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1. h rEcocNIzeE THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember itis your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual should not supersede existing practices but should be considered as supplemental information Amana October 1997 1 Fayetteville TN 37334 10759818 AA WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your b
2. 2 16x20x1 2 10x20x1 070 30 15 1 2 EJ 2 16x20x1 2 10x20x1 19 3 4 EET 2 20x20x1 2 10x20x1 14 1 4 2 16x20x1 2 15x20x1 2 1 3 2 24 1 4 2 25x20x 2 15x20x1 17 3 4 2 20x 20x 2 15x20x1 140_50 23 1 2 2 25x20x 2 15x20x1 Figure 30 Counterflow Furnaces 3 With the air flow direction arrow pointing toward the furnace insert the filters from the left side of the blower Starting with the right filter push the filter into the plenum so the bottom of the filter fits into the filter rack and the upper edge rests against the side of the plenum Repeat with the left filter Figure 29 OTHER FILTER OPTIONS External filter grilles can be used instead of the filter rack IX Sequence of Operation Integrated Ignition Control Refer to Timing Charts for sequencing NORMAL HEATING SEQUENCE 1 Thermostat calls for heat 2 The induced draft blower is energized 3 The ignitor is energized and is allowed to preheat for 17 seconds 4 The gas valve is energized delivering gas to the burners and starting combustion 5 The control checks for a signal from the flame sensor within seven seconds after the gas valve is energized Gas will only continue to flow if a signal is present 6 The control waits 30 seconds and turns on the air circulation blower to the speed that was selected for heating operation 7 The thermostat is satisfied and opens 8 The control de energize
3. 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 per 4 000 BTU per hour of the total input rating of all appliances in the enclosure Figure 4 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 5 3 4 Specially Engineered Installations The requirements of 5 3 3 shall not necessarily govern when special engineering approved by the authority hav ing jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue gases 5 3 5 Louvers and Grilles In calculating free area in 5 3 3 consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch mesh If the area through a design of louver or grille is known it should be used in calculating the size of opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with th
4. as shipped blower speed If the correct amount of temperature rise is not obtained it may be necessary to change the blower speed A faster blower speed will lower the temperature rise A slower blower speed will increase the temperature rise NOTE Blower speed must be set to give the correct air temperature rise through the furnace as marked on the rating plate CHANGING BLOWER SPEEDS AQ WARNING To avoid death or personal injury due to electrical shock turn off power to the furnace before changing speed taps All furnaces ship at high speed for cooling and the speed listed in Specification Sheet for heating These speeds should be adjusted by the installer to match the job require ments See Specification Sheet for details Connect the correct motor leads to the COOL HEAT and PARK terminals If heating speed will equal cooling speed use the jumper wire provided All unused motor leads that are not connected to PARK terminals on the control must be taped to prevent shorts High Limit Control Figure 42 High Limit Control CHECK HIGH LIMIT CONTROL A WARNING To prevent death personal injury property damage or premature failure of heat exchanger do not adjust the limit control factory preset Check limit control operation after 15 minutes of operation by blocking the return air grille s 1 After several minutes the burners must go OFF Blower will continue to run 2 Remov
5. CHECK MANIFOLD PRESSURE A tapped opening is provided in the gas valve to facilitate measurement of the manifold pressure See the Outlet Pressure Tap in Figures 36 37 38 amp 39 A U Tube manometer having a scale range from 0 to 12 inches of water should be used for this measurement The manifold pressure must be measured with the burners operating To adjust the pressure regulator remove the adjustment screw orcover onthe gas valve Turn out counterclockwise to decrease pressure turn in clockwise to increase pres sure Only small variations in gas flow should be made by means of the pressure regulator adjustment For natural gas the manifold pressure must be between 3 2 and 3 8 inches water column 8 5 nominal For propane gas the manifold pressure must be between 9 7 and 10 3 inches water column 10 0 nominal Any major changes in flow should be made by changing the size of the burner orifice CHECK GAS INPUT NATURAL GAS ONLY To measure the gas input using the gas meter proceed as follows 1 Turn off gas supply to all other appliances except the furnace 2 With the furnace operating time the smallest dial on the meter for one complete revolution If this is a 2 cubic foot dial divide the seconds by 2 if it is a 1 cubic foot dial use the seconds as is This gives the seconds per cubic foot of gas being delivered to the furnace 25 3 INPUT GAS HTG VALUE x 3600 SEC PER CUBIC FOOT 3600 is a con
6. due to asphyxiation common venting with other manufacturer s induced draft appliances is not allowed Common venting with specific Amana Category 80 furnaces is allowed with the addition of a common vent kit CVK for each appliance Contact the local installing dealer distributor or Amana directly for more information The minimum vent diameter for the Category venting system is as shown below MINIMUM VENT DIAMETER MODEL GUK GCI 4 Inch 4 Inch 4 Inch 5 Inch 5 Inch 90 4inch Under some conditions larger vents than those shown above may be required or allowed When an existing furnace is removed from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appliances The following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining con nected to the common venting system are notin operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 or the CAN CGA B149 Installation Codes and these instructions Determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Where practical close all building doors windows and
7. heating season begins to be sure there is adequate com bustion air and the vent system is working properly Have vent pipe checked to be sure it is not blocked by debris which could permit fumes to enter the house Replace any rusted or leaking sections of vent pipe AIR FILTER AA WARNING To prevent death personal injury or property damage due to fire never operate furnace without a filter installed Dust and lint will build up on internal parts resulting in loss of efficiency equipment damage and possible fire A return air filter is not supplied with this furnace however there must be a means of filtering all of the return air The installer will supply filter s at the time of installation Filters should be inspected cleaned or changed every two months or as required It is the owner s personal responsi bility to keep air filters clean Remember dirty filters are the most common cause of inadequate heating or cooling performance A WARNING To prevent death personal injury or property damage due to electrical shock disconnect electrical power to furnace before removing filter or performing any other maintenance Become familiar with filter location and procedures for removal cleaning and replacing them If help is needed contact the installer of the furnace or a qualified servicer AIR FILTER UPFLOW FURNACES If the filter is in the furnace retaining rails remove it as follows Pull off the
8. or death Damaging condensation can occur inside masonry chimneys when a single fan assisted Category appliance 80 AFUE furnace is vented without adequate dilution air Do not connect an 80 furnace to a masonry chimney unless the furnace is common vented with a draft hood equipped appliance or the chimney is lined with a metal liner or Type B metal vent All installations using Masonry chimneys must be sized in accordance with the appropriate Venting Tables If an 80 furnace is common vented with a draft hood equipped appliance the potential for condensation damage may still exist with extremely cold conditions long vent connectors exterior chimneys or any combination of these conditions The risk of condensation damage is best avoided by using the masonry chimney as a pathway for properly sized metal liner or Type B metal vent Crown Wash Roof Line Clay Tile Size Generally Be fats Soars 12 x 12 24 Length Clay Tile Size 8 x 8 x12 Each x 24 Length Attic Floor 1 2 to 1 Air Space Second Floor First Floor Water Heater F A F Vent Vent Connector Connector Natural Draft Water Heater Fan Assisted Forced Air munan Clean Out Basement Floor Figure 8 Typical Multiple Flue Clay Tile Chimney CHECKLIST SUMMARY This checklist serves as a Summary of the items to be
9. relined Fix 4 CHECK 7 COMPLETE THE INSTALLATION If Checks 1 through 6 have been satisfactory and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CGA B149 1 and CAN CGA B149 2 latest editions and amend ments then the clay tile liner can probably be used as avent for the gas appliances However the installer must keep in mind the following factors which may render the tile liner unsuitable for use as a vent e Extremely cold weather Long vent connectors Masonry chimneys with no air gap between the liner and the bricks In practice this can be difficult to detect Exterior chimneys The tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CGA B149 1 and CAN CGA B149 2 latest editions and amendments assume interior chimneys If in the judgment of the local gas utility installer and or local codes one or more of the above factors is likely to present a problem the chimney must be relined Fix 4 11 FIX 1 LINER TERMINATION Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use The liner and cap roof assembly must then terminate above the roof in accordance with the manufacturer s instructions In some cases a shorter extension above the roof may be possible with a liner than would
10. BTU Cubic Foot CFH NATURAL GAS CONNECTION Refer to Figure 11 for the general layout at the furnace The following rules apply 1 Use black iron or steel pipe and fittings for the building piping 2 Use pipe joint compound on male threads only Pipe joint compound must be resistant to the action of the fuel used 3 Use ground joint unions 4 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 5 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 the same as shipped from the factory 6 Within six feet of the unit install a manual cutoff valve between the meter and the unit If a union is installed the union must be downstream of the manual shutoff valve between the shutoff valve and the furnace 7 Tighten all joints securely 8 The furnace must be connected to the building piping by one of the following e Rigid metallic pipe and fittings e Semirigid metallic tubing and metallic fittings Alumi num alloy tubing must not be used in exterior loca tions Listed gas appliance connectors used in accor dance with the terms of their listing must be com pletely in the same room as the furnace The connectors or semirigid tubing must be pro tected against physical and thermal damage when installed Aluminum alloy tubing and connect
11. Through Right Side Counterflow Left side and right side above are as viewed for a counterflow installation Adaptation for horizontal airflow should be self explanatory CHECKING GAS PIPING AQ CAUTION To prevent personal injury or property damage due to fire the following instructions must be performed regarding gas connections pressure testing location of shutoff valve and installation of gas piping Before placing in operation leak test the unit and gas connections To avoid the possibility of explosion or fire never use a match or open flame to test for leaks Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause overfiring resulting in heat exchanger failure This unit and shutoff valve must be disconnected from the gas supply piping system before supply piping system pressure testing with test pressures in excess of 1 2 psig 3 48 kPa This unit must be isolated from the gas supply system by closing its manual shutoff valve before pressure testing of gas supply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa TANKS AND PIPING PROPANE GAS UNITS A WARNING To prevent death personal injury or property damage due to fire or explosion caused by a propane gas leak install a gas detecting warning device Since rust can reduce the level of odorant in propane gas a gas detecting warning device is the only reliable way
12. WARNING To prevent possible death or personal injury due to asphyxiation Amana Non Condensing Gas Fired Warm Air Furnaces must be Category vented Do not vent any of these furnaces using Category Ill venting Keep this literature in a safe place for future reference l Safety and Unit Location AA WARNING To prevent personal injury or death due to improper installation adjustment alteration service or maintenance refer to this manual or 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 AQ WARNING To prevent possible death personal injury or equipment damage due to fire the following points must be observed when installing the unit 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 NOTE This unit must not be used as a construction heater during the finishing phases of construction on a new structure This type of use may result in premature failure of the unit due to extremely low return air tempera tures and exposure to corrosive or very dirty atmospheres AQ WARNING To prevent po
13. all equipment in the enclosure Alternate Air Inlet ld A TTT ae C TI LETC hI T Ter i ot CR ES SS I Oe RA Ce E IA T OE TANE A SR WS Ventilation Louvers for Unheated Crawl Space Figure 2 Equipment Located in Confined Spaces All Air from Outdoors tInlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through verti cal 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 See Figure 3 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 BTUH of the total input rating of all equipment in the enclosure Inlet Air Duct Figure 3 Equipment Located in Confined Spaces All Air from Outdoors Through Ventilated Attic See 5 3 3 b 3 When communicating with the outdoors through hori zontal 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 Figure 4 NOTE The air duct openings must have a free area of not less than one square inch per 2000 BTUH of the total input rating of all equipment in the enclosure Chimney or Gas Vent i Cr 1 111 os A SDE S eee E i COE
14. components the resistance of the ignitor should not ex ceed 200 ohms If it does the ignitor should be replaced FLUE PASSAGES QUALIFIED SERVICER ONLY At the start of each heating season inspect and if nec essary clean the furnace flue passages CLEANING FLUE PASSAGES QUALIFIED SERVICER ONLY 1 Shut off electric power and gas supply to the furnace 2 Remove burner assembly by disconnecting the gas line and removing the manifold brackets from the partition panel Remove the flue from the induced draft blower and the collector box from the partition panel The primary heat exchanger tubes can be cleaned using a round 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 spring cable Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes While reversing the drill work the cable in and out several times to obtain sufficient cleaning Use a large cable for the large tube and then repeat the operation with a small cable for the smaller tube Repeat for each tube When all heat exchanger tubes have been cleaned replace the parts in the reverse order in which they were removed To reduce the chances of repeated fouling of the heat exchanger perform the steps listed in Section X Start up Adjustments and Checks BURNERS AQ WARNING To prevent personal inju
15. information 3 Pressure Switch Stuck Closed A sticking pressure switch can be caused by either a faulty pressure switch faulty wiring a disconnected hose or a restricted intake or flue piping In the case of a pressure switch sticking closed the probable cause is a faulty pressure switch or wiring If the ignition control senses that the pressure switch is closed and the induced draft blower is off it will shut down the unit until the fault is corrected The light code for this problem is two short flashes followed by a longer pause 4 Pressure Switch Stuck Open A sticking open pressure switch can be caused by a faulty pressure switch a disconnected hose to the pressure switch a restricted air intake or flue piping or a faulty wiring If the ignition control senses that the induced draft blower is energized but the pressure switch is not closed the control will keep the blower on and wait for the switch to close The diagnostic light code for this problem is three short flashes followed by a pause 5 Open Limit Control Primary or Auxiliary 8 Replace the door on the front of the furnace An open limit control can be caused by a low condi 9 Open the manual gas valve external to the furnace tioned air flow due to dirty filter or resistance in duct l work a faulty blower a blower speed set too low or a 10 Turn on the electrical power supply to the furnace faulty limit 11 Set the room thermostat to the desired t
16. left side of the furnace as viewed for an upflow installation If this is suitable for your installation no changes are necessary If the line voltage wiring is to enter through the right side of the furnace as viewed for an upflow installation relocate the junction box as shown in Figure 21 Junction A Jr Box Se M 5 ee z i Figure 21 Junction Box Left Side AA WARNING To prevent death or personal injury due to electric shock disconnect electrical power 1 Remove both doors from the furnace 2 Remove and save the screws holding the junction box to the left side of the furnace 3 Disconnect the hose from the pressure switch Leave the other end attached to the induced draft blower 4 Remove five wires entering junction box from split grommet in blower deck 5 Swap locations of the two bushings in the junction box 6 Rotate the junction box 180 degrees so the access panel continues to face forward The open snap bush ing should now be at the bottom 7 Insert five wires into the split grommet on the right side of the blower deck 8 Insert the five wires through the open bushing in the bottom of the junction box Attach the junction box to the right side of the furnace using the screws removed in step 2 10 Reconnect the hose to the pressure switch 11 Check the location of the pressure hose and all wiring Confirm that it will not be damaged by heat from the burners or by t
17. need to be added to the flexible liner if e It is required by the liner manufacturer s instructions e The previous liner was properly sized and installed and suffered from condensation damage e It is required by your local building codes Even if none of those three conditions exist which require additional liner insulation the installer may wish to con sider it if The local climate is very cold The chimney is very tall The vent connectors used are very long or have a large number of elbows Local experience indicates that flexible liners installed without insulation are likely to have condensation problems Insulation must be selected and installed in accordance with the liner manufacturer s instructions Finally cap the chimney and terminate the liner in accor dance with the liner manufacturer s instructions VI Gas Piping The rating plate is stamped with the model number type of gas and gas input rating Make sure the furnace is equipped to operate on the type of gas available Inlet Gas Pressure Min 5 0 W C Max 10 0 W C Min 11 0 W C Max 14 0 W C Inlet gas pressure must not exceed the maximum value shown in table above NOTE Adjusting the minimum supply pressure below the limits in the above table could lead to unreliable ignition Gas input to the burners must not exceed the rated input shown on the rating plate Overfiring of the furnace could result in premature heat exchang
18. non louvered door The blower motor will automatically stop through the interlock switch Grasp the lower portion of the filter lift up to disengage it from the lower railing move towards blower drop filter down Pull filter outward Figure 43 27 Front of Furnace Front of Furnace Blower Grab Here And Lift 1 Lift filter above bottom 2 Tilt filter to clear rail rail Front of Furnace Front of Furnace Blower 4 Pull filter out 3 Lower filter below top rail Figure 43 Filter Removal Replace the filter with the same type and size filter when needed Use a vacuum cleaner to clean out the blower area and the adjacent area of the return air duct Clean wash and dry a permanent filter When using a metal filter both sides should be sprayed with a dust adhesive as recommended on adhesive container Spray adhesives for use with permanent metal filters can be found at some hardware stores Reinstall filter by placing it into the furnace along the side of the blower Engage filter in top rail move toward side of furnace and drop it into the bottom rail BE SURE AIRFLOW DIRECTION ARROW POINTS TO WARDS THE BLOWER When the filter is located in the bottom of the furnace on a bottom return system the filter is held in place by a sheet metal retainer strap To change and clean the filter slide one end of the retainer towards the front and remove filter AIR FILTER COUNTERFLOW FURNACES A furnace mou
19. shock disconnect electrical power before changing any electrical wiring AQ CAUTION When servicing controls label all wires before disconnecting Wiring errors can cause improper and dangerous operation After servicing is completed always verify proper operation The unit wiring harness is an integral part of the furnace Field alteration to comply with electrical codes should not be required Power supply to the furnace must be NEC Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with the local codes or in their absence with the latest edition of the National Electrical Code ANSI NFPA No 70 and or the CSA C22 1 Electrical Code A fused disconnect must be provided and sized in accordance with the unit maximum overcurrent protection Heating Room Thermostat Heating and Cooling Furnace Furnace Figure 20 Typical Field Wiring 24 VAC Control Circuit A 40 VA transformer and an integrated electronic control are built into the furnace to allow use with most cooling equipment A CAUTION To avoid the risk of electrical shock wiring to the unit must be properly polarized and grounded To provide more reliable sensing of flame the ground wire must run to the electrical panel Line voltage wiring must enter into the junction box pro vided with the furnace As shipped the junction box is attached to the
20. AMA tables and rules If a metal liner is not present a clay tile liner must be present or the chimney must be lined Fix 4 Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner If any of the following problems are present e Tile sections misaligned Tile sections missing Gaps between tile sections Signs of condensate drainage at the cleanout or vent connectors Mortar protruding from between tile sections Use of sewer pipe or drainage pipe rather than an approved fire clay tile reline the chimney Fix 4 Next measure the size of the liner It may be possible to do this from the cleanout The liner must be at least as large as the minimum size established by the tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CGA B149 1 and 2 latest editions and amendments If the liner is too small or too large then the chimney must be relined Fix 4 CHECK 6 DILUTION AIR If gas fired appliances are to be vented into a clay tile liner a source of dilution air is required Dilution air cannot be obtained through e Induced draft appliances e Natural draft appliances with vent dampers Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance s vent connector does not include a vent damper If dilution air will not be available the chimney must be
21. Amana Heating_ Air Conditionin A higher standard of comfort GUI amp GCI Gas Fired Warm Air Furnace Table of Contents TO The Qwine lh eisein annie a neee enrarir KAAKAA ENAERE EREET EE To The Installer ceseceeeeeeeeeseeeeeeeeeeeeeeeeeeseeeeneneeeeeeeeees l Safety and Unit Location ssssssnseeneennnenennnnnnnnnnnn nnna Il General Information sssssssssnsnnnnnnnnnnnnnnnnnnnnn nunne ennen IIL Air Requirements cceceeeeseeeeeeeeeeseeeeeeeeeteneteeeees IV Category Venting Vertical Venting 0 0 V Masonry ChimneyS cccceeccececceseesesseessneeseeeeeeeeenees VIL Gas PIPING iassa contceccsenceceueicasturestetentercuecseeceeacetve VII Electrical Wiring ccccsseecseeeeeeeeeeeeeseeeeesteeeenseeeenes VIII Circulating Air and Filters cssccseeseeeseeeeeees IX Sequence of Operation Integrated Ignition Control 21 X Start Up Adjustments and Checks 0 0 XI Maintenance cccceeeeeeeeceeeeeenseeeeeeeeeenseeeeesenseneeeeees Amana Forced Air Central Furnace Design Complies With Requirements Embodied in The American National Standard National Standard of Canada Shown Below ANSI Z21 47 CAN CGA 2 3 Central Furnaces Installation Instructions Affix this manual Specification Sheet and Users Information Manual adjacent to the furnace APPROVED 8
22. C AIR CLEANER The control module is equipped with line voltage accessory terminals used for controlling the power to an optional field supplied humidifier and or electronic air cleaner Accessory Load Specification Air Cleaner 1 0 Amp max at 120 VAC Humidifier 1 0 Amp max at 120 VAC Accessory Installation Follow the electronic air cleaner and humidifier manufactur ers instructions for mounting and electrically grounding these accessories Check that the power supply to the furnace has been disconnected Wire the accessories to the control module as shown below All connections to the control module are to be made through 1 4 inch female terminals If it is necessary to supply additional line voltage wiring to the interior of the furnace the wiring must comply with all local codes This wiring must have a minimum temperature rating of 105 C and must be routed away from the burner compartment All line voltage wire splices must be made inside the furnace junction box Control Module Neutral 120 VAC ransformer ine ir Cool Heat Park Park Line Transformer O Cleaner Figure 24 Line Voltage Connection for Accessories Optional Accessories Accessory Operation The furnace control module ener gizes the humidifier whenever the induced draft blower is energized when an air cleaner is installed on the system the humidifier is not energized until the air cleaner is energized Th
23. ING To prevent death or personal injury due to electrical shock disconnect electrical power 2 Remove the round cutout from the side of the furnace Note The assembly starting from the outside is induced draft blower outer gasket rotation plate inner gasket partition panel See Figure 7 Partition Panel Stationary Hose to __ Pressure Switch Rotation Plate Outer Gasket Induced Draft Blower All can rotate together Figure 7 Blower Assembly 3 Remove and save the four screws which hold the rotation plate on the partition panel Note that one of the screws which hold the induced draft blower on the rotation plate needs to be removed 4 Turn the rotation plate 90 degrees counterclockwise The inner gasket must turn with the rotation plate 5 Reinstall the rotation plate on the partition panel using the four screws removed in step 3 Tighten screws to provide an airtight seal 6 Make sure all wires are at least one inch from flue pipe Relocate junction box to right side of cabinet if nec essary Refer to Section VI for instructions AA WARNING To prevent death or serious illness to building occupants due to flue products leaking into the building proper installation of gaskets and screws is essential for providing a gas tight seal between the partition panel and the induced draft blower V Masonry Chimneys AQ WARNING Possibility of property damage personal injury
24. ON position 24 Redundant Solenoid Inlet Pressure Tap Outlet Pressure Tap Side of Valve Side of Valve Main Regulator Adjust Figure 39 White Rodgers Model 36E22 CHECK GAS INPUT AND PRESSURES Gas supply pressure and manifold pressure with the burn ers operating must be as specified on the rating plate CHECKING GAS PRESSURE Gas inlet pressure should be checked and adjusted in accordance to the type of fuel being consumed With Power and Gas Off 1 Honeywell Model VR8205 or White Rodgers Models 36E36 or 36E22 or Robertshaw Model 7222 Connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve As an alternative method inlet gas pressure can also be measured by removing the cap from the drip leg and installing a predrilled cap with a hose fitting Figure 41 With Power and Gas On 2 Put furnace into heating cycle and turn on all other gas consuming appliances Inlet Gas Pressure Min 5 0 W C Max 10 0 W C Min 11 0 W C Max 14 0 W C Inlet Gas Pressure Must Not Exceed the Maximum Value Shown Figure 40 If operating pressures differ from above make necessary pressure regulator adjustments check piping size etc and or consult with local utility Gas Line Shutoff Valve f Gas Line To Furnace Open to Atmosphere Drip Leg Cap ___ WFFitting Manometer Hose Figure 41 Measuring Inlet Gas Pressure Alternate Method
25. The provisions of 5 3 apply to gas utilization equipment installed in buildings and which require air for combustion ventilation and dilution of flue gases from within the build ing 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 incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases b Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas proper venting and the maintenance of ambient tem perature 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 compres sors 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 a
26. all doors between the space where the appliances remain connected to the common venting system are located and other spaces of the building Turn on all gas appliances not connected to the common venting sys tem and operate on high speed all exhaust fans range hoods and bathroom except summer exhaust fans Close fireplace dampers d Following the lighting instructions place the furnace being inspected in operation Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance re maining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous con ditions of use g If improper venting is observed during any of the above tests the common venting system must be corrected in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223 1 Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace Top is as viewed for an upflow installation T
27. as diagonal offsets B vent probably cannot be used If B vent is to be used it must be supported adequately Supports such as fire stops or thimbles must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls Direct contact would result in higher heat loss with an increased possibility of poor venting system performance It is not acceptable to vent one appliance inside the B vent and other appliances outside The excess space between the B vent and the chimney walls must be covered at the top of the chimney by a weatherproof corrosion resistant flashing The B vent should then be topped with a listed vent cap The listed vent cap will when installed per the manufacturer s instructions prevent problems due to rain birds or wind effects AB vent installed as described in this section is considered to be an enclosed vent system and the sizing tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CGA B149 1 and CAN CGA B149 2 latest editions and amend ments may be used If a flexible liner is to be used it must be made of the proper materials e For most residential applications an aluminum liner should be acceptable If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine a liner of AL294C stainless steel should be used Common sources of chlorine and flu
28. be required with a masonry chimney For further information on relining see Fix 4 FIX 2 CHANGE VENTING ARRANGEMENTS If the masonry chimney has more than one channel it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance s into another channel s Do not vent an Air Command 80 inside of a metal liner with other appliances vented outside the liner Alternatively the homeowner may agree to discontinue use of the fireplace solid fuel appliance If so the tile liner must be cleaned to remove creosote buildup The fireplace opening must then be permanently sealed If oil fired appliance s are being replaced by gas fired appliance s the tile liner must first be cleaned to remove the fuel oil residue If none of the above options is practical the Air Command 80 may need to be vented vertically with a B Vent Under some conditions an Air Command 90 or 95 could be installed rather than an Air Command 80 The Air Com mand 90 or 95 can be vented horizontally or vertically through PVC pipe FIX 3 REBUILD THE CROWN If the chimney crown is damaged a qualified mason must repair it in accordance with nationally recognized building codes or standards One such standard which may be referenced is the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 FIX 4 RELINING Relining options include B vent and flexible liners If the chimney h
29. checked before venting an Air Command 80 furnace into a masonry chimney In addition we recommend that a quali fied serviceman use this checklist to perform a yearly inspection of the furnace venting system This checklist is only a summary For detailed information on each of the procedures mentioned see the paragraph referenced with each item This inspection is based upon a draft topical report Ma sonry Chimney Inspection and Relining issued by the Gas Research Institute While not yet finalized we believe this report represents the best information on this subject which is currently available Proper Chimney Line terminate with Termination No listed vent cap Check 1 Fix 1 Yes Chimney channel free of solid and Change venting liquid fuel No arrangements appliances Fix 2 Check 2 Yes Crown in good Rebuild crown condition No and ies heck Check 3 Fix 4 Yes Cleanout free of Reline debris No Fix 4 Check 4 Yes Liner in good i condition ie aon Check 5 Yes Dilution air Reline available No Fix 4 Check 6 Yes Complete the installation Check 7 CHECK 1 PROPER CHIMNEY TERMINATION A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it pas
30. e air restrictions and burners will relight after a cool down period of a few minutes Adjust the thermostat setting below room temperature 1 Burners must go off 2 Circulating air blower will continue to run for 60 90 120 or 180 seconds as set IMPORTANT NOTE This unit must not be used as a construction heater during the finishing phases of construc tion of a new structure This type of use may result in premature failure due to extremely low return air tempera tures and exposure to corrosive or very dirty atmospheres ir TURN OFF FURNACE Set the thermostat to lowest setting 2 Turn off the electrical power supply to the furnace 3 Honeywell Model VR 8205 or White Rodgers Model 36E36 or Robertshaw Model 7222 Turn the gas control knob clockwise N to the OFF position The knob should turn easily Do not use excessive force White Rodgers Model 36E22 Push switch to the OFF position 4 Close manual gas shutoff valve external to the furnace 5 Replace the door on the unit 26 XI Maintenance AQ WARNING To prevent death or personal injury due to electric shock disconnect electrical power before performing any maintenance IMPORTANT NOTE Handle the ignitor with care Touch ing the ignitor body with bare fingers rough handling or vibration could result in early ignitor failure Only a qualified servicer should ever handle the ignitor Have the furnace checked at least once a year before the
31. e control module energizes the air cleaner whenever the air circulation blower is energized VIII 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 Supply and return con nections 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 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 equipp
32. e equipment so that they are opened automatically during equipment operation 5 3 6 Special Conditions Created by Mechanical Ex hausting or Fireplaces Operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring spe cial attention to avoid unsatisfactory operation of installed gas utilization equipment IV Category I Venting Vertical Venting AA WARNING To prevent possible death or personal injury due to asphyxiation Amana Non Condensing Gas Fired Warm Air Furnaces must be Category I vented Do not vent any of these furnaces using Category Ill venting Category Venting is venting at a non positive pressure A furnace vented as Category is considered a fan assisted appliance and does not have to be gas tight NOTE Single stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing in some instances common venting with natural draft appli ances i e water heaters All installations must be vented in accordance with National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition In Canada the furnaces must be vented in accordance with the National Standard of Canada CAN CGA B149 1 and 2 latest editions and amendments NOTE The vertical height of the Category venting system must be at least as great as the horizontal length of the venting system A WARNING To prevent possible death or personal injury
33. e inside of the elbow or tee at the base of the liner A small amount of soot may be considered acceptable provided the installer vacuums it away If rusted pieces of the liner have collected here the metal liner must be removed and replaced Fix 4 Next gently tap the inside of the liner with a phillips screwdriver If the screwdriver perforates the liner or if the tapping does not sound like metal hitting metal the liner must be removed and replaced Fix 4 Remember that all appliances must be vented inside the liner Venting one appliance inside the liner and another appliance outside the liner is not acceptable Next use a flashlight and small mirror to sight up the liner B vent must be supported so as to not come into direct contact with the chimney walls or tile liner If it is not it can probably be rehung so as to be acceptable A thimble or fire stop may be helpful here Flexible liners should be hung straight or nearly straight If itis spiraled in the chimney and in good condition it should be rehung To do this break the top seal pull up and cut off the excess liner length and refit the top seal Use caution when doing this as the cut edges of flexible liners may be sharp The surfaces of the liner must be physically sound If gaps or holes are present the metal liner must be removed and replaced Fix 4 Finally confirm that the metallic liner is the correct size for the appliances to be installed Use the G
34. e power supply is interrupted while the furnace is firing The auxiliary limit control is suitable for both horizontal right and horizontal left installations Regardless of airflow direc tion it does not need to be relocated A WARNING To prevent death personal injury or property damage due to fire follow these directions for the auxiliary limit control If the auxiliary limit control opens it may be reset one time only SERVICER S NOTE If it becomes necessary to slide the blower assembly out of the furnace the auxiliary limit control should be removed first After the blower assembly is reinstalled the auxiliary limit must be reinstalled Manual Reset Auxiliary Limit Figure 35 Auxiliary Limit Control ABNORMAL OPERATION INTEGRATED IGNITION CONTROL The following presents the probable causes of question able furnace operation and how to fix them Look through 23 the observation window in the blower access door and make a note of the number of flashes in sequence between pauses Next refer to the Diagnostic Signal Chart for an interpretation of the signals and to this section for a descrip tion 1 Internal Control Failure with Integrated Ignition Control An internal control failure occurs when the integrated ignition control senses an internal problem and stops the unit To solve this problem replace the ignition control 2 System Lockout A system lockout occurs when the integ
35. ectly on carpeting tile or other combustible material other than wood flooring Note The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor The furnace must be level If the furnace is to be set on a floor that may become wet or damp at times the furnace should be supported above the floor on a concrete base sized approximately 1 1 2 larger than the base of the furnace ADDITIONAL LOCATION CONSIDERATIONS The furnace should be as centralized as is practical with respect to the air distribution system Do not install the furnace directly on carpeting tile or combustible material other than wood flooring e When suspending the furnace from rafters or joists use 3 8 threaded rod and 2 x 2 x 3 8 angle as shown on the Specification Sheet The length of the rod will depend on the application and clearance necessary e When installed in a residential garage the furnace must be positioned so the burners and ignition source are located not less than 18 inches 457 mm above the floor and protected from physical damage by vehicles ll General Information A WARNING Possible death personal injury or property damage due to fire explosion smoke soot condensation electrical shock or carbon monoxide may result from improper installation repair operation or maintenance on this product To ensure the furnace operates sa
36. ed space The total input of all gas utilization equipment installed in the combined space shall be consid ered in making this determination Each opening shall have a minimum free area of 1 square inch per 1 000 BTU per hour of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure Figure 1 Chimney or Gas Vents NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of ment in the enclosure but not less than 100 square inches Figure 1 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 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure Figure 2 Chimney or Gas Vent NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTUH of the total input rating of
37. ed 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 outlet air duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the 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 When a furnace is installed so that supply ducts carry air circulated by furnace to areas outside the space containing the furnace the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space containing the furnace Filters Read This Section Before Installing The Return Air Ductwork Filters must be used with this furnace Discuss filter main tenance with the building owner Filters do not ship with this furnace but must be provided by the installer Filter s must comply with UL900 or CAN ULCS111 standards If the furnace is installed without filters the warranty will be voided The following chart shows recommended minimum filter sizes for each furnace model Larger sizes are also accept able Mini
38. emperature When the limit control opens the induced draft and air circulation blowers are turned on The induced draft blower will remain on for the first fifteen seconds of this NOTE There is an approximate 20 second delay between period The air circulation blower will remain on until thermostat energizing and burner firing the limit control is closed The diagnostic light code for this is four short flashes followed by a pause Gas Valves 6 Open Rollout Control Pressure Regulator An open rollout control is can be caused by insufficient P combustion air a restricted flue passage or a re ma stricted heat exchanger Outlet Manifold Pressure Tap Pressure The opening of the rollout control signals the air circu Tap lation blower and the induced draft blower to turn on A The air circulation blower will remain on until the limit INLET gt ea OUTLET is manually reset The induced draft blower will remain on for the first fifteen seconds of this period The diagnostic light code for this is five short flashes followed by a pause 7 Flame Sensed with No Call for Heat Cas ConnalNvaWe Knob If the control senses a flame when the gas valve is de energized it will run the air circulation blower and the Figure 36 induced draft blower continuously The diagnostic light Honeywell Model VR 8205 code for this is continuous light flashing Probable cause is miswiring OPERATING INSTRUCTIONS 1 Close the man
39. er failure Gas pressures in excess of 14 inches water column could result in perma nent damage to the gas valve IMPORTANT NOTE The furnace will naturally derate itself with altitude Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure This can cause poor combustion and equipment failure At all altitudes the manifold pressure must be within 0 3 inches WC of that listed on the Specification Sheet for the fuel used At all altitudes and with either fuel the air temperature rise must be within the range listed on the furnace nameplate GAS PIPING IMPORTANT NOTE To avoid possible unsatisfactory op eration or equipment damage due to underfiring of equip ment do not undersize the natural propane gas piping from the meter tank to the furnace Include all appliances which may be operated simultaneously when sizing a trunk line The gas pipe supplying the furnace must be properly sized based on gas flow required specific gravity of the gas and length of the run The gas line installation must comply with local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code 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 ies eae Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas BTUH Furnace Input Heating Value of Gas
40. er normal use permanent filters should last for several years To reinstall the filters first MAKE CERTAIN THE AIRFLOW DIRECTION ARROW POINTS TOWARDS THE FURNACE Then insert the filters from the left side of the blower Starting with the right filter push the filter into the plenum so that the bottom of the filter rests in the filter rack and the upper edge rests against the side of the plenum Repeat with the left filter Figure 44 4a 4b 6 Replace the blower door then reconnect the electrical power Optional Access Door Figure 44 Furnace mounted Filter Rack Counterflow 28 BLOWER MOTOR The air circulating blower motor bearings are permanently lubricated No further lubrication is required INDUCED DRAFT BLOWER MOTOR The induced draft blower motor is permanently lubricated No further lubrication is required FLAME SENSOR INTEGRATED IGNITION CONTROL QUALIFIED SERVICER ONLY The fuel or combustion air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sensing signal To remove this coating a qualified servicer should carefully clean the flame sensor with emery cloth or steel wool After cleaning the microamp signal should be in the range listed in Specification Sheet IGNITOR QUALIFIED SERVICER ONLY If the ignitor and the surrounding air are at about 70 F and the ignitor wires are not connected to any other electrical
41. fely and efficiently it must be installed operated and maintained in accordance with these installation and operating instructions all local building codes and ordinances or in their absence with the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Codes The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated The total heat loss should be calculated by an approved method or in accordance with ASHRAE Guide or Manual J Load Calculations published by the Air Conditioning Contractors of America Obtain from American National Standards Institute 1430 Broadway New York NY 10018 TRANSPORTATION DAMAGE Check the furnace for any shipping damage If damage is found contact the company where the furnace was pur chased While checking for transportation damage remove all pack aging material and dispose or recycle according to local codes THERMOSTAT LOCATION Locate the thermostat about 5 feet high on a vibration free inside wall in an area having good air circulation Do not install the thermostat where it may be affected by drafts or dead spots behind door in corners or under cabinets e hot or cold air from ducts e radiant heat from sun or appliances concealed pipes and chimneys e unheated uncooled areas behind the thermostat such as an outside wall Consult the instructions packaged wi
42. he device must be relocated Supply lt Return Air i Air Figure 31 Right To Left Installation Return gt gt Supply Air Air Figure 32 Left To Right Installation If relocation is required proceed as follows 1 Disconnect electrical power AQ WARNING To prevent death or personal injury due to electric shock disconnect electrical power 2 See Figures 33 and 34 Remove the cover from the burner box Save the screws that held it in place Note There are several screw holes but only four screws This is intentional and not a manufacturing defect 3 As shipped the rollout protection device is located near the flame sensor end of the manifold assembly Re move and save the mounting screws 4 For most installations it will not be necessary to remove the wires from the rollout protection device 5 For horizontal left installations a hole is provided near the ignitor end of the manifold assembly Insert the rollout protection device into this hole and attach with screws removed in step 3 6 Secure rollout wires to manifold and insure no wires can come in contact with burners or other hot surfaces 7 Push the button to confirm the rollout control is in the closed position 8 Replace the cover on the burner box placing the screws from step 2 in their original locations A WARNING To prevent death personal injury or property damage due to fire or explosion a qualified servicer must determine t
43. he induced draft blower can be rotated 90 degrees counterclockwise for Category venting with the airflow horizontal left to right Figure 5 For horizontal installations a 4 inch single wall pipe can be used to extend the induced draft blower outlet 1 2 beyond the furnace cabinet Vent the furnace in accordance with the National Fuel Gas Code NFPA54 ANSI 2223 1 latest edition In Canada vent the furnace in accordance with the National Standard of Canada CAN CGA B149 latest editions and amendments Figure 5 Upflow Rotated Induced Draft Blower Counterflow units are shipped with the induced draft blower discharging from the top of the furnace Top as viewed for an counterflow installation The induced draft blower can be rotated 90 degrees counterclockwise for Category venting with the airflow horizontal right to left Figure 6 For horizontal installations a 3 inch B vent pipe can be used to extend the induced draft blower outlet 1 2 beyond the furnace cabinet Vent the furnace in accor dance with the National Fuel Gas Code NFPA54 ANSI 2223 1 latest edition In Canada vent the furnace in accordance with the National Standard of Canada CAN CGA B149 latest editions and amendments Vent an Supply Return ir Air Figure 6 Counterflow Rotated Induced Draft Blower To rotate the induced draft blower counterclockwise pro ceed as follows 1 Disconnect electrical power from furnace AA WARN
44. he reason the rollout protection device opened before the device is reset 22 j And Lf Rollout Switch Location Rollout Switch Location ee ai Relocation Secure Wires To Manifold With 2 Wire Ties All Excess Wire To Be Outside Burner Box Required Figure 33 Rollout Switch Relocation Upflow Rollout Switch Location Rollout Switch Relocation Location Required Secure Wires To Manifold With Two Wire Ties All Excess Wire To Be Outside The Burner Box Figure 34 Rollout Switch Relocation Counterflow BURNER BOX This furnace must use indoor air for combustion It is not a direct vent furnace and it cannot be installed as a direct vent furnace The burner box on some models is present only to reduce the burner sound transmission AUXILIARY LIMIT CONTROL FIGURE 35 A manual reset limit is located on the blower side of the blower deck near the center To access this auxiliary limit disconnect the electrical power and remove the blower door If the limit control opens the air circulation blower will run continuously The diagnostic light will flash four times These symptoms are identical to a trip of the primary limit control See Section X Abnormal Operation Integrated Ignition Control for diagnosis The auxiliary limit control is designed to prevent furnace operation in case of main blower failure on horizontal and counterflow installations It may also open if th
45. he rotation of the fan Also confirm that wiring location will not interfere with filter removal or other maintenance o After the junction box is in the desired location use washers to connect field supplied conduit to the junction box in accordance with NEC and local codes Connect hot neu tral and ground wires as shown in the furnace wiring diagram The wires and ground screw are located in the furnace junction box Low voltage wiring may enter through the right or left side of the furnace as viewed for an upflow installation top or bottom fora horizontal installation See Specification Sheet for hole locations Run the thermostat wires through either grommet in the blower deck Figure 21 Low voltage wires may be connected to the terminal strip as shown in Figure 22 IMPORTANT NOTE To avoid possible equipment mal function route the low voltage wires to avoid interference with filter removal or other maintenance Low Voltage Terminals Heating Fan Off Adjustments B3 Style B Jumper B4 Figure 22 Integrated Ignition Control Viewed in an Upflow Installation AIR CIRCULATION BLOWER FAN TIMING Allitems in this section refer to the air circulation blower fan not to the induced draft blower The timing sequence for the induced draft blower is not adjustable When a call for cooling occurs the circulation fan will come on It will remain on for 45 seconds after the call for cooling ends This fan ti
46. in stalled with the access doors vertical so that the burners fire horizontally into the heat exchanger The unit cannot be installed with the access doors on top or bottom See Specification Sheet Allow clearances from the enclosure as shown on Specification Sheet for fire protection proper opera tion and service access These clearances must be permanently maintained The combustion and venti lating air openings in the front and top panels of the furnace must never be obstructed e This furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel e When the furnace is used in connection with a cooling unit the furnace must be upstream of or in parallel with the cooling unit For details see Section VIII e On Counterflow Installations the air conditioning coil must be downstream from the heat exchanger of the furnace e Counterflow Installation over a noncombustible floor Before setting the furnace over the plenum opening insure the surface around the opening is smooth and level A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout e Counterflow Installation over a combustible floor lf installation over a combustible floor becomes neces sary use an accessory subbase as shown on the Specification Sheet Follow the instructions with the subbase for proper installation Do not install the furnace dir
47. ir plenum Heating Timing Chart for Integrated Ignition Control Normal Heating Operation On Induced Draft Blower Off I i I i j Open Hea s H Gas Valve Closed E geag S pg e Ignitor off l i I l l l l l Pressure Switch Gosea Li l __ l l l l 1 1 i Open Combustion Blower On r r A o Off 1 rot beat Thermostat an Seconds 0 17 21 24 54 0 5 60 90 120 TAA or 15 or 180 Timings may vary 2 seconds Integrated Ignition Control Diagnostic Signal Chart Refer to Abnormal Light Signal Operation Number Continuous Light 1 Internal Control Failure 1 Flash 2 System Lockout 2 Flashes 3 Pressure Switch Stuck Closed 3 Flashes 4 Pressure Switch Stuck Open 4 Flashes 5 Open Limit Control 5 Flashes 6 Open Rollout Control Continuous Flashing 7 Flame Sensed No Call For Heat Timing Chart for Normal Cooling Operation Indoor Fan Off L Jonne Outdoor Fan Oiler ee Ny And o a s s CS ee le Compressor On sas a SNES Thermostat Off L ELE PEPE sia ene eee Seconds 0 45 20 A CAUTION To prevent personal injury use only blunt pointed screws to attach the plenum to the furnace and filter rack Screws should not be placed where they could interfere with filter replacement Dimension A Minimum Recommended Size_Air Inches Filter Sizes Inches EOW Throwaway Perm Ese Permanent rowaway 045 30 15 1 2 8
48. locate the side and bottom return cutout locations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines An undersized opening will cause reduced airflow For bottom return connection remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct HORIZONTAL INSTALLATIONS Filter s must be installed external to the furnace casing Using a central return with filters installed in the duct behind the return air grille allows filters to be replaced by just removing the grille This prevents having to go into the attic or crawl space when a filter has to be changed Refer to the preceding chart on Recommended Minimum Filter Sizes Figure 25 COUNTERFLOW INSTALLATIONS A filter rack is shipped with the furnace To use this rack proceed as follows Figure 28 Furnace Mounted Filter Rack 1 Center the filter rack over the plenum flange and push down firmly Figure 28 Since the return air plenum will need to be attached later do not screw the filter rack down 2 Install the return air plenum on the furnace For proper filter performance the sides of the plenum must be at least as tall as dimension A shown in Figures 29 and 30 Return Air Optional Access Door Figure 29 Return Air Plenum Installation NOTE For easier filter inspection and replacement the installer may wish to provide a removable panel in the front of the return a
49. metimes referred to as LP liquefied petroleum gas are considered gas fired appliances CHECK 3 CHIMNEY CROWN CONDITION Damage from condensate usually shows up first in the crown If any of the following trouble signs are present the condition of the crown is not satisfactory a Crown leaning b Bricks missing c Mortar missing d Tile liner cracked e No tile liner f Salt staining at mortar pints White stains and mortar becomes sandy and or erodes ee For problems a b or c see Fix 3 If problems d e or f are present see Fix 4 IMPORTANT It may be necessary to follow both Fix 3 and Fix 4 CHECK 4 DEBRIS IN CLEANOUT A cleanout dropleg must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening Achimney without acleanout could become partially blocked by debris If no cleanout is present the chimney must be refined Fix 4 Remove the cleanout cover and examine the cleanout for debris If significant amounts of any of the following are found Fuel oil residue Bricks Mortar or sand Pieces of the tile liner Rusted pieces of the metallic liner reline the chimney Fix 4 CHECK 5 LINER CONDITION If a metal liner is present it must be checked It cannot be assumed that all existing metal liners are correctly installed and in good condition Remove the lowest existing vent connector and examine th
50. ming is not adjustable During normal heating operation the circulation fan will come on 37 seconds after the gas valve opens This timing is not adjustable As shipped the circulation fan will remain on for 90 seconds after the gas valve closes If desired this timing may be adjusted The adjustment pins or switches are near the low voltage terminal strip Figure 23 Style A Style B 60 nN B2 Second ox Delay are B1 Be e O B4 90 N B2 Second Bi E Delay Z m lOO O B4 120 a B2 Second a Delay Zo B1 5 B3 O 6 B4 180 o B2 Second a oe Delay Zu B1 ster O O B4 Switches viewed in an upflow installation Figure 23 Heating Fan Off Adjustments 17 HEAT ANTICIPATOR SETTING Adjust the heat anticipator in the room to obtain the proper number of heating cycles per hour The heat anticipator is a wire wound adjustable heater that prevents the room temperature from overshooting the room thermostat set ting The heat anticipator must be set at0 7 amps The heat anticipator is part of the thermostat If the thermostat fails for any reason replace the thermostat LINE VOLTAGE CONNECTION FOR OPTIONAL HUMIDIFIER AND ELECTRONI
51. mum Recommended Filter Sizes Qty Nominal Size Inches Sq In Surface Area Size_Air Flow Disposable Permanent 045_30 1 20 X 25 500 15 X 20 300 070_30 15 X 20 300 070_40 16 X 25 400 090_30 16 X 25 400 090_50 20 X 25 500 115 40 18 X 25 450 115 50 20 X 25 500 140_50 20 X 25 500 Figure 25 Upflow Horizontal Furnaces UPFLOW INSTALLATIONS This furnace contains rails for installing 16 x 25 x 1 filters on each side of the interior furnace cabinet A retainer is also included for bottom return Refer to the chart below for filter sizes when using bottom return Bottom Return Air Filters Filter Size Inches Type 045 070 14X25X1 90 X25 x1 115 140 20 X 25 X 1 Figure 26 Bottom Return Filter Sizes The illustration below shows how the filter is retained over the bottom return air opening FILTER RETAINER FILTER FURNACE BOTTOM Figure 27 Filter Retainer One inch throwaway filters should be sized for a face velocity of 300 feet per minute or less 14 x 25 x 1 throwaway 730 CFM max 16 x 25 x 1 throwaway 830 CFM max 18 x 25 x 1 throwaway 940 CFM max 20 x 25 x 1 throwaway 1040 CFM max All other filters should be sized according to their manufacturer s instructions For air delivery of less than 1800 CFM use one side return or bottom return For air delivery of 1800 CFM or higher use two side returns or one side return plus bottom return 19 Guide dimples
52. nd 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 Equipment 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 directly 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 Al 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 unconfin
53. nted filter rack shipped with the furnace can be used in counterflow installation The furnace mounted filter rack includes a rack mounted on the top of the furnace Two filters fit into the rack and rest against the sides of the return air plenum forming a V above the furnace The filters should be inspected frequently and cleaned or replaced when necessary In some installations the filters can be inspected after disconnecting the electrical power and removing the optional access door in the return air plenum If this access panel is not present proceed as follows 1 Disconnect the electrical power 2 Remove the non louvered door from the furnace 3 Remove the left filter by reaching to the left side of the blower pushing the filter up slightly to remove it from the filter rack and pulling it down to the left of the blower and out the blower door Repeat with the right filter Dirty throwaway filters must be replaced with the same filter type and size Dirty permanent metal filters must be cleaned as follows Wash rinse and dry the permanent filters Both sides should then be sprayed with a filter adhesive as is recommended on the adhesive container Many hard ware stores stock spray adhesives for use with perma nent filters If badly torn or uncleanable these filters must be replaced by equal size permanent high velocity filters Throwaway filters must not be used as replacement for permanent filters Und
54. only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description 3 Parts are available from your Amana distributor Blower Box Gasket Flame Roll out Switch Gas Valve Gas Orifice Natural Gas Orifice Propane Auxiliary Limit Burner Heat Exchanger Ignitor Door Switch Flame Sensor Transformer Gas Manifold Blower Wheel Ignition Control Blower Housing Limit Switch Blower Cutoff Blower Motor Motor Mount Bracket Capacitor Pressure Switch Pressure Switch Hose Induced Draft Blower Collector Box
55. orine com pounds include indoor swimming pools and chlorine bleaches paint strippers adhesives paints varnishes sealers waxes which are not yet dried and solvents used during construction and remodeling Various commercial and industrial processes may also be sources of chlorine fluorine compounds Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel appliances They are not suitable for use with gas fired appliances Flexible liners specifically intended and tested for gas applications are listed in the UL Gas and Oil Equipment Directory UL Standard 1777 For sizing of flexible liners see Note 22 and the tables in the National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CGA B149 1 and CAN CGA B149 2 latest editions and amendments To install the liner read and follow the liner manufacturer s instructions and your local codes Excess liner length should be pulled out of the chimney and cut off Use caution when doing this as the cut edges of flexible liners may be sharp Do not spiral excess liner inside of the chimney Support the liner as recommended by the liner manufac turer Some manufacturers of flexible liners offer an insulation sleeve designed to be added to the liner before it is installed in the chimney Poured insulation either vermiculite or other materials is no longer recommended Insulation will
56. ors must be coated to protect against external corrosion when in contact with masonry plaster or insulation or are subject to repeated wettings by such liquids as water except rain water detergents or sewage Location of Manual Valve Installed Ahead of Ground Joint Pipe Union Height Required By Local Code Ground Joint Pipe Union To Be Installed Ahead Of Gas Valve HII UA nv tL i Reducing Coupling 1 2 x 1 8 with 1 8 Pipe Plug to Measure Line Gas Pressure Figure 11 General Furnace Layout 13 UPFLOW INSTALLATIONS When the gas piping enters through the right side of the furnace the installer must supply the following fittings starting from the gas valve 90 degree elbow Close nipple 90 degree elbow Straight pipe to reach the exterior of the furnace Fig ures 12 amp 13 Figure 12 Gas Inlet Through Furnace Right Side A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 to another pipe size Figure 13 Gas Inlet Through Furnace Bottom Side Upflow When the gas piping enters through the left side of the furnace the installer must supply the following fittings starting from the gas valve e Straight pipe to reach the exterior of the furnace Fig ures 14 amp 15 e Aground joint union drip leg and manual shutoff valve m
57. ower to exhaust combustion products An interlock switch prevents furnace operation if the blower door is not in place Keep the blower access doors in place except for inspection and maintenance This furnace is also equipped with a self diagnosing elec tronic control module In the event a furnace component is not operating properly the control module LED will flash on and off in a factory programmed sequence depending on the problem encountered This light can be viewed through the observation window in the blower access door Refer to the Diagnostic Signal Chart for further explanation of the lighting codes and Section X Abnormal Operation Integrated Ignition Control for an explanation of the pos sible problem On new installations or if a functional part such as the gas valve pressure switch or limit control has been replaced verify that the furnace is operating properly after servicing Check furnace operation as outlined in the following in structions If any sparking odors or unusual noises are encountered shut off electrical power and recheck for wiring errors or obstructions in or near the blower motors Various shipping materials must be removed before the blower motor is operated ROLLOUT PROTECTION DEVICE If the flames from the burners are not properly drawn into the heat exchanger a protection device will open causing the gas valve to close In GUI furnaces installed horizon tal right to left airflow t
58. rated ignition control determines that a measurable combustion can not be established or maintained after three consecu tive tries four if flame is established then lost to turn on the furnace If a flame is not sensed during the first six seconds after a gas valve has been energized the ignition control will internally turn off the gas After 60 seconds during which time the induced draft blower purges the heat exchanger the ignitor will re energize and preheat for 27 seconds The gas valve is then re energized Ifa flame is not sensed again in six seconds the gas valve will de energize and another purge is performed The ignition control will cycle the gas valve three times before it determines it cannot establish measurable combustion and enter a lockout state If a flame is sensed but lost after 10 seconds the control will cycle four more times before locking out A lockout stops ignition attempts and causes the air blower to run continuously The diagnostic light will indicate either condition with one short flash followed by a longer off The control can be reset and brought out of lockout mode by turning the thermostat off and then back on It can also reset by turning off the electrical disconnect switch to the furnace for 30 seconds The control will reset after one hour IMPORTANT If you have to frequently reset your furnace it means that a problem exists that should be corrected Contact a qualified servicer for further
59. resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory Refer to Figure 19 for typical propane gas installations 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C Second Stage Regulator 200 PSIG Maximum Figure 19 Propane Gas Installation Typ PROPANE GAS PIPING CHARTS Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Pipe or Nominal Pipe Size Tubing Tubing Size O D Type L Schedule 40 Length 3 8 1 2 5 8 3 4 7 8 1 2 3 4 Feet 10 730 1 700 3 200 5 300 8 300 3 200 7 500 20 500 1 100 2 200 3 700 5 800 2 200 4 200 30 400 920 2 000 2 900 4 700 1 800 4 000 40 370 850 1 700 2 700 4 100 1 600 3 700 50 330 770 1 500 2 400 3 700 1 500 3 400 60 300 700 1 300 2 200 3 300 1 300 3 100 80 260 610 1 200 1 900 2 900 1 200 2 600 100 220 540 1 000 1 700 2 600 1 000 2 300 125 200 490 900 1 400 2 300 900 2 100 150 190 430 830 1 300 2 100 830 1 900 175 170 400 780 1 200 1 900 770 1 700 200 160 380 730 1 100 1 800 720 1 500 To convert to capacities at 15 psig settings multiply by 1 130 To convert to capacities at 5 psig settings multiply by 0 879 Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Ba
60. ry or death do not remove any internal compartment covers or attempt any adjustment Electrical components are contained in both compartments Contact a qualified service agent at once if an abnormal flame appearance should develop Periodically during the heating season make a visual check of the burner flames Turn the furnace on at the thermostat Wait a few minutes since any dislodged dust will alter the normal flame appearance Flames should be stable quiet soft and blue with slightly orange tips They should not be yellow They should extend directly outward from the burner ports without curling downward floating or lifting off the ports CLEANING OF BURNERS QUALIFIED SERVICER ONLY 1 Shut off electric power and gas supply to the furnace Remove the burner box front cover Remove the burner retention bracket Remove the burners Use bottle brush to clean burner insert and inside of burner 6 Replace burners and burner retention bracket inspect the burner assembly for proper seating of burners in retention slots 7 Reinstall the burner box front cover aR W PD Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Figure 45 Burner Flame 29 GENERAL INFORMATION 1 When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and se rial numbers with the order 2 Although
61. s the gas valve 21 9 After a 15 second delay while flue products are purged from the furnace heat exchanger the induced draft blower motor is de energized 10 The air circulation blower has an adjustable delay off timing of 60 90 120 or 180 seconds starting from the time the gas valve closes This allows more heat from the furnace to be transferred to the conditioned space After this time has elapsed the blower will be de energized NORMAL COOLING SEQUENCE INTEGRATED IGNITION CONTROL With the room thermostat in the FAN AUTO position the indoor air circulation blower and outdoor condensing unit will be energized when a call for cooling occurs When the call for cooling ends the outdoor condensing unit will be de energized The indoor air circulation blower will continue to run for 45 seconds OTHER ITEMS Constant Fan During normal operation the air circu lation blower will continually run at Cooling speed as long as power is present at terminal G If a call for heat occurs the blower will run at heating speed throughout the heating cycle If a trip on high auxiliary rollout limit occurs the air circulation blower will run at Heating speed Even if power is present at terminal G the blower will run at heating speed until the limit closes X Start Up Adjustments and Checks GENERAL OPERATION This furnace is equipped with an electronic ignition device to light the burners and an induced draft bl
62. sed on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour Nominal Pipe Size Tubing Tubing Size O D Type L sew 40 Length 3 8 1 2 5 8 3 4 7 8 1 1 8 1 2 3 4 1 1 4 1 1 2 Feet 10 39 92 199 329 501 935 275 567 1 071 2 205 3 307 20 346 630 732 1 496 2 299 30 277 500 590 1 212 1 858 40 233 427 504 1 039 1 559 50 198 376 448 913 1 417 60 187 340 409 834 1 275 80 155 289 346 724 1 066 100 11 6 78 307 630 976 275 567 866 9 252 511 787 200 8 19 39 66 100 187 54 112 209 439 665 8 17 36 60 93 172 48 100 185 390 590 Data in accordance with NFPA pamphlet NO 54 WARNING To prevent death serious personal injury or property damage due to fire or explosion caused by a propane gas leak install a gas detecting warning device AA WARNING If the propane gas furnace is installed in a basement an excavated area or a confined space a warning device is required due to e Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces e Propane gas odorant may fade making the gas undetectable except with a warning device If the presence of gas is suspected follow the instructions on Page 2 of this manual Vil Electrical Wiring AA WARNING To prevent death or personal injury due to electric
63. ses through the roof It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet In addition the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar If the chimney does not meet these termination require ments but all other requirements in the checklist can be met it may be possible for a mason to extend the chimney If this will not be practical see Fix 1 page 12 10 or TA p 2 Min 2 Min a i 3 Min Wall or Parapet a 10 or Less 4 x Ridge i 3 Min Chimney Figure 9 Termination 10 Feet Or Less From Ridge Wall or Parapet More than 10 gt 3 Min NOTE No Height above parapet Chimney Wall or required when distance Parapet from walls or parapet is more than 10 feet Height above any More than 10 roof surface within 10 feet horizontally Ridge 10 a2 2 Min Chimney i Figure 10 Termination More Than 10 Feet From Ridge Wall or Parapet CHECK 2 ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL Solid fuel appliances include fireplaces wood stoves coal furnaces and incinerators Liquid fuel appliances include oil furnaces oil fired boilers and oil fired water heaters Appliances which burn propane so
64. ssible death personal injury or property damage do not install this unit in a mobile home trailer or recreational vehicle ADDITIONAL SAFETY CONSIDERATIONS e This furnace is approved for Category Venting only When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F e Do not install the furnace where the combustion air is exposed to the following substances permanent wave solutions chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetra chloride halogen type refrigerants cleaning solutions such as perchloroethylene printing inks paint re movers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials If the furnace is installed near an area which will be frequently con taminated by these substances the furnace should be sealed from this area so that little contaminated air can reach the furnace The furnace must still have an adequate supply of combustion air either from a nearby uncontaminated room or from outdoors For details see AIR REQUIREMENTS Section Ill e Provisions must be made for venting combustion products outdoors through a proper venting system The length of flue pipe could be a limiting factor in locating the furnace e When installed horizontally the furnace must be
65. th the thermostat for mounting instructions lil Air Requirements COMBUSTION AND VENTILATION AIR WARNING Possible death personal injury or property damage may occur if the furnace and other fuel burning appliances are not provided with enoughfresh air for proper combustion and ventilation of flue gases Most homes require outside air to be supplied into the furnace area Improved construction and additional insulation in build ings has reduced the heat loss making these buildings much tighter around doors and windows so air infiltration is minimal This creates a problem supplying combustion and ventilation air for gas fired and other fuel burning appli ances Use of appliances pulling air out of the house clothes dryers exhaust fans fireplaces etc increases this problem causing appliances to starve for air This furnace must use indoor air for combustion It cannot be installed as a direct vent i e sealed combustion furnace The burner box is present only to help reduce sound transmission from the burners to the occupied space AIR REQUIREMENTS Most homes will require outside air supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA54 ANSI 2223 1 Section 5 3 5 3 1 General a
66. to detect a propane gas leak Contact a local propane gas supplier about installing a gas detecting warning device A WARNING All metal inserts screens or turbulators must be removed from the heat exchanger tubes when using propane gas Failure to comply could cause serious personal injury or death Failure to comply with this requirement will also void warranty coverage All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters See NBFU Manual 58 15 For satisfactory operation propane gas pressure must be 10 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 Since propane gas will quickly dissolve white lead or most standard commercial compounds special pipe dope must be used Shellac base compounds
67. ual gas valve external to the furnace 2 Turn off the electrical power supply to the furnace INLET I OUTLET 3 Set room thermostat to lowest possible setting Pressure Regulator Gas Control Adjustment 4 Remove the door on the front of the furnace Valve Knob Under Cap Screw Note This furnace is equipped with an ignition device to Aiea tad sie or vane mressureiTap automatically light the burners Do not try to light burners by hand Figure 37 White Rodgers Model 36E36 5 Honeywell Model VR8205 or White Rodgers Model 36E36 or Robertshaw Model 7222 Turn the gas control knob clockwise N to the OFF position Note The knob should turn easily Do not use exces Gas Control sive force i vawe kover E5 Peal Pressure Tap n osition i IV White Rodgers Model 36E22 Push the switch to the eta te OFF position E UTLET 6 Wait five minutes to clear out any gas Then smell for Nee d gas including near the floor coe ae justment Under 7 If gas can be smelled following the five minute waiting Cap Screw period in Step 6 immediately follow the instructions on Page 2 of this manual If you do not smell gas after five ep PressurerTap minutes Figure 38 Honeywell Model VR8205 or White Rodgers Model Robertshaw Model 7222 36E36 or Robertshaw Model 7222 Turn the gas control knob counterclockwise y to the ON posi tion The knob should turn easily Do not use exces sive force White Rodgers Model 36E22 Push the switch to the
68. uilding e 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 AQ WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the furnace before shutting off the electrical supply To The Owner It is important that you fill out the owner s registration card and mail it today This will assist Amana in contacting you should any service or warranty information change in the future When filling in the registration card be sure to include the Model Manufacturing and Serial Numbers plus the installation date Your warranty certificate is also supplied with the unit Read the warranty carefully and note what is covered Keep the warranty certificate in a safe place so you can find it if necessary If additional operating instructions are required call the dealer where the purchase was made To The Installer Before installing this unit please read this manual to familiarize yourself on the specific items which must be adhered to such as maximum external static pressure to unit air temperature rise minimum or maximum CFM motor speed connections and venting These furnaces are designed for Category venting only
69. ust also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 inch to another pipe size Figure 14 Gas Inlet Through Furnace Left Side Upflow Figure 15 Gas Inlet Through Furnace Top Side Upflow The gas piping connections shown in Figures 13 and 14 are for a furnace equipped for a right hand discharge Adapta tion for left hand discharge should be self explanatory IIIT I L LIN Figure 16 Horizontal Furnace Right Hand Discharge COUNTERFLOW INSTALLATIONS When the gas piping enters through the left side of the furnace the installer must supply a straight pipe to reach the exterior of the furnace Figure 17 Figure 17 Gas Inlet Through Left Side Counterflow A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 to another pipe size When the gas piping enters through the right side of the furnace the installer must supply the following fittings starting at the gas valve e 90 degree elbow e Close nipple 90 degree elbow Straight pipe to reach exterior of furnace Figure 18 A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 inch to another pipe size Figure 18 Gas Inlet
70. version factor 3600 seconds 1 hour Example Natural gas with a heating value of 1000 BTU per cubic foot and 34 seconds per cubic foot as deter mined by Step 2 then Input 1000 x 3600 x 34 106 000 BTU per Hour NOTE BTU content of the gas can be obtained from the gas supplier This measured input must not be greater than the input indicated in Specification Sheet 4 Relight all other appliances turned off in Step 1 Be sure all pilot burners are operating CHECK BURNER FLAMES Flames should be stable soft and blue dust may cause orange tips but they must not be yellow extending directly outward from the burners without curling floating or lifting off CHECK TEMPERATURE RISE Check the temperature rise through the unit by placing thermometers in supply and return air registers as close to the furnace as possible Be sure the thermometers do not see the heat exchangers or false readings could be obtained 1 All registers must be open all duct dampers must be in their final fully or partially open position and the unit operated for 15 minutes before taking readings 2 The temperature rise must be within the range specified on the rating plate or Specification Sheet NOTE Air temperature rise is the temperature difference between supply and return air With a properly designed system the proper amount of temperature rise will normally be obtained when the unit is operated at rated input with the

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