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AMV9-ACV9 IO MANUAL

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1. 8765 4321 8765 4321 Cooling mu Normal OO FF FF FF FF 87654321 87654321 Cooling Plus Adjust 00 FN FN F F 87654321 8765 4321 Cooling Minus m Adjust 00 x 87654321 Cooling Speed Tap D indicates factory setting NN 87654321 Cooling Speed Taps pos mn indicates factory setting TapA FF FF 87654321 Heating mg Speed m TapB 87654321 Heating m Speed Tap C 8765 4321 Heating Speed Tap D Heating Speed Taps indicates factory setting 5 The multi speed circulator blower also offers several custom ON OFF ramping profiles These profiles may be used to enhance cooling performance and increase comfort level The ramping profiles are selected using DIP switches 5 and 6 Refer to the following figure for switch positions and their corresponding taps Refer to the bullet points below for a description of each ramping profile Turn OFF power to the furnace for a minimum of 10 seconds allowing motor to reset and recognize the new profile selection Turn ON power to the furnace Verify profile selection by counting the green CFM LED blinks and timing each step of the ramping profile Profile A provides only an OFF delay of one 1 mi
2. 21 SINGLE STAGE THERMOSTAT APPLICATION scsssseceecenseesecneuseueuseneseeennauseeeusueeuseeeenuseeeaegunseeuaoeausesensuuseseenonueseuseoaeees 22 24 DEAUMIDISTAT WIRING 2 5 5 6 a aai iaa na 1 ca a ua nd RR dn a Enna n Ka da DER Na REN n RI RN n RR ERR B AN ER REN R GA ER AR 22 FOSSIL FUEL APPLICATIONS 252 sedis Iac eoa ga ams Un Luna an EUR Incun REDE COENA REOR NE DCN CER LU RR 22 115 Line CONNECTION or ACCESSORIES HUMIDIFIER AND ELECTRONIC AIR CLEANER ees 22 24 FUNDER 23 AIL Gas Supply and Pipih 23 A 23 GAS PIPING CONNECTIONS REM 24 PROPANE GAS TANKS AND PIPING nnn nan k hamum aaa Rana RR RR RR ARN RR RR DRAN RR RR SDN RR RR INR R R4 Sa nananana 25 XIII amp FIETS acct Pm 26 DUCTWORK AIR FEOW 26 FiLTERS READ Tuis SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK 26 UPRIGHT INSTALLATIONS es ON EE cusan apu axe tucsaasdedeatde 26 FIORIZONTAL INSTALLATIONS aaa duce na dax cunc eaa Fera dena E cre aka Cu sua o
3. 8 THERMOSTAT LOCATION PM 8 V Combustion amp Ventilation Air 9 VIL Installation POSiItIONS 2 aic Dn na n ux ak cauaa au aan Ra nav xd du cca c au uuu cu nu n uio o Cua in i dea rr i D a ma uu d o RR ET 10 VII Horizontal Applications amp Considerations 11 GENERA m m 11 DRAIN TRAP AND LINES ek E mca xk r E 11 HE AUTZBNICESTTTEIQTI INED T DRIN IB E KI TE EET 11 ALTERNATE VENT FLuE AND COMBUSTION AIR CONNECTIONS 11 ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS 11 BEP INITIUM 11 FREEZE PROTECTION 11 FURNACE SUSPENSION 2 5 11 VIII Propane Gas High Altitude 11 IX Vent Flue Pipe amp Combustion Air aara Nice rain ene aaa paaa 12 GENERAL 12 DUAL CERTIFI
4. 29 CIRCULATOR BLOWER SPEEDS cesis SNR RR RR RA RR RR EDASRR RR SNR ARR R4 Sansa R4 R4 anraa 29 BLOWER HEAT Orr DELAY TIMINGS 11 essere nennen aura Raum aaa RR Ra Ss EARN 31 XV Normal Sequence of Operation 31 POWER UP t 31 HEATING MODE ii 31 COOLING MODE TIENI IEEE ev 32 FAN ONLY ele 32 XV Operat oNna l O OO ccr 32 BURNER FLAME sssceseesesecnsesenneeecueseusceseuseeenucesaususenuussauaceeeunssenucesaususeauuusausueuaugsseanuesaususueueuseunueseugussseugusesnusesogs 32 PRIMARY LIMIT 32 XVII Safety Circuit DOSCri ritenere ete ee
5. 87654321 Ramping mu Profile TapA FF FF 87654321 Ramping Profile m TapB 8765 4321 Ramping m Profile m TapC 8765 4321 Ramping Profile mm TapD NN Ramping Profiles indicates factory setting 6 Select the heating speed from the heating speed chart in the Product Data Book applicable to your model for your model The adjust setting already established by the cooling speed 30 selection determines which set of speeds are available The selected speed must provide a temperature rise within the rise range listed with the particular model Example The MV90704BXA is set for 990 CFM on cooling the ADJUST is set to minus The four heating speeds available are A Minus B Minus C Minus and D Minus A Minus has a rise of 56 F for both stages which is within the 30 60 F rise range for the MV90704BXA This setting will keep electrical consumption to minimum Set the Heat speed DIP switches to A 7 Selectthe desired heating speed tap by positioning switches 7 and 8 appropriately Refer to figure above Turn off power to furnace for a minimum of 10 seconds allowing motor to reset and recognize new speed selection Turn on power to furnace Verify selected CFM by counting the green CFM LED blinks In general lower heating speeds will reduce electrical consump tion lower operating sound levels of the bl
6. Upflow Horizontal Two Stage Gas Valve Gas Line Entrance Alternate Pressure Switch es Gas Manifold Combustion Air Intake Connection Hot Surface Igniter Rollout Limit Burners Flame Sensor Flue Pipe Connection Flue Pipe Combustion Air Intake Alternate Primary Limit Gas Line Entrance Flue Pipe Connection Alternate Rubber Elbow Two Speed Induced Draft Blower Electrical Connection Inlets Alternate Coil Front Cover Pressure Tap Coil Front Cover Drain Port Drain Line Penetrations X pere A bla Fa i 1 5 BLOWER COMPARTMENT e d zi O M L4 BE Counterflow Horizontal Drain Trap Blower Door Interlock Switch Inductor Not All Models Two Stage Integrated Control Module with fuse and diagnostic LED 24 Volt Thermostat Connections Transformer 40 VA ECM Variable Speed Circulator Blower Auxiliary Limit Junction Box Electrical Connection Inlets Coil Front Cover Combustion Air Inlet Pipe e BURNE
7. FAY S ER KXYF CE RE 27 Table of Contents XIV Startup Procedure amp 27 HEAT ANTICIPATOR SETTING 27 DRAIN TRAP PRIMING 27 FURNACE OPERATION 5 25 53 3282 852 8 RR XA BER RARE oENFRRSREAEERNUEEREARRERARAERRRCRER ARN SSSNFRSNNESRERERAEARRKREAREN SREIREAENNRSENTREARNUNSRAARSREAANR NEAR 27 Gas SUPPLY PRESSURE MEASUREMENT eene nennen nna nmn 4 RR RR RR EAR RR RR RSS NRRR RR NAR RR RS ARN Rana raa dd 27 Gas PRESSURE MEASUREMENT AND ADJUSTMENT nennen nnne nene r annia nsus eran area nuu 28 Gas Input RATE MEASUREMENT NATURAL GAS ONLY 29 TEMPERATURE PRISE RERO RINT
8. Equipment Located in Confined Spaces All Air from Outdoors Through Ventilated Attic See 5 3 3 b 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent NOTE The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure Outlet air duct Water Heater Inlet air duct Equipment Located in Confined Spaces All Air from Outdoors Single Air Opening See 5 3 3 b 5 When directly communicating with the outdoors the single open ing shall have a minimum free area of 1 square inch per 3 000 BTU per hour of total input rating of all equipment in the enclo sure 5 3 4 Specially Engineered Installations The requirements of 5 3 3 shall not necessarily govern when special engi neering approved by the authority having jurisdiction provides an ad equate supply of air for combustion ventilation and dilution of flue gases 5 3 5 Louvers and Grilles In calculating free area in 5 3 3 consideration shall be given to the block ing effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch mesh If the area through a design of louver or grille is known it should be used in ca
9. Front of Furnace Blower And Lift Grab Here a Front of Furnace Blower Angle filter toward the blower until filter clears bottom rail Lower filter down and pull outward Front of Furnace Blower Front of Furnace Replace filter by reversing procedure BEFORE LEAVING AN INSTALLATION Cycle the furnace with the thermostat at least three times Verify cooling and fan only operation Review the Owner s Manual with the homeowner and discuss proper furnace operation and maintenance Leave literature packet near furnace XXII REPAIR amp REPLACEMENT PARTS When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and serial numbers with the order Although only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description Parts are available from your distributor Functional Parts List Gas Valve Gas Manifold Natural Gas Orifice Propane Gas Orifice Igniter Flame Sensor Rollout Limit Switch Primary Limit Switch Auxiliary Limit Switch Pressure Switch Induced Draft Blower Door Switch Blower Motor Blower Wheel Blower Mounting Bracket Blower Cutoff Blower Housing Capacitor Heat Exchanger Recuperator Coil Coil Front Cover Integrated Control Module Transformer 35 APPENDIX 36 Symptoms of Abnormal Operation Furnace fails to operate Integrated control modul
10. Valve Gas Line To Furnace Open To Atmosphere Drip Leg Cap With Fitting gt Manometer Hose Manometer Measuring Inlet Gas Pressure Alt Method NOTE If measuring gas pressure at the drip leg a field supplied hose barb fitting must be installed prior to making the hose connection If using the inlet pressure boss on the gas valve then use the 36G Valve Pressure Check Kit Goodman Part No 0151 000008 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 4 Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table Inlet Gas Supply Pressure Natural Gas Minimum 5 0 w c Maximum 10 0 w c Maximum 13 0 w c Minimum 11 0 w c If supply pressure differs from table make the necessary adjust ments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace 6 Turn OFF any unnecessary gas appliances stated in step 3 Gas ManiFo_p Pressure MEASUREMENT AND ADJUSTMENT To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS
11. 3 Secure the dehumidistat hot wire typically the black lead to the screw terminal marked R on the furnace integrated control module 4 Securethe dehumidistat ground wire typically the green lead to the ground screw on the furnace junction box NOTE Ground wire may not be present on all dehumidistats 5 Turn ON power to furnace To enable the dehumidify function on the integrated control module 1 Cut the jumper wire labeled CUT FOR DEHUM located adjacent to the DEHUM screw terminal Once the jumper wire is cut the dehumidify function is enabled dur ing a combination call for cooling T Stat and dehumidification Dehum Stat The yellow LED adjacent to the DEHUM screw ter minal will be illuminated during dehumidification CHM 0 Y N DEHUMIDIFICATION Go ae LED YELLOW 0 R QOO EQ gt el DEHUMDIFICATION JUMPER WRE CUT TO ENABLE FossiL FuEL APPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel application A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor tempera ture sensor to determine the most cost efficient means of heating heat pump gas furnace or bo
12. e Rand W1 R and W1 W2 thermostat contacts close initiating a call for heat Integrated control module performs safety circuit checks Induced draft blower is energized on high speed for a 10 second prepurge Humidifier terminals are energized with induced draft blower e Induced draft blower steps to low speed following prepurge Low stage pressure switch contacts are closed e Igniter warm up begins upon step to low speed and presence of closed low stage pressure switch contacts Gas valve opens at end of igniter warm up period delivering gas to burners and establishing flame Integrated control module monitors flame presence Gas valve will remain open only if flame is detected If the thermostat call is for low heat gas valve and induced draft blower will continue on low stage If the call is for high heat the gas valve and induced draft blower will change to high stage Circulator blower is energized on heat speed following a fixed thirty second blower on delay The circulator blower requires thirty 30 seconds to ramp up to full speed Electronic air cleaner terminals are energized with circulator blower Furnace is now operating on the specified stage called for by the two stage thermostat Furnace runs integrated control module monitors safety circuits continuously e If the two stage thermostat changes the call from low heat to high heat the integrated control module will immediately s
13. FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insu lator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will lock out The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool Following cleaning the flame sense signal should be as indicated in the Specifications Sheet FLuE Passaces QUALIFIED SERVICER ONLY The heat exchanger flue passageways should be inspected at the beginning of each heating season If necessary clean the pas sageways as outlined below 1 2 Turn OFF the electrical power and gas supply to the furnace Disconnect the gas line and remove the burner manifold assembly by removing the screws securing the assembly to the partition panel Disconnect the flue pipe system from the induced draft blower Remove the induced draft blower and drain and pressure tap hoses from the recuperator coil front cover Remove the recuperator coil front cover to expose the coil tubes and turbulators Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly Clean the recuperator coil tubes using a long handle wire brush such as a gun cleaning brush Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless ste
14. tions possess adequate structural integrity and support to prevent flue pipe separation shifting or sagging during furnace operation DuaL Non DireEct DirREcT VENT This furnace is dual certified and may be installed as a non direct vent single pipe or direct vent dual pipe appliance A non direct vent installation requires only a vent flue pipe while a direct vent installation requires both a vent flue pipe and a combustion air in take pipe Refer to the appropriate section for details concerning piping size length number of elbows furnace connections and ter minations MATERIALS AND JOINING METHODS To AVOID BODILY INJURY FIRE OR EXPLOSION SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES I E SPARKS OPEN FLAMES AND EXCESSIVE HEAT AS THEY ARE COMBUSTIBLE LIQUIDS AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND OR EYES Two or three inch nominal diameter PVC Schedule 40 pipe meet ing ASTM D1785 PVC primer meeting ASTM F656 and PVC sol vent cement meeting ASTM D2564 specifications must be used Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311 Carefully follow the manufacturer s instructions for cutting cleaning and solvent cementing of PVC As an alternative to PVC pipe primer solvent cement and fittings ABS materials which are in compliance with the following specifica tions may be used Two or three inch ABS Schedule 40 pipe must meet ASTM D1
15. 1 2 N oem 6 Insert short end of each Tube 2 through side panel grommet holes Secure tubes to Hose A and Hose B with green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting ALTERNATE VENT FLuE Drain Hose CONNECTIONS Upright installations using the alternate vent flue outlet will require right side only drain hoses to be connected as follows Refer to 19 Section IX Vent Flue Pipe and Combustion Air Pipe for details on alternate vent flue pipe connection 1 Remove the rubber plug from the front cover right side drain port Save for use in step 3 2 Secure Hose A to front cover drain port with a red hose clamp Route hose to rear right side panel grommet hole 3 Remove grommet from front right side panel drain hole Seal hole in grommet with large end of plug Reinstall grommet and plug into side panel drain hole 4 Cut 1 4 inch from the end of the drain port on the externally mounted rubber elbow Discard cut portion 5 Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp Angle tube outward toward front of furnace 6 Cut 17 7 8 inches from the long end of Hose B and discard 7 Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose tow
16. BUILDING SHOULD BE PROPERLY WINTERIZED AND THE WATER SOURCE CLOSED IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED Evectrostatic DiscHARGE ESD PRECAUTIONS grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object PRODUCT APPLICATION This furnace is primarily designed for residential home heating ap plications It is NOT designed or certified for use in mobile homes trailers or recreational vehicles This unit is NOT designed or certi fied for outdoor applications The furnace must be installed indoors i e attic space crawl space or garage area provided the garage area is enclosed with an operating door This furnace can be used in the following non industrial commercial applications Schools Office buildings Churches R
17. CONNECTIONS Before proceeding with electrical connections ensure that the sup ply voltage frequency and phase correspond to that specified on the unit rating plate Power supply to the furnace must be N E C Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 Use a separate fused branch electrical circuit containing properly sized wire and fuse or circuit breaker The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protec tion specified on the unit rating plate An electrical disconnect must be provided at the furnace location NOTE Line polarity must be observed when making field connections IN UPRIGHT UPFLOW INSTALLATIONS THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION Connect hot neutral and ground wires as shown in the wiring dia gram located on the unit s blower door For direct vent applications the cabinet opening to the junction box must be sealed air tight us ing either an UL approved bushing such as Heyco Liquid Tight or by applying non reactive UL approved sealant to bushing Line polarity must be observed when making field connections
18. E HOSE SIDE PANEL e GROMMET HOLES TUBE S 2 s HOSE m FRONTCOVER RED HOSE GREEN m DRAIN PORT CLAMP HOSE CLAMPS 3 PLACES Upright Standard Connections Right Side Upflow Shown Counterflow Similar LEFT SIDE PANEL ZN H OOOO FRONT COVER i RUBBER DRAIN PORT E 1 ELBOW RED HOSE RUBBER CLAMP ELBOW HOSEA JEE TIAN DRAIN PORT SIDE PANEL N S RED HOSE DRAIN y CLAMP HOLES TUBE 1 TUBE S 2 E GREEN HOSE CLAMPS 3 PLACES DRAIN TRAP A HOSE B Upright Standard Connections Left Side Upflow Shown Counterflow Similar 3 Cut and remove 1 4 inch from the end of the drain port on the rubber elbow 4 Insert Tube 1 into rubber elbow drain port and secure with red hose clamp Angle tube outward toward front of furnace 5 Right side drains Cut 17 3 4 inches from the long end of Hose B and discard Secure the remaining hose to Tube 1 with a green hose clamp Route the other end of Hose B to front right side panel grommet hole Left side drains Cut X inches from the long end of Hose B and discard Refer to table for appropriate length to cut Secure remaining hose to Tube 1 with a green hose clamp Route other end of Hose B to front left side panel grommet hole Cabinet Width Models X Length to Cut From Long inches KBTU Tons End of Hose B TT 48 30 70 40 3 1 2 inches 090 50 24
19. Heatin with Single Stage Coolin Furnace Integrated Control Module Remote Condensing Unit Single Stage Cooling Single Stage Heating with Single Stage Cooling NOTE To apply a single stage heating thermostat the thermostat selector jumper on the integrated Control module mustbe set on single stage Thermostat Two Stage b ith wit O Single Stage Coolin OO 69 CO 69 S GO 6 3 Remote Dehumidistat Optional Condensing Unit Single Stage Cooling Two Stage Heating with Single Stage Cooling Thermostat Two Stage Heating with Two Stage Cooling Furnace Integrated Control Module Remote Condensing Unit Two Stage Cooling Two Stage Heating with Two Stage Cooling Thermostat Diagrams This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 115 Volt and 24 Volt wiring SINGLE STAGE THERMOSTAT APPLICATION A single stage thermostat with only one heating stage can be used to control this furnace The application of a single stage thermostat does not offer true thermostat driven two stage operation but pro vides a timed transition from low to high fire The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the
20. Normal furnace operation Integrated control module diagnostic LED is flashing SEVEN 7 flashes Furnace not operating Integrated control module diagnostic LED is flashing EIGHT 8 flashes Furnace operating on low stage gas with high stage induced draft blower High stage circulator blower temperature of conditioned air lower than typical Integrated control module diagnostic LED is flashing NINE 9 flashes Furnace fails to operate Integrated control module diagnostic LED is flashing SIX 6 flashes TROUBLESH OOTING CHART Associated LED Code Fault Description s Primary or auxiliary limit circuit is open 4 FLASHES Rollout limit circuit is open Flame sensed with no call for heat 5 FLASHES Flame sense microamp signal is low 7 FLASHES Problem with igniter circuit 8 FLASHES 9 FLASHES High stage pressure switch circuit does not close in response to high stage induced draft blower operation Polarity of 115 volt power is reversed CONTINUOUS FLASHING Possible Causes Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower Flame rollout Misaligned burners blocked flue and or air inlet pipe or failed induced draft blower Loose or improperly connected wiring Short to ground in flame sense cir
21. TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION UPON COMPLETION OF THE FURNACE INSTALLATION CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS INCLUDING CARBON MONOXIDE A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place Be cause of the relatively low flue gas temperature and water conden sation requirements PVC pipe is used as venting material This furnace must not be connected to Type B BW or L vent or vent connector and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance Do not use commercially available no hub connectors other than those shipped with this product It is the responsibility of the installer to follow the manufacturers recommendations and to verify that all vent flue piping and connec tors are compatible with furnace flue products Additionally it is the responsibility of the installer to ensure that all piping and connec
22. Turn on electrical power and gas supply to the system 15 Turn on system power and energize valve 16 Using a leak detection solution or soap suds check for leaks at pressure boss screw Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY NOTE For gas to gas conversion consult your dealer for appropriate conversion Manifold Gas Pressure Range Nominal Natura ow Stage 9 w c HghStege 2 38 wc 35 wc Low Stage 57 63 we 6 0 w c 10 0 w c 7 10 3 w c 28 Gas Input RATE Measurement Naturat Gas The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas burning appliances except the furnace 2 While the furnace is operating time and record one complete revolution of the smallest gas meter dial 3 Calculate the number of seconds per cubic foot sec ft of gas being delivered to the furnace If the dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one If the dial is a two cubic foot dial divide the number of seconds recorded in step 2 by two 4 Calculate the furnace input in BTUs per hour BTU hr Input equals the sum of the installation s gas heating value and a conversion factor hours to seconds divided by the number of seconds
23. and internal to furnace e Wiring Check electrical connections for tightness and or corrosion Check wires for damage e Filters FILTERS To ENSURE PROPER UNIT PERFORMANCE ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED Minimum FILTER SIZE TABLE OR DATA Book APPLICABLE TO YOUR MODEL 33 MAINTENANCE Improper filter maintenance is the most common cause of inadequate heating or cooling performance Filters should be cleaned perma nent or replaced disposable every two months or as required When replacing a filter it must be replaced with a filter of the same type and size FiLTER REMOVAL Depending on the installation differing filter arrangements can be applied Filters can be installed in either the central return register or a side panel external filter rack upflow only A media air filter or electronic air cleaner can be used as an alternate filter Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance To remove filters from an external filter rack in an upright upflow installation follow the directions provided with external filter rack kit To remove internal filters see Internal Filter Removal section Inter nal filters are an accessory item and are not included with your furnace For further details see your distributor HonizoNTAL Unit REMOVAL Filters in horizontal installations are located in the central return r
24. and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure NOTE The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equip ment in the enclosure but not less than L the sum of the areas of all vent ms connectors in the confined space lt Chimney or Gas Vent Outlet Air Inlet Air Alternate lt Opening air inlet _ Alternate Water Opening Ventilation louvers for Furnace heater Location unheated crawl space pales Equipment Located in Confined Spaces All Air from Outdoors Inlet __ Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through vertical ducts ES each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet air duct ends 1 ft 300 mm above floor
25. be connected to the right side front cover drain port and the rubber elbow drain port NOTE On counterflow models relocation of the front cover pressure switch hose is required Make connections as follows 1 Remove the rubber plug from the coil front cover drain port Counterflow furnaces Relocate the front cover pressure switch hose connection from the left side pressure tap to the right down side tap The pressure switch hose must be connected to the down side to guard against blocked drain conditions Cut hose to appropriate length to minimize sagging Plug left unused pressure tap with plug removed from right side 2 Secure Hose Ato front cover drain tap with a red hose clamp Route hose to rear right down side panel grommet holes 3 Out 1 4 inch from the end of the drain port on the rubber elbow and discard 4 Insert Tube 1 into rubber elbow drain port and secure with a red hose clamp Angle tube outward toward front of furnace 5 Cut 17 3 4 inches from the long end of Hose B and discard 6 Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp Route hose to front right down side panel grommet holes 7 Cut 5 1 2 inches straight length from the long end of each Tube 2 FRONT COVER DRAIN PORT RED HOSE CLAMP ral HOSE A cn Do FRONT HOSE B Cel COVER SIDE PANEL 4 P
26. from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel NOTE Do not use gas piping as an electrical ground To confirm proper unit grounding turn off the electrical power and perform the following check 1 Measure resistance between the neutral white connection and one of the burners 2 Resistance should measure 10 ohms or less This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing Do not defeat this switch 24 THERMOSTAT WIRING NOTE Wire routing must not interfere with circulator blower operation filter removal or routine maintenance As a two stage furnace the furnace integrated control module pro vides terminals for both W1 W2 and YLO and Y thermo stat connections This allows the furnace to support the following system applications Two Stage Heating Only Two Stage Heat ing with Single Stage Cooling and Two Stage Heating with Two Stage Cooling Refer to the following figures and table for proper connections to the integrated control module Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located in the blower compartment Wire routing must not interfere with circulator blower operation filter removal or routine maintenance Thermostat Single Stage
27. intake pipe directly to the air intake coupling NOTE A PVC coupling or elbow is required on counterflow units BENE 4 SCREWS REMOVE 2 CLEARANCE REMOVE 4 SCREWS REQUIRED t NON DIRECT VENT ANDCUT 4 ET REMOVE 12 REMOVE 3 SCREWS AND RELOCATE 9 ADDITIONAL PLUG FROM DRAIN REMOVE RELOCATE UPFLOW 1 SECURE 2 TO CABINET 9 UPFLOW HORIZONTAL SHOWN COUNTERFLOW SIMILAR Alternate Combustion Air Intake Location Non DireEct VENT SINGLE PIPE PIPING Non direct vent installations require only a vent flue pipe The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building The vent can also be run through an existing unused chimney how ever it must extend a minimum of 12 inches above the top of the chimney The space between the vent pipe and the chimney must be closed with a weather tight corrosion resistant flashing For details concerning connection of the vent flue pipe to the furnace refer to Section IX Vent Flue Pipe and Combustion Air Standard Furnace Connections or Alternate Furnace Connections for specific details Refer to the following Non Direct Vent Single Pipe Piping Vent F
28. length elbows and termination Verify proper induced draft blower perfor mance Replace induced draft blower pressure Switch Repair short e Inspect pressure switch hose Repair if necessary e Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary e Correct pressure switch setpoint or contact motion e Tighten or correct wiring connection Cautions and Notes Turn power OFF prior to repair e Replace integrated control module fuse with 3A automotive fuse Read precautions in Electrostatic Discharge section of manual Turn power OFF prior to repair Improper thermo stat connection or setting Turn power OFF prior to repair gniter is fragile handle with care Sand flame sensor with emery cloth See Vent Flue Pipe section for piping details Turn power OFF prior to repair Replace pressure Switch with proper replacement part Turn power OFF prior to repair Replace pressure Switch with proper replacement part Symptoms of Abnormal Operation Circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FOUR 4 flashes Induced draft blower and circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 flashes
29. the integrated control module INTEGRATED MopuLE The integrated control module is an electronic device which if a potential safety concern is detected will take the necessary precau tions and provide diagnostic information through an LED Primary Limit The primary limit control is located on the partition panel and moni tors heat exchanger compartment temperatures It is a normally closed electrically automatic reset temperature activated sensor The limit guards against the overheating as a result of insufficient conditioned air passing over the heat exchanger 32 AuxiLiARY The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures They are a normally closed electrically manual reset sensors These limits guard against overheating as a result of insufficient conditioned air passing over the heat exchanger RoLLour Limit The rollout limit controls are mounted on the burner manifold as sembly and monitor the burner flame They are normally closed electrically manual reset sensors These limits guard against burner flames not being properly drawn into the heat exchanger PRESSURE SWITCHES The pressure switches are normally open closed during operation negative air pressure activated switches They monitor the airflow combustion air and flue products through the heat exchanger via pressure taps located on the induced draft blo
30. thermostat s call for heat The delay period prior to stepping up can be set at either 5 or 10 minutes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module To use a single stage thermostat turn off power to the furnace move the thermostat selection jumper on the integrated control module from the two stage position to the single stage position turn power back on Refer to the following figures T Stat selection jumper in ingle stage thermostat position 0 2 0 DIP switch position 3 ON Delay Period 10 minutes DIP switch position 3 OFF Delay Period 5 minutes 24 DEHuMIDISTAT WIRING The optional usage of a dehumidistat allows the furnace s circulator blower to operate at a slightly lower speed during a combined ther mostat call for cooling and dehumidistat call for dehumidification This lower blower speed enhances dehumidification of the condi tioned air as it passes through the AC coil For proper function a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise To install connect a dehumidistat 1 Turn OFF power to furnace 2 Secure the dehumidistat neutral wire typically the white lead to the screw terminal marked DEHUM on the furnace integrated control module
31. to combustible mate rials a minimum of 24 inches service clearance must be available in front of the unit TOP TOP SIDE SIDE M SIDE BOTTOM BOTTOM Upflow Counterflow Horizontal A furnace installed in a confined space i e a closet or utility room must have two ventilation openings with a total minimum free area of 0 25 square inches per 1 000 BTU hr of furnace input rating Re fer to Product Data Book applicable to your model for minimum clearances to combustible surfaces One of the ventilation open ings must be within 12 inches of the top the other opening must be within 12 inches of the bottom of the confined space In a typical construction the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement FURNACE SUSPENSION If suspending the furnace from rafters or joists use 3 8 threaded rod and 2 x2 x1 8 angle iron as shown below The length of rod will depend on the application and the clearances necessary PROVIDE 8 MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL 3 8 DIAMETER THREADED ROD 6 PLACES ASSURE FURNACE IS LEVEL FROM END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 0 3 4 BELOW THE BACK OF THE FURNACE Z x2 x1 8 ANGLE IRON 8 PLACES TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCU
32. use other commercially available no hub con nectors due to possible material conflicts The vent flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue see Section IX Materials and Joining Methods NOTE For non direct vent installations a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage Ain PIPE Direct VENT INSTALLATIONS On upflow units secure the combustion air intake pipe directly to the air intake coupling On counterflow units secure the combus tion air intake pipe to the air intake coupling using the rubber cou pling and worm gear hose clamps provided with the unit The coun terflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment NOTE Because of probable material conflicts do not use other commercially avail able no hub connectors The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling VENT INSTALLATIONS A minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage COMBUSTION VENT FLUE PIPE COMBUSTION VENT FLUE AIR PIPE PIPE DIRECT VENT ONLY AIR PIPE DIRECT VENT ONLY V pvc RUBBER COUPLINGS WITH WORM GEAR CLAMPS ELBOW ELBOW NON DIRE
33. your distributor for details HORIZONTAL INSTALLATIONS Filters must be installed in either the central return register or in the return air duct work XIV STARTUP PROCEDURE amp ADJUSTMENT Furnace must have a 115 VAC power supply properly connected and grounded Proper polarity must be maintained for correct op eration In addition to the following start up and adjustment items refer to further information in Section XVI Operational Checks Heat ANTICIPATOR SETTING The heat anticipator in the room thermostat must be correctly ad justed to obtain the proper number of cycles per hour and to prevent overshooting of the setting Set the heat anticipator setting to 0 7 amps Follow the thermostat manufacturer s instructions on how to adjust the heat anticipator setting Drain TRAP PRIMING The drain trap must be primed prior to furnace startup To prime fill the drain trap with water This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system FURNACE OPERATION Purge gas lines of air prior to startup Be sure not purge lines into an enclosed burner compartment Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved method Verify that all required kits propane gas high altitude etc have been appropriately installed FURNACE STARTUP 1 Close the manual gas shutoff valv
34. 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 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 Propane Gas Piping Chart I 25 Sizing Between Single or Second Stage Regulator and Appliance Maximum Propane Capacities Listed are Based on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour Pipe or Tubing Tubing Size O D L Length 3 8 1 2 Feet Nominal Pipe Size Schedule 40 1 1 1 4 1 1 2 10 39 92 3 307 20 26 62 2 299 30 21 50 1 858 40 19 41 1 559 50 18 37 1 417 60 16 35 1 275 80 13 29 1 066 100 11 26 976 125 10 24 866 150 9 21 202 63 787 200 8 19 187 54 665 250 8 17 36 60 93 172 48 100 185 390 590 Data in accordance with NFPA pamphlet NO 54 Propane Gas Piping Chart Il XIII CIRCULATING AIR amp FILTERS Ductwork FLow Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of America M
35. 527 and if used in Canada must be CSA listed Solvent cement for ABS to ABS joints must meet ASTM D2235 and if used in Canada must be CSA listed The solvent cement for the PVC to ABS transition joint must meet ASTM D3138 Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and if used in Canada must be CSA listed Carefully follow the manu facturers instructions for cutting cleaning and solvent cementing PVC and or ABS All 90 elbows must be medium radius 1 4 bend DWV or long ra dius Long sweep 1 4 bend DWV types conforming to ASTM D3311 A medium radius 1 4 bend DWV elbow measures 1 16 mini mum from the plane of one opening to the centerline of the other opening for 2 diameter pipe and 4 9 16 minimum for 3 pipe Proper VENT FLUE AND ComBUSTION Ain PIPING PRACTICES Adhere to these instructions to ensure safe and proper furnace per formance The length diameter and number of elbows of the vent flue pipe and combustion air pipe when applicable affects the per formance of the furnace and must be carefully sized All piping must be installed in accordance with local codes and these instruc tions Piping must be adequately secured and supported to prohibit sag ging joint separation and or detachment from the furnace Hori zontal runs of vent flue piping must be supported every three feet and must maintain a 1 4 inch per foot downward slope back to wards the furnace to properly return conde
36. AMV9 ACV9 Heating amp Air Conditioning T wo STAGE VARIABLE SPEED mana GAS FIRED WARM AIR FURNACE LASTS AND LASTS AND LASTS INSTALLATION INSTRUCTIONS Installer Affix all manuals adjacent to the unit Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace These furnaces comply with requirements embodied in the American National Standard National Standard of Canada ANSI Z21 47 CSA 2 3 Gas Fired Central Furnaces US Liste A RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual are intended as supplemental to existing practices However if there is a direct conflict between existing practices and the content of thi
37. ARTS MUST BE USED WHEN SERVICING VT VIOLET BU BLUE 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE GN GREEN GY GRAY REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE BKBLACK RORED RATING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY 4 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES 22314701 REV 00 Wiring is subject to change always refer to the wiring diagram on the unit for the most up to date wiring 39 Amana is a trademark of Maytag Corporation and is used under license to Goodman Company L P All rights reserved 2550 North Loop West Suite 400 Houston TX 77092 www amana hac com 2004 2005 Goodman Company L P 40
38. ATE LL AND RELOCATE Q DETACH RUBBER DETATCH RUBBER ELBOW FROM ELBOW FROM ID BLOWER AND ID BLOWER AND VENT FLUE VENT FLUE PIPE PIPE UPFLOW COUNTERFLOW ADDITIONAL PLUG FROM DRAIN KIT Q EXTERNALLY MOUNT RUBBER ELBOW SECURE TO ID BLOWER WITH RUBBER COUPLING AND HOSE CLAMPS COUNTERFLOW UPRIGHT UPFLOW SIMILAR SECURE TO ID BLOWER WITH RUBBER COUPLING SECURE TO AND HOSE CABINET WITH CLAMPS SCREWS UPFLOW HORIZONTAL COUNTERFLOW SIMILAR Alternate Vent Flue Location ALTERNATE COMBUSTION Ain INTAKE LOCATION The alternate combustion air intake location consists of a large unobstructed hole alternate vent connection is aligned with the In 14 duced Draft Blower To use the alternate combustion air intake lo cation refer to the following steps and the Alternate Combustion Air Intake Location figure NOTE Counterflow unit instructions follow the upflow instructions 1 Remove and save the four screws securing the combustion air intake coupling to the furnace s top panel upflow Counterflow units Remove and save the four screws securing the combustion air intake coupling to the basepan Remove an additional three screws securing the furnace s internal combustion air intake pipe to the blower deck 2 Remove the combustion air intake coupling and gasket from the top panel Counterflow units Remove the combus
39. Bottom J Return gt Duct N AIR Connection DISCHARGE UPFLOW HORIZONTAL RIGHT AIR DISCHARGE Recommended Installation Positions NOTE Alternate vertical piping connections can not be used when an upflow furnace is installed with supply air discharging to the right or when a counterflow furnace is installed with supply air discharging to the left In either case use the standard flue and combustion air piping connections DRAIN LINE WITH 1 4 PER FOR TERN ATE ELECTRICAL AND Gas LINE CONNECTIONS This furnace has provisions allowing for electrical and gas line con nections through either side panel In horizontal applications the connections can be made either through the top or bottom of the furnace Drain PAN A drain pan must be provided if the furnace is installed above a conditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if applicable FREEZE PROTECTION Refer to Section VI Horizontal Applications and Conditions Drain Trap and Lines FURNACE SUSPENSION If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad Never install the furnace on the ground or allow it to be exposed to water Refer to Section IV Location Requirements and Considerations Furnace Suspension for further details Vill PROPANE GAS HIGH ALTITUDE INSTALLATIONS POSSIBLE PROPERTY DAMAGE PE
40. CATION NON DIRECT DIRECT VENT asa aaa RR RR ARN RR RR ERAN RR R4 DAR 44 amar aAA 12 MATERIALS AND JOINING METHODS 12 PROPER VENT FLUE AND COMBUSTION PIPING PRACTICES daa m aad una 12 TERMINATION LOCATIONS R RR RR RR RR RR SNR 12 CANADIAN VENTING REQUIREMENTS SAN R RR 4 SEDAN RR RR DANN RR RR ISSN NR RR 4 13 STANDARD FURNACE CONNECTIONS hamum IRR RR RR RS Ra Dad 13 ALTERNATE FURNACE CONNECTIONS anra RR RR RR AS RNR RR EARN R RR SEDAN NR RR DANN R RR R44 amara dA 13 NON DIREGT VENT SINGLE PIPE PIPING secuit acus sano runi xxx uasa SEE Ea x MRvO chua CE dan EC EIE KR E n T 15 DIRECT VENT DUAE PIPE PIPING sicsvecsntaccanccnseenscecsceescec
41. CT VENT NON DIRECT VENT UPFLOW COUNTERFLOW STANDARD CONNECTIONS Standard Connections ALTERNATE FURNACE CONNECTIONS If the standard locations are undesirable for a specific installation alternate side panel locations are available for both combustion air inlet and vent flue pipe connections These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil or to upright counterflow installations requiring additional access to a filter or electronic air cleaner or to horizontal installations desiring vent flue and combustion air intake piping run vertically from the side of the cabinet NOTE Standard and alternate locations can be combined i e an installation may use the standard combustion air intake location but use the alternate vent flue location or vice versa if needed EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS A PRE CAUTION WHEN REMOVING HOLE PLUGS ALTERNATE VENT FLUE LOCATION The alternate vent flue location is the large hole directly in line with the induced draft blower outlet To use the alternate vent flue loca tion refer to the following steps the Vent Flue Pipe Cuts figure and the Alternate Vent Flue Location figure NOTE Counterflow instructions follow the upflow instructions 1 Remove and save the four screws securing the vent flue coupling to the furnace top panel Counterflow units Remove and save the four screws se
42. Keep the warranty certificate in a safe location for future reference If additional information or operating instructions are required con tact the dealer where the purchase was made Homeowner Notice If the residence is left unattended for an extended period of time i e 4 hours or greater have your heating system periodically checked to ensure proper operation Potential circumstances be yond our control such as power outages gas service interruptions product installation or component failures could result in heating System operational problems To THE INSTALLER Before installing this unit please read this manual thoroughly to familiarize yourself with specific items which must be adhered to including but not limited to unit maximum external static pressure gas pressures BTU input rating proper electrical connections cir culating air temperature rise minimum or maximum CFM and mo tor speed connections TRANSPORTATION DAMAGE All units are securely packed in shipping containers tested accord ing to International Safe Transit Association specifications The car ton must be checked upon arrival for external damage If damage is found a request for inspection by carrier s agent must be made in writing immediately The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit In the event of damage the consignee should 1 Make a notation on delive
43. LATOR BLOWER REMVOAL Suspended Furnace ExisriNG FURNACE REMOVAL NOTE When an existing furnace is removed from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appliances The following vent testing procedure is reproduced from the American National Standard National Standard of Canada for Gas Fired Cen tral Furnaces ANSI Z21 47b 2002 CSA 2 3b 2002 Section 1 23 1 The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances con nected to the venting system are not in operation Seal any unused openings in the venting system b Inspect the venting system for proper size and horizontal pitch as required by the National Fuel Gas Code ANSI Z223 1 or the CSA B149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficien cies which could cause an unsafe condition c Inso far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bath room exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Follow
44. Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a left side right side for counterflows electrical connection with the junction box lo cated inside the blower compartment To make electrical connec tions through the opposite side of the furnace the junction box must be relocated to the other side of the blower compartment prior to making electrical connections To relocate the junction box follow the steps shown below NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES A PRECAUTION WHEN REMOVING HOLE PLUGS 1 Remove the burner compartment door 2 Remove and save the two screws securing the junction box to the side panel 21 Relocate junction box and associated plugs and grommets to opposite side panel Secure with screws removed in step 2 ALTERNATE JUNCTION BOX JUNCTION BOX LOCATION LOCATION gt 2 d v Ree cta Junction Box Relocation To AVOID THE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC Cope To ensure proper unit grounding the ground wire should run
45. N ERE iaai aia iai 33 XIX Maintenance EE E E ERAS ENEEESNNRINSOERRRPRKEGNRSUENE 33 ANNUAL INSPECTION 33 FILTERS sresecicceavacesvixeasssausncivenciacnarsacaaisecasiceuaaitaateaecaeicuteiacanaseuaasieas chnehasnauastauaneiuasaiagacniauaasiseuasiauausiwasaiieanasanenis 33 BURNERS sirate EEEE ESSNFAEREFIUEEKERIRNENIXER RIRERKTEERER 34 INDUCED DRAFT AND CIRCULATOR BLOWERS sssesecsssesceucncessecseneceeueecenssesennaseuausensssueneeuseuueeeanseeeaneaseesensunssensenass 34 CONDENSATE TRAP AND DRAIN SYSTEM QUALIFIED SERVICER 34 FLAME SENSOR QUALIFIED SERVICER ONLY 34 FLUE PASSAGES QUALIFIED SERVICER ONLY essccccesseeeeeeeeeeeeeeneeseeeeeeseeeensnnaaaeeeeseeeseenenneneeseeseeeesanaeseeeesnseeeneeneaees 34 XX Internal Filter Removal reae ona niai anna ag uu ud niat iu a kann rw eu ma c a a a n a inr e i i o o 34 XXI Bef
46. OO ALINDYIO S TWO STAGE INTEGRATED CONTROL MODULE YOLOANNOO LINDYIO 6 SNOLLO3NNOO LVLSOWHSHL Ave PSt 12 24V HUM FRONT COVER TOW FIRE PRESSURE PRESSURE SWITCH SWITCH CIRCULATOR BLOWER 16 WIRE MTR HARNESS HIGH FIRE PRESSURE SWITCH Ave GND 10 BLOWER INDUCTOR COIL COMPARTMENT TR 9 7OKBTU 90KBTU DOOR SWITCH 115kBTU MODELS OPEN WHEN e ONLY DOOR OPEN INTEGRATED CONTROL MODULE STEADY ON NORMAL OPERATION LOW VOLTAGE 24V 1 FLASH SYSTEM LOCKOUT RETRIES RECYCLES EXCEEDED LOWVOLTAGEFIBID 2 FLASHES LOW FIRE PRESSURE SWITCH STUCK CLOSED 3 FLASHES LOW FIRE PRESSURE SWITCH STUCK OPEN HINOLTAGE Mey FIELD SPLICE 4 FLASHES THERMAL PROTECTIVE DEVICE OPEN HI VOLTAGE FIELD 5 FLASHES FLAME SENSED WITH GAS VALVE DE ENERGIZED JUNCTION 7 FLASHES LOW FLAME SENSE SIGNAL TERMINAL TENDER 8 FLASHES CHECK IGNITER OR IMPROPER GROUNDING INTERNAL TO SWITCH PRESS 9 FLASHES HIGH FIRE PRESSURE SWITCH STUCK OPEN INTEGRATED CONTROL CONTINUOUS FLASHES 115 VOLT AC POWER REVERSED PLUG CONNEGHON EQUIPMENT GND SWITCH TEMP OVERCURRENT PROT DEVICE COLOR CODES PK PINK NOTES YL YELLOW BR BROWN 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS OR ORANGE WH WHITE 2 MANUFACTURER S SPECIFIED REPLACEMENT P
47. OW REQUIREMENT CFM vom oo vo vo ao ee ee ome ee j o oo oo 280 COOLING AIRFLOW REQUIREMENT CFM vom vo T wo ao or Minimum filter area dictated by heating airflow requirement Disposable Minimum Filter area sq in Based on 300 ft min filter face velocity UPRIGHT INSTALLATIONS Depending on the installation and or customer preference differing filter arrangements can be applied Filters can be installed in the central return register or a side panel external filter rack kit up flows As an alternative a media air filter or electronic air cleaner can be used as the requested filter The following figure shows possible filter locations 26 FILTER ACCESS DOOR AIR FLOW RETURN DUCT CENTRAL RETURN GRILLE CENTRAL RETURN GRILLE 1 SIDE RETURN EXTERNAL FILTER RACK KIT EITHER SIDE FILTER SUPPORT BRACKET PROVIDED AIR FLOW Possible Upright Counterflow Possible Upright Upflow Filter Locations NOTE Internal filter retention is not provided on this furnace If an internal installation is desired an internal filter retention kit is avail able as an accessory Please see
48. P USE GLOVES A PRECAUTION WHEN REMOVING HOLE PLUGS 24 DinEcT SrANDARD INLET PIPING When gas piping enters directly to the gas valve through the stan dard inlet hole the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet to seal the grom met cabinet penetration A semi rigid connector to the gas piping can be used outside the cabinet per local codes INDIRECT ALTERNATE INLET PIPING When gas piping enters indirectly to the gas valve through the alter nate gas inlet hole the following fittings starting from the gas valve to reach the outside of the cabinet must be supplied Coupling 90 degree elbow e 2 inch close nipple 90 degree elbow Straight pipe with a ground joint union to reach the exterior of the furnace The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration A semi rigid connector to the gas piping be used outside the cabinet per local codes Gas Piping CHECKS Before placing unit in operation leak test the unit and gas connec tions To AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved testing methods NOTE Never exceed specifi
49. R COMPARTMENT Il SAFETY Please adhere to the following warnings and cautions when install ing adjusting altering servicing or operating the furnace To PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FOR ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM To PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER THIS UNIT MUST NOT BE USED AS A CONSTRUCTION HEATER DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE THIS TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TERMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUTINE INSPECTION MAINTENANCE AND SUPERVISION IF THE BUILIDNG IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED MAINTAINED AND MONITORED IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT ALL WATER BEARING PIPES SHOULD BE DRAINED THE
50. R SIZE OF i NATURAL PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE Tighten all joints securely METER TANK TO THE FURNACE Connect the furnace to the building piping by one of the following methods GENERAL When sizing a trunk line be sure to include all appliances which will operate simultaneously when sizing a trunk line Rigid metallic pipe and fittings The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of Semi rigid metallic tubing and metallic fittings the run The gas line installation must comply with local codes or in Aluminum alloy tubing must not be used in exterior their absence with the latest edition of the National Fuel Gas Code locations In order to seal the grommet cabinet NFPA 54 ANSI Z223 1 penetration rigid pipe must be used to reach the outside Natural Gas Capacity of Pipe of the cabinet A semi rigid connector to the gas piping In Cubic Feet of Gas Per Hour CFH may be used from there Length of Nominal Black Pipe Size m i Pipe Feet 74 TTF Use listed gas appliance connectors in accordance with their 10 1050 1600 instructions Connectors must be fully in the same room as the furnace e Protect connectors and semirigid tubing against physical and thermal damage when installed Ensure aluminum alloy tubing and connectors are coated to protect against external corrosion when in conta
51. RESSURE RUBBER GROMMET 2 ELBOW HOLES y E gt H RIGHT CO SIDE TUBES 2 PANEL RUBBER ELBOW GREEN DRAIN PORT 1 RED HOSE DRAIN TRAP CLAMP GAME 3 PLACES Horizontal Connections Right Side Down Upflow Shown Counterflow Similar 8 Insert approximately one inch of each Tube 2 through the right down side panel grommet holes Secure tubes to Hose A and Hose B using green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting Lert Sibe Down Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow 1 Remove the rubber plug from the coil front cover left down side drain port 2 Relocate the front cover pressure switch hose connection from the right side as shipped pressure tap to the left down side tap The pressure switch hose must be connected to the down side to guard against blocked drain conditions Cut hose to appropriate length to minimize sagging Plug right unused pressure tap with plug removed from left side 3 Secure Hose A to front cover drain port with a red hose clamp Route hose to rear left down side panel grommet holes NOTE For left side drainage gro
52. RSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This furnace is shipped from the factory configured for natural gas at standard altitude Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas High altitude installations may require both a pressure switch and an orifice change These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude For installations above 7000 feet please refer to your distributor for required kit s Manifold Pressure Pressure Gas Altitude Kit Orifice j High Stage Low Stage Switch Change Natural None 43 3 5 w c 1 9 w c None 0 7000 Propane 03 55 10 0 w c 6 0 w c None NOTE In Canada gas furnaces are only certified to 4500 feet Contact the distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude installations The indicated kits must be used to insure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency IX VENT FLUE PIPE amp COMBUSTION AIR PIPE GENERAL FAILURE
53. SUPPLY AND PIPING GENERAL The furnace rating plate includes the approved furnace gas input rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any conversion kits required for alternate fuels and or high altitude To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified below The supply pressure must be constant and avail able with all other household gas fired appliances operating The minimum gas supply pressure must be maintained to prevent unre liable ignition The maximum must not be exceeded to prevent unit overfiring Inlet Gas Supply Pressure Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C Natural Gas ALTITUDE DERATE When this furnace is installed at high altitude the appropriate High Altitude orifice kit must be applied This is required due to the natu ral reduction in the density of both the gas fuel and combustion air as altitude increases The kit will provide the proper design certified input rate within the specified altitude range High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas Contact your distributor for a tabular listing of appropriate altitude ra
54. T PIPE UNION 2 OM aoon Use black iron or steel pipe and fittings for building piping pdt MN ho al Where possible use new pipe that is properly chamfered ines MES amie ee reamed and free of burrs and chips If old pipe is used be mmu 19 ay sure it is clean and free of rust scale burrs chips and old pipe joint compound Use pipe joint compound on male threads ONLY Always use pipe joint compound pipe dope that is APPROVED FOR mt f 7 Pen ALL GASSES DO NOT apply compound to the first two threads pea nid TAN Riese i SERA TON e Use ground joint unions pure HORIZONTAL COUNTERFLOW HORIZONTAL UPFLOW MODEL e Install a drip leg to trap dirt and moisture before it can enter a PN NOTES 1 WHEN GAS LINE IS IN THE ALTERNATE 2 DRIP LEG MAY TERMINATE WITH the gas valve The drip leg must be a minimum of three LOCATION SWAP THE POSITION OF 1 2 X 1 8 PIPE PLUG TO THE PLUG AND GROMMET ACCOMMODATE LINE GAS inches long PRESSURE MEASUREMENT e Install a 1 8 NPT pipe plug fitting accessible for test gage Gas Piping Connections connection immediately upstream of the gas supply connection to the furnace Always use a back up wrench when making the connection A CAUTION to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped EDGES OF SHEET METAL HOLES MAY BE SHAR
55. TECTION DEVICE Hor OVERCURRENT SURFACE HIGH FIRE IGNITER PRESS SWITCH WARNING DISCONNECT PROPERLY POLARIZED SERVICING WIRING TO UNIT MUST BE AND GROUNDED TWO STAGE DISCONNECT POWER BEFORE GAS VALVE 2 CIRCUIT CONNECTOR 115VAC 10 60 HZ POWER SUPPLY WITH FRONT COVER e OVERCURRENT PROTECTION DEVICE PRESSURE SWITCH L GND N WARNING 1 DISCONNECT POWER MUST BE PROPERLY BEFORE SERVICING WIRING TO UNIT POLARIZED AND GROUNDED MANUAL RESET ROLLOUT LIMIT CONTROLS LOW FIRE SINGLE CONTROL ON 45 kBTU PRESS SWITCH w Cn AUTO RESET PRIMARY LIMIT CONTROL DISCONNECT WOH VT SISSVHO Lo 1 19 INDUCED DRAFT JUNCTION BOX BLOWER 115kBTU MODELS INDUCTOR COIL 7OKBTU 90kBTU BURNER COMPARTMENT INDOOR CIRCULATOR BLOWER COMPARTMENT BLWR MANUAL RESET AUXILIARY LIMIT CONTROL ELECTRONIC AIRGLEANER 24 V THERMOSTAT CONNECTIONS Sjo huworren 7 JINON 10H1NOO G31VHO31NI JINON 10H1NOO 1 HOT SURFACE IGNITER FP 3 oo FLAME SENSOR 115 VAC T STAT SELECTOR HEAT OFF DELAY DIP SWITCHES HLO 11 HOLO3NNN
56. VALVE PRESSURE REGULATOR Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace Turn off all electrical power to the system 3 Back outlet pressure test screw inlet outlet pressure boss out one turn counterclockwise not more than one turn 4 Attach a hose and manometer to the outlet pressure boss of the valve 5 Turn ON the gas supply 6 Turn on power and energize main M solenoid Do not energize the HI solenoid 7 Measure gas manifold pressure with burners firing Adjust manifold pressure using the Manifold Gas Pressure table shown below 8 Remove regulator cover screw from the low LO outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure 9 Energize main M solenoid as well as the HI terminal 10 Remove regulator cover screw from the HI outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure 11 Turn off all electrical power and gas supply to the system 12 Remove manometer hose from outlet pressure boss 13 Turn outlet pressure test screw in to seal pressure port clockwise 7 in Ib minimum 14
57. a fireplace Concealed hot or cold water pipes or chimneys e Unconditioned areas behind the thermostat such as an outside wall NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual DRAFTS OR DEAD SPOTS BEHIND DOORS IN CORNERS UNDER CABINETS HOT COLD Thermostat Influences Consult the instructions packaged with the thermostat for mounting instructions and further precautions V COMBUSTION amp VENTILATION AIR REQUIREMENTS POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows These changes have helped in reducing heat ing cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air House depressurization can cause back drafting or improper com bustion of gas fired appliances thereby exposing building occupants to gas combustion products that could include carbon monoxide If this furnace is to be instal
58. al Fuel Gas Code NFPA 54 ANSI 2223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes A copy of the National Fuel Gas Code NFPA 54 ANSI 2223 1 be obtained from any of the following American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 A copy of the CAN CSA B149 Installation Codes can also be ob tained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated The total heat loss should be calculated by an approved method or in accordance with ASHRAE Guide or Manual J Load Calculations published by the Air Conditioning Contractors of America IV LOCATION REQUIREMENTS amp CONSIDERATIONS GENERAL TO PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT Follow the instructions listed below when selecting a furnace loca tion Refer also to the guidelines provided in Section V Combus tion and Ventilation Air Requirements Centrally locate the furnace with respect to the proposed or existing air distribution system Ensure the temperature of the retur
59. an adversely affect electrical components Use the following precautions during furnace installation and ser vicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electro static potential these steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is appli cable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnace near the control Any tools held in a person s hand during manual for specifics pertaining to the installation and application of this product POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSTAION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE To ensure proper furnace operation install operate and maintain the furnace in accordance with these installation and operation in structions all local building codes and ordinances In their absence follow the latest edition of the Nation
60. anual D A duct system must be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Condi tioning Warm Air Heating and Ventilating Systems Pamphlets No 90A and 90B A closed return duct system must be used with the return duct con nected to the furnace NOTE Ductwork must never be attached to the back of the furnace Supply and return connections to the fur nace 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 fur nace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recom mended that a removable access panel be provided in the outlet air duct This opening shall be accessible when the furnace is installed and shall be of su
61. ard right side panel grommet holes 8 Insert short end of one Tube 2 through rear right side panel grommet drain hole Secure tube to Hose A with a green hose clamp 9 Insert short end of remaining Tube 2 into Hose B from rubber elbow and secure with green hose clamp Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding RUBBER ELBOW RUBBER EXTERNALLY ELBOW ERONTOOVER MOUNTED DRAIN PORT DRAIN PORT RED HOSE CLAMP TUBE 1 GREEN HOSE CON i CLAMPS V 8 PLACES e HOSEB SIDE PANEL GROMMET Les E EET v HOLES RED HOSE DRAIN TRAP CLAMP TUBE S 2 Upright Alternate Connections Right Side Only Upflow Shown Counterflow Similar For details concerning mounting of the drain trap refer to the fol lowing section UPRiGHT DRAIN TRAP Lert Sipe PANEL 1 Insert drain tubes into drain trap and position the drain trap against the side panel NOTE Drain tubes must reach the bottom of the drain trap 2 Secure drain trap to side panel at the mounting holes dimples or crosshairs on counterflow models located below the grommet drain holes 3 Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling HORIZONTAL INSTALLATIONS Sipe Down Horizontal installations with the right side down require that the drain hoses
62. as pressure to rating plate info Adjust as needed Check and correct wiring from integrated control module to igniter Replace bad igniter Check and correct unit ground wiring Inspect pressure switch hose Repair if necessary Inspect flue and or inlet air piping for blockage proper length elbows and termina tion Check drain system Correct as necessary Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Review wiring diagram to correct polarity Verify proper ground Correct if necessary Check and correct wiring Cautions and Notes Turn power OFF prior to repair See Product Data Book applicable to your model for allowable rise range and proper circulator speed See Vent Flue Pipe section for piping details Replace pressure switch with proper replacement part Turn power OFF prior to repair Turn power OFF prior to repair Sand flame sensor with emery clot See Vent Flue Pipe section for piping details See rating plate for proper gas pressure Turn power OFF prior to repair Replace igniter with proper silicon nitride replace ment part Turn power OFF prior to repair Replace pressure Switch with proper replacement part Turn power OFF prior to repair WIRING DIAGRAM ID BLOWER Ti TWO STAGE PRESSURE 115 VAC 1 60 HZ SWITCH ASSEMBLY POWER SUPPLY WITH TENTEN PRO
63. atic electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object DiAGNosrTIC CHART To AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems The red diagnostic LED blinks to assist in troubleshooting the unit The number of blinks refers to a specific fault code RESETTING FRom Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts It is characterized by a non functioning fur nace and a one flash diagnostic LED code If the furnace is in lock out it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace for 0 20 seconds 3 Manual thermostat cycle Lower the thermostat so that there is no longer a cal
64. bows Inch 1121314 5 6 7 3 7168 65 62 59 56 53 50 2 61 58 55 52 49 46 43 40 71 68 65 62 59 56 53 50 70 000 90 000 1 One 90 elbow should be secured to the combustion air intake con nection 2 Minimum vent length is five feet and one elbow tee 3 Tee used in the vent flue termination must be included when determin ing the number of elbows in the piping system 4 3 diameter pipe can be used in place of 2 diameter pipe VENT FLUE PIPE TERMINATIONS The vent flue pipe may terminate vertically as through a roof or horizontally as through an outside wall Vertical vent flue pipe terminations should be as shown in the fol lowing figure Refer to Section IX Vent Flue Pipe and Combustion Air Pipe Termination Locations for details concerning location re strictions The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumb ing vent Horizontal vent flue pipe terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe and Combus tion Air Pipe Termination Locations for details concerning loca tion restrictions A 2 3 8 diameter wall penetration is required for 2 diameter pipe while a 3 1 2 diameter hole is required for 3 diameter pipe To secure the pipe passing through the wall and prohibit damage to piping connections a coupling should be in stalle
65. ch a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be in serted into the airstream The access panel must be made to pre vent air leaks when the furnace is in operation When the furnace is heating the temperature of the return air enter ing the furnace must be between 55 F and 100 F Fitters READ THis SECTION BEFORE INSTALLING THE Return DucrTwoRK Filters must be used with this furnace Discuss filter maintenance with the building owner Filters do not ship with this furnace but must be provided by the installer Filters must comply with UL900 or CAN ULCS111 standards If the furnace is installed without filters the warranty will be voided On upflow units guide dimples locate the side return cutout locations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines NOTE An undersized opening will cause reduced airflow Refer to Minimum Filter Area tables to determine filter area require ments COOLING AIRFLOW REQUIREMENT CFM 1o so va ve rer er oe es P oe oe pm o you so se COOLING AIRFLOW REQUIREMENT CFM soo 1000 1200 1400 1600 2000 EECCA ESESESEGEGEGE Minimum filter area dictated by heating airflow requirement Permanent Minimum Filter Area sq in Based on a 600 ft min filter face velocity COOLING AIRFL
66. condensate drainage from the heat ex changer and induced draft blower For proper flue pipe drainage the furnace must be level lengthwise from end to end The furnace should also be level from back to front or have a slight tilt with the access doors downhill approximately 3 4 inches from the back panel The slight tilt allows the heat exchanger condensate gener ated in the recuperator coil to flow forward to the recuperator coil front cover ALTERNATE VENT FLUE AND COMBUSTION AiR CONNECTIONS In horizontal installations provisions for alternate flue and combus tion air piping are available for upflow furnaces with left discharge and counterflow furnaces with right air discharge This configuration allows the flue and combustion air piping to be run vertically through the furnace Refer to the Recommended Installation Positions fig ure for further detail The standard piping connections may also be used in these positions Refer to Section IX Vent Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent flue and combustion air connections FURNACE MUST BE LEVEL OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0 3 4 BELOW THE BACK PANEL 11 ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS AIR A DISCHARGE iConnection UPFLOW UPRIGHT ALTERNATE FLUE AND COMBUSTION AIR PIPE LOCATIONS s AIR a DISCHARGE N J N UPFLOW HORIZONTAL LEFT AIR DISCHARGE y
67. ct with masonry plaster or insulation or subjected to repeated wetting by liquids such as water except rain water detergents or sewage PLUGIN 100 38 79 150 305 460 Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on suut OFF VALVE 0 60 Specific Gravity Gas oe um SRIPEUNON 8 BTUH Furnace Input P EE AG Heating Value of Gas BTU Cubic Foot EG HEIGHT REQUIRED HEIGHT REQUIRED BY LOCAL CODE BY LOCAL CODE ALTERNATE GAS LINE HOLE GAS VALVE To connect the furnace to the building s gas piping the installer must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply transition piece from 1 2 pipe to a larger GROMMET IN STANDARD GAS LINE HOLE GROMMET IN STANDARD GAS LINE HOLE MANIFOLD DRIP LEG DRIP LEG BURNERS pipe size The following stipulations apply when connecting gas piping Refer UPFLOW COUNTERFLOW to Gas Piping Connections figure for typical gas line connections to T va ve the furnace JOIN
68. cuit Lingering burner flame Slow closing gas valve Flame sensor is coated oxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to improper gas pressure or combustion air Improperly connected igniter Bad igniter Poor unit ground Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain system or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning Switch contacts Loose or improperly connecteq Polarity of 115 volt AC power to furnace or integrated control module is reversed Poor unit ground Corrective Action Check filters and ductwork for blockage Clean filters or remove obstruction Check circulator blower speed and performance Correct speed or replace blower if necessary Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check induced draft blower for proper performance Replace if necessary Tighten or correct wiring Correct short at flame sensor or in flame sensor wiring Check for lingering flame Verify proper operation of gas valve Sand flame sensor is coated oxidized Inspect for proper sensor alignment Check inlet air piping for blockage proper length elbows and termination Compare current g
69. curing the vent flue coupling to the furnace basepan Also remove the three screws securing the furnace s internal vent flue piping to the blower deck Upflow and Counterflow units Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent flue pipe Upflow and Counterflow units Remove the vent flue pipe from the furnace Cut the vent flue pipe 3 75 inches from the flanged end of the pipe See Vent Flue Pipe Cuts figure The section of pipe attached to the coupling will reach through the side panel to the induced draft blower Discard remaining pipe and elbows Counterflow units Cut the vent flue pipe 3 75 inches from the blower deck coupling See Vent Flue Pipe Cuts figure Save vent flue pipe attached to blower deck coupling for use in the alternate location Discard remaining pipe and elbows FLANGE TT 1 3 75 CUT HERE 3 73 Vent Flue Pipe Cuts Remove plastic plug from alternate vent flue location Relocate and install plug in standard vent flue location top cover Counterflow units Remove plastic plug from alternate vent flue location Relocate and install plug in standard vent flue location basepan Plug remaining hole in blower deck with plastic plug included in the drain kit bag Upflow and Counterflow units Insert cut section of vent flue pipe and coupling into alternate vent flue location Using a rubber coupling and worm gear hose clamps
70. d Considerations for leveling of horizontal furnaces Ensure upflow or horizontal furnaces are not installed directly on carpeting or any other combustible material The only combustible material allowed is wood A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood Refer to subbase instructions for installation details NOTE A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is exposed to the following substances chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials Seal off a non direct vent furnace if it is installed near an area frequently contaminated by any of the above substances This protects the non direct ventfurnace from airborne contaminants To ensure that the enclosed non direct vent furnace has an adequate supply of combustion air vent from a nearby uncontaminated room or from
71. d on either side of the wall and solvent cemented to a length of pipe connecting the two couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be in stalled on the inside and outside of the wall The wall penetration should be sealed with silicone caulking material In a basement installation the vent flue pipe can be run between joist spaces If the vent pipe must go below a joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows TEE 12 Min To Roof Or Highest Anticipated Snow Level Vertical Termination Single Pipe 90 MEDIUM RADIUS ELBOWS 12 MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL Alternate Vertical Termination Single Pipe WALL INSIDE OUTSIDE TEE or 90 ELBOW TURNED DOWN COUPLING ELBOW OR COUPLING GROUND OR HIGHEST ANTICIPATED SNOW LEVEL Horizontal Termination Single Pipe VENT FLUE TEE or 90 ELBOW TURNED Se 12 MIN ABOVE HIGHEST ANTICIPATED sn CD SNOW Ta 224 SS Horizontal Termination Single Pipe Above Highest Anticipated Snow Level Direct Vent DuaL PIPING The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals
72. e Canadian Fuel Gas Code takes precedence over the preceding termination restrictions CANADIAN VENTING REQUIREMENTS In Canada venting must conform to the requirements of the current CAN CSA B149 Installation Code Use only CSA listed two or three inch diameter PVC or ABS pipe solvent cement and fittings through out Carefully follow the manufacturers instructions for cutting clean ing and solvent cementing PVC and or ABS The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather tight corrosion resistant flashing 13 STANDARD FURNACE CONNECTIONS It is the responsibility of the installer to ensure that the piping con nections to the furnace are secure airtight and adequately sup ported As shipped attachment couplings for vent flue and combustion air intake pipe connections are provided on the furnace s top cover upflow or basepan counterflow To use the standard connec tions field supplied vent flue pipe and combustion air intake pipe when applicable should be secured directly to the furnace at these locations VENT FLUE PIPE Vent flue pipe can be secured to the vent flue coupling using the rubber coupling and worm gear hose clamps provided with this fur nace see Standard Connections figure The rubber coupling al lows separation of the vent flue pipe from the furnace during servic ing NOTE Do not
73. e cesis drea 32 Mee H 32 INTEGRATED CONTROL MOD LE 2 wud va co soda a 2 cundbouseceeues 32 PRIMARY EIMIT iiis secun scvuu setaseanduunsbucusnaeasuuebvaaseudaneuusducusslauwelusucadesasussausudsudeasaussebavasvacesansansenwadea 32 AUXILIARY LIMIT A nans cna saa dana nnn a5 n anu a canna E E E E 33 leben EM 33 PRESSURE SWITCHES enean nian hahaha De aa RR RR RR RR RR DEI SNR RR SNR RR RR RR RD DAN RR RR ERR RR HR a SD s aae arua uasa sanas Da 33 FRAME SENSOR A E A ia coedeasavsiecuaaiedvasnckiancenach nzesaed shi A E A E 33 Troubleshooting aaa aaan aaraa eaaa aa aeaaaee eaer a aa aAa Aaa AEE aE a a aa e aa Eaa aaa E aaa aa EAE 33 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS sidcisisscisessssandsissstesiescxsisdesueseeusssatnesea aweisinesdnscssencssdcrnseansescctenics 33 DIAGNOSTIC CHART susiskiicsciuauecduuscesavassacenscuwsnausussncundecudacaauss vases suvucauusuadseeslaves saduacauuus NK TR E NER KKNRKEFEREDE 33 RESETTING FROM cur an ka 2o ada nra Deua Da Ex Se ES E
74. e diagnostic LED provides no signal Furnace fails to operate Integrated control module diagnostic LED is lit continuously Furnace fails to operate Integrated control module diagnostic LED is flashing ONE 1 flash Furnace fails to operate Integrated control module diagnostic LED is flashing TWO 2 flashes Induced draft blower runs continuously with no further furnace operation Integrated control module diagnostic LED is flashing THREE 3 flashes Associated LED Code NONE CONTINUOUS ON 1 FLASH 2 FLASHES 3 FLASHES TROUBLESHOOTING CHART Fault Description s No 115 volt power to furnace or no 24 volt power to integrated control module Blown fuse or circuit breaker Integrated control module has an internal fault No signal from thermostat Furnace lockout due to an excessive number of ignition retries 3 total Pressure switch circuit is closed Induced draft blower is not operating Pressure switch circuit not closed Induced draft blower is operating Possible Causes Manual disconnect switch OFF door switch open or 24 volt wires improperly connected or loose Blown fuse or circuit breaker Integrated control module has an internal fault e Improper thermostat connection or setting Failure to establish flame Cause may be no gas to burners front cover pressure switch stuck open bad igniter
75. e external to the furnace 2 Turn off the electrical power to the furnace 3 Set the room thermostat to the lowest possible setting 4 Remove the burner compartment door NOTE This furnace is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Move the furnace gas valve manual control to the OFF position 6 Wait five minutes then smell for gas Be sure check near the floor as some types of gas are heavier than air 7 f you smell gas after five minutes immediately follow the instructions on page 4 of this manual If you do not smell gas after five minutes move the furnace gas valve manual control to the ON position 8 Replace the burner compartment door 9 Open the manual gas shutoff valve external to the furnace 10 Turn on the electrical power to the furnace 11 Adjust the thermostat to a setting above room temperature 12 After the burners are lit set the thermostat to desired temperature FuRNACE SHUTDOWN 1 Setthe thermostat to the lowest setting The integrated control will close the gas valve and extinguish flame Following a 15 second delay the induced draft blower will be de energized After a 120 150 180 or 210 second delay period field selectable delay OFF 90 120 150 180 plus 30 second ramp down the circulator blower de energizes 2 Remove the burner compartment door and move the furnace gas valve manual control to the OFF po
76. e from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap UPRIGHT INSTALLATIONS In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet NOTE Refer to Section X Condensate Drain Lines and Drain Trap Alternate Vent Flue Hose Connections for upright installations us ing an alternate vent flue outlet STANDARD Ricut Lert Sipe DRAIN Hose CONNECTIONS Upright installations using the standard vent flue outlet require drain hoses to be connected as follows The following quantity of hoses tubes and hose clamps are provided with the unit i REIER REEERE RRR RRES GREEN R HOSE CLAMPS HOSE CLAMPS QTY 3 QTY 2 Hose and Tube Identification Remove the rubber plug from the front cover drain port right or left side depending on the intended drain trap mounting Secure Hose Ato front cover drain port with a red hose clamp Route hose to rear side panel grommet hole NOTE For left side drainage grommets will have to be relocated to left side panel 18 _ RIGHT SIDE PANEL RUBBER ELBOW RUBBER ELBOW DRAIN PORT RED HOSE CLAMP TUBE 1
77. e furnace to operate with burners firing continuously for approximately ten minutes 2 Gradually block the return air to furnace Remove airflow blockage when limit control is activated and turns off burners Airflow blockage causes unit overheating and will produce the following reactions The gas valve to close and extinguish flame The induced draft blower to deenergized after a fifteen second postpurge and The circulator blower to remain energized continuously until limit control resets NOTE If testing is performed on high stage the circulator blower will switch to low stage speed following the selected heat off delay 3 Remove the return air blockage to clear overheating condition After an acceptable temperature is reached during the cool down period the limit control will reset and allow the furnace to resume normal operation These checks establish that the primary limit control is functioning and will respond to a restriction in the return air or a circulator blower failure If the primary limit control does not function during this test the cause must be determined and corrected XVII SAFETY CIRCUIT DESCRIPTION GENERAL Anumber of safety circuits are employed to ensure safe and proper furnace operation These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of ab normal function These circuits are continuously monitored during furnace operation by
78. ed 56 of high stage cooling following a five 5 second delay Electronic air cleaner terminals are energized Circulator blower runs integrated control module monitors safety circuits continuously R and G thermostat contacts open completing the call for fan Circulator blower is de energized Electronic air cleaner terminals are de energized Furnace awaits next call from thermostat XVI OPERATION AL CHECKS BuRNER FLAME The burner flames should be inspected with the burner compart ment door installed A sight glass is provided for inspection pur poses Flames should stable quiet soft and blue dust may cause orange tips but they must not be yellow Flames should extend directly outward from the burners without curling floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Burner Flame Primary Limit The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger If the primary limit control does not function during this test the cause must be determined and corrected Function of this control should be verified by gradually blocking the furnace return air after the fur nace has been operating burners firing for approximately ten min utes Check the control as follows 1 Allow th
79. ed pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pres sures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa Propane Gas TANKS AND PIPING PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK INSTALL A GAS DETECTION WARNING DEVICE A gas detecting warning system is the only reliable way to detect a propane gas leak Rust can reduce the level of odorant in propane gas Do not rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence of gas is suspected follow the instructions on Page 4 of this manual All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 11 inch w c at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three mai
80. ed when de termining the number of elbows in the piping system i of elbows tabulated are for each Vent Flue amp Combustion air intake pipe 9 Minimum length of each Vent Flue amp Combustion Air Intake pipe is five feet and one elbow tee 3 diameter pipe can be used in place of 2 diameter pipe 45 000 Alternate Standard 90 000 Standard 70 000 Alternate Standard VENT FLuE AND ComBusTION Ain PIPE TERMINATIONS The vent flue and combustion air pipes may terminate vertically as through a roof or horizontally as through an outside wall Vertical pipe terminations should be as shown in the following fig ure Hefer to Section IX Vent Flue Pipe and Combustion Pipe Termination Locations for details concerning location restrictions The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent TEE VENT FLUE MEDIUM RADIUS ELBOWS COMBUSTION AIR INTAKE 12 MIN 12 MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL SCREEN Vertical Terminations Dual Pipe Horizontal terminations should be as shown in the following figure Refer to Section IX Vent Flue Pipe and Combustion Pipe Termi nation Location for location restrictions A 2 3 8 inch diameter wall penetration is required for 2 diameter pipe while a 3 1 2 inch diam eter hole is required for 3 diameter pipe To secure the pipe pass ing throu
81. eg ister or the ductwork near the furnace To remove 1 Turn OFF electrical power to furnace 2 Remove filter s from the central return register or ductwork 3 Replace filter s by reversing the procedure for removal 4 Turn ON electrical power to furnace Menia Air Fitter ELECTRONIC AiR CLEANER REMOVAL Follow the manufacturer s directions for service BURNERS Visually inspect the burner flames periodically during the heating season Turn on the furnace at the thermostat and allow several minutes for flames to stabilize since any dislodged dust will alter the flames normal appearance Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow They should extend directly outward from the burners without curl ing floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes INDUCED AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower mo tors are permanently lubricated by the manufacturer No further lu brication is required Check motor windings for accumulation of dust which may cause overheating Clean as necessary CoNDENSATE TRAP AND DRAIN SYSTEM QUALIFIED SERVICER Annually inspect the drain tubes drain trap field supplied drain line for proper condensate drainage Check drain system for hose connection tightness blockage and leaks Clean or repair as nec essary
82. el cable such as drain cleanout cable Attach a variable speed reversible drill to the other end of the cable Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes While reversing the drill work the cable in and out several times to obtain sufficient cleaning Repeat for each tube Clean residue from furnace using a vacuum cleaner Replace the parts removed in the previous steps in reverse order Turn on electrical power and gas to furnace Check for leaks and proper unit operation Severe heat exchanger fouling is an indication of an operational problem Perform the checks listed in Section XIV Startup Procedure and Adjustments to reduce the chances of repeated fouling e 11 12 XX INTERNAL FILTER REMOVAL Internal filters are an accessory item and are not included with your furnace For further details see your distributor Bottom RETURN REMOVAL 1 Turn OFF electrical power to furnace 2 Remove blower compartment door 3 Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan 4 Slide filter forward and out 5 Replace filter by reversing the procedure BLowER COMPARTMENT REMOVAL 1 Turn OFF electrical power to furnace 2 Remove blower compartment door 3 Grasp lower portion of filter and lift up NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual 34
83. etail stores Nursing homes Hotels motels Common or office areas In such applications the furnace must be installed with the follow ing stipulations It must be installed per the installation instructions provided and per local and national codes It must be installed indoors in a building constructed on site It must be part of a ducted system and not used in a free air delivery application It must not be used as a make up air unit It must be installed with two pipe systems for combustion air especially if VOC s or other contaminants are present in the conditioned space All other warranty exclusions and restrictions apply This furnace is an ETL dual certified appliance and is appropriate for use with natural or propane gas NOTE If using propane a propane conversion kit is required Dual certification means that the combustion air inlet pipe is op tional and the furnace can be vented as a Non direct vent single pipe central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or Direct vent dual pipe central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions To ensure proper installation and operation thoroughly read this NOTE Discharge static electrictiy accumulated in the body before touching the unit An electrostatic discharge c
84. example weather stripping heavily insulated caulked vapor barrier etc addi tional 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 All Air from Inside the Building The confined space shall be pro vided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each open ing 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 open ing shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure lt Chimney or Gas Vent NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equip ment in the enc
85. for natural gas The appropriate manufacturer s propane gas conversion kit must be applied for pro pane gas installations Refer to the Section VIII Propane Gas High Altitude Installations section for details Gas VALVE This unit is equipped with a 24 volt gas valve controlled during fur nace operation by the integrated control module As shipped the valve is configured for natural gas The valve is field convertible for use with propane gas by replacing the regulator spring with a pro pane gas spring from an appropriate manufacturer s propane gas conversion kit Taps for measuring the gas supply pressure and manifold pressure are provided on the valve The gas valve has a manual ON OFF control located on the valve itself This control may be set only to the ON or OFF position Refer to the lighting instructions label or Section XIV Startup Proce dure amp Adjustment for use of this control during start up and shut down periods 23 Gas PiPING CONNECTIONS from the factory Maximum torque for the gas valve connection is 375 in lbs excessive over tightening may damage the gas valve Install a manual shutoff valve between the gas meter and A CAUTION unit within six feet of the unit If a union is installed the union must be downstream of the manual shutoff valve between To AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE the shutoff valve and the furnace DUE TO UNDERFIRING OF EQUIPMENT USE THE PROPE
86. from building nests in the combustion air pipe Installation of screens while strongly recommended is not required and will not affect performance of the unit Direct vent installations require both a combustion air intake and a vent flue pipe The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building The pipes may be run through an existing unused chimney however they must extend a minimum of 12 inches above the top of the chimney The space between the pipes and the chimney must be closed with a weather tight corrosion resistant flashing Both the combustion air intake and a vent flue pipe termi nations must be in the same atmospheric pressure zone Refer to Section IX Vent Flue and Combustion Air Pipe Termination Lo cations or Concentric Vent Termination for specific details on ter mination construction For details concerning connection of pipes to the furnace refer to the Section IX Vent Flue Pipe and Com bustion Pipe Standard Furnace Connections or Alternate Furnace Connections VENT FLuE AND ComBusTION Ain Pipe LENGTHS AND DIAMETERS Refer to the following table for applicable length elbows and pipe diameter for construction of the vent flue and combustion air in take pipe systems of a direct vent dual pipe installation The number of elbows tabulated represents the number of elbows and or tees in each Vent Flue amp Combustion Air Intake p
87. from the drain kit bag attach the vent flue pipe and coupling to the induced draft blower Secure the coupling to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT FLUE PIPING AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE 7 Upflow and Counterflow units For upright installations externally mount the rubber elbow to the vent flue coupling using a worm gear hose clamp Secure field supplied vent flue piping to the rubber elbow using a worm gear hose clamp NOTE Use of the alternate vent flue location for upright installations requires the drain trap be installed on the same side of the unit as the flue pipe Upflow and Counterflow units For horizontal installations externally secure the field supplied vent flue pipe directly to the vent flue coupling using a PVC or ABS coupling or elbow T REMOVE BE E REMOVE 0 4 SCREWS EET 4 SCREWS 3 SCREWS REMOVE f REVE AND RELOC
88. gh the wall and prohibit damage to piping connections a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetra tion should be sealed with silicone caulking material VENT FLUE s MIN ABOVE HIGHEST ANTICIPATED MIN Ed 2 HIGHEST ANTICIPATED NOW on p pa LEVEL Standard Horizontal Terminations Dual Pipe L 12 ABOVE anian ABOVE SNOW LEVEL md Alternate Horizontal Vent e Dual Pipe VENT FLUE SUPPORT TEE STRAPS 12 MIN ABOVE HIGHEST ANTICIPATED SNOW LEVEL SCREEN 12 MIN ABOVE p uu 90 HIGHEST ANTICIPATED ILE SNOW PEE red COMBUSTION AIR INTAKE Standard Horizontal Terminations Above Anticipated Snow Level Dual Pipe 17 Alternate Vent Termination Above Anticipated Snow Level Dual Pipe In a basement installation the pipes may be run between the joist spaces If the pipes must go below the joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows 12 Min Above Highest Anticipated m Level VENT INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE Direct VENT FURNACES If more than one direct vent furnace is to be installed vertically through a co
89. ial Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas Carbon monoxide producing devices such as an automobile space heater gas water heater etc should not be operated in enclosed areas such as unventilated garages utility rooms or parking areas because of the danger of carbon monoxide CO poisoning resulting from the exhaust emissions If a furnace or air handler is installed in an enclosed area such as a garage utility room or parking area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 To THE OwNER It is important that you fill out the owner s registration card and mail it today This will assist us in contacting you should any service or warranty information change in the future When filling in the regis tration card be sure to include the model manufacturing and serial numbers plus the installation date Your warranty certificate is also supplied with the unit Read the warranty carefully and note what is covered
90. ield wiring must conform to applicable codes Connections should be made as shown 12 CIRCUIT CONNECTOR INTEGRATED CONTROL MODULE HUMIDIFIER ELECTRONIC AIR CLEANER OPTIONAL ACCESSORIES Accessories Wiring If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace the wiring must conform to all local codes and have a minimum temperature rating of 105 C All line voltage wire splices must be made inside the furnace junction box The integrated control module humidifier terminals HUM are ener gized with 115 volts whenever the induced draft blower is energized The integrated control module electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is ener gized 24 HUMIDIFIER 5 long brown wire in the wire harness at the low fire pressure provides 24 VAC humidifier control This wire is powered any time the pressure switch is closed To connect 24 VAC HUM connect the 24 VAC line of the humidifier to the 5 brown wire The connec tion can be made by either stripping the wire and using a wire nut or by using a field supplied quick connect terminal The wiring must conform to all local and national codes Connect the COM side of the humidifier to the B C terminal on the furnace control board or to the COM side of the 24 VAC transformer Do not connect 115V humidifier to these terminals XII GAS
91. in TRAP Mountine LErr on Ricut SipE PANEL 1 Position the drain trap against side panel with drain tubes inserted into trap Note that the trap may be orientated with the outlet facing either the furnace s top cover or base pan Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding Attach PVC drain line to drain trap outlet with either a 90 elbow or coupling XI ELECTRICAL CONNECTIONS AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED AVOID INJURY ELECTRICAL SHOCK OR DEATH DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING 20 LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Wirinc HARNESS The wiring harness is an integral part of this furnace Field alter ation to comply with electrical codes should not be required Wires are color and number coded for identification purposes Refer to the wiring diagram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Any replacement wiring must be copper conductor 115 Line
92. ipe Elbows and or tees used in the terminations must be included when deter mining the number of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objection able insulation of the combustion air pipe may be required Use 1 2 thick closed cell foam insulation such as Armaflex or Insul tube where required UPFLOW Direct Vent Dual Pipe Maximum Allow able Length of Vent Flue amp Combustion Air Intake Pipe ft Unit Input Termination Pipe sye 2 Jsa a 58 55 52 49 46 48 40 37 2 49 46 43 40 37 34 81 28 nenas 2 35 27 24 2t 18 15 sz 4 45 42 so Standard s 62 se se 53 so Atemae 3 sr 54 5r 45 2 39 06 3 49 46 40 s7 oe ot 28 Atemae 3 35 32 2 26 5 20 17 14 COUNTERFLOW Direct Vent Dual Pipe Maximum Allow able Length of Vent Flue amp Combustion Air Intake Pipe ft Pu Termination E e eem ETE S 4 8 78 CVE oa s oe ss se s 55 5 50 ss so zz z 2 15 3 57 54 51 48 45 42 39 36 2 35 20 27 s sr 54 or 45 Elbows and or Tees used in the terminations must be includ
93. l for heat then reset to previous setting Interrupt thermostat signal to the furnace for 0 20 seconds NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to Section XVIII Troubleshooting Diagnostic Chart for aid in determining the cause XIX MAINTENANCE To AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE IF YOU MUST HANDLE THE IGNITER HANDLE WITH CARE TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FAILURE ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER ANNUAL INSPECTION The furnace should be inspected by a qualified installer or service agency at least once per year This check should be performed at the beginning of the heating season This will ensure that all fur nace components are in proper working order and that the heating System functions appropriately Pay particular attention to the fol lowing items Repair or service as necessary e Flue pipe system Check for blockage and or leakage Check the outside termination and the connections at and internal to the furnace Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways Burners Check for proper ignition burner flame and flame sense Drainage system Check for blockage and or leakage Check hose connections at
94. lculating the size of opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened au tomatically during equipment operation 5 3 6 Special Conditions Created by Mechanical Exhausting or Fire places Operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfac tory operation of installed gas utilization equipment Air from Inside Building See 5 3 3 a VI INSTALLATION POSITIONS This furnace may be installed in an upright position or horizontal on either the left or right side panel Do not install this furnace on its back For upright upflow furnaces return air ductwork may be at tached to the side panel s and or basepan For horizontal upflow furnaces return air ductwork must be attached to the basepan For both upright or horizontal counterflow furnaces return ductwork must be attached to the basepan top end of the blower compartment 10 NOTE Ductwork must never be attached to the back of the fur nace Contact your distributor for proper airflow requirements and number of required ductwork connections Refer to Recommended Installation Positions figure fo
95. led in the same space with other gas appliances such as a water heater ensure there is an adequate supply of combustion and ventilation air for the other appliances Refer to the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 or CSA B149 Installation Codes Sec tions 7 2 7 3 or 7 4 or applicable provisions of the local building codes for determining the combustion air requirements for the ap pliances Most homes will require outside air be 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 repro duced from the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 5 3 1 General a The provisions of 5 3 apply to gas utilization equipment installed in buildings and which require air for combustion ventilation and di lution of flue gases from within the building They do not apply to 1 direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere or 2 enclosed furnaces which 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 combustio
96. losure but not less than 100 square inches 1 lt Opening Water Heater Opening Equipment Located in Confined Spaces All Air from Inside Building See 5 3 3 a b All Air from Outdoors The confined space shall be provided with two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 BTU 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 Equipment Located in Confined Spaces All Air from Outdoors See per hour of total input rating of all equipment in the enclosure 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 lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet
97. lue Pipe Terminations for specific details on termination con struction Although non direct vent installations do not require a combustion air intake pipe a minimum of one 90 elbow should be attached to the furnace s combustion air intake f an upright installation uses the standard intake location or a horizontal installation uses the alternate air intake location This elbow will guard against inadvert ent blockage of the air intake VENT FLuE PIPE LENGTHS AND DIAMETERS Refer to the following table for applicable length elbows and pipe diameter for construction of the vent flue pipe system of a non di rect vent installation In addition to the vent flue pipe a single 90 elbow should be secured to the combustion air intake to prevent inadvertent blockage The tee used in the vent flue termination must be included when determining the number of elbows in the piping system 15 UPFLOW Non Direct Vent Single Pipe Maximum Allowable Length of Vent Flue Pipe ft ON Unit Input PiPe Number of Elbows Inch 3 1 2 7 8 45000 2 71 68 65 62 59 56 53 50 2 149 46 43 40 37 31 28 gt 3 71 65 62 59 56 53 50 90000 3 71 68 65 62 59 56 53 50 115 000 3 49 46 43 40 37 34 31 28 COUNTERFLOW Non Direct Vent Single Pipe Maximum Allowable Length of Vent Flue Pipe ft Me Unit Input PiPe Number of El
98. minals are de energized Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period Furnace awaits next call from thermostat CooLiNc The normal operational sequence in cooling mode is as follows Rand YLO G or Y G thermostat contacts close initiating a call for cool Integrated control module performs safety circuit checks Outdoor fan and compressor are energized to their appropriate speed Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile Electronic air cleaner terminals are energized with circulator blower Furnace circulator blower and outdoor cooling unit run their appropriate speed integrated control module monitors safety circuits continuously R and YLO G or Y G thermostat contacts open completing the call for cool Outdoor fan and compressor are de energized Circulator blower continues running during a cool off delay period The OFF delay time and airflow level are determined by the selected ramping profile Electronic air cleaner terminals and circulator blower are de energized e Furnace awaits next call from thermostat Fan OnLy The normal operational sequence in fan only mode is as follows Rand G thermostat contacts close initiating a call for fan Integrated control module performs safety circuit checks Circulator blower is energized on continuous fan spe
99. mmets must be relocated to left side panel For details concerning mounting of the drain trap refer to Section X Condensate Drain Lines and Drain Trap Upright Drain Trap H 2 F 10 2 0 __ INDUCED O 2 DRAFT BLOWER DRAIN PORT O HOSEB FRONT COVER HOSE A PRESSURE GREEN HOSE a CLAMPS 3 PLACES LEFT SIDE_ TUBE S 2 PANEL FRONT COVER DRAIN PORT RED HOSE CLAMP I DRAIN TRAP SIDE PANEL GROMMET HOLES Horizontal Connections Left Side Down Upflow Shown Counterflow Similar Remove the rubber cap from the side drain port on the rubber elbow Secure the short end of Hose B to rubber elbow side drain port using a green hose clamp NOTE For left side drainage route hose to far left down side panel grommet holes NOTE Horizontal left side connections when using new side port drain elbow does not require connecting a hose to the induced draft blower housing Cut 5 1 2 inches straight length from the long end of each Tube 2 Insert approximately one inch of each Tube 2 through left side panel grommet hole Secure tubes to Hose A and Hose B with a green hose clamps NOTE Tube must reach bottom of trap Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding Mounting Horizontat Dra
100. mmon roof top maintain the same minimum clearances be tween the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit If more than one direct vent furnace is to be installed horizontally through a common side wall maintain the clearances as in the fol lowing figure Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation I ABOVE 12 Min qe RE a Ne Horizontal Venting Of Multiple Units CONCENTRIC VENT TERMINATION Refer to the directions provided with the Concentric Vent Kit DC Vk for installation specifications X CON DEN SATE DRAIN LINES amp DRAIN TRAP GENERAL A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place The condensate which is generated must be piped to an appropriate drain location In upright installations the furnace s drain hoses may exit either the right or left side of the furnace NOTE If the alternate vent flue outlet is utilized in an upright installation the drain trap and drain connections must be located on the same side as the alternate vent flue outlet In horizontal installations the drain hoses will exit through the bot tom down side of the unit with the drain trap suspended beneath the fur
101. n air entering the furnace is between 55 F and 100 F when the furnace is heating Provide provisions for venting combustion products outdoors through a proper venting system Special consideration should be given to vent flue pipe routing and combustion air intake pipe when applicable Refer to Section IX Vent Flue Pipe and Combustion Air Pipe Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given NOTE The length of flue and or combustion air piping can be a limiting factor in the location of the furnace Locate the furnace so condensate flows downwards to the drain Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection Refer to Section X Condensate Drain Lines and Trap for further details Ensure adequate combustion air is available for the furnace Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide Refer to Section V Combustion and Ventilation Air Requirements Setthe furnace on a level floor to enable proper condensate drainage If the floor becomes wet or damp at times place the furnace above the floor on a concrete base sized approximately 1 1 2 larger than the base of the furnace Refer to the Section VII Horizontal Applications an
102. n factors 1 Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended for both cost and efficiency 3 Pressure drop in lines between regulators and between second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization recom mended regulator settings and pipe sizing is available from most regulator manufacturers and propane gas suppliers Since propane gas will quickly dissolve white lead and most stan dard commercial compounds special pipe dope must be used Shel lac based compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic Clyde s or John Crane are satisfactory Refer to the following illustration for typical propane gas installa tions 5 to 15 PSIG 20 PSIG Max First Stage Regulator Continuous 11 W C 200 PSIG Second Stage Maximum Propane Gas Installation Typ Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Nominal Pipe Size Tubing Size O D Type L Schedule 40 1 2 3 4 3 200 7 500 20 1 100 2 200 2 200 4 200 2 900 4 700 1 800 4 000 40 370 850 1 700 2 700
103. n of gas proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use Equipment shall be located so as not to interfere with proper circulation of air When normal infiltration does not provide the necessary air outside air shall be introduced 9 c In addition to air needed for combustion process air shall be pro vided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilution safety exhaust odor control and air for compressors d In addition to air needed for combustion air shall be supplied for ventilation including all air required for comfort and proper work ing conditions for personnel e While all forms of building construction cannot be covered in de tail air for combustion ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5 3 3 and 5 3 4 f Air requirements for the operation of exhaust fans kitchen ventila tion systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air re quirements 5 3 2 Equipment Located in Unconfined Spaces In unconfined spaces see definition below in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of tight construction for
104. nace The field supplied drain system must be in accordance with all local codes and the instructions in the following sections IN UPRIGHT UPFLOW INSTALLATIONS THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK Follow the bullets listed below when installing the drain system Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups The drain trap supplied with the furnace must be used The drain line between furnace and drain location must be constructed of 3 4 PVC or CPVC The drain line between furnace and drain location must maintain a 1 4 inch per foot downward slope toward the drain Do not trap the drain line in any other location than at the drain trap supplied with the furnace Do not route the drain line outside where it may freeze If the drain line is routed through an area which may see temperatures near or below freezing precautions must be taken to prevent condensate from freezing within the drain line If an air conditioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressur
105. nges and correspond ing manufacturer s high altitude Natural propane gas and or Pres sure Switch kits Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate The com bination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner This may cause incomplete combustion flashback and possible yellow tipping In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If the gas is artifi cially derated the appropriate orifice size must be determined based upon the content of the derated gas and the altitude Refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and infor mation provided by the gas supplier to determine the proper orifice size A different pressure switch may be required at high altitude regard less of the BTU ft content of the fuel used Contact your distributor for a tabular listing of appropriate altitude ranges and correspond ing manufacturer s pressure switch kits PROPANE GAS CONVERSION POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This unit is configured
106. nsate to the furnace s drain system Allowances should be made for minor expansion and contraction due to temperature variations For this reason particu lar care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches Precautions should be taken to prevent condensate from freezing inside the vent flue pipe and or at the vent flue pipe termination All vent flue piping exposed to freezing temperatures below 35 F for extended periods of time must be insulated with 1 2 thick closed cell foam Also all vent flue piping exposed outdoors in excess of the terminations shown in this manual or in unheated areas must be insulated with 1 2 thick closed cell foam Inspect piping for leaks prior to installing insulation TERMINATION LOCATIONS NOTES Refer to Section IV Location Requirements and Considerations for combustion air contaminant restrictions The following bullets and diagram describe the restrictions concern ing the appropriate location of vent flue pipe and combustion air intake pipe when applicable terminations Refer to Non Direct Vent Single Pipe Piping and Direct Vent Dual Pipe Piping located in this section for specific details on termination construction 12 All terminations flue and or intake must be located at least 12 inches above ground level or the anticipated snow level Vent terminations non direct and direct vent must terminate at least 3 feet above any f
107. nute at 100 of the cooling demand airflow 10096 CFM 10096 CFM OFF OFF Cooling E 1 min Demand Profile B ramps up to full cooling demand airflow by first stepping up to 50 of the full demand for 30 seconds The motor then ramps to 100 of the required airflow A one 1 minute OFF delay at 100 of the cooling airflow 100 CFM OFF 100 gt OFF 50 1 2 min lt 31 min Cooling Demand e Profile C ramps up to 82 of the full cooling demand airflow and operates there for approximately 7 1 2 minutes The motor then steps up to the full demand airflow Profile C also has a one 1 minute 100 OFF delay 82 7 1 2 min 100 100 CFM OFF 1 min Cooling Demand Profile D ramps up to 50 of the demand for 1 2 minute then ramps to 82 of the full cooling demand airflow and operates there for approximately 7 1 2 minutes The motor then steps up to the full demand airflow Profile D has a 1 2 minute at 50 airflow OFF delay 82 CFM gt OFF 50 CFM 1 2 min 7 1 2 min 100 CFM 5096 CFM OFF 1 2 min c Cooling Demand
108. or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor Loss of flame after establishment Cause may be interrupted gas supply lazy burner flames improper gas pressure or restriction in flue and or combustion air piping front cover pressure Switch opening or improper induced draft blower performance Induced draft blower pressure switch contacts sticking Shorts in pressure switch circuit Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain system or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning Switch contacts Loose or improperly connected wiring Integrated control module will automatically attempt to reset from lockout after one hour 37 Corrective Action Assure 115 and 24 volt power to furnace integrated control module Check integrated control module fuse 3A Replace if necessary Check for possible shorts in 115 and 24 volt circuits Repair as necessary Replace bad integrated control module Check thermostat connections and settings Locate and correct gas interruption Check front cover pressure switch operation hose wiring contact operation Correct if necessary Replace or realign igniter Check flame sense signal Sand sensor if coated and or oxidized Check flue piping for blockage proper
109. orced air inlet located within 10 feet NOTE This provision does not apply to the combustion air intake termination of a direct vent application The vent termination of a non direct vent application must terminate at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building door window or gravity air inlet The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line or the anticipated snow level and be at least 12 inches from any vertical wall including any anticipated snow build up A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty Non Direct Vent amp Direct Vent Vent Flue Terminations Non Direct Vent Vent Flue Termination No Terminations Above Walkway Grade or Highest Anticipated Snow Level eae Vent Vent Flue Termination Forced Air Inlet Direct Vent Vent Flue Termination Vent Termination Clearances NOTE In Canada th
110. ore Leaving an Installation seen nennen menn nna nnmnnn ennnen nnn asas mn Rusia 35 XXII Repair amp Replacement Parts 35 APPENDIX Troubleshooting Chart duck Ux DU On v ecu cn UE UR pene uoc CUN 37 Wiring Diagram Mem 39 AQ Warnine IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE Do NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WHAT TO DO IF YOU SMELL GAS Do NOT TRY TO LIGHT ANY APPLIANCE Do NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER AQ WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY DANGER PELIGRO SL CARBON MONOXIDE POISONING HAZARD Spec
111. outdoors Refer to the Section V Combustion and Ventilation Air Requirements for details If the furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling unit Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace If the furnace is installed in a residential garage position the furnace so that the burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the furnace from physical damage by vehicles If the furnace is installed horizontally the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger Do not install the unit with the access doors on the up top or down bottom side of the furnace CLEARANCES AND ACCESSIBILITY Installations must adhere to the clearances to combustible materi als which this furnace has been design certified to The minimum clearance information for this furnace is provided on the unit s clear ance label These clearances must be permanently maintained Clearances must also accommodate an installation s gas electri cal and drain trap and drain line connections If the alternate com bustion air intake or vent flue connections are used additional clear ance must be provided to accommodate these connections Refer to Section IX Vent Flue Pipe and Combustion Air Pipe for details NOTE In addition to the required clearances
112. ower speed is set at D These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM Use the CFM LED green adjacent to the integrated control mod ule fuse to verify airflow quantity The green CFM LED blinks once for each 100 CFM of airflow 1 Determine the tonnage of the cooling system installed with the furnace If the cooling capacity is in BTU hr divide it by 12 000 to convert capacity to TONs Example Cooling Capacity of 30 000 BTU hr 30 000 12 000 2 5 Tons 2 Determine the proper air flow for the cooling system Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton Most manufacturers recommend an air flow of about 400 CFM per ton Example 2 5 tons X 400 CFM per ton 1000 CFM The cooling system manufacturer s instructions must be checked for required air flow Any electronic air cleaners or other devices may require specific air flows consult installation instructions of those devices for requirements 3 Knowing the furnace model locate the high stage cooling air flow charts in the Product Data Book applicable to your model Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting Example MV90704BXA furnace installed with a 2 5 ton air conditioning system The air flow needed is 1000 CFM Looking at the cooling
113. ower and increase the outlet air temperature delivered to the home The speeds available allow the blower performance to be optimized for the particular homeowner s needs Brower Heat Orr DeLay TiMINGS The integrated control module provides a selectable heat off delay function The heat off delay period may be set to 90 120 150 180 seconds using the DIP switches or jumper provided on the control module The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and or homeowner pref erence Refer to the following figures for switch positions and corre sponding delay times 3 Heat Off Delay gt 90 Seconds 3 Heat Off 2 Delay OFF Ei 120 Seconds 3 Heat Off 2 Delay ON BH 1 150 Seconds 3 Heat Off OFF 2 Delay OFF M 180 Seconds Heat Off Delay indicates factory setting Heat Off Delay Switches XV NORMAL SEQUENCE OF OPERATION Power Up The normal power up sequence is as follows 115 VAC power applied to furnace e Integrated control module performs internal checks e Integrated control module flashes LED one time Integrated control module monitors safety circuits continuously Furnace awaits call from thermostat HEATING The normal operational sequence in heating mode is as follows
114. per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating HTG value 1 000 BTU ft Obtained from gas supplier Installation s seconds per cubic foot 34 sec ft Conversion Factor hours to seconds 3600 sec hr Input Htg value x 3600 seconds per cubic foot Input 1 000 BTU ft x 3600 sec hr 34 sec ft Input 106 000 BTU hr Minor changes to the input rate may be accomplished through mani fold pressure adjustments at the gas valve Refer to Section XIV Startup Procedure and Adjustment Gas Manifold Pressure Mea surement and Adjustment for details NOTE The final manifold pressure cannot vary by more than 0 3 w c from the specified setting Consult your local gas supplier if additional input rate ad justment is required 5 Repeat steps 2 through 4 on high stage 6 Turn ON gas to and relight all other appliances turned off in step 1 Be certain that all appliances are functioning properly and that all pilot burners are operating TEMPERATURE RISE Temperature rise must be within the range specified on the unit rat ing plate An incorrect temperature rise may result in condensing in or overheating of the heat exchanger An airflow and temperature rise table is provided in the Product Data Book applicable to your model Determine and adjust temperature rise as follows 1 Operate furnace with burners firing for approximately
115. r appropriate installation positions ductwork connections and resulting airflow arrangements Vil HORIZONTAL APPLICATIONS amp CONSIDERATIONS GENERAL Horizontal applications in particular may dictate many of the installation s specifics such as airflow direction ductwork connec tions flue and combustion air pipe connections etc The basic ap plication of this furnace as a horizontal furnace differs only slightly from an upright installation When installing a furnace horizontally additional consideration must be given to the following gt 4 FURNACE MUST LEVEL FROM END TO END ALTERNATE VENT FLUE AND COMBUSTION AIR INTAKE LOCATIONS GAS LINE WITH DRIP LEG 3 MINIMUM DRAIN PAN DOWNWARD SLOPE FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE CLEARANCE REQUIRED Horizontal Furnace DRAIN TRAP AND LINES In horizontal applications the condensate drain trap is secured to the furnace side panel suspending it below the furnace A mini mum clearance of 4 3 4 inches below the furnace must be provided for the drain trap Additionally the appropriate downward piping slope must be maintained from the drain trap to the drain location Refer to Section X Condensate Drain Trap and Lines for further details If the drain trap and drain line will be exposed to tempera tures near or below freezing adequate measures must be taken to prevent condensate from freezing LEVELING Leveling ensures proper
116. ry receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 With concealed damage carrier must be notified as soon as possible preferably within five days 4 File the claim with the following support documents within a nine month statute of limitations Original or certified copy of the Bill of Lading or indemnity bond Original paid freight bill or indemnity in lieu thereof Original or certified copy of the invoice showing trade and other discounts or reductions Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage Keep this literature in a safe place for future reference BLOWER COMPARTMENT BURNER COMPARTMENT 1 COMPONENT IDENTIFICATION n po a a a oa on
117. s manual the precautions listed here take precedence NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual Amana is a trademark of Maytag Corporation and is used under license to Goodman Company L P All rights reserved www amana hac com IO 253F 2004 2005 Goodman Company L P Effective November 2005 Table of Contents Berenice 5 STORY 6 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS ssiscsesensantnasnsinsuedenusnensasncunsdenecnaghvancuseeeueavatannsdiudeetsnsasanceadeueantaanis 6 Product Application me 6 IV Location Requirements amp Considerations 7 CJ I MEETICIT TIC ICI HEX 7 7 CLEARANCES AND ACCESSIBILITY seccccsnsesecccesscecscnnnseceensnssesecenensseeennnesanensoeseeseonnasescnenansuseensosssseonosnesecennossssecoansen 8 FURNACE SUSPENSION canna CRRR YER SRSUSSNECE SRERARESRESREEERERESRERIERSARENN IPSE 8 EXISTING FURNACE REMOVAL
118. sition 3 Close the manual gas shutoff valve external to the furnace 4 Replace the burner compartment door Gas SupPPLv Pressure MEASUREMENT To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Wuite Ropcers 36G54 Gas VALVE The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be measured at the gas valve inlet pressure boss or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following procedure 27 Open to eed Atmosphere Hose w High Fire Regulator Outlet Adjust Regulator Pressure Boss x Vent g X s 6 S V Low Fire Regulator Adjust CA 5 J Pressure Boss High Fire f 1 1 Manometer Coil Terminal HI On Off Switch Common Terminal C White Rodgers Model 36G54 Connected to Manometer 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pressure boss or the gas piping drip leg Gas Line Gas Shutoff
119. speed chart for MV90704BXA find the air flow closest to 1000 CFM A cooling airflow of 990 CFM 29 can be attained by setting the cooling speed to C and the adjustment to minus NOTE Continuous Fan Speed will be 56 of high stage cooling 4 Locate the blower speed selection DIP switches on the integrated control module Select the desired cooling speed tap by positioning switches 1 and 2 appropriately Select the desired adjust tap by positioning switches 3 and 4 appropriately Refer to the following figure for switch positions and their corresponding taps Turn off power to furnace for a minimum of 10 seconds allowing motor to reset and recognize new speed selection Turn on power to furnace Verify CFM by counting the number of times the green CFM LED blinks
120. sscsseecseeccscccecsccescecseccscusecccscxscosissscenscduevedzexseenerscaveceaneces 16 VENT INTAKE TERMINATIONS FoR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES eene nnn nnne 18 CONCENTRIC VENT TERMINATION 18 X Condensate Drain Lines amp Drain Trap s sisien disinni Conner neniace e cutie 18 jul M M OP N 18 UPRIGHT INSTALLATIONS ices cix ua ER arcus ER Pan CERE EXESR CEN NS RNEESRESRAREREEBARKEYRRSST RFSSERNIUA 18 HORIZONTAL INSTALLATIONS 5 5522223222525 222253 ciam R5 22x EE n ERR RR EXER SERERRRRERREEAERE RESKREAERASENNR RENE 19 XI Electrical GonnectlOLFis eror n an unii a Dn iu a n cin a i er cr ra da nu eu n c a ESAE AEE 20 WIRING FIARNESS 22 A EUER Kin 21 115 LINE CONNECTIONS 1 5 0 131 aon Cue EM NN aERNHE 21 24 VOLT THERMOSTAT WIRING
121. ten minutes Ensure all registers are open and all duct dampers are in their final fully or partially open position 2 Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger HEAT EXCHANGER RADIATION LINE OF SIGHT SUPPLY gt AIR RISE Tguppy TreTurn lU RETURN AIR Temperature Rise Measurement 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 4 Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Refer to Section XIV Startup Procedure and Adjustment Circulator Blower Speeds for speed changing details CIRCULATOR BLOWER SPEEDS To AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS This furnace is equipped with a multi speed circulator blower This blower provides ease in adjusting blower speeds The Product Data Book applicable to your model provides an airflow table showing the relationship between airflow CFM and external static pressure E S P for the proper selection of heating and cooling speeds The heating blower speed is shipped set at B and the cooling bl
122. th A heat pump thermostat with three stages of heat is required to properly use a two stage furnace in conjunction with a heat pump Refer to the fossil fuel kit installation instructions for additional thermostat requirements Strictly follow the wiring guidelines in the fossil fuel kit instal lation instructions All furnace connections must be made to the furnace two stage integrated control module and the FURNACE terminal strip on the fossil fuel control board 115 Line oF Accessories HUMIDIFIER AND ELECTRONIC AIR CLEANER To AVOID INJURY ELECTRICAL SHOCK OR DEATH DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING The furnace s integrated control module is equipped with line volt age accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows 1 0 Amp maximum at 120 VAC Electronic Air Cleaner 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any accessories Follow the humidifier or air cleaner manufacturers instructions for locating mounting grounding and controlling these accessories 22 Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the furnace integrated control mod ule The humidifier and electronic air cleaner hot and neutral termi nals are identified as HUM and EAC All f
123. the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continu ously e Test for draft hood equipped spillage at the draft hood relief open ing after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above re turn doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use If improper venting is observed during any of the above tests the common venting system must be corrected Corrections must be in accordance with the latest edition of the Na tional Fuel Gas Code NFPA 54 ANSI Z223 1 and or CSA B149 In stallation Codes If resizing is required on any portion of the venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CSA B149 Installation Codes THERMOSTAT LOCATION The thermostat should be placed approximately five feet fom the floor on a vibration free inside wall in an area having good air circu lation Do not install the thermostat where it may be influenced by any of the following Drafts or dead spots behind doors in corners or under cabinets e Hot or cold air from registers e Radiant heat from the sun e Light fixtures or other appliances Radiant heat from
124. tion air intake pipe from the furnace and cut the pipe at the basepan coupling Save the basepan coupling and gasket from the blower deck coupling for use in the alternate location Discard the remaining pipe 3 Remove plastic plug from alternate combustion air intake location Relocate and install plug in standard air intake location top cover Counterflow units Remove plastic plug from alternate combustion air intake location Relocate and install plug in standard air intake location basepan Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag 4 Upflow and Counterflow units With the gasket facing the cabinet side panel and the flange s flat spot facing forward secure the combustion air intake coupling to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws A caution BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS 5 Upflow and Counterflow units For non direct vent installations installed horizontally a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage No elbow is required on the alternate combustion air intake of upright installations however a minimum clearance of 2 inches is required to assure proper air supply 6 Upflow and Counterflow units For direct vent installations secure field supplied combustion air
125. wer and the coil front cover These switches guard against insufficient airflow combus tion air and flue products through the heat exchanger and or blocked condensate drain conditions FLAME SENSOR The flame sensor is a probe mounted to the burner manifold as sembly which uses the principle of flame rectification to determine the presence or absence of flame XVIII TROUBLESHOOTING Evectrostatic DiscHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and ser vicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electro static potential these steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is appli cable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnaces near the control Any tools held in a person s hand during grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with st
126. witch the induced draft blower gas valve and circulator blower to their high stage settings e If the two stage thermostat changes the call from high heat to low heat the control will immediately switch the induced draft blower and gas valve to their low stage settings The circulator blower will remain on high heating speed for thirty 30 seconds before switching to the low heat circulating speed W1 or R and W1 W2 thermostat contacts open completing the call for heat Gas valve closes extinguishing flame Induced draft blower is de energized following a fifteen second post purge Humidifier terminals are de energized Circulator blower continues running for the selected heat off delay period 90 120 150 or 180 seconds The speed run during this period depends on the last heat call provided by the thermostat If the last call for heat was a call for low heat the air circulator motor will run on low heat speed for the duration of the heat off delay period 90 120 150 or 180 seconds If the last call for heat was a call for high heat the air circulating motor will run on the high heating speed for thirty 30 seconds NOTE Please contact your distributor or our website for the applicable product data book referred to in this manual 31 and then switch to the low heating speed for the balance of the heat off delay period 60 90 120 or 150 seconds Circulator blower and electronic air cleaner ter

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