Home

High Efficiency Gas-Fired Furnace

1. BLOWER COMPARTMENT BURNER COMPARTMENT Upflow Horizontal GULA Models Gas Valve Gas Line Entrance Alternate Pressure Switch Gas Manifold Hot Surface Igniter Rollout Limit Burners Flame Sensor Flue Pipe Connection Coupling Flue Pipe Internal Primary Limit Gas Line Entrance Flue Pipe Connection Alternate Rubber Elbow Induced Draft Blower Electrical Connection Inlets Alternate 17 Coil Front Cover Pressure Tap 18 Coil Front Cover Drain Port 19 Drain Line Penetrations 20 Drain Trap 21 Blower Door Interlock Switch 22 Capacitor 23 Integrated Control Module with fuse and diagnostic LED 24 24 Volt Thermostat Connections 25 Transformer 40 VA 26 Circulator Blower 27 Auxiliary Limit 28 Junction Box 29 Electrical Connection Inlets 30 Coil Front Cover A WARNING To prevent possible death personal injury or property damage due to electrical shock the furnace must be located to protect the electrical components from water AA CAUTION This unit must not be used as a construction heater during the finishing phases of construction ona new structure This type of use may result in premature failure of the unit due to extremely low return air temperatures and expos
2. F FRONT COVER DRAIN PORT ae RED HOSE Le H kl CLAMP A O HOSEA AC S a V K w FRONT HOSE BS J BL cover v SIDE PANEL PJA PRESSURE RUBBER DRAIN s lt ELBOW HOLES ee aa Ss iE d j kV A Td N A A 8 NS RIGHT l O O S SIDE TUBES 3 Ke PANEL ah In RUBBER ELBOW GREEN DRAIN PORT e HOSE TUuBE1 NO DRAIN TRAP lt CLAMP Gg e E 3 PLACES Horizontal Connections Right Side Down Cut 1 4 inch from the end of the drain port on the rubber elbow and discard Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp Angle tube outward toward front of furnace Cut 17 3 4 inches from the long end of Hose B and discard Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose to front right down side panel grommet holes Cut 5 1 2 inches straight length from the long end of each Tube 2 Insert approximately one inch of each Tube 2 through the right down side panel drain holes Secure tubes to Hose A and Hose B using green hose clamps NOTE Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting Lert Soe Down Horizontal installations with the left side panel down will
3. To prevent unreliable operation or equipment damage the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following proce dure 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pressure tap or the gas piping drip leg NOTE At either location a hose fitting must be installed prior to making the hose connection Gas Valve On Off Selector Switch Inlet Pressure 7 A Tap OUTLET duer Pressure Regulator Outlet Pressure Adjustment gt Tap Under Cap Screw White Rodgers Model 36G22 Gas Valve On Off Selector Switch INLET gt gt OUTLET Ka Inlet Pressure Tap Side of Valve Outlet Manifold Pressure Regulator Pressure Tap Adjustment Under Cap Screw White Rodgers Model 36F22 Gas Line Gas Shutoff Valve Gas Line To Furnace Open To Atmosphere Drip Leg Cap W
4. UMIDIFIER HUM N 120 VAC EAC N HOT AND PAR TERMINALS INTEGRATED CONTROL MODULE 120 VAC NEUTRAL TERMINALS 12 PIN CONNECTOR Accessories Wiring If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace the wiring must conform to all local codes and have a minimum tempera ture rating of 105 C All line voltage wire splices must be made inside the furnace junction box The integrated control module humidifier terminals HUM are energized with 115 volts whenever the induced draft blower is energized The integrated control module elec tronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized XII GAS SUPPLY AND PIPING GENERAL The furnace rating plate includes the approved furnace gas input rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any conversion kits required for alternate fuels and or high altitude A CAUTION To prevent unreliable operation or equipment damage the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating Inlet gas supply pressures must be maintained within the ranges specified below The supply pressure must be constant and available with all other household gas fired appliances operating The minimum gas supply pressure must be maintaine
5. module diagnostic LED conTINUOUS is flashing continuously Troubleshooting Chart Fault Description s e Primary or auxiliary limit circuit is open e Rollout limit circuit is open e Polarity of 115 or 24 volt power is reversed e Flame sense microamp signal is low Flame sensed with no call for heat Possible Causes e Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower e Loose or improperly connected wiring e Flame rollout e Misaligned burners blocked flue and or air inlet pipe or failed induced draft blower e Loose or improperly connected wiring e Polarity of 115 volt AC power to furnace or integrated control module is reversed Orange and gray wires to transformer are reversed e Poor unit ground e Flame sensor is coated oxidized e Flame sensor incorrectly positioned in burner flame e Lazy burner flame due to improper gas pressure or combustion air e Short to ground in flame sense circuit 35 Corrective Action e Check filters and ductwork for blockage Clean filters or remove obstruction e Check circulator blower speed and perfor mance Correct speed or replace blower if necessary e Tighten or correct wiring connection e Check burners for proper alignment e Check flue and air inlet piping for blockage proper length elbows and te
6. AA WARNING To avoid fire explosion or bodily injury solvent cements must be kept away from all ignition sources i e sparks open flames and excessive heat as they are combustible liquids Avoid breathing cement vapors or contact with skin and or eyes Two or three inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785 PVC primer meeting ASTM F656 and PVC solvent cement meeting ASTM D2564 specifica tions must be used Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311 Carefully follow the manufacturer s instructions for cutting cleaning and solvent cementing of PVC As an alternative to PVC pipe primer solvent cement and fittings ABS materials which are in compliance with the following specifications may be used Two or three inch ABS Schedule 40 pipe must meet ASTM D1527 and if used in Canada must be CSA listed Solvent cement for ABS to ABS joints must meet ASTM D2235 and if used in Canada must be CSA listed Carefully follow the manufacturers instructions for cutting cleaning and solvent cementing PVC and or ABS All 90 elbows must be medium radius 1 4 bend DWV or long radius Long sweep 1 4 bend DWV types conforming to ASTM D3311 Amedium radius 1 4 bend DWV elbow measures 3 1 16 minimum from the plane of one opening to the centerline of the other opening for 2 diameter pipe and 4 9 16 minimum for 3 pipe PROPER VENT FLUE AND COMBUSTION AIR PIPING PRACTICES
7. Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual are intended as supplemental to existing practices However ifthere is a direct conflict between existing practices and the content of this manual the precautions listed here take precedence A WARNING If the information in these instructions is not followed exactly fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier AA WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas shut off valve external to the furnace before turning off the electrical supply To THE OWNER It is important that you fill out the owner s registration card and mailittoday This will assist us in contacting you should any service or warranty information change in the future When filling in the registrati
8. enclosed furnaces which incor porate an integral total enclosure and use only outside air for combustion and dilution of flue gases b Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use Equipment shall be located so as not to interfere with proper circulation of air When normal infiltration does not provide the necessary air outside air shall be introduced c In addition to air needed for combustion process air shall be provided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilution safety exhaust odor control and air for compressors d In addition to air needed for combustion air shall be supplied for ventilation including all air required for comfort and proper working conditions for personnel e While all forms of building construction cannot be covered in detail air for combustion ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5 3 3 and 5 3 4 f Air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements 5 3 2 Equipme
9. for installation specifications 16 Di ke 1 REMOVE L PIPE REMOVE 4 SCREWS J REMOVE AND RELOCATE D E DETACH RUBBER ELBOW FROM ID BLOWER AND VENT FLUE PIPE Rtl D EXTERNALLY MOUNT pe ELBOW SECURE TO ID BLOWER WITH RUBBER COUPLING AND HOSE CLAMPS UPFLOW UPRIGHT SECURE TO ID BLOWER WITH RUBBER COUPLING SECURE TO AND HOSE CABINET WITH CLAMPS SCREWS UPFLOW HORIZONTAL Alternate Vent Flue Location TEE 12 Min To Highest Anticipated Snow Level Vertical Termination Single Pipe 90 Medium Radius Pa Elbow Alternate Vertical Termination Single Pipe aa INSIDE OUTSIDE TEE or 90 ELBOW TURNED DOWN COUPLING MIN _ 42 FROM WALL ELBOW OR COUPLING TO GROUND OR HIGHEST ANTICIPATED Horizontal Termination Single Pipe VENT FLUE TEE or 90 ELBOW TURNED DOWN 12 MIN ABOVE HIGHEST ANTICIPATED e SNOW LEVEL Horizontal Termination Single Pipe Above Highest Anticipated Snow Level 17 X CONDENSATE DRAIN LINES AND DRAIN TRAP GENERAL A condensing gas furnace achieves its high level of effi ciency by extracting almost all of the heat from the products of combustion and co
10. nections Refer to Section IX Vent Flue Pipe for details NOTE In addition to the required clearances to combus tible materials a minimum of 36 inches service clearance must be available in front of the unit TOP BOTTOM BOTTOM Upflow Horizontal A furnace installed in a confined space i e aclosetor utility room must have two ventilation openings with a total minimum free area of 0 25 square inches per 1 000 BTU hr of furnace input rating Refer to Specification Sheet for minimum clearances to combustible surfaces One of the ventilation openings must be within 12 inches of the top the other opening must be within 12 inches of the bottom of the confined space In a typical construction the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement FURNACE SUSPENSION If suspending the furnace from rafters or joist use 3 8 threaded rod and 2 x2 x1 8 angle iron as shown below The length of rod will depend on the application and the clearances necessary CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAI 3 8 DIAMETER N THREADED ROD 6 PLACES ASSURE FURNACE IS LEVEL FROM END TO END AND HAS A SLIGHT K FORWARD TILT WITH THE FRONT OF THE FURNACE 0 3 4 BELOW THE BACK OF THE FURNACE HOLD DOWN NUTS SUPPORT _ NUTS d Fa AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMVOAL 2 x
11. starting from the gas valve to reach the outside of the cabinet must be supplied e Coupling e 90 degree elbow e 2 inch close nipple s 90 degree elbow e Straight pipe with a ground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration Asemi rigid connec tor to the gas piping can be used outside the cabinet per local codes Gas PIPING CHECKS Before placing unit in operation leak test the unit and gas connections Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Tubing Tubing Size O D Type L Schedule 40 Feet 60 300 700 1 300 2 200 3 300 1 300 3 100 80 260 610 1200 1 900 2 900 1 200 2 600 __125 200 490 900 1400 2300 900 2100 To convert to capacities at 15 psig settings multiply by 1 130 To convert to capacities at 5 psig settings multiply by 0 879 Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Based on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour Nominal Pipe Size Tubing Size O D Type L Schedule 40 205 1 496 60 16 35 72 121 187 340 103 217 409 834 1 275 80 13 29 62 104 155 289 89 185 346 72
12. Adhere to these instructions to ensure safe and proper furnace performance The length diameter and number of elbows of the vent flue pipe and combustion air pipe when applicable affects the performance of the furnace and must be carefully sized All piping must be installed in accordance with local codes and these instructions Piping must be adequately secured and supported to pro hibit sagging joint separation and or detachment from the furnace Horizontal runs of vent flue piping must be sup ported every three feet and must maintain a 1 4 inch per foot downward slope back towards the furnace to properly return condensate to the furnace s drain system Allow ances should be made for minor expansion and contraction due to temperature variations For this reason particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches Precautions should be taken to prevent condensate from freezing inside the vent flue pipe and or at the vent flue pipe termination All vent flue piping exposed to freezing tem peratures below 35 F for extended periods of time must be insulated with 1 2 thick closed cell foam Also all vent flue piping exposed outdoors in excess of the terminations shown in this manual or in unheated areas must be insulated with 1 2 thick closed cell foam Inspect piping for The vent shall not be located leaks prior to installing insulation e Less than 12 inches
13. BLOWER OFF ON THERMOSTAT OFF SECONDS 0 tign tcirc 0 15 60 90 120 or IGNITER FIXED HEAT 180 WARM UP PERIOD ON DELAY see note 30 SECONDS NOTE CUSTOM CONTROLS INC HSI 4 INTEGRATED CONTROL MODULE HAS A FIXED STANDARD SEVEN SECOND IGNITER WARM UP PERIOD MINI IGNITER WHITE RODGERS 50A55 INTEGRATED CONTROL MODULE HAS A VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN A 17 SECOND MAXIMUM AND A FIVE SECOND MINIMUM WHITE RODGERS 50A65 INTEGRATED CONTROL MODULE HAS A 20 SECOND IGNITER WARM UP PERIOD SILICON NITRIDE Timing Chart for Normal Cooling Operation Indoor Fan ON OFF Outdoor Fan and ON Compressor OFE Thermostat ON OFF Seconds 0 5 0 45 30 CIRCULATOR BLOWER SPEEDS A WARNING To prevent death personal injury property damage or premature failure of heat exchanger do not adjust the limit control factory set This furnace is equipped with a multi speed circulator blower This blower provides ease in adjusting blower speeds The Specification Sheet provides an airflow table showing the relationship between airflow CFM and exter nal static pressure E S P for the proper selection of heating and cooling speeds The cooling blower speed is shipped set on HIGH and the heating blower speed is set as indicated in the Specifications Sheet These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heat ing temperature rise an
14. WITH A 1 2 X 1 8 PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT Gas Piping Connections 22 This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 115 Volt and 24 Volt wiring 115 Voit LINE CONNECTION OF ACCESSORIES HUMIDIFIER AND ELECTRONIC AIR CLEANER AA WARNING To avoid electrical shock injury or death disconnect electrical power before servicing or changing any electrical wiring The furnace s integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows 1 0 Amp maximum at 120 VAC Electronic Air Cleaner 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any acces sories Follow the humidifier or air cleaner manufacturers instructions for locating mounting grounding and control ling these accessories Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the furnace integrated control module The humidifier and electronic air cleaner hot and neutral termi nals are identified as HUM and EAC All field wiring must conform to applicable codes Connections should be made as shown below OPTIONAL ACCESSORIES ELECTRONIC AIR CLEANER H
15. a propane gas leak install a gas detection warning device A gas detecting warning system is the only reliable way to detect a propane gas leak Rust can reduce the level of odorant in propane gas Do not rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence of gas is sus pected follow the instructions on Page 4 of this manual All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 11 inch WC at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers Proper pressure regulation Two stage regulation is recommended for both cost and efficiency Pressure drop in lines between regulators and be tween second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporiza tion recommended regulator settings and pipe sizing is available from most regulator manufacturers and propane gas suppliers 26 Since propane gas will quickly dissolve white lead and most standard commercial compounds special pipe dope must be used Shella
16. and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet air duct ends 1 ft 300 mm above floor Equipment Located in Confined Spaces All Air from Outdoors Through Ventilated Attic See 5 3 3 b 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent NOTE The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure Outlet air duct A Furnace Heater Inlet air duct If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors each opening shall have a free area of not less than one square inch p
17. as a result of insufficient conditioned air passing over the heat exchanger Ro tour Limit The rollout limit controls are mounted on the burner mani fold assembly and monitor the burner flame They are normally closed electrically manual reset temperature activated sensors These limits guard against burner flames not being properly drawn into the heat exchanger PRESSURE SWITCHES The pressure switches are normally open closed during operation single pole single throw negative air pressure activated switches They monitor the airflow combustion air and flue products through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover These switches guard against insufficient airflow combustion air and flue products through the heat exchanger and or blocked condensate drain conditions FLAME SENSOR The flame sensor is a probe mounted to the burner manifold assembly which uses the principle of flame recti fication to determine the presence or absence of flame ANIL TROUBLESHOOTING ELECTROSTATIC DISCHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and servicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electrostatic potential these steps w
18. be smaller than 1 4 inch mesh If the area through a design of louver or grille is known it should be used in calculating the size of opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers 11 and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 5 3 6 Special Conditions Created by Mechanical Exhausting or Fireplaces Operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment Air from Inside Building See 5 3 3 a VI INSTALLATION POSITIONS This furnace may be installed in an upright position or horizontal on either the left or right side panel Do notinstall this furnace on its back For upright upflow furnaces return air ductwork may be attached to the side panel s and or basepan For horizontal upflow furnaces return air duct work must be attached to the basepan For both upright or horizontal counterflow furnaces return ductwork must be attached to the basepan top end of the blower compart ment NOTE Ductwork must never be attached to the back of the furnace Refer to the product Specifications Sheet for proper
19. contact motion e Tighten or correct wiring connection Cautions and Notes e Turn power OFF prior to repair e Replace integrated control module fuse with 3A automotive fuse e Improper thermo stat connection or setting e Turn power OFF prior to repair e Read precautions in Electrostatic Discharge section of manual e Turn power OFF prior to repair e Igniter is fragile handle with care e Sand flame sensor with emery cloth e See Vent Flue Pipe section for piping details e Turn power OFF prior to repair e Replace pressure switch with proper replacement part e Turn power OFF prior to repair e Replace pressure switch with proper replacement part Associated LED Code Symptoms of Abnormal Operation e Circulator blower runs Ly A Sy continuously No furnace IA operation nA Integrated control module diagnostic LED is flashing FOUR 4 flashes 4 FLASHES e Induced draft blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 flashes 5 FLASHES e Furnace fails to operate Integrated control module diagnostic LED is flashing SIX 6 flashes e Induced draft blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing SEVEN 7 flashes 7 FLASHES e Induced draft blower runs continuously No furnace operation e Integrated control
20. determined based upon the BTU ft content of the derated gas andthe altitude Refer to the National Fuel Gas Code NFPA 54 ANSI 2223 1 and information provided by the gas supplier to determine the proper orifice size A different pressure switch may be required at high altitude regardless of the BTU ft content of the fuel used Refer to the product Specification Sheet or an Amana distributor for 23 a tabular listing of appropriate altitude ranges and corre sponding manufacturer s pressure switch kits PROPANE GAS CONVERSION AA WARNING Possible death personal injury or property damage may occur if the correct conversion kits are not installed The appropriate kits must be applied to insure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit must be ap plied for propane gas installations Refer to the propane gas and or High Altitude Installations section for details Gas VALVE This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module As shipped the valve is configured for natural gas The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer s propane gas conver sion kit Taps for measuring the gas supp
21. e Blown fuse or circuit breaker e Blown fuse or circuit breaker e No signal from thermostat e Improper thermostat connection or setting e Furnace fails to operate Integrated control module diagnostic LED is lit continuously e Integrated control module has an internal fault e Integrated control module has an internal fault e Failure to establish flame Cause may be no gas to burners front cover pressure switch stuck open bad igniter or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor e Furnace lockout due to an excessive number of ignition retries 3 total or recycles 5 total e Furnace fails to operate Integrated control module diagnostic LED is flashing ONE 1 flash 1 FLASH Loss of flame after establishment Cause may be interrupted gas supply lazy burner flames im proper gas pressure or restriction in flue and or combustion air piping front cover pressure switch opening or improper induced draft blower performance Induced draft blower pressure switch contacts sticking Shorts in pressure switch circuit Pressure switch circuit is closed e Furnace fails to operate Integrated control module diagnostic LED is flashing TWO 2 flashes Induced draft blower is not operating Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain syste
22. equal to the total heat loss of the area to be heated The total heat loss should be calculated by an approved method or in accordance with ASHRAE Guide or Manual J Load Calculations published by the Air Conditioning Contractors of America IV LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL AA WARNING To prevent possible death personal injury equipment damage or property damage the following bullet points must be observed when installing the unit Follow the instructions listed below when selecting a fur nace location Refer also to the guidelines provided in Section V Combustion and Ventilation Air Requirements e Centrally locate the furnace with respect to the pro posed or existing air distribution system e Ensure the temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating e Provide provisions for venting combustion products outdoors through a proper venting system Special consideration should be given to vent flue pipe rout ing Refer to Section IX Vent Flue Pipe and Com bustion Air Pipe Termination Locations for appropri ate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given NOTE The length of flue piping can be a limiting factor in the location of the furnace e Locate the furnace so that the condensate can be piped at a downward slope between furnac
23. to table for appropriate length to cut Secure remaining hose to Tube 1 with a green hose clamp Route other end of Hose B to front left side panel drain hole X Length Cut From inches kKBTU Tons Long End of Hose B 6 Insertshort end of each Tube 2 through side panel drain holes Secure tubes to Hose A and Hose B with green hose clamps NOTE Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting ALTERNATE VENT FLUE DRAIN Hose CONNECTIONS Upright installations using the alternate vent flue outlet will require right side only drain hoses to be connected as follows Refer to Section IX Vent Flue Pipe for details on alternate vent flue pipe connection 1 Remove the rubber plug from the front cover right side drain port Save for use in step 3 2 Secure Hose A to front cover drain port with a red hose clamp Route hose to rear right side panel drain hole SRUBBER ELBOW pos RUBBER EXTERNALLY ELBOW FRONTCOVER MOUNTED DRAIN PORT DRAIN PORT Pere e A RED HOSE CLAMP B FA IP i A Tuge 1 GREEN HOSE e CLAMPS ESCH N LS pa 3 PLACES ey 4 HOSE B Sie SIDE PANEL A Ld DRAIN Geen
24. 2 x1 8 ANGLE IRON 3 PLACES ___ TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL Suspended Furnace EXISTING FURNACE REMOVAL NOTE When an existing furnace is removed from a vent ing system serving other appliances the venting system may be too large to properly vent the remaining attached appliances The following vent testing procedure is reproduced from the American National Standard National Standard of Canada for Gas Fired Central Furnaces ANSI Z21 47 1998 CSA 2 3 M98 Section 1 23 1 The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances connected to the venting system are not in operation a Seal any unused openings in the venting system b Inspect the venting system for proper size and horizontal pitch as required by the National Fuel Gas Code ANSI Z223 1 or the stalled in buildings and which require air for combustion ventilation and dilution of flue gases from within the building They do not apply to 1 direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere or 2 enclosed furnaces which incor porate an integral total enclosure and use only outside air for combustion and dilution of flue gases c Inso far as practical close all building doors and windows and all doors between the spa
25. 4 100 11 26 55 90 138 255 78 162 307 630 125 10 24 48 81 122 224 69 146 275 567 866 150 9 21 43 72 109 202 63 132 252 511 787 _ 200 8 19 39 6e 100 187 54 112 209 439 665 250 8 17 36 60 93 172 48 100 185 390 590 Data in accordance with NFPA pamphlet NO 54 Propane Gas Piping Charts 25 A WARNING To avoid the possibility of explosion or fire never use a match or open flame to test for leaks Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved testing methods NOTE Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pres sure testing supply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE GAs TANKS AND PIPING A WARNING Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces To prevent death personal injury or property damage due to fire or explosion caused by
26. Heating amp Air Conditioning G U L A anao High Efficiency Gas Fired Furnace Somit Quality Dense INSTALLATION INSTRUCTIONS Amana Forced Air Central Furnace design complies with requirements embodied in The American National Standard National Stan dard of Canada shown below ANSI Z221 47 CSA 2 3 Gas Fired Central Furnaces Type FSP Category IV Non Direct Vent Forced Air Furnace Goodman Company L P 1810 Wilson Parkway Fayetteville Tennessee 37334 10318739 www amana hac com October 2002 1 Table of Contents WS ANU oo cca cece E E N cas ave E AE EE T sss seeeueas Seu dave teetes ecu E E E A E E 4 Il Component Identification sic cccicscvcccssccscdeccensccscenseeeecaeccetesceectdetscasecsssdsveasccassctbiensecencodcesenaceasvedsradsccaduanaacceensscsieaneeeess 5 Ill PRODUCT APPLIGATION a iz cece c 25 ara a aaa a aa aara co ete usen vec oh es ca vane Sante Seen vd ects doen ected sans se x daudacvansdeeei ce avevesdeecs 7 IV LOCATION REQUIREMENTS AND CONSIDERATIONS cccsceeceeeeeeeeseseeeaeesaseeeeeeeeseseesaeageasasseeeeeeeessesaaesaaans 7 V Combustion and ventilation Air Requirements eccecceee eee cent NEEN eee EEEEE KEREN EEN 9 VlSlostalfattoreEosltlong egessg esgegier Secs sed be ccc ce eves a d ses devavedeccxdecttadstetSacnesti cs cxdenetestsebeeass 11 VII Ho
27. KE AT et HOLES RED HOSE HOSEA DRAIN TRAP CLAMP TUBE S 2 Upright Alternate Connections Right Side Only Cut 1 4 inch from the end of the drain port on the externally mounted rubber elbow Discard cut portion Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp Angle tube outward toward front of furnace Cut 17 7 8 inches from the long end of Hose B and discard Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose toward right side panel drain holes Insert short end of one Tube 2 through rear right side panel drain hole Secure tube to Hose A with a green hose clamp Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp NOTE Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding For details concerning mounting of the drain trap refer to the following section HORIZONTAL INSTALLATIONS Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port Make connections as follows 1 Remove the rubber plug from the coil front cover drain port 2 Secure Hose A to front cover drain tap with a red hose clamp Route hose to rear right down side panel drain holes 19
28. MPS HOSE CLAMPS QTY 3 QTY 2 Hose and Tube Identification 1 Remove the rubber plug from the front cover drain port right or left side depending on the intended drain trap mounting 2 Secure Hose A to front cover drain port with a red hose clamp Route hose to rear side panel drain hole RIGHT SIDE PANEL RUBBER ELBOW RUBBER ELBOW DRAIN PORT WV RED HOSE CLAMP TUBE 1 E SIDE PANEL _7 DRAIN 7 TUBE S 2 FRONT COVER DRAIN PORT gt 7 HOSE RED HOSE CLAMP A GREEN HOSE Ir DRAIN TRAP CLAMPS 3 PLACES Upright Standard Connections Right Side LEFT Le SIDE PANEL J FRONT COVER a 4 RUBBER DRAIN PORT Bow RED HOSE d i AI RUBBER CLAMP Bleech HOSEA DRAIN PORT SIDE PANEL IL RED HOSE DRAIN CLAMP HOLES TUBE 1 GREEN HOSE CLAMPS 3 PLACES Upright Standard Connections Left Side 3 Cut and remove 1 4 inch from the end of the drain port on the rubber elbow 4 Insert Tube 1 into rubber elbow drain port and secure with red hose clamp Angle tube outward toward front of furnace 5 Right side drains Cut 17 3 4 inches from the long end of Hose B and discard Secure the remaining hose to Tube 1 witha green hose clamp Route the other end of Hose B to front right side panel drain hole Left side drains Cut X inches from the long end of Hose B and discard Refer
29. ND DRAIN SYSTEM QUALIFIED SERVICER ONLY Annually inspect the drain tubes drain trap and field supplied drain line for proper condensate drainage Check drain system for hose connection tightness blockage and leaks Clean or repair as necessary FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will lock out The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool Following cleaning the flame sense signal should be as indicated in the Specifications Sheet 37 FLue Passaces QUALIFIED SERVICER ONLY The heat exchanger flue passageways should be inspected at the beginning of each heating season If necessary clean the passageways as outlined below 1 Turn OFF the electrical power and gas supply to the furnace Disconnect the gas line and remove the burner mani fold assembly by removing the screws securing the assembly to the partition panel Disconnect the flue pipe system from the induced draft blower Remove the induced draft blower and drain and pres sure tap hoses from the recuperator coil front cover Remove the recuperator coil front cover to expose the coil tubes and turbulators Remove the recuperator coil t
30. Return any old or new controls to their containers before touching any ungrounded object This furnace can be used in the following non industrial commercial applications Schools Office buildings Churches Retail stores Nursing homes Hotels motels Common or office areas In such applications the furnace must be installed with the following stipulations e It must be installed per the installation instructions provided and per local and national codes e It must be installed indoors in a building constructed on site e must be part of a ducted system and not used in a free air delivery application e It must not be used as a make up air unit e It must be installed with two pipe systems for com bustion air especially if VOC s or other contaminants are present in the conditioned space e All other warranty exclusions and restrictions apply This furnace is an CSA certified appliance and is appropriate for use with natural or propane gas NOTE If using propane a propane conversion kit is required To ensure proper installation and operation thoroughly read this manual for specifics pertaining to the installation and application of this product Possible death personal injury or property damage due tofire explosion smoke soot condensation electrical shock or carbon monoxide may result from improper installation repair operation or maintenance of this product To prevent death personal injur
31. ZONTAL RIGHT AIR DISCHARGE Recommended Installation Positions Vill PROPANE GAS AND OR HIGH ALTITUDE INSTALLATIONS A WARNING Possible death personal injury or property damage may occur if the correct conversion kits are not installed The appropriate kits must be applied to insure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency This furnace is shipped from the factory configured for natural gas at standard altitude Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas High altitude installations may require both a pressure switch and an orifice change These changes are neces sary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude Refer to the product Specification Sheet or contact an Amana distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude installations The indicated kits must be used to insure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency IX VENT FLUE PIPE GENERAL A WARNING Failure to follow these instructions can result in bodily injury or death Carefully read and follow all instructions given in this section A WARNING Upon completion of the furnace installation careful
32. above the finished grade line TERMINATION LOCATIONS e Less than 36 inches from any building opening or any gas service regulator For gas service regulators in the NOTES Refer to Section IV Location Requirements and Province of Ontario 72 inches Considerations for combustion air contaminant restrictions e Less than 72 inches from the combustion air intake of The following bullets and diagram describe the restrictions another appliance for vent flue pipe placement and termination construction e All terminations must be located at least 12 inches above ground level or the anticipated snow level e Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet STANDARD FURNACE CONNECTIONS Itis the responsibility of the installer to ensure that the piping connections to the furnace are secure airtight and ad equately supported e The vent termination must terminate at least 4 feet jg shipped attachment couplings for vent flue and com EE SEN bustion air intake pipe connections are provided on the BE furnace s top cover To use the standard connections e The vent termination of vent pipe run vertically through secure the field supplied vent flue pipe directly to the a roof must terminate at least 12 inches above the roof furnace line or the anticipated snow level and be at least 12 inches from any vertical wall including any anticipated Went FLue Bug snow build up Vent flue
33. airflow requirements and number of re quired ductwork connections Refer to Recommended Installation Positions figure for appropriate installation positions ductwork connections and resulting airflow ar rangements Vil HORIZONTAL APPLICATIONS AND CONSIDERATIONS GENERAL Horizontal applications in particular may dictate many of the installation s specifics such as airflow direction duct work connections flue and combustion air pipe connec tions etc The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation When installing a furnace horizontally addi tional consideration must be given to the following tL FURNACE MUST BE LEVEL Ka FROM END TO END ALTERNATE VENT FLUE AND COMBUSTION AIR at INTAKE LOCATIONS Z FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0 3 4 BELOW THE BACK PANEL 4 3 4 MINIMUM DRAIN TRAP CLEARANCE Z GAS LINE WITH DRIP LEG 3 MINIMUM DRAIN LINE WITH 1 4 PER FOOT DOWNWARD SLOPE Ss eA MINIMUM SERVICE FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE CLEARANCE REQUIRED Horizontal Furnace DRAIN PAN DRAIN TRAP AND LINES In horizontal applications the condensate drain trap is secured to the furnace side panel suspending it below the furnace A minimum clearance of 4 3 4 inches below the furnace must be provided for the drain trap Additionally the appro
34. ber of blinks refers to a specific fault code REsETTING FRom Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts or when it has lost flame five times during a single call for heat It is characterized by a non functioning furnace and a one flash diagnostic LED code If the furnace is in lockout it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically resetitselfand attempt to resume normal operations following a one hour lockout period Manual power interruption Interrupt 115 volt power to the furnace for 0 20 seconds Manual thermostat cycle Lower the thermostatso that there is no longer a call for heat then reset to previous setting Interrupt thermostat signal to the furnace for 0 20 seconds NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to Section XVIII Troubleshooting Diagnostic Chart for aid in determining the cause Troubleshooting Chart Associated LED Code Symptoms of Abnormal S Possible Causes Operation Fault Description s NONE e Manual disconnect switch OFF door switch open or 24 volt wires improperly connected or loose e Furnace fails to operate Integrated control module diagnostic LED provides no signal e No 115 volt power to furnace or no 24 volt power to integrated control module
35. c based compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory Refer to the following illustration for typical propane gas installations 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C 200 PSIG Second Stage Maximum Regulato ONN Propane Gas Installation Typ XIII CIRCULATING AIR AND FILTERS Ductwork AIR FLow Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contrac tors of America Manual D A duct system must be installed in accordance with Stan dards of the National Board of Fire Underwriters for the Installation of Air Conditioning Warm Air Heating and Ventilating Systems Pamphlets No 90A and 90B A closed return duct system must be used with the return duct connected to the furnace NOTE _Ductwork must never be attached to the back of the furnace Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission To prevent the blower from interfering with combustion air or draft when a central return is used a connecting duct must be installed between the unit and the utility room wall A room closet or alcove must not be used as a return air chamber When the furnace
36. cation must maintain a 1 4 inch per foot downward slope toward the drain e Do not trap the drain line in any other location than at the drain trap supplied with the furnace e Do not route the drain line outside where it may freeze e If the drain line is routed through an area which may see temperatures near or below freezing precautions must be taken to prevent condensate from freezing within the drain line e Ifan air conditioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressure from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap UPRIGHT INSTALLATIONS In anuprightinstallation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet NOTE Refer to Section X Condensate Drain Lines and Drain Trap Alternate Vent Flue Hose Connections for upright installations using an alternate vent flue outlet STANDARD RIGHT OR LEFT SIDE DRAIN Hose CONNECTIONS Upright installations using the standard vent flue outlet require drain hoses to be connected as follows The following quantity of hoses tubes and hose clamps are provided with the unit GREEN RED HOSE CLA
37. ce in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any appliance not con nected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continuously e Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Ifimproper venting is observed during any of the above tests the common venting system must be corrected limits under normal conditions of use Equipment shall be located so as not to interfere with proper circulation of air When normal infiltra tion does not provide the necessary air outside air shall be introduced Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 and or CSA B149 Installation Codes If resizing is required on any portion of the venting system use the app
38. checks establish that the primary limit control is functioning and will respond to a restriction in the return air oracirculator blower failure Ifthe primary limit control does not function during this test the cause must be determined and corrected VII SAFETY CIRCUIT DESCRIPTION GENERAL A number of safety circuits are employed to ensure safe and proper furnace operation These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function These circuits are continuously monitored during furnace opera tion by the integrated control module INTEGRATED ConTROL MopuLE The integrated control module is an electronic device which a potential safety concern is detected the module will take the necessary precautions and provide diagnostic informa tion through an LED PRIMARY LIMIT The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures It is a normally closed electrically automatic reset tem perature activated sensor The limit guards against the overheating as a resulting of insufficient conditioned air passing over the heat exchanger AUXILIARY Limit The auxiliary limit controls are located on or near the circulator blower and monitors heat exchanger compart ment temperatures They are a normally closed electri cally manual reset temperature activated sensor These limits guard against overheating
39. ches 090 50 24 1 2 11550 11 1 4 inches 5 Secure short end of Hose B to induced draft blower drain port using a green hose clamp Route hose to front left down side panel grommet holes Cut 5 1 2 inches straight length from the long end of each Tube 2 Upflow Units with a 16 1 2 cabinet width Insert approximately one inch of cut Tube 2 through left side panel grommet hole and secure to Hose A with a hose clamp Insert remaining Tube 2 through other drain hole and splice to Hose B with Tube 1 green hose clamps and a short section of hose as shown below NOTE Tube must reach bottom of trap 20 Short Section of Hose Junction Box Y Green Hose Clamps Li Tube Installation with Green Hose Clamps All Units with a 20 1 2 and 24 1 2 cabinet width Insert approximately one inch of each Tube 2 through left side panel drain hole Secure tubes to Hose A and Hose B with a green hose clamps NOTE Tube must reach bottom of trap NOTE Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Up right Drain Trap Mounting HoriZONTAL DRAN TRAPMounTING LEFTORRIGHTSIDEPANEL 1 Position the drain trap against side panel with drain tubes inserted into trap Note that the trap may be orientated with the outlet facing
40. d When replacing a filter it must be replaced with a filter of the same type and size 36 FILTER REMOVAL Depending on the installation differing filter arrangements can be applied Filters can be installed in the central return register the bottom of the blower compartment upflow only aside panel external filter rack kit upflow only orthe ductwork above a counterflow furnace A media air filter or electronic air cleaner can be used as an alternate filter The filter sizes given in the Specifications Sheet must be fol lowed to ensure proper unit performance Refer to the following for removal and installation of filters UPRIGHT UPFLOW FILTER REMOVAL To remove a filter from the bottom of the blower compart ment Turn OFF electrical power to furnace Remove blower compartment door Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan Slide filter forward and out Replace filter by reversing the procedure for removal To remove internal filter s from the retaining rails on the side s of the blower compartmentin an uprightinstallation 1 Turn OFF electrical power to furnace 2 Remove the blower compartment door 3 Grasp the lower portion of the filter and lift up 4 Angle the filter towards the blower until the filter is clear of the bottom rail 5 Lower the filter down and pull outward 6 Replace the filter by reversing the procedure fo
41. d the correct cooling CFM To adjust the circulator blower speed proceed as follows 1 Turn OFF power to the furnace 2 Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Specification Sheet 3 Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module Terminals are identified as HEAT and COOL hot If heating and cooling blower speeds are the same a jumper wire must be used between the heat and cool terminals 4 Connect all unused blower motor leads to the PARK terminals on the integrated control module Any leads not connected to the PARK terminals must be taped 5 Turn ON power to furnace 6 Verify proper temperature rise as outlined in Section XIV Startup Procedure and Adjustment Temperature Rise Circulator Blower Speeds low IL Bed Common Neutral XV NORMAL SEQUENCE OF OPERATION Power Up The normal power up sequence is as follows e 115 VAC power applied to furnace e Integrated control module performs internal checks e Integrated control module flashes LED one time e Integrated control module monitors safety circuits con tinuously e Furnace awaits call from thermostat HEATING Mope The normal operational sequence in heating mode is as follows e Rand W thermostat contacts close initiating a call for heat e Integrated control module performs sa
42. d to prevent unreliable ignition The maximum must not be exceeded to prevent unit overfiring Inlet Gas Supply Pressure Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C Natural Gas Hien ALTITUDE DERATE When this furnace is installed at high altitude the appropri ate High Altitude orifice kit must be applied This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases The kit will provide the proper design certified input rate within the specified altitude range High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas Refer to the product Specification Sheet or an Amana distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer s high altitude Natural pro pane gas and or Pressure Switch kits Do not derate the furnace by adjusting the manifold pres sure to alower pressure than specified on the furnace rating plate The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from draw ing the proper amount of air into the burner This may cause incomplete combustion flashback and possible yellow tipping In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If the gas is artificially derated the appropriate orifice size must be
43. delay Electronic air cleaner terminals are energized with circulator blower e Furnace circulator blower and outdoor cooling unit run integrated control module monitors safety circuits con tinuously e RandY thermostat contacts open completing the call for cool e Outdoor fan and compressor are de energized e Circulator blower is de energized following a fixed forty five second cool off delay period Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat Fan OnLy Move The normal operational sequence in fan only mode is as follows e Rand G thermostat contacts close initiating a call for fan e Integrated control module performs safety circuit checks e Circulator blower is energized on cool speed Elec tronic air cleaner terminals are energized e Circulator blower runs integrated control module moni tors safety circuits continuously e Rand G thermostat contacts open completing the call for fan e Circulator blower is de energized Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat XVI OPERATIONAL CHECKS BuRNER FLAME The burner flames should be inspected with the burner compartment door installed A sight glass is provided for inspection purposes Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow Flames should extend directly outward from the burners without curlin
44. e and drain Do not locate the furnace or its condensate drainage system in any area subject to below freez ing temperatures without proper freeze protection Refer to Section X Condensate Drain Lines and Trap for further details e Set the furnace on a level floor to enable proper condensate drainage If the floor becomes wet or damp at times place the furnace above the floor on a concrete base sized approximately 1 1 2 larger than the base of the furnace Refer to the Section VII Horizontal Applications and Considerations for level ing of horizontal furnaces e Ensure upflow or horizontal furnaces are not installed directly on carpeting or any other combustible mate rial The only combustible material allowed is wood e A special accessory subbase must be used for up right counterflow unit installations over any combus tible material including wood Refer to subbase instructions for installation details NOTE A sub base will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor e Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is ex posed to the following substances chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants c
45. either the furnace s top cover or base pan Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling XI ELECTRICAL CONNECTIONS A WARNING To avoid the risk of electrical shock wiring to the unit must be properly polarized and grounded A WARNING To avoid electrical shock injury or death disconnect electrical power before servicing or changing any electrical wiring A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Wirinc HARNESS The wiring harness is an integral part of this furnace Field alteration to comply with electrical codes should not be required Wires are color and number coded for identifica tion purposes Refer to the wiring diagram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Any replacement wiring must be copper conductor 115 Voit LinE CONNECTIONS Before proceeding with electrical connections ensure that the supply voltage frequency and phase correspond to that specif
46. er 4 000 BTU per hour of the total input rating of all appliances in the enclosure Equipment Located in Confined Spaces All Air from Outdoors See 5 3 3 b 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 inches NOTE The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equip ment in the enclosure but not less than the sum of the areas of all vent connectors in the confined space lt Chimney or Gas Vent lt Opening Alternate Opening Location Equipment Located in Confined Spaces All Air from Outdoors Single Air Opening See 5 3 3 b 5 When directly communicating with the outdoors the single opening shall have a minimum free area of 1 square inch per 3 000 BTU per hour of total input rating of all equipment in the enclosure 5 3 4 Specially Engineered Installations The requirements of 5 3 3 shall not necessarily govern when special engineering approved by the authority having jurisdiction pro vides an adequate supply of air for combustion ventilation and dilution of flue gases 5 3 5 Louvers and Grilles In calculating free area in 5 3 3 consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not
47. esonera n anaE areas nei ein edel gedeien 36 Le 36 UPRIGHT UPFLOW FILTER REMOVAL ssssssssssesiissseestittttetttttbteet ttt bbbr Artt tben EEE bb EAEE E ENEE A EEA EAEE EEE EEEE NEEE E EANNA EEEE EEE AEAEE EEEE EAEE EnEn arree enant 36 MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL E 36 BURNERS het ebe seeseteee a ii Moe eee de a Sed a a e hbo rate tee 36 XX Before Leaving an Install ation 0 ccccesseacecccscessnceccedeesnecteedeeedseccueeesveusuceteseseceystececeseeussecteeedeussectnecetedseccereeseeessecce 38 XXI Repair and Replacement Pat iis is cveisinissaraassacncaesndaenntnaeentednewenevesapnevsnsnsunanaunvsonsaasdnnnnseauansduonexacensunhasaiuysaannawasdoden 38 ATTENTION INSTALLING PERSONNEL Affix this manual Specification Sheet and Users Information Manual adjacent to the unit As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install the product safely and to knowitwell enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting
48. fety circuit checks e Induced draft blower is energized causing pressure switch contacts to close Humidifier terminals are energized with induced draft blower e Igniter warm up begins upon close of pressure switch contacts e Gas valve opens at end of igniter warm up period delivering gas to burners and establishing flame e Integrated control module monitors flame presence Gas valve will remain open only if flame is sensed e Circulator blower is energized on heat speed following a fixed thirty second blower on delay Electronic air cleaner terminals are energized with circulator blower e Furnaceruns integrated control module monitors safety circuits continuously e Rand W thermostat contacts open completing the call for heat e Gas valve closes extinguishing flame e Induced draft blower is de energized following a fifteen second post purge Humidifier terminals are de ener gized e Circulator blower is de energized following a select able heat off delay period 60 90 120 or 180 seconds Electronic air cleaner terminals are de energized e Furnace awaits next call from thermostat CooLinc Mope The normal operational sequence in cooling mode is as follows e Rand Y thermostat contacts close initiating a call for cool e Integrated control module performs safety circuit checks e Outdoor fan and compressor are energized e Circulator blower is energized on cool speed following a fixed five second on
49. g floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Burner Flame PRIMARY Limit The primary limit control guards against overheating result ing from insufficient conditioned air passing over the heat exchanger If the primary limit control does not function during this test the cause must be determined and cor rected Function of this control should be verified by gradually blocking the furnace return air after the furnace has been operating burners firing for approximately ten minutes Check the control as follows 1 Allow the furnace to operate with burners firing continu ously for approximately ten minutes 2 Gradually block the return air to furnace Remove airflow blockage when limit control is activated and turns off burners Airflow blockage causes unit over heating and will produce the following reactions 32 e The gas valve to close and extinguish flame e The induced draft blower to deenergized after a fifteen second postpurge and e The circulator blower to remain energized continu ously until limit control resets 3 Remove the return air blockage to clear overheating condition Afteran acceptable temperature is reached during the cool down period the limit control will reset and allow the furnace to resume normal operation These
50. ied on the unit rating plate Power supply to the furnace must be N E C Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 Use a separate fused branch electrical circuit containing properly sized wire and fuse or circuit breaker The fuse or circuit breaker must be sized in accordance with the maxi mum overcurrent protection specified on the unit rating plate An electrical disconnect must be provided at the furnace location A WARNING In upright upflow installations the drain trap must be mounted on the opposite side of the unit from the junction box This will reduce the risk of water reaching the junction box in the event of a blocked drain condition Connect hot neutral and ground wires as shown in the wiring diagram located on the unit s blower door NOTE Line polarity must be observed when making field connections Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a left side right side for counterflows elec trical connection with the junction box located inside the blower compartment To make electrical connections 21 through the opposite side of the furnace the junction box must be relocated to the other side of the blower compart men
51. ill help avoid exposing the integrated control module to electro static discharge This procedure is applicable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground Firmly touch a clean unpainted metal surface of the furnaces near the control Any tools held ina person s hand during grounding will be discharged Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an un grounded object repeat step 2 before touching control or wires Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object 33 DIAGNosTIC CHART AA WARNING To avoid electrical shock injury or death disconnect electrical power before performing any service or maintenance Refer to the troubleshooting chart on the following pages for assistance in determining the source of unit operational problems The red diagnostic LED blinks to assist in troubleshooting the unit The num
52. ing 4 Remove the burner compartment door NOTE This furnace is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Move the furnace gas valve manual control to the OFF position Wait five minutes then smell for gas Be sure check near the floor as some types of gas are heavier than air If you smell gas after five minutes immediately follow the instructions on page 4 of this manual If you do not smell gas after five minutes move the furnace gas valve manual control to the ON position Replace the burner compartment door Open the manual gas shut off valve external to the furnace Turn on the electrical power to the furnace Adjust the thermostat to a setting above room tempera ture After the burners are lit set the thermostat to desired temperature 6 8 9 10 11 12 FURNACE SHUTDOWN 1 Set the thermostat to the lowest setting The integrated control will close the gas valve and extinguish flame Following a 15 second delay the induced draft blower will be de energized After a 60 90 120 or 180 second delay period field selectable the circulator blower will be de energized 2 Remove the burner compartment door and move the furnace gas valve manual control to the OFF position 3 Close the manual gas shut off valve external to the furnace 4 Replace the burner compartment door Gas SuppPLY PRESSURE MEASUREMENT AA CAUTION
53. ion and ventilation air for gas fired and other fuel burning appliances Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air If this furnace is to be installed in the same space with other gas appliances such as a water heater ensure there is an adequate supply of combustion and ventilation air for the other appliances Refer to the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 Section 5 3 or CSA B149 Installation Codes Sections 7 2 7 3 or 7 4 or applicable provisions of the local building codes for deter mining the combustion air requirements for the appliances Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts con necting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 5 3 1 General a The provisions of 5 3 apply to gas utilization equipment in stalled in buildings and which require air for combustion ventilation and dilution of flue gases from within the building They do not apply to 1 direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere or 2
54. is used in connection with a cooling unit the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recommended that a removable access panel be provided in the outletair duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the air stream The access panel must be made to prevent air leaks when the furnace is in operation When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F Fitters READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DucTworRk Filters must be used with this furnace Discuss filter main tenance with the building owner Filters do notship with this furnace but must be provided by the installer Filters must comply with UL900 or CAN ULCS111 standards If the furnace is installed without filters the warranty will be voided On upflow units guide dimples locate
55. ise must be within the range specified on the unit rating plate An incorrect temperature rise may result in condensing in or overheating of the heat exchanger An airflow and temperature rise table is provided in the speci fication sheet Determine and adjust temperature rise as follows 1 Operate furnace with burners firing for approximately ten minutes Ensure all registers are open and all duct dampers are in their final fully or partially open posi tion Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger HEAT EXCHANGER RADIATION LINE OF SIGHT SUPPLY AIR UV RISE Tsuppiy TRETURN i TRETURN T RETURN AIR Temperature Rise Measurement gt 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to sta bilize Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to reduce tem perature rise Decrease blower speed to increase tem perature rise Refer to Section XIV Startup Procedure and Adjustment Circulator Blower Speeds for speed changing details Timing Chart for Normal Heating Mode CIRCULATOR ON BLOWER OFF GAS VALVE OPEN CLOSED ON IGNITER OFF PRESSURE SWITCH CLOSED CONTACTS OPEN INDUCED DRAFT ON
56. ith Fitting Manometer Hose Manometer Measuring Inlet Gas Pressure Alt Method 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 4 Measure furnace gas supply pressure with burners firing Supply pressure must be within the range speci fied in the table below Inlet Gas Supply Pressure Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C Natural Gas Propane Gas If supply pressure differs from above make necessary adjustments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace 6 Turn OFF any unnecessary gas appliances started in step 3 Gas MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT A CAUTION To prevent unreliable operation or equipment damage the gas manifold pressure must be as specified on the unit rating plate Only minor adjustments should be made by adjusting the gas valve pressure regulator Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the follow ing procedure 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibra
57. jury or death due to exposure to flue gases including carbon monoxide 7 For upright installations externally mount the rubber elbow to the vent flue coupling using a worm gear hose clamp Secure field supplied vent flue piping to the rubber elbow using a worm gear hose clamp NOTE Use of the alternate vent flue location for upright instal lations requires the drain trap be installed on the same side of the unit as the flue pipe 8 For horizontal installations externally secure the field supplied vent flue pipe directly to the vent flue coupling using a PVC or ABS coupling or elbow Non DirREctT VENT SINGLE PIPE PIPING Non direct vent installations require only a vent flue pipe The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building The vent can also be run through an existing unused chimney however it must extend a minimum of 12 inches above the top of the chimney The space between the vent pipe and the chimney must be closed with a weather tight corrosion resistant flashing For details concerning connection of the vent flue pipe to the furnace refer to Section IX Vent Flue Pipe Standard Furnace Connections or Alternate Furnace Connections for specific details Refer to the following Non Direct Vent Single Pipe Piping Vent Flue Pipe Terminations for specific details on termination construction Although non direct vent i
58. leaning solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials e Ifthe furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling unit Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace e Ifthe furnace is installed in a residential garage position the furnace so that the burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the furnace from physical damage by vehicles e H the furnace is installed horizontally the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger Do not install the unit with the access doors on the up top or down bottom side of the furnace CLEARANCES AND ACCESSIBILITY Installations must adhere to the clearances to combustible materials which this furnace has been design certified to The minimum clearance information for this furnace is provided on the unit s clearance label These clearances must be permanently maintained Clearances must also accommodate an installation s gas electrical and drain trap and drain line connections If the alternate combustion air intake or vent flue connections are used additional clearances must be provided to accommodate these con
59. ly inspect the entire flue system both inside and outside the furnace to assure it is properly sealed Leaks in the flue system can result in serious personal injury or death due to exposure to flue products including carbon monoxide A condensing gas furnace achieves its high level of effi ciency by extracting almost all of the heat from the products of combustion and cooling them to the point where conden sation takes place Because of the relatively low flue gas temperature and water condensation requirements PVC pipe is used as venting material This furnace must not be connected to Type B BW or L vent or vent connector and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance Do not use commercially available no hub connectors other than those shipped with this product It is the responsibility of the installer to follow the manufac turers recommendations and to verify that all vent flue piping and connectors are compatible with furnace flue products Additionally itis the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separa tion shifting or sagging during furnace operation 13 MATERIALS AND JOINING METHODS
60. ly pressure and manifold pressure are provided on the valve The gas valve has a manual ON OFF control located on the valve itself This control may be set only to the ON or OFF position Refer to the lighting instructions label or the Putting the Furnace Into Operation section for use of this control during start up and shut down periods Gas PIPING CONNECTIONS GENERAL A CAUTION To avoid possible unsatisfactory operation or equipment damage due to underfiring of equipment use the proper size of natural propane gas piping needed when running pipe from the meter tank to the furnace When sizing a trunk line be sure to include all appliances which will operate simultaneously when sizing a trunk line The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of the run The gas line installation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH Length of Nominal Black Pipe Size Pipe in Feet IA 114 KA 10 132 1500 1700 980 760 670 610 f w o o mo CR 460 490 Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas 84 aa Gol oQ ojo ae CO cFH BTUH Furnace Input Heating Value of Gas BTU Cubic Foot To connec
61. m or weak induced draft blower Pressure switch circuit not closed e Induced draft blower runs continuously with no further furnace operation Integrated control module diagnostic LED is flashing THREE 3 flashes Induced draft blower is operating e Incorrect pressure switch setpoint or malfunctioning switch contacts e Loose or improperly connected wiring Integrated control module will automatically attempt to reset from lockout after one hour 34 Corrective Action e Assure 115 and 24 volt power to furnace integrated control module e Check integrated control module fuse 3A Replace if necessary e Check for possible shorts in 115 and 24 volt circuits Repair as necessary e Replace bad integrated control module Locate and correct gas interruption e Check front cover pressure switch operation hose wiring contact operation Correct if necessary Replace or realign igniter Check flame sense signal Sand sensor if coated and or oxidized e Check flue piping for blockage proper length elbows and termination e Verify proper induced draft blower perfor mance e Replace induced draft blower pressure switch e Repair short Inspect pressure switch hose Repair if necessary Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary e Correct pressure switch setpoint or
62. nada venting must conform to the requirements of the current CAN CSA B149 Installation Code Use only CSA listed two or three inch diameter PVC or ABS pipe solvent UPFLOW STANDARD CONNECTIONS cement and fittings throughout Carefully follow the manu facturers instructions for cutting cleaning and solvent cementing PVC and or ABS E l ALTERNATE FURNACE CONNECTIONS The vent can be run through an existing unused chimney If the standard location is undesirable for a specific instal provided the space between the vent pipe andthe chimney lation an alternate side panel location is available for vent is insulated and closed with a weather tight flue pipe connections This location may be of particular corrosion resistant flashing 14 benefit to upright upflow installations requiring additional access to an A coil or to horizontal installations desiring vent flue and combustion air intake piping run vertically from the side of the cabinet NOTE Standard and alternate locations can be combined e an installation may use the standard combustion air intake location but use the alternate vent flue location or vice versa if needed AA CAUTION Edges of sheet metal holes may be sharp Use gloves as a precaution when removing hole plugs ALTERNATE VENT FLUE LOCATION The alternate vent flue location is the large hole directly in line with the induced draft blower outlet To use the alternate vent flue location refer to the foll
63. nd fittings Semi rigid metallic tubing and metallic fittings Aluminum alloy tubing must not be used in exterior locations In order to seal the grommet cabinet penetration rigid pipe must be used to reach the outside of the cabinet A semi rigid connector to the gas piping may be used from there e Use listed gas appliance connectors in accordance with their instructions Connectors must be fully in the same room as the furnace e Protect connectors and semirigid tubing against physi cal and thermal damage when installed Ensure alumi num alloy tubing and connectors are coated to protect against external corrosion when in contact with ma sonry plaster or insulation or subjected to repeated wetting by liquids such as water except rain water detergents or sewage AA CAUTION Edges of sheet metal holes may be sharp Use gloves as aprecaution when removing hole plugs DiREcT STANDARD INLET PIPING When gas piping enters directly to the gas valve through the standard inlet hole the installer must supply straight pipe with aground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration A semi rigid connector to the gas piping can be used outside the cabinet per local codes INDIRECT ALTERNATE INLET PIPING When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the following fittings
64. ne within 12 inches of the bottom of the enclosure lt Chimney or Gas Vent NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equip ment in the enclosure but not less than 100 square inches lt Opening 1 lt Opening Equipment Located in Confined Spaces All Air from Inside Building See 5 3 3 a b All Air from Outdoors The confined space shall be provided with two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening shall have a minimum free area of square inch per 10 4 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet Air Alternate air inlet Ventilation louvers for unheated crawl space Equipment Located in Confined Spaces All Air from Outdoors Inlet Air from Ventilated Crawl Space
65. nstallations do not require a combustion air intake pipe a minimum of one 90 elbow must be attached to the furnace s combustion air intake if an upright installation uses the standard intake location or a horizontal installation uses the alternate air intake loca tion This elbow will guard against inadvertent blockage of the air intake Vent FLue Pe LENGTHS AND DIAMETERS Refer to the following table for applicable length elbows and pipe diameter for construction of the vent flue pipe system of a non direct vent installation In addition to the vent flue pipe a single 90 elbow must be secured to the combustion air intake to prevent inadvertent blockage The tee used in the vent flue termination must be included when determining the number of elbows in the piping system Non Direct Vent Single Pipe Maximum Allowable Length of Vent Flue Pipe ft Unit Input BTU Pipe Size Number of Elbows nc 213 4 s e 7 e 45000 2 68 05 o2 59 56 53 50 w E os oz so se sa so 1 One 90 elbow must be secured to the combustion air intake connection 2 Minimum vent length is five feet and one elbow tee 3 Tee used in the vent flue termination must be included when determining the number of elbows in the piping system 4 3 diameter pipe can be used in place of 2 diameter pipe VENT FLUE PIPE TERMINATIONS The vent flue pipe may terminate vertically as through a roof or hori
66. nt Located in Unconfined Spaces In unconfined spaces see definition below in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air may need to be provided using the methods described in 5 3 3 b or 5 3 4 Space Unconfined For purposes of this Code a space whose volume is not less than 50 cubic feet per 1 000 BTU per hour of the aggregate input rating of all appliances installed in that space Rooms communicating di rectly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space 5 3 3 Equipment Located in Confined Spaces a All Air from Inside the Building The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an uncon fined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of square inch per 1 000 BTU per hour of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches One opening shall be within 12 inches of the top and o
67. o the furnace If the dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one Ifthe dial is a two cubic foot dial divide the number of seconds recorded in step 2 by two Calculate the furnace input in BTUs per hour BTU hr Input equals the sum of the installation s gas heating value and a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating HTG value 1 000 BTU ft Obtained from gas supplier Installation s seconds per cubic foot 34 sec ft Conversion Factor hours to seconds 3600 sec hr 2 29 Input Htg value x 3600 seconds per cubic foot Input 1 000 BTU ft x 3600 sec hr 34 sec ft Input 106 000 BTU hr Minor changes to the input rate may be accomplished through manifold pressure adjustments at the gas valve Refer to Section XIV Startup Procedure and Adjustment Gas Manifold Pressure Measurement and Adjustment for details NOTE The final manifold pressure cannot vary by more than 0 3 w c from the specified setting Consult your local gas supplier if additional input rate adjustment is required Turn ON gas to and relight all other appliances turned off instep 1 Be certain that all appliances are function ing properly and that all pilot burners are operating TEMPERATURE RISE Temperature r
68. oling them to the point where conden sation takes place The condensate which is generated must be piped to an appropriate drain location In upright installations the furnace s drain hoses may exit either the right or left side of the furnace NOTE If the alternate vent flue outlet is utilized in an upright installation the drain trap and drain connections must be located on the same side as the alternate vent flue outlet In horizontal installations the drain hoses will exit through the bottom down side of the unit with the drain trap suspended beneath the furnace The field supplied drain system must be in accordance with all local codes and the instructions in the following sections A WARNING In upright upflow installations the drain trap must be mounted on the opposite side of the unit from the junction box This will reduce the risk of water reaching the junction box in the event of a blocked drain condition Failure to follow these instructions can result in possible death personal injury or property damage due to electrical shock Follow the bullets listed below when installing the drain system Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups e The drain trap supplied with the furnace must be used The drain line between furnace and drain location must be constructed of 3 4 PVC or CPVC e The drain line between furnace and drain lo
69. on card be sure to include the model manufacturing and serial numbers plus the instal lation date Yourwarranty certificate is also supplied with the unit Read the warranty carefully and note what is covered Keep the warranty certificate in a safe location for future reference If additional information or operating instructions are re quired contact the dealer where the purchase was made To THE INSTALLER Before installing this unit please read this manual thor oughly to familiarize yourself with specific items which must be adhered to including but not limited to unit maximum external static pressure gas pressures BTU input rating proper electrical connections circulating air temperature rise minimum or maximum CFM and motor speed con nections TRANSPORTATION DAMAGE All units are securely packed in shipping containers tested according to International Safe Transit Association specifi cations The carton must be checked upon arrival for external damage If damage is found a request for inspec tion by carrier s agent must be made in writing immediately The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit In the event of damage the consignee should 1 Make a notation on delivery receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 With concealed damage carrier must be notified a
70. owing steps the Vent Flue Pipe Cuts figure and the Alternate Vent Flue Location figure 1 Remove and save the four screws securing the vent flue coupling to the furnace top panel Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent flue pipe 2 Remove the vent flue pipe from the furnace 3 Cutthe vent flue pipe at the elbow nearest the coupling end of the pipe see Vent Flue Pipe Cuts figure The section of pipe attached to the coupling will reach through the side panel to the induced draft blower Discard unused pipe and elbows a CUT AT ELBOW NEAREST COUPLING ELBOWS UPFLOW Vent Flue Pipe Cuts 5 Remove plastic plug from alternate vent flue location Relocate and install plug in standard vent flue location top cover 6 Insert cut section of vent flue pipe and coupling into alternate vent flue location Using a rubber coupling and worm gear hose clamps from the drain kit bag attach the vent flue pipe and coupling to the induced draft blower Secure the coupling to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws A WARNING The rubber elbow is not designed to support aload When the rubber elbow is mounted externally to the furnace cabinet extreme care must be taken to adequately support field supplied vent flue piping As damage can result in leaks causing bodily in
71. pipe can be secured to the vent flue coupling e A vent termination shall not terminate over public using the rubber coupling and worm gear hose clamps walkways or over an area where condensate or vapor provided with this furnace see Standard Connections could create a nuisance or hazard or could be detri figure The rubber coupling allows separation of the vent mental to the operation of regulators relief valves or flue pipe from the furnace during servicing NOTE Do not other equipment use other commercially available no hub connectors due to possible material conflicts The vent flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue see Section IX Materials and Joining e Directly above a gas utility meter or service regulator e Overa walkway unless located 84 inches above grade NOTE This provision does not apply to the combus tion air intake termination of a direct vent application NOTE In Canada the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions Non Direct Vent h Methods Direct Vent Vent Flue Terminations VENT FLUE Non Direct Vent PIPE Vent Flue Termination No Terminations RUBBER Above Walkway Se e GEAR CLAMPS Oo Grade or Highest is Anticipated a Non Direct Vent Snow Level 1 Forced Air Vent Flue Termination Inlet Direct Vent Vent Flue Termination Vent Termination Clearances CANADIAN VENTING REQUIREMENTS In Ca
72. priate downward piping slope must be maintained from the drain trap to the drain location Refer to Section X Condensate Drain Trap and Lines for further details If the drain trap and drain line will be exposed to temperatures near or below freezing adequate measures must be taken to prevent condensate from freezing LEVELING Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower For proper flue pipe drainage the furnace must be level lengthwise from end to end The furnace should also be level from back to front or have a slight tilt with the access doors downhill approximately 3 4 inches from the back panel The slight tilt allows the heat exchanger condensate generated in the recuperator coil to flow forward to the recuperator coil front cover ALTERNATE VENT FLUE CONNECTIONS In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge In these positions the flue piping can be run vertically through the side of the furnace Refer to the Recommended Installation Positions figure for further detail The standard piping connections may also be used in these positions Refer to Section IX Vent Flue Pipe for details concerning the conversion to the alternate vent flue and combustion air connections NOTE Alternate vertical piping connections can not be used when an upflow furnace is installed with supply ai
73. r discharging to the right Install using standard flue and combustion air piping connections ALTERNATE ELECTRICAL AND Gas LINE CONNECTIONS This furnace has provisions allowing for electrical and gas line connections through either side panel In horizontal applications the connections can be made either through the top or bottom of the furnace DRAIN PAN A drain pan must be provided if the furnace is installed above a conditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if applicable FREEZE PROTECTION Refer to Section VI Horizontal Applications and Conditions Drain Trap and Lines FURNACE SUSPENSION If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad Never install the furnace on the ground or allow it to be exposed to water Refer to Section IV Location Re quirements and Considerations Furnace Suspension for further details 12 AIR DISCHARGE ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS Side Return S Duct Connection Side _ Return Duct Connection Bottom Return Duct Connection UPFLOW UPRIGHT ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS JDJ UPFLOW HORIZONTAL LEFT AIR DISCHARGE Bottom Return Duct 3 Connection lt AIR DISCHARGE Bottom P Return J Duct Connectio AIR DISCHARGE UPFLOW HORI
74. r door interlock switch which interrupts unit voltage when the blower door is opened for servicing Do not defeat this switch 24 Vor THERMOSTAT WIRING NOTE Wire routing must notinterfere with circulator blower operation filter removal or routine maintenance Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located adjacent to the junction box locations in the blower compartment Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance Refer to the following figure for thermostat connections to the integrated control module terminal strip PIPE UNION HEIGHT REQUIRED BY LOCAL CODE HR es Ng HEATING HEATING AND ROOM FURNACE COOLING ROOM FURNACE REMOTE THERMOSTAT THERMOSTAT ere e Thermostat Diagram GAS VALVE MANUAL MANIFOLD BURNERS SHUT OFF VALVE ALTERNATE UPSTREAM FROM GAS LINE GROUND JOINT LOCATION GROUND JOINT PIPE UNION DRIP LEG UPFLOW _ MANUAL SHUT OFF VALVE _ UPSTREAM FROM GROUND GROUND JOINT ba JOINT PIPE UNION PIPE UNION H DRIP LEG GAS VALVE U BURNERS m V DRAIN TRAP MANIFOLD ALTERNATE GAS LINE LOCATION HORIZONTAL UPFLOW MODEL NOTE DRIP LEG MAY TERMINATE
75. r re moval To remove filters from an external filter rack in an upright upflow installation follow the directions provided with exter nal filter rack kit Menia Air FILTER oR ELECTRONIC AIR CLEANER REMOVAL Follow the manufacturer s directions for service HorRIZONTAL UNIT FILTER REMOVAL Filters in horizontal installations are located in the central return register or the ductwork near the furnace To remove Turn OFF electrical power to furnace Remove filter s from the central return register or ductwork Replace filter s by reversing the procedure for re moval Turn ON electrical power to furnace BURNERS Visually inspect the burner flames periodically during the heating season Turn on the furnace at the thermostat and allow several minutes for flames to stabilize since any dislodged dust will alter the flames normal appearance Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow They should extend directly outward from the burners without curling floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes INDUCED DRAFT AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufac turer No further lubrication is required Check motor windings for accumulation of dust which may cause over heating Clean as necessary CONDENSATE TRAP A
76. re failure Only a qualified servicer should ever handle the igniter ANNUAL INSPECTION The furnace should be inspected by a qualified installer or service agency atleast once per year This check should be performed at the beginning of the heating season This will ensure that all furnace components are in proper working order and that the heating system functions appropriately Pay particular attention to the following items Repair or service as necessary e Flue pipe system Check for blockage and or leakage Check the outside termination and the connections at and internal to the furnace Combustion air intake pipe system where applicable Check for blockage and or leakage Check the outside termination and the connection at the furnace Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways Burners Check for proper ignition burner flame and flame sense Drainage system Check for blockage and or leakage Check hose connections at and internal to furnace Wiring Check electrical connections for tightness and or corrosion Check wires for damage Filters FILTERS A CAUTION Toensure proper unit performance adhere to the filter sizes given in the Specifications Sheet MAINTENANCE Improper filter maintenance is the most common cause of inadequate heating or cooling performance Filters should be cleaned permanent or replaced disposable every two months or as require
77. require drain hoses to be connected to the left side front cover drain port and the induced draft blower drain port NOTE On upflow models relocation of the front cover pressure switch hose is required 1 Remove the rubber plug from the coil front cover left down side drain port 2 Upflow furnaces Relocate the front cover pressure switch hose connec tion from the right side as shipped pressure tap to the left down side tap The pressure switch hose must be connected to the down side to guard against blocked drain conditions Cut hose to appropriate length to minimize sagging Plug right unused pressure tap with plug removed from left side 3 Secure Hose A to front cover drain port with a red hose clamp Route hose to rear left down side panel drain holes oa INDUCED DRAFT BLOWER DRAIN PORT HOSEB O por PQ SY cover WU 2 HOSE A M PRESSURE NS KA TAP ml Ss d a K GREEN HOSE oT SEAN CLAMPS br di NL er Ze v i 3 PLACES LEFT SIDE J d ms PANEL FRONT COVER wa DRAINPORT Ai SY RED HOSE CLAMP gt DRAIN TRAP SIDE PANEL DRAIN HOLES Horizontal Connections Left Side Down 4 Cut X inches from the long end of Hose B and discard Refer to table below for appropriate length to cut Cabinet Width Model GULA X Length Cut From inches kKBTU Tons Long End of Hose B 045 20 070_40 20 1 2 09040 14 3 4 in
78. rizontal Applications and Considerations ENEE EEEEE KEREN ENEE 11 VIII Propane Gas and or High Altitude Installations cccceceeeeceeeeeen ne eee eneee seen eeeeene eee eeeeneeeeeeeenaneceeeeeenaneceeeeeeennnes 12 IX VOMt FUG Pipe acces ccceccccccetivesectteavetenesadscenecctbeiicanaecheces ites cteeevescteadeneneeda scene censendcnnaadecebessscesevevsstssasssavesdsaaustenseesdenseesee 13 PROPER VENT FLUE AND COMBUSTION AIR PIPING PRACTICES ssssssssssisssaieeniissiriseninsnnnssninsnininrnennniennninnninnaarnannrnannnnannnnannnrann nn 13 TERMINATION eet te 14 CANADIAN VENTING REQUIREMENTS supenan tenia gees Eege Eed 14 VENUFIUC PIDG EE 14 ALTERNATE FURNACE ee ege 14 Alternate Vent Flue Location NON DIREGT VENT SINGLE PIPE PIPING ege GEELEN 15 Vent Flue Pipe Lengths and BET 15 EH CONCENTRIC VENT TERMINATION X Condensate Drain Lines and Drain Trapp c ce cceseeeeeeee cee REENEN NEEN EE REENEN 17 ere ere 18 Standard Right or L ftSide Drain Hose Ee 18 Alternate Veni Flue Drains HOSC C ONNGCUOINS asse reseo gedeelt 18 HORIZONTAL INSTALLATIONS LOT SIA DOWD EE Horizontal Drain Trap Mounting Lettor Right Side Panel seminarni ne a S RIE AEE ST E AARE 20 XI Electrical COMME CtiOmS sssrinin eaea ar aaar aaaea ar E AA EAEE AAEE aaan EAEE CEPETAN AE EEEIEE ENOCE e 115 VOLT LINE CONNECTIONS 24 VOLT THERMOSTAT WIRING u cccscscssssssscssessssessssessssucsessssecsssssssssssssucessusssssssssssssssssssissusisasssesusasssea
79. rmination Correct as necessary e Check induced draft blower for proper performance Re place if necessary e Tighten or correct wiring connection e Review wiring diagram to correct polarity e Reverse orange and gray wires going to transformer e Verify proper ground Correct if necessary e Sand flame sensor is coated oxidized Inspect for proper sensor alignment e Check inlet air piping for blockage proper length elbows and termination Compare current gas pressure to rating plate info Adjust as needed e Correct short at flame sensor or in flame sensor wiring Cautions and Notes e Turn power OFF prior to repair e Replace pressure switch with proper replacement part e Turn power OFF prior to repair e See Vent Flue Pipe section for piping details e Ensure the correct pressure switch replacement is used e Turn power OFF prior to repair e Turn power OFF prior to repair Sand flame sensor with emery clot e See Vent Flue Pipe section for piping details e See rating plate for proper gas pressure e Turn power OFF prior to repair XIX MAINTENANCE AA WARNING To avoid electrical shock injury or death disconnect electrical power before performing any maintenance If you must handle the igniter handle with care Touching the igniter element with bare fingers rough handling or vibration could damage the igniter resulting in prematu
80. ropriate table in Appendix G in the latest edition ofthe National Fuel Gas Code ANSI 2223 1 and or CSAB149 Installation Codes THERMOSTAT LOCATION In an area having good air circulation locate the thermostat about five feet high on a vibration free inside wall Do not install the thermostat where it may be influenced by any of the following e Drafts or dead spots behind doors in corners or under cabinets e Hot or cold air from registers e Radiant heat from the sun e Light fixtures or other appliances e Radiant heat from a fireplace e Concealed hot or cold water pipes or chimneys e Unconditioned areas behind the thermostat such as an outside wall N DRAFTS OR DEAD SPOTS BEHIND DOORS IN CORNERS UNDER CABINETS ae wt Thermostat Influences Consult the instructions packaged with the thermostat for mounting instructions and further precautions V COMBUSTION AND VENTILATION AIR REQUIREMENTS A WARNING Possible death personal injury or property damage may occur if the furnace is not provided with enough fresh air for proper combustion and ventilation of flue gases Most homes require outside air to be supplied to the furnace area Improved construction and additional insulation in buildings have reduced heatloss by reducing air filtration and escape around doors and windows These changes have helped in reducing heating cooling costs but have created a prob lem supplying combust
81. s soon as possible preferably within five days 4 File the claim with the following support documents within a nine month statute of limitations e Original or certified copy of the Bill of Lading or indemnity bond e Original paid freight bill or indemnity in lieu thereof e Original or certified copy of the invoice showing trade and other discounts or reductions e Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection of damage and fora thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage I SAFETY Please adhere to the following warnings and cautions when installing adjusting altering servicing or operating the furnace A WARNING To prevent personal injury or death due to improper installation adjustment alteration service or maintenance refer to this manual For additional assistance or information consult a qualified installer service agency or the gas supplier A WARNING This product contains or produces a chemical or chemicals which may cause serious illness or death and which are known to the State of California to cause cancer birth defects or other reproductive harm o JO Om E Go MM wk ak k N gt o O 13 14 15 16 Il COMPONENT IDENTIFICATION
82. t prior to making electrical connections To relocate the junction box follow the steps shown below NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance AA CAUTION Edges of sheet metal holes may be sharp Use gloves as a precaution when removing hole plugs 1 Remove the burner compartment door Remove and save the two screws securing the junction box to the side panel Relocate junction box and associated plugs and grom mets to opposite side panel Secure with screws removed in step 2 STANDARD ALTERNATE JUNCTION BOX JUNCTION BOX LOCATION LOCATION NN e A Wg p A fe Ja Junction Box Relocation AA WARNING To avoid the risk of electrical shock injury or death the furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code To ensure proper unit grounding the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel NOTE Do not use gas piping as an electrical ground To confirm proper unit grounding turn off the electrical power and perform the following check 1 Measure resistance between the neutral white con nection and one of the burners 2 Resistance should measure 10 ohms or less This furnace is equipped with a blowe
83. t the furnace to the building s gas piping the installer must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size The following stipulations apply when connecting gas pip ing Refer to the previous figures for typical gas line connections to the furnace e Use black iron or steel pipe and fittings for the building piping e Use pipe joint compound on male threads only Pipe joint compound must be resistant to the action of the fuel used e Use ground joint unions Install a drip leg to trap dirt and moisture before it can enter the gas valve The drip leg must be a minimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace e Use two pipe wrenches when making connection to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped from the factory e Install a manual shutoff valve between the gas meter and unit within six feet of the unit Ifa union is installed the union must be downstream of the manual shutoff valve between the shutoff valve and the furnace Tighten all joints securely Connect the furnace to the building piping by one of the following methods Rigid metallic pipe a
84. ted water manometer or appropriate gas pressure gauge at the gas valve outlet pressure tap refer to gas valve figure in previous section 3 Turn ON the gas supply and operate the furnace 4 Measure gas manifold pressure with burners firing Adjust manifold pressure using the table below Manifold Gas Pressure C Nawai Gas 3 5 we The final manifold pressure must not vary more than 0 3 w c from the above specified pressures Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice 5 To adjust the gas valve pressure regulator remove the regulator cap Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pres sure Securely replace the regulator cap Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall gas valve outlet pressure tap plug before turning on gas to furnace 6 Gas INPUT RATE MEASuREMENT NATURAL Gas ONLY The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas burning appliances except the furnace While the furnace is operating time and record one complete revolution of the smallest gas meter dial Calculate the number of seconds per cubic foot sec ft of gas being delivered t
85. th the order Although only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description Parts are available from your Amana distributor Functional Parts List Gas Valve Blower Motor Gas Manifold Blower Wheel Natural Gas Orifice Blower Mounting Bracket Propane Gas Orifice Blower Cutoff Igniter Blower Housing Flame Sensor Capacitor Rollout Limit Switch Heat Exchanger Primary Limit Switch Recuperator Coil Auxiliary Limit Switch Coil Front Cover Pressure Switch Integrated Control Module Induced Draft Blower Transformer Door Switch 38 Amana a trademark of Maytag World wide N V and is used under license to Goodman Company L P All rights reserved 39 40
86. the side return cutout locations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines NOTE An undersized opening will cause reduced airflow Upflow units with an air delivery of less than 1800 CFM should either use the bottom return or one side return Upflow units with an air delivery of 1800 CFM or higher must either use a two side return combination or a one side return and one bottom return combination These combi nations provide proper airflow through the unit To ensure proper unit performance follow the filter sizes given in the Specifications Sheet UPRIGHT INSTALLATIONS Depending on the installation and or customer preference differing filter arrangements can be applied Filters can be installed in the central return register or a side panel external filter rack kit upflows As an alternative a media air filter or electronic air cleaner can be used as the requested filter Review and follow the filter sizes given in the Specifications Sheet to ensure proper unit perfor mance The following figures show possible filter locations AIR FLOW CENTRAL RETURN _ GRILLE SIDE RETURN EXTERNAL FILTER RACK KIT EITHER SIDE POSSIBLE UPRIGHT UPFLOW FILTER LOCATIONS HORIZONTAL INSTALLATIONS Filters must be installed in either the central return register or in the return air duct work Refer to the Specification Sheet for recommended mini m
87. tsicsussvssssusissusassusicsusacsisscsesseesestsaesssacensaees 22 115 VOLT LINE CONNECTION OF ACCESSORIES HUMIDIFIER AND ELECTRONIC AIR CLEANER un s ssssessssessssesssstssestssesessessssceressene 22 Keep this literature in a safe place for future reference Table of Contents XII Gas Supply and Rping icsies seves iii cece cvevescicaweesaveesionteceneesiecsiewsnecie cacectecevvectecterevvehiscenseanstedcdde canta diniseseverssteveversverdaes 23 GENERAL eege SEENEN 23 Propane Gas Piping Ghats E 25 Propane Gas TankSiand PIPINO GE 26 XIII Circulating Air and Filters UPRIGHT INSTALLATIONS c ccscescssseseesteseestesees HORIZONTAL INSTALLATIONS XIV Startup Procedure and ase siccisccvcssceesseasscessescecensscetssedensccctscvessassevedsceeesassasseesecensetedansecceaceescressaavecdesasuessscuanaateceneedeee PRCJUSUUMO INE os occ cect dee ccc cceeet ct ceeatecenes cxvdececenne sca sedecemen tice sacdeqqed cxeaececuauaccesacecanoacecesaddenpen E cesses ESINGEN EES Eed te FURNACE SHUTDOWN ett eats ents ana estan a ded Seal dette ies Pande anaes ina tee Ai 28 AV Normal Sequence Of Operation in siiscvcaisecccnsiidevsnnsnavaxcavsscngnbeisesmneens ooncaiansaventuaevyennuswan cine vaclonsadannaian EEEE Ea 31 Laien CT 32 VII Safety Circuit DESCHIPUOM E 32 AVIAN Troubleshooting E 33 RESETTING FROM LOCKOUT sicisiccecserenarncariccnaseriacvovesasiiestaviencin erties tet aecetiadincaea tian tend geen nin aerate anne 33 XIX MAME Ell 36 MAINTENANGE
88. um filter sizes 27 XIV STARTUP PROCEDURE AND ADJUSTMENT Furnace must have a 115 VAC power supply properly connected and grounded Proper polarity must be main tained for correct operation In addition to the following start up and adjustment items refer to further information in Section XVI Operational Checks HEAT ANTICIPATOR SETTING The heat anticipator in the room thermostat must be cor rectly adjusted to obtain the proper number of cycles per hour and to prevent overshooting of the setting Set the heat anticipator setting to 0 7 amps Follow the thermostat manufacturer s instructions on how to adjust the heat anticipator setting DRAIN TRAP PRIMING The drain trap must be primed prior to furnace startup To prime fill the drain trap with water This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system FURNACE OPERATION Purge gas lines of air prior to startup Be sure not purge lines into an enclosed burner compartment Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved method Verify that all required kits pro pane gas high altitude etc have been appropriately installed FURNACE STARTUP 1 Close the manual gas shut off valve external to the furnace 2 Turn off the electrical power to the furnace 3 Set the room thermostat to the lowest possible sett
89. urbulators individually by slowly pulling each turbulator forward firmly Clean the recuperator coil tubes using a long handle wire brush such as a gun cleaning brush Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable such as drain cleanout cable Attach a variable speed reversible drill to the other end of the cable Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes While reversing the drill work the cable in and out several times to obtain sufficient cleaning Repeat for each tube Clean residue from furnace using a vacuum cleaner Replace the parts removed in the previous steps in reverse order Turn on electrical power and gas to furnace Check for leaks and proper unit operation Severe heat exchanger fouling is an indication of an operational problem Perform the checks listed in Section XIV Startup Procedure and Adjustments to reduce the chances of repeated fouling 2 JE 12 XX BEFORE LEAVING AN INSTALLATION Cycle the furnace with the thermostat at least three times Verify cooling and fan only operation Review the Owner s Manual with the homeowner and discuss proper furnace operation and maintenance Leave literature packet near furnace XXI REPAIR AND REPLACEMENT PARTS When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and serial numbers wi
90. ure to corrosive or very dirty atmospheres ELECTROSTATIC DiscHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and servicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electrostatic potential these steps will help avoid exposing the integrated control module to electro static discharge This procedure is applicable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnaces near the control Any tools held ina person s hand during grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an un grounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing anew control from its container Follow steps 1 through 3 if installing the control on a furnace
91. y or property damage due to fire do not install this furnace in a mobile home trailer or recreational vehicle To ensure proper furnace operation install operate and maintain the furnace in accordance with these installation and operation instructions all local building codes and ordinances In their absence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 and or CAN CSAB149 Installation Codes local plumbing or waste water codes and other applicable codes lil PRODUCT APPLICATION This Amana furnace is primarily designed for residential home heating applications Itis NOT designed or certified for use in mobile homes trailers or recreational vehicles Neither is it designed or certified for outdoor applications The furnace must be installed indoors i e attic space crawl space or garage area provided the garage area is enclosed with an operating door This furnace can be used in the following non industrial 2223 1 can be obtained from any of the following American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 A copy of the CAN CSA B149 Installation Codes can also be obtained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 The rated heating capacity of the furnace should be greater than or
92. zontally as through an outside wall Vertical vent flue pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe Termination Locations for details concerning location re strictions The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent Horizontal vent flue pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe Termination Locations for details concerning location restrictions A 2 3 8 diameter wall penetration is required for 2 diameter pipe while a 3 1 2 diameter hole is required for 3 diameter pipe To secure the pipe passing through the wall and prohibit damage to piping connections a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetration should be sealed with silicone caulking material In a basement installation the vent flue pipe can be run between joist spaces Ifthe vent pipe must go below a joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows CONCENTRIC VENT TERMINATION Refer to the directions provided with the concentric vent kit

High Efficiency Gas-Fired Furnace

Contents

Download Pdf Manuals

Related Search

Related Contents