR DEATH DOWNFLOW UNIT DESIGN IS CERTIFIED FOR INSTALLATION ON NON COMBUSTIBLE FLOOR A SPECIAL COMBUSTIBLE FLOOR SUB BASE IS REQUIRED WHEN INSTALLING ON A COMBUSTIBLE FLOOR FAILURE TO INSTALL THE SUB BASE MAY RESULT IN FIRE PROPERTY DAMAGE PERSONAL INJ URY OR DEATH THIS SPECIAL BASE IS OFFERED AS AN ACCESSORY FROM THE
6. 16 FIGURE 12 GAS PIPING INSTALLATION UPFLOW amp DOWNFLOW MANUAL GAS VALVE IN CLOSED POSITION UNION GAS VALVE 4TO5FEET ABOVE FLOOR REQ D BY SOME UTILITIES DRIP LEG FLAME SENSOR MANIFOLD BURNERS DIRECT SPARK STA 0764 01 HORIZONTAL IN CLOSED POSITION m MANUAL GAS VALVE 4 5 FEET ABOVE FLOOR REQD BY SOME UTILITIES DRIP LEG FLAME SENSOR BURNERS DIRECT SPARK MANIFOLD jf IMPORTANT It is permissible to run flexible gas connector inside the unit to a piece of black pipe If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a connector which has previously serviced another gas appliance Under Massachusetts law the use of flexible gas connectors is not permitted Install a ground joint union outside the cabinet to easily remove the control valve assembly Install a manual shut off valve in the gas line outside the furnace casing The valve should be readily accessible to turn the gas supply on or off Install a drip leg in the gas supply line as close to the furnace as possible Always use a pipe compound resistant to the action of liquefied petroleum gases on all threaded connections Te
7. L USINE POUR FOR GAS GAZ NATURAL NATUREL CANADA ONLY M PIEDS M NATURAL GAS LP GAS OR PROP GAZ NATUREL GAZ DE P TROLE 00016 00 PROP F C IN M C KPA IN W C kPa FC 33 SAFETY FEATURES LIMIT CONTROL The high limit cut off temperature is set at the factory and cannot be adjusted The temperature setting prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature which if exceeded will shut the furnace down There are several reasons for a limit switch to open and almost always involve low airflow through the furnace 1 Adirty or restricted air filter 2 A dirty or restricted cooling coil 3 Undersized or restricted return air system 4 Undersized or restricted supply air system 5 A problem affecting the main blower A A wrong speed tap selection B Failing motor bearings C Low voltage to the motor D Dirty blower wheel E Wrong motor rotation F Blower wheel slipping on the motor shaft 6 Overfiring the furnace with too much gas pressure 7 Ventilation problems 34 FLAME ROLL OUT SAFETY SWITCHES Furnaces are equipped with safety switches to protect against flame roll out conditions in the burner compartment which if tripped will terminate the heating cycle In the event of a flame roll out condition the switch will shut the furnace down Switches for the GPN GPP fu
8. The following types of installation may require OUTDOOR AIR for combustion due to chemical exposures e Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces in hobby or craft rooms Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply may also require OUTDOOR AIR for combustion Permanent wave solutions Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid e Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials ENCLOSURE BUT NOT LESS THAN 100 SQUARE INCHES Combustion air must be free of acid forming chemicals such as sulphur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products Vapors from these products when burned in a gas flame form acid compounds The acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense WARNING ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS C
9. 25 26 10 20 Heating Value of Gas BTU Ft x 3600 x correction factor Input BTU HR Time in Seconds for 1 cu ft of Gas 19 ELECTRICAL WIRING A WARNING TURN OFF ELECTRIC POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS ALSO THE GROUND CONNECTION MUST BE COMPLETED BEFORE MAKING LINE VOLTAGE CONNECTIONS FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK SEVERE PERSONAL INJ URY OR DEATH IMPORTANT The furnace must be installed so that the electrical components are protected from water furnace condensate ELECTRICAL CONNECTIONS A WARNING THE CABINET MUST BE PERMANENTLY GROUNDED GROUND SCREW IS PROVIDED IN THE J UNCTION BOX FOR THIS PURPOSE FAILURE TO DO SO CAN RESULT IN FIRE ELECTRICAL SHOCK PERSONAL INJ URY OR DEATH The electrical supply requirements are listed on the furnace rating plate Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker Run this circuit directly from the main switch box to an electrical disconnect which must be readily accessible and located within sight of the furnace Connect from the disconnect to the junction box on the left side of the furnace inside the control compartment See appropriate wiring diagram NOTE The electrical junction box inside the furnace control compartment may be relocated to the right side if necessary A knock
10. MAXIMUM EXTERNAL STATIC PRESSURE PRESSION STATIQUE MIE N C kPa PO C E 2 125 125 ANSI 221 47a SA 2 3a 2001 CENTRAL FURN CATEGORY IV FORCED AIR FURNACE USING INDOOR AIR FOR COMBUSTION CATEGORY IV TYPE FSP DIRECT VENT FORCED AIR FURNACE WHEN USING OUTDOOR AIR FOR COMBUSTION FOR INDOOR CATEGORIE IV GENERATEUR D AIR CHAUD AIR FORCEE LORSOUE DE L AIR INT RIEUR EST EMPLOY POUR LA COMBUSTION CATEGORIE IV TYPE FSP EVACUATION DIRECTE GENERATEUR D AIR 000 AIR FORCEE LORSOUE DE L AIR EXTERIEUR EST EMPLOY POUR LA COMBUSTION POUR INSTALLATION L INTEREIER SEULEMENT DANS UN BATIMENT CONSTRUIT SUR LE SITE ELECTRIQUE 115 V 60 HZ 1 PH PUISSANCE D ENTREE TOTALE MAXIMUM 6 3 A MAXIMUM OVERCURRENT PROCTECTION 15 AMPERES DISJONCTEUR MAXIMA 15 Btu hr Kwi Btu hr 06 52 500 15 39 THIS APPLIANCE EQUIPPED FOR ALTITUDES CET APPAREIL EST EQUIPE POUR ALTITUDES COMPRISES MINUMUM GAS SUPPLY PRESSURE FOR PURPOSES OF INPUT ADJUSTMENT MANIFOLD PRESSURE LOW INPUT NAT 1 7WC 4 32CM LP 4 9WC 12 45 CM 45 25 TO 75 42 PO C E kPa PO C E kPa 10 5 2 61 13 0 3 23 10 5 2 61 13 0 3 23 5 0 1 24 11 0 2 73 5 0 1 24 11 0 2 73 3 5 0 87 10 0 2 49 F C BLOWER MOTOR SOUFFLEUR FORCE INCH mm PO mm HP 11 7 279 178 1 2 373 11 7 279 178 1 2 373 MADE IN THE USA 91 22176 09 CANADIAN ENERGY N W 6 3 AMPS FACTORY EQUIPPED FOR AGENCE
11. module verifies that both sets of pressure switch contacts are open the induced draft motor starts on high until the low pressure switch contacts close a maximum of 60 seconds then changes to low speed b After a 30 second pre purge the spark igniter energizes and the gas valve low stage opens lighting the burners c After the burners light the remote flame sensor must prove ignition If the burners do not light the system goes through another ignition sequence It does this up to 4 times 2 tries on low fire and 2 tries on high fire d The main blower starts on low speed 20 seconds after the gas valve opens The furnace continues to run on low until the call for heat is satisfied or the 2nd stage contacts close If the 1st stage call for heat is satisfied the gas valve closes and the induced draft motor continues running for a 10 second post purge time the main blower runs for 120 seconds this timing is field adjustable See Figure 21 for switch settings Call for 2nd stage heat after 1st stage R and W2 thermostat contacts close calling for 2 stage heat The induced draft motor then switches to high speed and the high pressure switch contacts will close The gas valve switches to high fire and the main blower switches to heating speed 2nd stage heat satisfied 1st stage heat still required R and W2 thermostat contacts open The induced draft motor switches to low speed the main blower motor switc
12. NATURAL GAS ORIFICE MANIFOLD ALTITUDE INPUT OUTPUT SIZE PRESSURE 35 000 52 500 70 000 87 500 105 000 2001 4500 FIGURE 17 HIGH FIRE LP GAS ORIFICE MANIFOLD ALTITUDE INPUT OUTPUT SIZE PRESSURE 50 000 40 000 75 000 60 000 100 000 80 000 125 000 100 000 150 000 120 000 36 000 54 000 72 000 90 000 108 000 45 000 67 500 90 000 112 500 135 000 2001 4500 LOW FIRE LP GAS ORIFICE MANIFOLD ALTITUDE INPUT OUTPUT SIZE PRESSURE 35 000 52 500 70 000 87 500 105 000 2001 4500 MANIFOLD PRESSURE CHANGE LABEL THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES BETWEEN 2 000 FEET AN D 4 500 FEET ELEVATION LA PRESSION DU DISTRIBUTEUR D ALIMENTATION DECET APPAREIL A ETE AJUSTE SUR LES LIEUX AFIN D OBTENIR LA BONNE PUISSANCE D ENTR E POUR UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS 007 TUDE 92 24399 01 01 23 BAOQB 1 UO sluiod OM JO BY SI ENPIAIPUI UI 15 ey uBiu 1981109 1 041 02 1544 Y u Ino J9A97 BAS JE SU pue SAOQE eyo y UO 81890 300 0 Guipuods8 109 y 159199 1 911S y 401 J9A9J BAS SU
13. OR MAY NOT NEED TO BE CHANGED THE FOLLOWING EXAMPLES SHOW HOW TO DETERMINE IF AN ORIFICE CHANGE WILL BE NECESSARY AND HOW TO DETERMINE THE NEW ORIFICE SIZE IN CANADA AS AN ALTERNATE TO ADJ USTING THE BURNER ORIFICE SIZE THE MANIFOLD GAS PRESSURE MAY BE ADJ USTED THIS METHOD IS COVERED LATER IN THIS SECTION THIS METHOD OF ADJ USTING MANIFOLD PRESSURE MAY ONLY BE USED IN CANADIAN INSTALLATIONS 34 80 Plus furnaces installed above 2 000 ft require the furnace to be de rated 4 per thousand feet IMPORTANT Factory installed orifices are calculated and sized based ona sea level Natural Gas heating value of 1075 BTU per cubic ft NOTE Orifices are available through your local distributor The following are examples of orifice sizing using the National fuel Gas Code Appendix F For a simplified estimation of orifice size based on altitude and fuel heating value Tables 5 and 8 can be used However calculations are the best method Example 900 BTU ft Regional Natural Gas Heating Value I H Q 25000 900 27 78 fl Sea Level input per burner 25000 H Sea Level Heating Value 900 Q 27 78 Natural Gas per hour From Table F 1 of National Fuel Gas Code Handbook 2002 3 5 w c column Orifice required at Sea Level 440 From Table F 4 of National Fuel Gas Code Handbook 2002 Orifice required at 5000 ft elevation 4 de rate per thousand ft 442 Orifice required at 8000 ft
14. OVER 11 12 TO 12 12 4 50 60 75 OVER 18 12 TO 28 12 3 25 OVER 16 12 TO 18 12 7 5 8 0 These shall be assembled in accordance with the manufacturer s instructions See Figure 9 5 Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal distance of a vent plus the horizontal vent connector serving draft hood equipped appliances shall not be greater than 75 percent of the vertical height of the vent NOTE Refer to the National Fuel Gas Code ANSI 7223 1 and or the Natural Gas Installation Code CSA B149 1 8 2 Single appliance venting of a fan assisted furnace into a tile lined masonry chimney is prohibited The chimney must be lined with either Type B vent or with a listed single wall metal lining system Reference National Fuel Gas Code ANSI 7223 1 and or the Natural Gas Installation Code CSA B149 1 8 2 See Figure 11 for typical B 1 vent chase OVER 28 12 TO 21 12 A WARNING DO NOT CONNECT THIS FURNACE TO A CHIMNEY USED TO VENTA SOLID FUEL APPLIANCE WOOD OR COAL VENTING WITH A SOLID FUEL APPLIANCE CAN LEAD TO IMPROPER FUNCTIONING OF THE UNIT AND DUE TO SOOTING THE POSSIBILITY OF FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH SPECIAL VENT SYSTEMS SVS IMPORTANT It is THE FURNACE MANUFACTURER s position now that new installations of any HTPV pipe used in a category vent application including
15. SIELU SO UBD 1 JO 1004 4 JeU le SABU NOA 99U0 1 404 1004 21012 Aloedeo JO 1 7 BAS JE 1004 2102 S SU JO YEAH Aq snid 08 101 000 9 ENPIAIPUI eu SONJBA 896 uo paseq 9HS 15 8 sey EINEN 1 SI 8 5 3 JO SUL JO EOS TESH ALON IM S E douunq Jod SI 0 aNJEA U UMOUS UOREJJEJSUI EOS JE GUREGU pue 9215 Mg SUOREJNDJED Aue AJUO UOREULOJU JO SULUNJOD 1544 SL Buisn Aq SUOREJNDIEJ 000 9L 000 1 00081 00061 000 02 000 12 000 000 000 2 000 S7 Jed 1 00143 87 Ly Ly 99 Sr Gp Gp tr 0611 1042 tr Ly 9 Sv 99 tr 144 gr LLL 6852 gr 9b Gp tr tr zb zb zb 2001 G6 te zb Gp tr tr zb zh zb 1 296 9692 rr 144 gr er zb zb zb Lp Ob Ob 926 0
16. Z21 47 1993 CSA 2 3 M93 or latest edition tables VERTICAL VENT SYSTEMS 1 A gas vent shall terminate above the roof surface with a listed cap or listed roof assembly Gas vents 12 inches in size or smaller with listed caps shall be permitted to be terminated in accordance with Figure 10 provided they are at least 8 feet from a vertical wall or similar obstruction All other gas vents shall terminate not less than 2 feet above the highest point where they pass through the roof and at least 2 feet higher than any portion of a building within 10 feet 2 A type B 1 gas vent shall terminate at least 5 feet in vertical height above the highest connected equipment draft hood or flue collar 3 Must rise per foot away from the furnace on horizontal runs and be supported with straps or hangers so it has no sags or dips Supports at 4 foot intervals and at all elbows are recommended 4 The vent connector must be mechanically fastened to the outlet collar of the furnace with at least 2 sheet metal screws except vent connectors that are B 1 material 14 FIGURE 10 TYPICAL VENTING WITH B 1 VENT LISTED CAP LISTED GAS VENT MIN DISCHARGE OPENING ROOF PITCH X 12 MINIMUM ALLOWABLE HEIGHT FROM ROOF TO DISCHARGE OPENING FLAT TO 6 12 18 OVER 6 12 TO 7 12 125 OVER 7 12 TO 8 12 15 OVER 8 12 1092 20 OVER 12 12 TO 14 12 OVER 14 12 TO 16 12 258 3 25
17. allow the largest part of the furnace to pass or b allow anv other appliance such as a water heater to pass ELECTRICAL CONDUIT 0799 01 Guloej sioop 889995 YIM S uo UONEJ EJSUI 3dIS 1H IM 10 JO SI 3 4 SIU LNV LHOdAMI IQIS 1437 JNVHH Y31714 ACIS TYNYILX3I 38 3018 HIV NHALIH TYNOIL O ASVLIOA MOT NOILOANNOO 81 33 VIG 8 90 NOILOANNOO SVD 9 MOTIV adh ABN quan g adh O ABN Jejdepe G 10 6 10 b 0 O 30011 9 0 991051 9 0 91911 9 0 3150 9 L ee 1 av 980 apis dius ybry 1 043 dol NI 33 8 3 3 G3ONG3U STAGOW WLNOZIYOH MO14dN MO14dN SIHONI TVIHALVW A18LLSNAWOD OL JDNVYVIA1ID uv 2 lt N u a gt a gt FIGURE 2 G3LLINYId LON SI LNOLNO HIV TYNOLLdO NOLLVHMDIHNOD NI 3LON VIG 931 INOLLOS3NNOO SVD yZ 9 92 NOILOS3NNOO 91919573 FOVLIOA MOT MOT434YUN VE yuan g dA AN lt g d 0 ABN 191depe 9 10 8 10
18. become obstructed by insects nests or anything else which may effect performance REPLACEMENT PARTS Contact your local distributor for a complete parts list See enclosed sheet TROUBLESHOOTING Refer to Figure 32 for determining cause of unit problems WIRING DIAGRAM Figure 33 is the complete wiring diagram for the furnace and power source FIGURE 32 INTEGRATED FURNACE CONTROL IFC TROUBLESHOOTING GUIDE FOR UTEC 1095 101 22 Z QE lt lt lt gt 63 LU LU l z 2 HAZARDOUS VOLTAGE SERVICE MUST BE BY A TRAINED QUALIFIED SERVICE TECHNICIAN LINE VOLTAGE CONNECTIONS w START 1 SET FAN SWITCH TO AUTO 2 SET THERMOSTAT TO CALL FOR HEAT INDUCED DRAFT MOTOR STARTS HIGH SPEED YES INDUCED DRAFT MOTOR SWITCHES TO LOW SPEED 3 SEC PREPURGE YES SPARK IGNITER ENERGIZES YES NO NO NO INT GRAT URNACE CONTROL IFC TROUBLESHOOTING GUIDE SPARK IGNITION SYSTEM REMOVE IFC COVER CHECK LIGHTS POWER LED ON gt CHECK LINE VOLTAGE POWER NO CHECK LOW VOLTAGE TRANSFORMER YES CHECK IN LINE FUSE ON TRANSFORMER LOW VOLTAGE LINE MICROPROCESSOR STATUS LED ON NO NOTE LED WILL FLASH TO INDICATE EXTERNAL CIRCUIT FAULTS CHECK FOR 24 FROM WTO C ON IFC CHECK LIMITS CLOSE
19. comfort This feature is only available in the cooling mode Switch Selection GPL GLL 05EBMKR GPL GLL 07EBRKR GPL GLL 07EBRQR GPL GLL 10EBRMR GPL GLL 12EARMR Air Flow Air Flow A 1200 1200 1600 2000 2000 TABLE 15 TWO STAGE IFC S SWITCHES 1 2 amp 4 COOLING OFF DELAY TIMINGS amp PROFILES SEE FIGURES 20 23 SWITCH 1 SWITCH 2 SWITCH 4 PROFILE SWITCH 4 PROFILE OFF SWITCHES 3 amp 4 ON SWITCHES 3 amp 4 On Interface Board On Interface Board Off On 30 sec A B C or D 0 sec A B C or D Off Off 40 sec A B C or D 30 sec A B C or D On 60 sec A C or D 20 sec A B C or D On On 90 sec A B C or D 50 sec A B C or D Switch Air Flow Selection Adjustment A 15 Less cooling Airflow B Normal Cooling Air Flow for Table 7 C On Demand Dehumidification Humidistat controls cooling airflow D Normal Cooling Air Flow 28 FIGURE 21 COOLING HEAT PUMP OFF DELAY PROFILES B D ON m ON m ON OFF H H OFF m OFF m OF
20. flue passageways however it is recommended that a qualified installer service agency or the gas supplier actually inspect the flue passageways the vent system and the main and pilot burners for continued safe operation paying particular attention to deterioration from corrosion or other sources WARNING HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE POISONING OR DEATH THE VENT PIPE OR HEAT EXCHANGER MUST BE REPLACED IF THEV LEAK e IMPORTANT It is recommended that at the beginning of the heating season and approximately midway in the heating season a visual inspection be made of the main burner flames and pilot flame on standing pilot models for the desired flame appearance by a qualified installer service agency or the gas supplier IMPORTANT It is also recommended that at the beginning of the heating season the flame sensor on hot surface ignition models be cleaned with steel wool by a qualified installer service agency or the gas supplier IMPORTANT It is recommended that an annual inspection and cleaning of all furnace markings be made to assure legibility Attach a replacement marking which can be obtained through the distributor if any are found to be illegible or missing IMPORTANT FOR Nox MODELS At the beginning of the heating season a visual inspection of the Nox device should be made to ensure they have not
21. opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and have a minimum free area of a One square inch for each 3000 BTUH of the total input rating of all equipment located in the enclosure AND b Not less than the sum of the areas of all vent connectors in the confined space FIGURE 8 IMPORTANT If the furnace is in a location with an exhaust fan there must be sufficient ventilation to prevent the exhaust fan from creating a negative pressure in the room Combustion air openings must NOT BE RESTRICTED in any manner CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS Air opening in the furnace casing front return air grilles and warm air registers must not be obstructed OUTSIDE AIR USING A HORIZONTAL INLET amp OUTLET OUTLET AIR 450 INCH PER 4000 BTUH INLET AIR 159 INCH PER 4000 BTUH ro 2000 BTUH 1 VENTING GENERAL INFORMATION The furnace must be vented in accordance with these instructions National Fuel Gas Code ANSI Z223 1 and or the Natural Gas Installation Code CSA B149 1 amp 2 and requirements or codes of the local utility or other authority having jurisdiction IMPORTANT This furnace is not certified for use with a power venter or any other type of horizontal venting A WARNING DEVICES ATTACHED TO THE F
22. or the Natural Gas Installation Code CSA B149 1 8 2 for proper installation practices Single wall vent connectors to B 1 vent or masonry chimneys may be used under the guidelines of the National Fuel Gas Code ANSI Z223 1 and or the Natural Gas Installation Code CSA B149 1 6 2 The entire length of the vent connector shall be readily accessible for inspection cleaning and replacement 13 B 1 VERTICAL VENTING Type B 1 vents must be installed in accordance with the terms of their listings and the vent manufacturer s instructions 8 1 vents must be supported and spaced in accordance with their listings and the manufacturer s instructions All vents must be supported to maintain their minimum clearances from combustible material VERTICAL VENTING Categorized Furnace Vent Input Size Required 50K 3 75K 4 100K 4 125K 4 NOTE All furnaces have a 3 vent connection as shipped from the factory A 3 to 4 or 3 to 5 vent transition is required on all but the 50 000 BTUH models when vertically vented or common vented with metal vent pipes THE VENT TRANSITION CONNECTION MUST BE MADE AT THE FURNACE VENT EXIT It must originate with an adapter if required at the furnace flue collar and terminate either in a listed cap or roof assembly When common venting the vent connector size may differ from the above diameters depending on application See ANSI
23. present on the furnace There should be no additional modifications necessary A NOTE ABOUT DEHUMIDIFICATION High SEER systems may require the use of the onboard dehumidification feature of this system Be sure to consult the section titled DEHUMIDIFICATION on page 28 of this document work with two stage cooling systems ap CONDENSER SELECTION PREMIUM COOLING SYSTEMS 1 STAGE COOL ONLY r FURNACE ARROW CONDENSING 62 24340 01 SWITCH SETTINGS MODEL WIDTH CFM SWITCH 5 SWITCH 6 2 GPL 05 178 800 24 OFF ON 2 1 2 GPL 05 176 1000 30 ON OFF 2 1 2 GPL 07EBRKR 21 1000 ARA 30 ON OFF 2 1 2 GPL 07EBRQR 21 1000 ARA 30 ON ON 3 GPL 05 17 5 1000 30 ON OFF 3 GPL 07EBRKR 21 1200 ARA 36 OFF OFF 3 GPL 07EBRQR 21 1200 ARA 36 OFF ON 3 GPL 10 21 1200 ARA 36 ON ON 3 GPL 12 245 1200 ARA 36 ON ON 3 1 2 GPL 07EBRQR 21 1400 ARA 42 ON OFF 3 1 2 GPL 10 21 1400 ARA 42 OFF ON 3 1 2 GPL 12 245 1400 ARA 42 OFF ON Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace See condenser spec sheet 180 and other literature for evaporator selection TABLE 10 AIRFLOW AND CONDENSER SELECTION PREMIUM COOLING SYSTEMS 2 STAGE COOL ONLY FURNACE R W CONDENSING 62 24340 01 SWI
24. pressure tap See Figure 25 3 Turn on the gas supply and operate the furnace in high speed 4 Note or adjust the manifold gas pressure to give A 3 5 w c for natural gas high fire B 10 w c for LP gas high fire 5 To adjust the pressure regulator for high fire remove the regulator cap located on the side of the regulator See Figure 14 6 Turn the adjustment screw clockwise to increasre pressure or counterclockwise to decrease pressure 7 Securely replace the regulator cap for high fire 8 Operate the furnace in low speed FIGURE 13 TYPICAL HOSE CONNECTION TO LINE PRESSURE TAP FIGURE 14 TYPICAL GAS VALVE O a O HIGH FIRE MANIFOLD z PRESSURE ADJUSTMENT gt OUTLET PRESSU 6 lt PRESSURE Sr 2 TABLE 2 NATURAL GAS PIPE CAPACITV TABLE CU FT HR LOW FIRE PRESSURE MANIFOLD ADJUSTMENT Capacitv of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific 9 Noteor adjust the manifold gravity of 0 60 natural gas pressure to give A 1 7 w c for natural gas low fire Iron Pipe Size Inches 10 20 30 40 50 60 70 80 B 4 9 w c for LP gas low fire 12 132 92 73 63 56 50 46 43 10 To adjust the pressure regulator 3 4 278 190 152 130 115 105 96 90 for low fire remove the regulator 1 520 350 285 245 215 195 180 170 1 1
25. robbing type are compatible with the integrated furnace control we use HEAT ANTICIPATOR SETTINGS If a current reading taken at the thermostat is not performed an initial setting of 15 amps is recommended Adjust as needed to improve comfort level ISOLATION RELAY IMPORTANT Not all electronic night setback thermostats are compatible with the furnace control system Some may require an isolation relay If an isolation relay is needed part number 42 25104 01 install it as close to the control board as possible Use a single pole single throw relay with a 24 volt operating coil The relay contacts should be designed for 24 volt loads Connect one end of the operating coil to the thermostat W terminal Connect the other end of the coil to the C terminal on the control board See Figure 15 Connect one side of the normally open contacts to the control board W terminal When the thermostat calls for heat it powers the 24 volt operating coil This closes the relay contacts and conducts power from terminal 3 and 4 to terminal W on the control board and starts the furnace ignition sequence FIELD INSTALLED OPTION ACCESSORIES ELECTRONIC AIR CLEANER 1 Electronic air cleaner line voltage power can be supplied from the screw terminal EAC and a line voltage neutral screw terminal on the control board See Figure 16 This will power the electronic air cleaner whenever the circula
26. the W2 terminal on the control board and the furnace will remain in the low fire mode To adjust the pressure remove the regulator cover on top of the valve and adjust as noted under Step 2 above After the adjustment replace the screw cover securely NOTE Use a 3 32 allen wrench for making the pressure adjustment TO CHANGE ORIFICE SPUDS 1 Shut off the manual main gas valve and remove the gas manifold 2 Replace the orifice spuds Reassemble in reverse order 4 Turn the gas supply back on and check for proper operation and manifold pressure Check of input is important to prevent over firing of the furnace beyond its design rated input NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE TO CHECK FURNACE INPUT 1 Make certain that all other gas appliances are shut off with the exception of pilot burners 2 Start the furnace 3 Time the meter to measure the time required to burn one cubic foot of gas 4 Use Table 4 to determine input rate W METER HEATING VALUE OF GAS BTU PER CU FT INPUT BTU HR 5125 900 1000 1040 1100 2500 CU FT MIN SEC MIN SEC MIN SEC MIN SEC ONE 50 000 TEN ONE 44 75 000 TEN 12 1 12 12 1 15 1 16 3 20 00 12 30 13 12 30 00 50 53 19 48 33 100 000 TEN 24 38 40 15 36 ONE 26 125 000 19 30 32 0 17 31 150 000 TEN 36
27. 1 1 606 1 496 Example LP Input BTU requirement of unit 150 000 Equivalent length of pipe 60 ft 3 4 IPS required 13 Verify pressures for high and low fire operation 14 Shut off gas at the manual gas valve and remove the U Tube manometer 15 Replace the manifold pressure tap plug before turning on gas NATURAL GAS If the supply gas line pressure is above the operating range install an in line gas regulator to the furnace If supply gas line pressure is below the operating range either remove any restrictions in the gas supply piping or enlarge the gas pipe See Table 7 LP GAS If the supply gas line pressure is above the operating range have the LP supplier reduce the line pressure at the regulator If supply gas line pressure is below operating range have the LP supplier adjust the line pressure at the regulator See Table 8 NOTE Depending on the amount of LP vapor and the outdoor ambient temperature the LP storage tank may require supplemental heat to maintain proper pressure levels ADJUSTING OR CHECKING FURNACE INPUT CAUTION ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJ USTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY OR MAY NOT NEED TO BE CHANGED SEE THE SECTION TITLED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS NATURAL GAS The
28. 1 2 50 amp 100 15 X 25 15 X 25 1 inside the furnace or air handler or a 21 75 amp 100 19 X 25 15 X 25 1 filter base For systems with a return air 24 1 2 125 22 X 25 15 X 25 1 filter grill or multiple filter grills can have DOWNFLOW FILTER SIZES a filter installed at each of the return air openings DO NOT DOUBLE FILTER er STH SIZE QUANTITY THE RETURN AIR DUCT SYSTEM DO NOT FILTER THE SUPPLY AIR 14 50 14 20 DUCT SYSTEM 171 2 75 8 100 12 X 20 uF ae 21 100 12 X 20 If high efficiency filters or electronic air 241 2 125 amp 150 14 X 20 cleaners are used in the system it is GA ban Jen Bon aid important that the airflow is not reduced Size Width 20 p le ad to maximize system performance and AE 61659 02 61659 03 life Always verify that the system s ej 1 2 airflow is not impaired by the filtering a Sa ie system that has been installed by OGG ZE i CUKOR SI 55 performing a temperature rise and 125000 241 2 1 Asis Cut Off 31 gt temperature drop test i NOTE Airflow external static pressure NOTE Some filters must be measurements do not include filter or resized to fit certain units and coil applications PD FIGURE 29 JACKET ASSEMBLY BOTTOM RETURN JACKET ASSEMBLY TA SOLID BOTTOM FILTER ROD NOTE BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET SIDES
29. 20 60 20 140 90 50 TABLE 12 HEATING AIR FLOW SELECTIONS SWITCHES 1 amp 2 Switch Selection Temperature Rise Mid Rise Mid Rise Mid Rise 10 Mid Rise 10 F NOTE Airflow for models GPL 07EBRKR and GLL 07EBRKR cannot be adjusted to give a rise lower than mid rise on high fire COOLING AIRFLOW ADJUSTMENTS The furnace motor is programmed to provide cooling airflows of 1 2 2 and 3 tons in the GPL LL 05 EBMKR and 07 EBRKR units Airflows of 252 3 3 and 4 tons are available in the GPL LL 07 EBRQR units Airflows of 3 3 4 and 5 tons are available in the 10 EBRMR and 12 EARMR units See Tables 14 and 16 for airflow options Furnaces are shipped from the factory set for maximum cooling airflow Adjustments to the cooling airflow may be made using switches 7 and 8 as shown in Table 13 TABLE 13 AIR FLOW ADJ USTMENT SWITCHES 7 amp 8 Switch Air Flow Selection Adjustment A No Adjustment B 10 10 D No Adjustment 27 CONTINUOUS FAN ADJUSTMENTS There are two options for the adjustment of continuous fan With switch 9 ON the speed will be high fan With switch 9 OFF the speed will be soft fan The cfm for these speeds will be a calculated percentage of the heating airflow speeds selected SETTING BLOWER OFF TIMINGS FOR COOLING AND HEAT PUMP OPERATION There is a bank of four
30. 22 Ob tr Er zb zb 1 Ob 68 65 288 282 65 Er zb zb 1 Lb Ob 65 85 85 998 9262 85 er zb zb Lb Ob 6 65 85 LE Ze 918 69 08 Ze 6666 0006 6668 0008 666 000 6669 0009 6665 0005 666v 000v 666 000 666Z 000Z 6667 0007 666 0 000 2 90 e peuinba 558 pue ENDT LIS JE 4 JO UORJBSIEJU uo p seq JO 300 0007 104 JVP p seq DAN LYWHD NOLLVA313 snid 08 1 91 555 5 1 0 TYNIH JLVWIXOHddV ANY 740 S LV NOLLO313S LHVHO AOINO SVD TVHALVN SJOPOLLI 06 Aue 40 14 9 siy asn 100 oq 4804 Jed s nlg 000 GZ 08 215 ADIHIHO 71 04930437144 5 8 371901 24 For two stage cooling the input for low cooling YL is on the ECM interface control part number 62 24340 04 only and not on the main IFC This was done for convenience of production This should be noted when routing thermostat connections since low speed cooling is not wired to the same control board as all other thermostat terminals UP TO 16 SEER COOLING OPERATION SINGLE STAGE COOLING All IFC part numbers and revisions are compatible TWO STAGE COOLING Check the part number of two stage int
31. 26 If the measured temperature rise is above the approved range the air flow is too low More air must be moved by speeding up the blower by removing restrictions in the duct system or by adding more supply or return air duct If the measured temperature rise is below the approved range the air flow is too much Use dip switches on the blower interface board to adjust airflow Ideally the measured temperature rise should be in the middle of the range The rise range is the same for high and low inputs FIGURE 25 TEMPERATURE RISE MEASUREMENT F FIGURE 26 FURNACE NAME PLATE 4 AIR CONDITIONING DIVISION FORT SMITH ARKANSAS MODEL NO NUMERO DE MODELE SERIAL NO NUMERO DE SERIE INSTALLATION ONLY IN BUILDING CONSTRUCTED ON SITE ELECTRIC 115 V 60 HZ 1 PH MAXIMUM TOTAL INPUT HOURLY INPUT RATING DEBIT CALORIFQUE MAXIMUM HOURLY INPUT RATING DEBIT CALORIFQUE MINIMUM 75 000 21 98 ENTIREO 2 000 ORIFICE INJECTEUR 50 DMS LIMIT SETTING LIMITE COUPE CIRCUIT AUXILIARY LIMIT SETTING LIMITE COUPE CIRCUIT AUXILIAIRE 0 610 ANADA ONLY 200 93 MAXIMUM PERMISSIBLE GAS SUPPLY PRESSURE TO FURNACE PRESSION MAXIMUM D ALIMENTATION EN GAZ CHAUDI RE PRESSION MINIMUM D ALIMENTATION EN GAZ POUR LE REGLAGE DE PUISSANCE D ENTR E MANIFOLD PRESSURE PRESSION A LA TUBULURE AIR TEMPERATURE RISE AUGMENTATIONDE LA TEMPEATUREDE L AIR
32. 4 1 050 730 590 500 440 400 370 350 cap the top of the regulator See Figure 14 1 1 2 1 600 1 100 890 760 670 610 560 530 After length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour 11 Turn the adjustment screw required for the gas input rating of the furnace formula clockwise to increase pressure or counterclockwise to decrease Nominal Length of Pipe Feet Gas Input of Furnace BTU HR Heating Value of Gas BTU FT3 Cu Ft Per Hr Required pressure The gas input of the furnace is marked on the furnace rating plate The heating value of the gas BTU FT3 may be 12 Securely replace the regulator cap determined by consulting the local natural gas utility or the LP gas supplier for low fire 18 TABLE 3 LP GAS PIPE CAPACITY TABLE CU FT HR Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column inlet pressure Based on a Pressure Drop of 0 5 Inch Water Column Nominal Length of Pipe Feet Iron Pipe Size Inches 10 20 30 40 50 60 70 90 100 125 1 2 275 129 114 3 4 567 393 315 267 237 1 1 071 732 590 504 448 2 205 1 496 1 212 1 039 913 3 307 2 299 1 858 1 559 1 417 2 6 221 4 331 3 465 2 992 2 646 103 96 83 78 69 63 217 196 173 132 409 378 322 307 275 252 834 771 677 630 567 511 1 275 1 181 1 023 976 866 787 2 394 2 205 1 921 1 81
33. AND FRONT FILTER amp ROD LOCATION SCREW FLANGES FIT OVER FLANGES ON JACKET 2 REQ D SOLID BOTTOM MAY BE ORDERED AS AN OPTION FROM THE FACTORY 36 FIGURE 30 FILTER RETAINING RODS SIDE RETURN UPFLOW DRILL 2 3 16 DIA HOLES JACKET ANGLE DETAIL ATTACH WITH SHEET METAL SCREWS 2 REQ D FILTER ROD FILTER SUPPORT ANGLE SEE ANGLE DETAIL FIGURE 31 DOWNFLOW FILTER INSTALLATION 37 Keep the air filters clean at all times Vacuum dirt from filter wash with detergent and water air dry thoroughly and reinstall 1 172 50 000 btuh unit requires removal of 3 segment of filter and frame to get proper width for a bottom filter 21 75 000 100 000 btuh units requires removal of 3 segment of filter and frame to get proper width for a side filter 24 125 000 btuh unit require removal of 7 segment of filter and frame to get proper width for a side filter IMPORTANT Do not operate the system without filters A portion of the dust entrained in the air may temporarily lodge in the air duct runs and at the supply registers Any recirculated dust particles will be heated and charred by contact with the furnace heat exchanger This residue will soil ceilings walls drapes carpets and other household articles SYSTEM OPERATION INFORMATION Advise The Customer To 1 38 Keep the air filters clean The heating system will operate better m
34. CLEANING MATERIALS 1 NOTE This furnace is shipped with heat exchanger support brackets installed under the back of the heat exchanger These may be removed before installation but it is not required LOCATION A WARNING THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME DO NOT INSTALL THIS FURNACE IN A MOBILE HOME INSTALLATION IN A MOBILE HOME COULD CAUSE FIRE PROPERTY DAMAGE PERSONAL INJ URY OR DEATH 2 IMPORTANT This furnace is not approved or recommended for installation on its back with access doors facing upwards 3 This furnace is suitable for installation in buildings constructed on site This heating unit should be centralized with respect to the heat distribution system as much as practicable 4 IMPORTANT If installing the unit over a finished ceiling or living area be certain to install an auxiliary condensate drain pan under any evaporator coil installed with the furnace NOTE These furnaces are approved for installation in attics as well as alcoves utility rooms closets and crawlspaces FIGURE 1 HORIZONTAL FURNACE INSTALLED W SUPPORT BRACKETS GAS PIPE EXHAUST VENT 5 IMPORTANT Support this unit when installed For attic or crawl space installation horizontal furnaces may be installed on combustible wood flooring or bv using support brackets See Figure 1 6 IMPORTANT If installing in a utility room be sure the door is wide enough to a
35. D CHECK WIRING CHECK PRESSURE SWITCH OPEN REPLACE IFC CHECK THERMOSTAT WIRING REPLACE SWITCH NO REPLACE SWITCH REPLACE IFC CHECK LOW PRESSURE SWITCH CLOSED CHECK FOR 115VAC AT IDM MOTOR LOW SPEED LEAD RED REPLACE INDUCED DRAFT BLOWER IF THE PRESSURE SWITCH DOESN T CLOSE WITHIN 62 SEC THE IDM WILL STOP FOR 5 MIN AND RETRY CHECK FOR 115VAC TO DRAFT MOTOR YES REPLACE IFC IF WIRING TO DRAFT MOTOR IS OK REPLACE DRAFT MOTOR NO CHECK FOR BLOCKED VENT CHECK AIR PROVING SWITCH CLOSED REPLACE SWITCH REPLACE IFC IF WIRING TO IGNITER IS OK CHECK WIRING TO IGNITER NO CHECK FOR SPARK AT IGNITER ELECTRODE CHECK SPARK GAP 1 8 YES REPLACE IGNITER TS REMAINS OPEN REMAINS CLOSED FAU D FURNACE CONTROL KOUT CATE FAILURE OPEN FAILURE TEGRA ES T FAULT 1 HOUR LO SWITC SWITC FLASH TO INDI AN DAMAGE FLASH CO PRESSURE TWINNING CIRCU SOFT LOCKOUT PRESSURE ED WILI 3 BLINKS LIMIT SWITCH STATUS 1 BLINK 2 BLINKS 4 BLINKS 5 BLINKS MAIN BURNER SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES FIRST TWO 2 ATTEMPS LIGHTS AT LOW FIRE SECOND TWO 2 HIGH FIRE VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION SYSTEM YES WILL
36. F 3 4 4 3 3 4 NTERFACE CONTROL SWITCH POSITIONS 3 4 I ST A0827 01 29 FIGURE 22 COOLING HEAT PUMP ON DELAY PROFILES D B ON ON ON ON OFF MM OFF OFF M OFF 4 4 3 4 POSITIONS 3 4 3 INTERFACE CONTROL SWITCH ST A0828 01 30 FIGURE 23 LOW HEAT OFF DELAY PROFILES HEAT CYCLE ENDS ej MAIN CONTROL SWITCHS 180 200 220 240 SWI SWZ OFF OFF ST A0829 01 31 FIGURE 24 HIGH HEAT OFF HEAT CYCL MAIN CONTROL SWITC 5 1 OFF ST A0830 01 32 DELAY PROFILES ENDS gt HS DS 180 200 220 240 SW2 OFF
37. FACTORY SEE THE CLEARANCE LABEL LOCATED INSIDE THE FURNACE FOR THE APPROPRIATE MODEL NUMBER THE SPECIAL BASE IS NOT REQUIRED WHEN THE FURNACE IS INSTALLED ON TOP OF AN AIR CONDITIONING PLENUM A gas fired furnace for installation in a residential garage must be installed so that the burner s and the ignition source are located not less than 18 above the floor and the furnace is located or protected to avoid physical damage by vehicles UPFLOW UNIT DESIGN REQUIRES A SOLID METAL BASE PLATE SEE TABLE 1 OR FURNACE CLEARANCE LABEL FOR PART NUMBER IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS INCLUDING CARBON MONOXIDE POISONING TABLE 1 FURNACE BASE BASE WIDTH PLATE NO PLATE SIZE 17 RXGB D14 11 x 23 1772 RXGB D17 1518 28 21 RXGB D21 18 x 2818 24 2 RXGB D24 25 x 28 SITE SELECTION 1 Select a site in the building near the center of the proposed or existing duct system 2 Give consideration to the vent system piping when selecting the furnace location Be sure the venting system can travel from the furnace to the termination with minimal length and elbows 3 Locate the furnace near the existing gas piping Or if running a new gas line locate the furnace to minimize the length and elbows i
38. Figure 1 and connect supply plenum 3 If summer air conditioning is desired position the indoor coil on the supply air side of the unit Insure that no air can bypass this coil 4 Secure the four angle brackets shipped with the unit to the return air opening See Figure 5 Connect the return air ducting to the return air opening at the top of the unit Make the connection air tight to prevent entraining combustion gases from an adjacent fuel burning appliance NOTE Do not block furnace access with support rods Maintain clearances recommended in Figure 2 Allow enough space for proper service maintenance or replacement of the heat exchanger and blower assembly FIGURE 5 HORIZONTAL RETURN AIR DUCT LEFT HAND AIRFLOW POSITION SHOWN REAR VIEW FOUR ANGLE BRACKETS ARE SHIPPED WITH EACH UNIT THAT CAN BE INSTALLED HORIZONTALLY THESE BRACKETS MAY BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT COMBUSTION AND VENTILATION AIR WARNING THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING Adequate facilities for providing air for combustion and ventilation must be provided in accordance with section 5 3 Air for Combustion and Ventilation of the National
39. Fuel Gas Code ANSI Z223 1 latest edition or CSA B149 1 and 2 or applicable provisions for the local building codes and not obstructed so as to prevent the flow of air to the furnace OVERTEMPERATURE SAFETY SWITCHES This furnace is equipped with safety switches in the burner compartment to protect against overtemperature conditions caused by inadequate combustion air supply The switches are located just above the burners on the furnace center panel on upflow and downflow models and also on each side of the burners on upflow horizontal and horizontal only models and must be manually reset if tripped DO NOT jumper this switch If this switch should trip a qualified furnace installer service agency or the 10 gas supplier should be called to check and or correct for adequate combustion air supply If this unit is mounted in closet the door must be closed when making this check of the installation DO NOT reset the overtemperature switch without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation Replace this switch only with the identical replacement part FIGURE 6 AIR FROM HEATED SPACE COM BUSTION AIR REQUIREMENTS IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage
40. G FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE ALSO THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH WARNING INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING PROPER VENT INSTALLATION FURNACE OPERATING UNDER THERMOSTATIC CONTROL RETURN AIR DUCT SEALED TO THE FURNACE AIR FILTERS IN PLACE SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION RETURN AIR TEMPERATURE MAINTAINED BETWEEN 557 13 C AND 80 F 27 C AND CLEAN FURNACE DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION INPUT RATE TEMPERATURE RISE AND VENTING ACCORDING TO THE INSTRUCTIONS GENERAL INFORMATION The GPL and GLL series furnaces are design certified by CSA for use with natural and propane gases as follows As a Category furnace it may be vented vertically with type B 1 vent pipe and also may be common vented as described in these instructions These furnaces are design certified by CSA for use with natural or propane gases as Category 1 furnaces and must be vented vertically only They are not designed for horizontal venting This furnace should be in
41. GO INTO 1 HOUR LOCKOUT AFTER 4 TRIES CHECK FOR 24VAC ACROSS THE VALVE AND VALVE TERMINALS ON THE IFC CHECK IGNITER POSITION EPLACE VALVE IF ND R MDM N CHECK FOR GAS FLOW TO AND FROM VALVE FLOW THRU VALVE REPLACE IFC IF WIRING TO VALVE IS OK NOTE IF IFC GOES INTO LOCKOUT WAIT 39 SECONDS THEN RESET SYSTEM CHECK POLARITY OF 115VAC SUPPLY CHECK CONTINUITY OF GROUND WIRE CHECK INSULATION ON IGNITER CHECK FLAME SENSE CURRENT YELLOW LED LED IS ON IF FLAME CURRENT IS GOOD IT FLASHES IF CURRENT IS MARGINAL TURN POWER OFF TO UNIT CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES RESTORE POWER TO UNIT IF CHECKS ARE OK REPLACE IFC MAIN BURNER REMAINS POWERED AND LIT eee CHECK FOR 115VAC ACROSS BLOWER REPLACE MAIN IFC IF WIRING MOTOR AND BLOWER MOTOR TERMINALS TO BLOWER AND OR ICM LOW HEAT AND NEUTRAL ON MAIN IFC INTERFACE CONTROL IS OK YES DOES THIS FURNACE HAVE A G E ICM YES CHECK FOR 12 VAC ON LOW HEAT INPUT BLOWER AND ICM INTERFACE CONTROL TERMINAL ON ICM INTERFACE CONTROL INDOOR BLOWER MOTOR STARTS 28 SECONDS AFTER IGNITION NO Y REPLACE BLOWER MOTOR CHECK OR REPLACE WIRE TO TERMINAL REPLACE ICM CONTROL CABLE OR INSPECT IT MAKING SURE THE PINS ARE SEATED PROPERLY IN BOTH PLUGS NOTE IF IFC GOES INTO LOCKOUT WAIT 3 SECONDS THEN RESET SYSTEM CHECK CONTINUITY OF GROUND WIRE N
42. I 8 5 2091409 33 3834 WII ATANINYAHId 38 LSAW 12 8 3 1378 LYLSOWHJHL HOLOW NOILINJI MHYdS 193810 ONINHYM 301134493 NOY 5 9 SHJ900H 31IHM 0003 S D 7919130 SV NOLLYINSNI d 138 838018 LY3H HOIH 3 AOLIVA 04 1069397131 LYN AIAL E 30 3344 ONY 3215 3WYS 3 1 38 LSNU HJLIMS 011 8 5 Nun 9 7 11 17 03151559 163 G3ONANI 8 O Q INIWIIVIJIU G AND 09 130 AV 138 5 9 9 9 1807 90 JSNMOG Addi 1 Q1314 1 1 38 55 384 93N HNIHIM 716318173 NOLLdO AY012394 1 AEA ENE 8 0 15 8013 4 19140 VS AMIGA SY NIGW 3 3 HIV 51519373 MOTIJA AI 3991 0A MOT 3993434 WOJ I0 OpEbc 29 1 3 553 4 MOT H31IMS LOANNOOSIG ii LN3SdHd LON 38IM SIHL 3 8035 4 IOHLNOJ ALIHM N3389 9 3 5 01314 5 AV 138 7 1005 1140 AY401994 331 NO ZM OL LOSNNOD 4 13 GI WII SIND HOLIVINOJ YOSSIYdNOD 3 Hd MOHd 8 c 114 1304 115504 jek OHVONVIS AYOLIVA LYISONYIHL 3991 319NIS AV 133 NOLLINOI JONVYO 0 0 1 INIT 1 1 3 3O99NH03 QLHOHINI 19 915 8 dWNd 1V3H 3003 0103 3HIM NOILVWHOJNI JNIH
43. IM 5 310 SAIS 09 D090600 18 HOLIMS 3000 H3MO 18 9210 599 AlddNS 83809 yn Gt OL lt MU 9 24314 2 NOILINNO H0193NN03 80123NN03 NId NId 2 A va 10H LNOJ AT M 33 4831 B si nol 33 10 0v v2 29 D 1009 S q YOLIZNNOD NId v SI WII 4 3 MOT 7031409 30YN8N1 21 14 9 54 gt 03198931NI 4 38 lt 5 4 we 15 O Z NOT 40 006 115 018 SNOILdO JOHLNOI MS NIMI 9 ZM MI LO LSOWHSH l oz 5 OBY mm 303 SNOILINYLSNI a Wal 218 82809 3 07 NOLLYTIGLSNI 335 CEO JLON gogoda lalala ASK z 9 d 92MM JH NNNIXYN E MOTSNMOG erst BOLJINNOI LV LSOWGJHL S3HILIMS 105103 104 LNOJ IHNLUHIHW3ALHJAO 1N011O4 LIWII NIVW HOSNAS 3 7 Ka abu ug woo 000 FINO 59 335
44. INSTALLATION INSTRUCTIONS FOR UPFLOW HORIZONTAL GPL AND DOWNFLOW JGLL TWO STAGE INDUCED DRAFT GAS FURNACES RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION AWARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH AWARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION ADJUSTMENT AND OPERATION OF THIS UNIT READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION ADJUSTMENT SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE ELECTRICAL SHOCK CARBON MONOXIDE POISONING EXPLOSION PROPERTY DAMAGE PERSONAL INJURY OR DEATH AWARNING PROPOSITION 65 WARNING THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM A WARNING GB Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department
45. IRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS INCLUDING CARBON MONOXIDE POISONING OR DEATH 2 If summer air conditioning is desired position the indoor coil on the top of the unit Insure that no air can bypass this coil 3 Connect the supply air plenum to the furnace plenum opening DOWNFLOW UNITS A WARNING THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NON COMBUSTIBLE FLOOR IF INSTALLED ON A COMBUSTIBLE FLOOR USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL FAILURE TO INSTALL THE SPECIAL BASE MAY RESULT IN FIRE PROPERTY DAMAGE PERSONAL INJ URY OR DEATH THIS SPECIAL BASE IS SHIPPED FROM THE FACTORY AS AN ACCESSORY 1 Position the unit over the supply air plenum and connect a If installing on a combustible floor and not using an evaporator coil box install the special combustible floor base See Figure 4 FIGURE 4 COMBUSTIBLE FLOOR BASE b If summer air conditioning is desired position the indoor coil on the bottom of the unit Insure that no air can bypass this coil 2 Connect the return air ducting to the return air opening at the top of the unit Make the connection air tight to prevent entraining combustion gases from an adjacent fuel burning appliance HORIZONTAL UNITS 1 Unit can be mounted for left or right side airflow configuration 2 Position the unit on adequate supports or by using support brackets see
46. LOW THIS WARNING CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH To check for gas leakage use an approved chloride free soap and water solution an electronic combustible gas detector or other approved method LP CONVERSION NOTE For installation see specific LP kit installation instructions The valve can be converted to use liquefied petroleum LP gas by replacing the pressure regulator spring with the conversion kit spring This LP kit spring allows the regulator to maintain the proper adjusted manifold pressure for LP gas The correct burner LP orifices are included in the kit NOTE Order the correct LP conversion kit from the local distributor Furnace conversion to LP gas must be performed by a qualified technician CAUTION ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJ USTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY OR MAY NOT NEED TO BE CHANGED SEE THE SECTION TITLED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS NOx MODELS When converting furnaces equipped with NOx inserts to LP gas remove the NOx insert assemblies Steps for removal are listed below 1 Turnoffall electrical power and the gas supply to the furnace 2 Remove the burner door from the furnace 3 Remove the igniter assembly hand
47. LUE OR VENT FOR THE PURPOSE OF REDUCING HEAT LOSS UP THE CHIMNEY HAVE NOT BEEN TESTED AND HAVE NOT BEEN INCLUDED IN THE DESIGN CERTIFICATION OF THIS FURNACE WE THE MANUFACTURER CANNOT AND WILL NOT BE RESPONSIBLE FOR URY OR DAMAGE CAUSED BY THE USE OF SUCH UNTESTED AND OR UNCERTIFIED DEVICES ACCESSORIES OR COMPONENTS DRAFT INDUCER LA WARNING VENT PIPE ATTACHING HOLES MUST BE PREDRILLED IN THE DRAFT INDUCER COLLAR TO PREVENT PLASTIC MATERIAL FROM CRACKING DRILL 1 8 DIAMETER HOLES THROUGH THE VENT PIPE AND COLLAR AND USE 8 SCREWS TO ATTACH SEE FIGURE 9 FAILURE TO FOLLOW THIS WARNING CAN CAUSE RECIRCULATION OF FLUE PRODUCTS CAUSING CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJ URY OR DEATH NOTE On downflow units be certain that the vent pipe is positioned over the induced draft motor outlet Attach the vent pipe to the induced draft motor collar as noted above FIGURE 9 ATTACHING TO DRAFT INDUCER COLLAR DRAFT INDUCER OUTLET FURNACE CATEGORY INFORMATION This furnace is shipped as a Category type induced draft furnace A Category furnace operates with a nonpositive vent pressure and has a vent gas temperature at least 140 F above the dew point of the vent gases A Category type may be a draft hood equipped furnace or have a fan assisted combustion system induced draft The inducer is used to pull flue products through the combustion chamber and as they leave the furna
48. ODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE FAILURE TO DO SO CAN CREATE HAZARDOUS CONDITIONS RESULTING IN PROPERTY DAMAGE BODILY INJ URY OR DEATH FROM SMOKE FIRE OR CARBON MONOXIDE Combustion air requirements are determined by whether the furnace is in an open unconfined area or in confined space such as a closet or small room EXAMPLE 1 FURNACE LOCATED IN AN UNCONFINED SPACE Using indoor air for combustion An unconfined space must have at least 50 cubic feet for each 1 000 BTUH of the total input for all appliances in the space Here are a few examples of the room sizes required for different inputs The sizes are based on 8 foot ceilings BTUH Minimum Sq Feet Typical Room Size Input With 8 Ceiling With 8 Ceiling 50 000 312 14 x24 or 18 x18 75 000 469 15 x31 or 20 x24 100 000 625 20 x31 or 25 x25 125 000 833 23 x34 or 26 30 If the open space containing the furnace is in a building with tight construction contemporarv construction outside air mav still be required for the furnace to operate and vent properly Outside air openings should be sized the same as fora confined space FIGURE 7 AIR FROM ATTIC CRAWL SPACE ATTIC GABLE OR SOFFIT VENTS 4000 BTUH INLET AIR EXAMPLE 2 FURNACE LOCATED IN CONFINED SPACE A confined space anv space smaller than shown above as unconfined must have openings into the space which are located in
49. ONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH DO NOT UNDER ANY CIRCUMSTANCES CONNECT RETURN OR SUPPLY DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS FIREPLACE INSERT STOVE ETC DOING SO MAY RESULT IN FIRE CARBON MONOXIDE POISONING EXPLOSION PERSONAL INJURY OR PROPERTY DAMAGE LA WARNING BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE THIS IS TO PREVENT DRAWING GAS FUMES WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH UPFLOW UNITS 1 Set furnace in place and connect the return duct or return air cabinet to unit Make the connection air tight to prevent entraining combustion gases from any adjacent fuel burning appliances Unit return air may be connected on the sides or bottom of the return air compartment a Openings in the side must be cut out the full width of the knockouts on the unit If using side return air THE BOTTOM base must be installed NOTE Where the maximum airflow is 1800 CFM or more both sides or the bottom must be used for return air b If using bottom return air place furnace over return air plenum and seal furnace bottom to return air plenum A WARNING A SOLID METAL BASE PLATE SEE TABLE 1 MUST BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE C
50. OTE IF GROUND IS POOR OR ERATIC SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK FLAME SENSE CURRENT TURN POWER OFF TO UNIT CLEAN FLAME SENSOR WITH STEEL WOOL RESTORE POWER TO UNIT IF CHECKS ARE OK REPLACE IFC SYSTEM RUNS UNTIL CALL FOR HEAT ENDS FURNACE STARTS ON LOW FIRE FURNACE WILL SWITCH TO HIGH FIRE IF LOW FIRE DOES NOT SATISFY THERMOSTAT DEMAND OR HEAT LOAD STATIC DISCHARGE NO TURN THERMOSTAT TO OFF VALVE SHUTS OFF FLAME OFF pe NO DRAFT MOTOR STOPS AFTER 5 SECONDS pe FOR OPEN LIMITI ON HIGH FIRE OR 1 SECONDS ON LOW FIRE CHECK FOR OPEN LIMIT REPLACE REPLACE INTERFACE CONTROL CHECK FOR PROPER THERMOSTAT OPERATION REMOVE VALVE LEAD AT IFC IF VALVE CLOSED RECHECK THERMOSTAT AND WIRING IF NOT REPLACE VALVE INDOOR BLOWER MOTOR STOPS AFTER 9 12 16 18 SECONDS TROUBLESHOOTING ENDS REPEAT PROCEDURE UNTIL TROUBLEFREE OPERATION IS OBTAINED 92 22744 16 2 ad m 155980 3 YOLOW 13994 0330041 HOLOW 1d YOQANI AV 138 HAlHIGIWNH 1 3YNSS3Hd HJIH lt O bletc J6G 8 318991 IddY SV 53003 19901 NY IFO 3 za ER 10 34 0 AB ddy ag ya 3 IIE OL 3 ONY 30 89 300419313 N9
51. SONAL INJ URY OR DEATH See the conversion kit index supplied with the furnace This index identifies the proper LP Gas Conversion Kit required for each particular furnace IMPORTANT Any additions changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer service agency or the gas supplier using factory specified or approved parts In the commonwealth of Massachusetts installation must be performed by a licensed plumber or gas fitter for appropriate fuel IMPORTANT Connect this furnace only to gas supplied by a commercial utility IMPORTANT A U L recognized fuel gas and CO detector s are recommended in all applications and their installation should be in accordance with the detector manufacturer s recommendations and or local laws rules regulations or customs GAS PIPING Install the gas piping according to all local codes state codes and regulations of the utility company whichever holds jurisdiction If possible run a separate gas supply line directly from the meter to the furnace Consult the local gas company for the location of the manual main shut off valve The gas line and manual gas valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the combination gas valve on the furnace Refer to Table 2 for the recom mended pipe size for natural gas and Table 3 for LP gas pipe sizes
52. Selkirk s Selvent II HTPV product should cease immediately EXISTING VENT SYSTEMS IMPORTANT RETROFIT VENTING INSTRUCTIONS If this furnace is a replacement installation ALWAYS INSPECT the existing vent system to be sure there are no obstructions blockages or signs of corrosion When the existing furnace is removed from a venting system serving other appliances the venting is likely to be too large to properly vent the remaining attached appliances The following steps shall be followed with each appliance that remains connected to the common venting system while the other appliances that remain connected to the common venting systems are not in operation NOTE When the vent table permits more than one diameter of pipe for a connector or vent the smallest permitted diameter must be used 1 Seal any unused openings in the common venting system 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors windows and all doors between the space where the appliances remaining connected to the common venting system are located Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range
53. TCH SETTINGS MODEL WIDTH CFM SWITCH 5 SWITCH 6 2 GPL 05 17 5 800 ARL 24 OFF ON 3 681 05 175 1200 ARL 36 OFF OFF 3 GPL 07EBRKR 21 1200 ARL 36 OFF OFF 3 GPL 07EBROR 21 1200 ARL 36 OFF ON 3 GPL 10 21 1200 ARL 36 ON ON 3 GPL 12 24 1200 ARL 36 ON ON 4 GPL 07EBROR 21 1600 ARL 48 OFF OFF 4 GPL 10 21 1600 ARL 48 ON OFF 4 GPL 12 24 1600 ARL 48 ON OFF 5 GPL 10 21 1800 ARL 60 OFF OFF 5 GPL 12 24 1800 ARL 60 OFF OFF Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace See condenser spec sheet 180 and other literature for evaporator selection interface 62 24340 01 can not be used with two stage cooling since there is no YL input 25 START UP PROCEDURES DIRECT SPARK IGNITION LIGHTING INSTRUCTIONS This appliance is equipped with a direct spark ignition device This device lights the main burners each time the room thermostat closes calls for heat See lighting instructions on the furnace TO START FURNACE WARNING 1 BE SURE THAT THE MANUAL GAS CONTROL HAS BEEN IN THE OFF POSITION FOR AT LEAST FIVE MINUTES DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS FAILURE TO FOLLOW THIS WARNING CAN CAUSE A FIRE OR AN EXPLOSION RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH 2 Set the room thermostat to the lowest setting 3 Turn the gas control knob to the On position or mov
54. TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS ANY CIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER THIS SOOTY RESIDUE WILL SOIL CEILINGS WALLS DRAPES CARPETS AND OTHER HOUSEHOLD ARTICLES SOOT DAMAGE MAY ALSO RESULT WITH OR WITHOUT FILTERS IN PLACE WHEN CERTAIN TYPES OF CANDLES ARE BURNED OR CANDLEWICKS ARE LEFT UNTRIMMED NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS A WARNING ALWAYS INSTALL FURNACE TO OPERATE WITHIN THE FURNACE S INTENDED TEMPERATURE RISE RANGE WITH DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE AS SPECIFIED IN DUCTING SECTION OF THESE INSTRUCTIONS SEE ALSO FURNACE RATING PLATE a WARNING WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE FURNACE TO AREAS OUTSIDE THE SPACE CONTAINING THE FURNACE THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT S SEALED TO THE FURNACE CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE FURNACE A WARNING WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR THIS IS TO REDUCE THE RISK OF IGNITIN
55. accordance with the requirements set forth in the following subsections A and B Size the openings bv how thev are connected to the heated area or to the outside and bv the input of all appliances in the space If confined space is within a building with tight construction combustion air must be taken from outdoors or area freelv communicating with the outdoors A USING INDOOR AIR FOR COMBUSTION See Figure 6 IMPORTANT Air should not be taken from a heated space with a fireplace exhaust fan or other device that mav produce a negative pressure If combustion air is taken from the heated area the openings must each have at least 100 square inches of free area Each opening must have at least one square inch of free area for each 1 000 Btuh of total input in the space Here are some examples of tvpical openings required Btuh Free Area Input Each Opening 100 000 100 Square Inches 150 000 150 Square Inches USING OUTDOOR AIR FOR COMBUSTION See Figure 7 IMPORTANT Never take combustion air from an attic space that is equipped with power ventilation The confined space must communicate with the outdoors according to Methods 1 and 2 The minimum air opening dimension shall not be less than 3 inches When using ducts they shall be of the same cross sectional area as the free area of the openings to which they connect 11 12 B Method 1 Provide two permanent openings one located within 12 inch
56. burners d After the gas valve opens the remote flame sensor must prove ignition for one second using the process of flame rectification If the burners do not light the system goes through another ignition sequence It does this up to 4 times 2 tries on low fire and 2 tries on high fire e The main blower starts on low speed 20 seconds after the burners light The furnace operates on low fire for 12 minutes and then if the thermostat is not satisfied shifts to high fire causing the draft inducer to 90 to high speed the gas valve to 100 and the main blower goes to heat speed f When the thermostat cycle ends the gas valve closes and the burners go out g The draft inducer will continue running for a 10 second low speed or 5 second high speed post purge h The main blower will run for 90 seconds on high speed or 120 seconds on low speed This timing is field adjustable for 60 90 120 or 150 seconds See Figure 19 for switch settings Sequence if the system doesn t light or doesn t sense flame a If is not sensed within 8 seconds after the gas valve opens the valve closes and the ignitor is de energized The induced draft motor will run for 60 seconds on low stop momentarily and then restart b The ignition process goes through one more try on low fire If this fails there are two tries on high fire with a 30 second interpurge between trials During high fire ignition attempts t
57. ce most of the energy has been dissipated The buoyant effect of the flue gases provides venting to the outdoors During the off cycle the inducer is off and there is very little flow through the vent cooling the vent During the on cycle there is no dilution airflow as with a draft hood type furnace Although the vent heats up rapidly without dilution air the flue products contain more water vapor which results in a higher dew point temperature It is most important that you follow the guidelines in these instructions to prevent the possible formation of condensation in the venting system As a Category furnace it may be vented vertically with type B 1 vent pipe and also may be common vented as described in these instructions VENT PIPE _ ADAPTER I CONNECTOR PRE DRILL ATTACHING HOLES SEE PAGE 14 VERTICAL VENTING A0991 01 IMPORTANT APPLICATION NOTES When the furnace is used as replacement the existing vent system should be inspected to assure that there are no obstructions blockage or any signs of corrosion NOTE When the vent table permits more than one diameter of pipe for a connector or vent the smallest permitted diameter must be used vent pipe may be type B 1 either rigid or suitable flexible construction that carries a U L listing Common venting is allowed with vertical B 1 vent systems and lined masonry chimneys Follow the National Fuel Gas Code ANSI Z223 1 and
58. ce change is specifically mandated by local codes an alternate method of altitude deration through a reduction in manifold pressure is acceptable as described in Table 7 This information is based on a heating value of 1000 BTU per cubic feet of natural gas and 2500 BTU per cubic feet of LP gas TABLE 7 IMPORTANT Actual input rates must be measured onsite with manifold pressure adjustment to ensure that an actual 10 reduction in input rate is achieved this field adjustment has been made the label shown in Figure 17 must be affixed in a conspicuous location on the front of the furnace cabinet NOTE This label is supplied in the information packet shipped with each furnace FURNACE INSTALLATION WITH HIGH EFFICIENCY PREMIUM COOLING SYSTEMS Furnace installation with Rheem Ruud ARA or ARL outdoor condensing units can provide high efficiency up to 16 SEER cooling operation Using Tables 9 and 10 and literature provided with the cooling equipment the installer needs to make sure that the proper evaporator coil condensing coil and airflow is configured to achieve rated efficiency ALTERNATE METHOD FOR CANADIAN HIGH ALTITUDE DERATE IMPORTANT 80 MODELS ONLY DO NOT USE THIS CHART FOR ANY 90 MODELS HIGH FIRE NATURAL GAS ORIFICE MANIFOLD ALTITUDE INPUT OUTPUT SIZE PRESSURE 50 000 75 000 100 000 125 000 150 000 45 000 67 500 90 000 112 500 135 000 2001 4500 LOW FIRE
59. ception The recommended LP Gas high altitude orifice selections differ slightly in that the NFGC LP orifice chart as they are not accurate for Rheem products The National Fuel Gas Code LP orifices are based on an 11 of water column pressure at the orifice which differs from Rheem products that use 10 of water column at the orifice This difference requires a deviation from the orifice size recommendations The Sea Level input should still be reduced by 4 per thousand ft and the orifice size must be selected based on the reduced input in Table 6 TABLE 6 IMPORTANT 80 MODELS ONLY DO NOT USE THIS CHART WITH ANY 90 MODELS LP GAS Input per 0rifice Altitude burner 25000 Size 0 to 2000 ft 25000 54 2001 3000 24000 54 3001 4000 23000 54 4001 5000 22000 54 5001 6000 21000 54 6001 7000 20000 54 7001 8000 19000 55 8001 9000 18000 55 9001 10000 17000 55 ORIFICE ORDERING INFORMATION Orifice sizes are selected by adding the 2 digit drill size required in the orifice part number Drill sizes available are 39 through 64 metric sizes available 1 10mm 90 and 1 15mm 91 Orifice Part Number 62 22175 drill size Example 1 60 drill size orifice required Part 62 22175 60 Example 2 1 15mm drill size orifice required Part 62 22175 91 ALTERNATE METHOD FOR CANADIAN HIGH ALTITUDE DERATE In Canada unless an orifi
60. de s Benzene More details are available at the Websites for OSHA Occupational Safety and Health Administration at www osha gov and the State of California s OEHHA Office of Environmental Health Hazard Assessment at www oehha org Consumer education is important since the chemicals and substances on the list are found in our daily lives Most consumers are aware that products present safety and health risks when improperly used handled and maintained CONTENTS stua L T uu SG 1 installation Check Listi ii u l a 2 Gerieral Information un O uyu 5 Location Requirements and Considerations lt lt 5 Combustion and Ventilation Air a 10 Vent Pipe Installation ad A A ALE 13 Gas Supply and Piping o A oe 16 Electrical Wiring xu suter 20 ACCOSSOMIOS is u a 21 High Altitude Installations sean 22 Installation with High Efficiency Premium Cooling Systems 23 Start Up Pro edufes iii kn r dad ie tape 26 Arr FlOW ei ia ia 244 94 AE Radi 33 Safety FealUreS ii iii ii
61. dip switches on the main furnace control board for setting blower off timings Switches 1 and 2 adjust the times See Figure 20 IMPORTANT Switch 3 on the integrated furnace control board is not used and must be in the OFF position If put in the On position a 5 blink fault will be flashed on the IFC When Switch 4 is in the on position on the main IFC the blower will continue its normal speed for 0 30 20 or 50 seconds after a cooling or heat pump cycle has ended This also is dependent upon the settings of Switches 1 and 2 on the IFC see Figure 20 The blower will TABLE 14 COOLING AIR FLOW SWITCHES 5 amp 6 then enter one of four off delay profiles as shown in Figure 21 The profile is determined by the settings of Switches 3 and 4 on the interface board For example If the switches are in position A as shown in Figure 19 then profile as shown in Figure 21 is entered after the blower off timing These switch combinations between the main IFC and interface control board allow for a wide range of off delay timings Switches 3 and 4 on the ECM interface control can be used with any main IFC switch 1 and 2 setting to control how the blower turns on and off Possible off delay timings and profiles are shown in Table 15 A corresponding cooling heat pump On delay is also chosen by Switches 3 and 4 on the interface control as shown in Figure 22 For e
62. e the gas control lever to the On position 4 Replace the control access door Turn on the electrical power 6 Set the room thermostat to a point above room temperature to light the main burners After the burners are lit set room thermostat to a desired temperature TO SHUT DOWN FURNACE 1 Set the room thermostat to its lowest setting 2 Shut off the gas to main burners by turning the gas control knob to the Off position or by depressing the gas control lever and moving it to the Off position A WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH Sequence of operation with a single stage thermostat a Connect the W terminal on the thermostat to the W2 terminal on the control board b When there is a call for heat the R and W2 contacts close and the IFC runs a self check routine to verify that the pressure switch contacts are open The limit switch contacts are constantly monitored 26 c The induced draft motor starts on high until the low pressure switch contacts close a maximum of 60 seconds and then changes to low speed After a 30 second pre purge the spark ignitor energizes and the low stage of the gas valve opens lighting the
63. ecklist and complete one for every Low Profile Furnace service call for your records INSTALLATION CHECKLIST Refer to this manual for specifics GAS SUPPLY Adequate pipe size No gas leaks Proper supply and manifold gas pressure check with an accurate U tube manometer with the furnace and all other gas appliances operating ELECTRICAL Correct thermostat and subbase Thermostat model Subbase model Correct thermostat mode and setting Correct line supply voltage Correct power supply polarity is required with electronic ignition Correct furnace ground to electrical panel DC microamp uA flame signal hot surface ignition units Correct control voltage Measure and set heat anticipator amperage Air conditioning low voltage wires connected to terminals Y C not with wire nuts VENTING Correct vent pipe diameter and length according to CSA tables Vent connection size Correct venting material according to CSA tables Correct lining for masonry chimneys Adequate clearance from combustibles Proper negative pressure reading in the vent Vent pipe secured to induced draft blower housing COMBUSTION AIR Proper source of combustion air Correct combustion air opening size FURNACE INSTALLATION Adequate clearance from combustibles Adequate clearance for service Proper air temperature rise See furnace rating plate External static pressure inches
64. ed of the entire system should not exceed 0 5 w c Be sure to have adequate space for unit filter IMPORTANT Some high efficiency filters have a greater than normal resistance to air flow This can adversely affect furnace operation BE SURE TO CHECK AIR FLOW if using any filter other than the factory provided filter NOTE DO NOT take return air from bathrooms kitchens furnace rooms garages utility or laundry rooms or cold areas IMPORTANT When using outside air design and adjust the system to maintain a return air temperature above 50 F during the heating season WARNING NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTS TO ENTER THE RETURN AIR DUCTWORK OR THE CIRCULATING AIR SUPPLY ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS AND J OINTS TAPED WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM THE RETURN AIR PLENUM MUST BE PERMANENTLY ENCLOSED NEVER USE ADOOR AS A PART OF THE RETURN AIR PLENUM THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE WITHOUT SAGGING CRACKS GAPS ETC AROUND THE BASE AS TO PROVIDE A SEAL BETWEEN THE SUPPORT AND THE BASE FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS INCLUDING CARBON MONOXIDE POIS
65. elevation 4 de rate per thousand ft 444 Example 1050 BTU ft Regional Natural Gas Heating Value I H Q 25000 1050 23 81 f Sea Level input per burner 25000 H Sea Level Heating Value 1050 Q 23 81 Natural Gas per hour From Table F 1 of National Fuel Gas code Handbook 2002 3 5 w c column Orifice required at Sea Level 443 From Table F 4 of National Fuel Gas code Handbook 2002 Orifice required at 5000 ft elevation 4 de rate per thousand 45 Orifice required at 8000 ft elevation 4 de rate per thousand ft 447 TABLE 5 NATURAL GAS ORIFICE DRILL SIZE 4 PER 1000 FT DE RATE IMPORTANT 80 MODELS ONLY DO NOT USE THIS CHART WITH ANY 90 MODELS BURNER INPUT PER BURNER 25 000 amp SEA LEVEL Annual Avg Heat Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to Value btu per ft to 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 6999 ft 7999 ft 8999 ft 850 38 39 40 41 41 42 42 43 900 40 41 42 42 42 43 43 44 975 41 42 42 42 43 43 44 44 1075 42 42 43 43 43 44 44 45 1170 43 44 44 44 45 45 46 47 LP GAS AT HIGH ALTITUDE ELEVATION TABLE 6 NOTE Keep any parts removed during LP conversion procedure stored with the product literature for future use LP Gas is a manufactured gas that has consistent heating value across most regions The guidelines are used with the following ex
66. erface control part 462 24340 01 or 62 24340 04 For proper operation of high SEER equipment with two stage cooling the part should be 62 24340 04 The 62 24340 01 will not operate low speed cooling and therefore will not and should be replaced with the 62 24340 04 for high SEER two stage cooling systems One way to tell if the control is the 62 24340 04 is to look at the part to see if there is a thermostat connection for low speed cooling YL on the control This will be a screw type input like those of the thermostat inputs on the main IFG If no YL connection is available on the interface control the furnace is not compatible with high SEER equipment or will need to be replaced A Furnaces constructed up to January 2005 are not compatible with high SEER two stage systems and will need to be replaced with the newer furnace to insure proper operation with high SEER cooling equipment B For furnaces constructed after February 2005 but before June 2005 the interface control can be replaced with the newer version to convert the furnace for high SEER two stage cooling For this scenario contact the Rheem service department and a replacement control will be shipped BE SURE TO REPLACE THE CONTROL BEFORE OR DURING INSTALLATION OTHERWISE THE SYSTEM MAY BE DOWN WHILE PARTS ARE BEING SHIPPED C For furnaces constructed after June 2005 all components necessary for proper operation of high SEER equipment are
67. es of the top and one located within 12 inches of the bottom of the enclosure Each opening shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors a Where directly communicating with the outdoors or where communicating to the outdoors through VERTICAL DUCTS each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure see Figure 7 Here are typical duct sizes VERTICAL OUTDOOR AIR OPENING DIMENSIONS BTUH Free Area Round Input Each Opening Pipe Size 50 000 12 50 sq inches 4 75 000 18 75 sq inches 55 100 000 25 00 sq inches 6 125 000 31 25 sq inches T b Where communicating with outdoors through HORIZONTAL DUCTS each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating for all equipment in the enclosure see Figure 8 Here are typical duct sizes HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS BTUH Free Area Round Input Each Opening Pipe Size 50 000 25 00 sq inches 6 75 000 37 50 sq inches 7 100 000 50 00 sq inches 8 125 000 62 50 sq inches 9 B Method 2 One permanent opening located within 12 inches of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance The
68. he inducer steps to high speed the high pressure switch closes both pressure switches are now closed and the gas valve steps to 100 c If there is no ignition after the 2nd trial on high fire the furnace goes into soft lockout for one hour d The sequence repeats after a one hour delay and continues repeating until ignition is successful or the call for heat is terminated e To reset the lockout make and break power either at the thermostat or at the unit disconnect switch for 5 to 10 seconds The furnace will then go through another set of trials for ignition f If flame is established and maintained during the trial for ignition period and flame is lost the gas valve is de energized the draft inducer completes a post purge of 10 seconds The indoor blower motor will be energized and or remain energized on low speed for low fire and heat speed for high fire for the selected delay off time When the inter purge delay is over the control verifies the pressure switch has opened and then initiates another ignition trial period The control will recycle up to 5 flame losses 4 re cycles within a single call for heat before going into lockout Sequence of operation with two stage thermostat Connect W1 and W2 terminals on the thermostat to W and W2 terminals on the control board Call for 1st stage heat a R and W thermostat contacts close and the control module runs a self check routine After the control
69. hes to low speed and the gas valve changes to low fire The furnace continues to run in this mode until the 151 stage heat call is satisfied The system will shut down as noted in c under 1st stage call for heat INTEGRATED FURNACE CONTROL amp ECM MOTOR SETTINGS These furnaces have ECM blower motors These motors deliver a constant level of air flow over a wide range of external static pressures 0 1 to 0 8 W C The interface board found beside the furnace integrated control board provides the required communications between the main integrated furnace control and the ECM blower motor There is a bank of 4 dip switches on the integrated furnace control which controls the blower off timings See section on BLOWER OFF TIMINGS FOR ECM MOTORS and Figure 20 for proper switch settings There is a bank of 12 dip switches on the interface board which define the operation of the ECM motor Only the first eleven switches are used for this application See Figure 18 These switches except for switches 9 and 12 are actually broken down into five dip switch pairs Switches 1 and 2 act as a pair as do switches 3 and 4 5 and 6 7 and 8 and 10 and 11 The assignments of the switch pairs are shown in Table 11 Only traditional humidistats will work with this feature FIGURE 18 TABLE 11 SWITCHES FUNCTION 1 amp 2 Heating Airflow 3 amp 4 Cooling Off On Delay Profiles 586 N
70. hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so the appliance will operate continuously FIGURE 11 DEDICATED VENTING THROUGH CHIMNEY WITH B 1 VENT 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance that remains connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use 7 improper venting is observed during any of the above tests the common venting system must be resized Refer to National Fuel Gas Code ANSI Z223 1 and or the Natural Gas Installation Code CSA B149 1 8 2 15 GAS SUPPLY AND PIPING GAS SUPPLY A WARNING THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER MAILING ADDRESSES ARE LISTED ON THE FURNACE RATING PLATE PARTS LIST AND WARRANTY FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE CARBON MONOXIDE POISONING EXPLOSION PROPERTY DAMAGE PER
71. ie 34 Maintenance i 36 Troubleshooting nsien 39 Wiring Diagram n 41 IMPORTANT To insure proper installation and operation of this product completely read all instructions prior to attempting to assemble install operate maintain or repair this product Upon unpacking of the furnace inspect all parts for damage prior to installation and start up SAFETY INFORMATION A WARNING A WARNING USE ONLY WITH TYPE OF GAS APPROVED FOR THIS FURNACE REFER TO THE FURNACE RATING PLATE A WARNING INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS A WARNING PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS A WARNING COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS CONNECT THIS FURNACE TO AN APPROVED VENT SYSTEM ONLY AS SPECIFIED IN VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS a WARNING THE SYSTEM FOR EXTENDED PERIODS WITHOUT FILTERS PORTION OF THE DUST ENTRAINED IN THE AIR MAY
72. le with care 4 Remove the two screws attaching the NOx insert retainer brackets to the center panel Pull the retainer rod 5 Put the two screws back into the holes in the center panel 6 Re install the igniter and burner assemblies 7 Replace burner door 8 Turn on electrical power and gas supply to the unit NOTE Some NOx models may have one less NOx insert 17 SETTING GAS PRESSURE The maximum gas supply pressure to the furnace should be 10 5 w c natural gas or 13 w c LP gas The minimum supply gas pressure to the gas valve should be 5 w c natural gas or 11 w c LP gas A properly calibrated manometer is required for accurate gas pressure measurements A CAUTION ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJ USTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY OR MAY NOT NEED TO BE CHANGED SEE THE SECTION TITLED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS Manifold Gas Pressure Measurement Natural gas manifold pressure should be 3 5 w c LP gas manifold pressure should be 10 w c Only small variations on gas pressure should be made by adjusting the pressure regulator 1 With the gas shut off at the manual gas valve remove the pressure tap plug in the gas manifold or the gas valve outlet See Figure 24 2 Connect a U Tube manometer to this
73. maximum gas supply pressure to the furnace should be 10 5 W C for natural gas The minimum gas supply pressure for purposes of input OE to the furnace should be 5 A properly calibrated manometer or gauge is required for accurate gas pressure readings 1 When adjusting the furnace input the high fire input should be checked The high fire manifold pressure should be 3 5 W C Follow these steps to be sure the furnace is high fire mode a With a single stage thermostat the furnace runs for 12 minutes on low fire before shifting to high fire To be certain that it is on high fire jump terminals W and W2 on the control board in the blower compartment b With a two stage thermostat set the thermostat to its highest setting to keep the furnace operating in the high fire mode TABLE 4 METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS 2 To adjust high fire manifold pressure remove the adjustment cover screw on the outlet end of the gas valve and turn the adjustment screw clockwise to increase the pressure and counterclockwise to reduce the pressure Replace the cover screw securely See Figure 24 3 The low fire manifold pressure should be 1 7 W C As mentioned above the furnace remains in the low fire mode for 12 minutes upon a heat call with a single stage thermostat With a two stage thermostat disconnect the thermostat lead to
74. n the gas piping 4 Locate the furnace to maintain proper clearance to combustibles as shown in Figures 2 8 3 CAUTION WHEN COILS ARE USED WITH AIR HANDLERS OR FURNACES AND INSTALLED ABOVE A FINISHED CEILING OR LIVING AREA IT IS RECOMMENDED THAT AN AUXILIARY SHEET METAL CONDENSATE DRAIN PAN BE FABRICATED AND INSTALLED UNDER ENTIRE UNIT FAILURE TO DO SO CAN RESULT IN PROPERTY DAMAGE A WARNING COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE J ACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS PLACEMENT OF COMBUSTIBLE MATERIALS ON AGAINST OR AROUND THE FURNACE J ACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH THE FURNACE OWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS ABROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES DUCTING Proper air flow is required for the correct operation of this furnace Too little air flow can cause erratic operation and can damage the heat exchanger The duct system must carry the correct amount of air for heating and cooling Position the unit minimize long runs or runs with many turns and elbows Size the ducts according to acceptable industry standards and methods The total static pressure drop including evaporator coil if us
75. ominal Cooling Heat Pump Air Flow 7 amp 8 Latent Sensible Airflow Adjustment 9 Continuous Fan Airflow 108 11 On Demand Dehumidification Settings Not Used Dehumidistats will not work properly with this feature See Page 27 under Dehumidification HEATING AIRFLOW ADJUSTMENTS The furnace is shipped with low and high fire heating airflows These are set from the factory to let the furnace operate at the mid point of the temperature rise range The temperature may vary slightly due to furnace input and voltage variations The installer is given the option of three air flow options in the heating mode as shown in Table 12 Switches 1 and 2 on the interface control regulate the steady state heating mode airflow In the heating mode the ECM motor is programmed to ramp up to its target CFM over a fifteen 15 second period After any of the user selected Off delays see Figures 23 and 24 the motor will ramp down to 50 of steady state CFM for approximately thirty 30 seconds The motor will then ramp down to an off position 9 10 11 12 Tisispi FIGURE 19 OFF OFF OFF ON ON ON FIGURE 20 BLOWER OFF TIMINGS UTEC 1095 101 CONTROL WITH INTERFACE BOARD AND ECM MOTOR 0001 NOTE SWITCH 3 MUST BE IN OFF POSITION NORMAL ECM LOW HIGH COOLING COOLING SWITCH SWITCH FIRE FIRE SWITCH 4 ON 1 2 4 OFF 80 50 30 0 ON 80 40 30 OFF 1
76. ore efficiently and more economically Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed Close doors and windows This will reduce the heating load on the system Avoid excessive use of kitchen amp bathroom exhaust fans Do not permit the heat generated by television lamps or radios to influence the thermostat operation Except for the mounting platform keep all combustible articles three feet from the furnace and vent system IMPORTANT Replace all blower doors and compartment covers after servicing the furnace Do not operate the unit without all panels and doors securely in place Proper operation of the system with constant air circulation WARNING COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE J ACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS PLACEMENT OF COMBUSTIBLE MATERIALS ON AGAINST OR AROUND THE FURNACE J ACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE PERSONAL INJ URY OR DEATH THE FURNACE OWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES ANNUAL INSPECTION The furnace should operate for many years without excessive scale build up in the
77. out is provided NOTE LI hot and neutral polarity must be observed when making field connections to the furnace The ignition control on electric ignition models will not sense flame if L1 and neutral are reversed Installation of the electric supply line should be in accordance with the National Electric Code ANSI NFPA No 70 latest edition or Canadian Electrical Code Part 1 CSA Standard C22 1 and local building codes This can be obtained from National Fire Protection Association Batterymarch Park Quincy MA 02269 Canadian Standards Association 178 Rexdale Blvd Etobicoke Toronto Ontario Canada M9W 1R3 20 FIGURE 15 ISOLATION RELAY TO THERMOSTAT W TERMINAL TO THERMOSTAT R TERMINAL FURNACE CONTROL BOARD FIGURE 16 LINE VOLTAGE CONNECTIONS 0804 01 UT ELECTRONIC CONTROLS 1028 928 CONTROL BOARDS HEAT COOL MI M2 H C LOW Li LI 0000000 06 9 ej NEUTRA THERMOSTAT A single or two stage thermostat may be used however a two stage thermostat is recommended for optimum performance The room thermostat must be compatible with the integrated furnace control on the furnace All thermostats available from the furnace manufacturer s Parts Department are acceptable Generally all thermostats that are not of the current
78. ower motor and induced draft motor are permanently lubricated by the manufacturer and do not require further attention The motor must be cleaned periodically by a qualified installer service agency or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior And as suggested elsewhere in these instructions the air filters should be kept clean because dirty filters can restrict airflow and the motor depends upon sufficient air flowing across and through it to keep from overheating Reference Figure 27 for proper removal of blower assembly on downflow models 35 MAINTENANCE FIGURE 28 RESIZING FILTERS amp FRAME WARNING DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL URY OR DEATH FILTERS Filter application and placement are critical to airflow which may affect the Ke EN TO SIZE heating and cooling system a performance Reduced airflow can shorten the life of the system s major Copaan such motor limits TABLE 17 FILTER SIZES elements heat exchanger evaporator coil or compressor Consequently we ans ALTER SIESS recommend that the return air duct FURNACE INPUT BOTTOM SIDE QUANTITY system have only one filter location WIDTH BTUH SIZE SIZE The most common location will be 17
79. rnaces are located on either side of the burner cover plate and just above the burners on the blower divider panel If a switch is tripped it must be manually rest DO NOT jumper or reset this switch If this switch should trip a qualified installer service agency or the gas supplier should be called to diagnose and or correct the sourse of tripping If this unit is mounted in a closet the door must be closed when making this check FIGURE 27 DOWNFLOW BLOWER REMOVAL TOP PLATE JACKET STEP 1 FRONT SCREW TO BE REMOVED amp TOP PLATE LIFTED STEP 2 REMOVE FLUE PIPE ENCLOSURE SCREW 1 REQ D ENCLOSURE DOOR STEP 3 REMOVE BLOWER MOUNTING SCREWS AND SLIDE OUT BLOWER SEE BIM NOTE FLUE PIPE ENCLOSURE amp ENCLOSURE DOOR MUST BE REMOVED FOR BLOWER REMOVAL PRESSURE SWITCHES This furnace has two pressure switches for sensing a blocked vent condition One is for high pressure and the other for low pressure When the draft inducer is running on high speed both switches will normally close when running on low inducer speed only the low pressure switch will close If there is a blocked vent condition failed inducer motor or leak in the pressure switch hoses the pressure switch contacts will remain open The STATUS light will blink twice indicating a pressure switch problem The high fire pressure switch is located in the upper position on the furnace LUBRICATION The bl
80. stalled in accordance with the American National Standard Z223 1 latest edition booklet entitled National Fuel Gas Code NFPA 54 in Canada CSA B149 1 and 2 Installation Codes for gas burning appliances and the requirements or codes of the local utility or other authority having jurisdiction including local plumbing or waste water codes Additional helpful publications available from the National Fire Protection Association are NFPA 90A Installation of Air Conditioning and Ventilating Systems 1985 or latest edition NFPA 90B Warm Air Heating and Air Conditioning Systems 1984 These publications are available from National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 CSA INTERNATIONAL 178 Rexdale Blvd Etobicoke Toronto Ontario Canada M9W 1R3 LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION CAUTION USE THIS FURNACE DURING CONSTRUCTION IF AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH AS CHLORINE AND FLUORINE OTHERWISE PROVISIONS MUST BE TAKEN TO PROVIDE CLEAN UNCONTAMINATED COMBUSTION AND VENTILATION AIR TO THE FURNACE FURNACE COMBUSTION AND VENTILATION AIR CONTAMINATED WITH THESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH CORRODES THE HEAT EXCHANGER AND COMPONENT PARTS SOME OF THESE CONTAMINANTS ARE FOUND IN BUT NOT LIMITED TO PANELING DRY WALL ADHESIVES PAINTS STAINES VARNISHES SEALERS AND MASONRY
81. the National Fuel Gas Code NFGC Specific orifices should always be recalculated for all high altitude installations as outlined below Orifices should be changed if necessary based on gas heating value and elevation GPL GLL HIGH ALTITUDE OPTION 278 Furnaces can be ordered from the factory already converted for high altitude elevations The factory option for high altitude elevations would be ordered as a 278 option example a 100k BTU upflow furnace which is factory converted for high altitude elevations would have the model number GPL 10EBRMR278 These factory converted furnaces come with pressure switches for high altitude elevations already attached Also different burner orifices are installed at the factory which are one drill size smaller 43 DMS than standard GPL GLL gas furnaces 42 DMS The smaller orifice is installed to accommodate for average heating values expected in most high altitude areas and a required 4 per thousand feet reduction in input as specified by the National Fuel Gas Code NFGC Specific orifices should always be recalculated for all high altitude 22 installatons as outlined below Orifices should be changed if necessary based on gas heating value and elevation A CAUTION ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJ USTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY
82. ting air blower is in operation HUMIDIFIER GPH 8 JGLH MODELS ONLY 2 Humidifier line voltage power can be supplied from screw terminal HUM to a line voltage neutral screw terminal on the control board See Figure 16 This will power the humidifier whenever the inducer is operating in the heating mode NOTE Maximum current 1 0 amps for each option RXGW B01 CHIMNEY ADAPTER This appliance is CSA certified for use with RXGW B01 chimney adapter Refer to Kit Installation Instructions 92 101682 01 FURNACE TWINNING IMPORTANT Twinning of GPL and GLL models is not allowed 21 80 HIGH ALTITUDE INSTRUCTIONS CAUTION THE NATIONAL FUEL GAS CODE NFGC GUIDELINES SHOULD BE FOLLOWED WHEN CONVERTING THESE FURNACES FOR HIGH ALTITUDE OPERATION GPL GLL HIGH ALTITUDE KITS All GPL GLL models can be converted for high altitude using the following kits High Altitude Kit Models RXGY F13 ALL GPL models RXGY F28 GLL 05 GLL 07 all GLL 10 RXGY F27 GLL 12 The kits include pressure switches and instructions for converting the furnace for elevations above 5 000 ft These kits should never be used at elevations below 5 000 ft In addition the kit instructions detail how to re calculate burner orifice size based on gas heating value and elevation The instructions are based on a required 4 per thousand feet reduction in input as specified by
83. w c Correct filter s Correct cooling coil or accessories if equipped _ Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size Air ducts sealed to prevent leakage IMPORTANT All Rheem products meet current Federal OSHA Guidelines for safety California Proposition 65 warnings are required for certain products which are not covered by the OSHA standards California s Proposition 65 requires warnings for products sold in California that contain or produce any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation lead in brass and combustion products from natural gas All new equipment shipped for sale in California will have labels stating that the product contains and or produces Proposition 65 chemicals Although we have not changed our processes having the same label on all our products facilitates manufacturing and shipping We cannot always know when or if products will be sold in the California market You may receive inquiries from customers about chemicals found in or produced by some of our heating and air conditioning equipment or found in natural gas used with some of our products Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers Glass Wool Fiberglass Insulation e Carbon Monoxide CO Formaldehy
84. xample if Off delay profile A is chosen in Figure 21 then ON delay profile A in Figure 22 is automatically chosen DEHUMIDIFICATION The interface control has two optional 24 volt AC only inputs The B terminal input is provided for heat pump applications This signal comes from a heat pump thermostat and tells the heat pump to switch its reversing valve to heat mode If this B signal is also routed to the interface control all airflow adjust switches 7 amp 8 and On Demand Dehumidification are bypassed in the heat mode only The airflow will remain at the normal airflow as selected by switches 5 amp 6 throughout the heat mode This allows the user to have a switched 10 airflow adjustment for dehumidification or the Demand Dehumidification in cooling mode but not the adverse humidity and heat rise effects of using these adjustments during a heat pump s heat mode The B terminal does not apply to gas operation The On Demand Dehumidification input allows the user to have automatic dehumidification that is controlled by the user s humidistat setting Dehumidistats are not compatible with the interface control When the humidity exceeds the humidistat setting it routes a 24 volt AC only signal to the Demand Dehumidification terminal This will in turn decrease the airflow by 15 This results in higher latent capacity and increases the level of

92-24161-24 Revision 07 GPL, GLL Installation Instructions

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