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1. WARNING DISCONNECT POWER BEFORE INTEGRATED SERVICING WIRING TO UNIT MUST BE CONTROL MODULE PROPERLY POLARIZED ANDGROUNDED TXEMR 6 uo S 1 24VAC NPE 12 HUMIDIFIER MVC 9 MVH 12 E J 1 lt IDBLOWER D D E D AUXILIARY r PRESSURE LIMIT CONTROLS SWITCH G R Ww N S 5 6 Psm AUTO B Pope aK CT Psom 150SEC 27 1005 5 3 6 02 FRO 5 6 MICRO HLI 7 WH Q F 9 AB BL 5 HLO 1 g FUSE 5 AUTO RESET Moe J 1552 L PRIMARY SEE NOTE 6 95 8 RO2 11 LIMIT AUXILIARY CONTROL BR LIMITS RO1 5 INTEGRATED zay CO
2. Proper Chimney Line terminate with Termination No listed vent cap Check 1 Fix 1 Yes Chimney channel free of solid and Change venting liquid fuel No arrangements appliances Fix 2 Check 2 Yes Rebuild crown Crown in good Fix 3 condition No and or Reline Check 3 Fix 4 Yes Cleanout free of Reline debris No 4 Liner good condition No INS Check 5 Fix 4 Yes Dilution air Reline available No Check 6 Yes Complete the installation Check 7 13 CHECK 1 PROPER CHIMNEY TERMINATION A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it passes through the roof It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet In addition the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet The chimney must extend at least five feet above the highest connected equip ment draft hood outlet or flue collar If the chimney does not meet these termination requirements but all other requirements in the checklist can be met it may be possible for a mason to exte
3. Zz gt For problems a b or c see Fix 3 If problems d e or f are present see Fix 4 IMPORTANT It may be necessary to follow both Fix 3 and Fix 4 4 DEBRIS INCLEANOUT A cleanout dropleg must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening Achimney without a cleanout could become partially blocked by debris If no cleanout is present the chimney must be re lined Fix 4 Remove the cleanout cover and examine the cleanout for debris If significant amounts of any of the following are found Fuel oil residue e Bricks e Mortar or sand e Pieces of the tile liner e Rusted pieces of the metallic liner reline the chimney Fix 4 5 LINER CONDITION If a metal liner is present it must be checked It cannot be assumed that all existing metal liners are correctly installed and in good condition Remove the lowest existing vent connector and examine the inside of the elbow or tee at the base of the liner Asmall amount of soot may be considered acceptable provided the installer vacuums it away If rusted pieces of the liner have collected here the metal liner must be removed and replaced Fix 4 Next gently tap the inside of the liner with a Phillips screw driver If the screwdriver perforates the liner or if the tapping does not sound like metal hitting metal the liner mus
4. NOTES COLOR CODES PK PINK YL YELLOW BR BROWN OR ORANGE WH WHITE PU PURPLE BL BLUE RATING OF AT LEAST 105 GR GREEN GY GRAY BK BLACK RD RED 0140F00662 REV A 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS 2 MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE C USE COPPER CONDUCTORS ONLY 4 BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE CORRECT COOLING CFM SEE SPEC SHEET FOR AIR FLOW CHART 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES 6 TO RECALL THE LAST 5 FAULTS MOST RECENT TO LEAST RECENT DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY NO THERMOSTAT INPUTS 45 Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring THIS PAGE LEFT INTENTIONALLY BLANK 46 THIS PAGE LEFT INTENTIONALLY BLANK 47 NOTE SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE Quality Makes the Difference All of our systems are designed and manufactured with the same high quality standards regardless of size or effi ciency We have designed these units to significantly reduce the most frequent causes of product failure The
5. AN O Honeywell Model VR9205 Connected to Manometer Outlet Pressure Tap 1 8 NPT 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connecta calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pressure boss or the gas piping drip leg See Honeywell VR9205 gas valve figure or White Rodgers 36G54 gas valve figure for location of inlet pressure boss NOTE If measuring gas pressure at the drip leg or Honeywell VR9205 gas valve a field supplied hose barb fitting must be installed prior to making the hose connection If using the inlet pressure boss on the White Rodgers 36G54 gas valve then use the 36G Valve Pressure Check Kit Goodman Part No 0151K00000S 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 27 4 Measure furnace gas supply pressure with burners firing Consult the appliance rating plate to ensure burner manifold Supply pressure must be within the range specified in pressure is as specified If another outlet pressure is required the Inlet Gas Supply Pressure table follow these steps INLET GAS SUPPLY PRESSURE 1 Turn OFF gas to furnace at the manual gas shutoff valve Natural Gas Maximum 10 0 w c external to the furnace 11 0 w c M 2 Turn OFF all electrical power to the system aximum 13 0 w c 3 Outlet pressure tap connections If supply press
6. JUNCTION o RD PRIMARY LIMIT 7 YL PRESSURE YL SWITCH DISCONNECT POWER BEFORE SERVICING DISCONNECT WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH E z gt 2 a lt n x 2 gt 4 N 2 L m x z 4 lt o 2 2 o 2 H gt x M1 C2 SURFACE IGNITER FLAME SENSOR GAS VALVE WARNING STEADY ON OFF COLOR CODES YL YELLOW OR ORANGE PU PURPLE GR GREEN BK BLACK 0140F00119 REV A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 3 FLASHES 4 FLASHES 5 FLASHES 6 FLASHES OPEN ROLLOUT 7 FLASHES SINGLE CONTROL ON SOME MODELS NORMAL OPERATION CONTROL FAILURE 1 FLASH SYSTEM LOCKOUT RETRIES RECYCLES EXCEEDED 2 FLASHES PRESSURE SWITCH STUCK CLOSED PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT FLAME SENSE WITHOUT GAS VALVE LOW FLAME SIGNAL RAPID FLASHES REVERSED 115 VAC POLARITY VERIFY GND PK PINK NOTES L GND N TO 115 B 60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE JUNCTION BOX INDUCED D
7. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP SAFETY CIRCUIT DESCRIPTION GENERAL A number of safety circuits are employed to ensure safe and proper furnace operation These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function These circuits are con tinuously monitored during furnace operation by the integrated control module INTEGRATED CONTROL The integrated control module is an electronic device which controls all furnace operations Responding to the thermostat the module initiates and controls normal furnace operation and monitors and addresses all safety circuits If a potential safety concern is detected the module will take the necessary pre cautions and provide diagnostic information through an LED PRIMARY The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures It is an automatic reset temperature sensor The limit guards against the overheating resulting from insufficient air passing over the heat exchanger AUXILIARY The auxiliary limit control is located either on or near the circu lator blower and monitors heat exchanger compartment tem peratures The control is an automatic reset temperature sensor It guards against overheating resulting from insufficient air passing over the heat exchanger RoLL
8. 2 sus usiisai as is is ski ss ius sasas iu sausasis ses da i das asai a skio i da a a das a Gas asi Garsas a as aa es ssi as 36 TROUBLESHOOTING CHART 37 PAPE NID 5 a s 37 TROUBLESHOOTING CHART 37 TROUBLESHOOTING CHART 38 TROUBLESHOOTING CHART 39 BLOWER PERFORMANCE DATA 40 PIV CIPS RARETAT Las ais as sa aaa sa aa E AB ves case SN Oe E Es a La a 40 a DYA a a eee ob us O ua a amato e E Oa a a P E AA 41 BLOWER PERFORMANCE DATA ccssccseeceecceeccusecueeccunseeusecuaeenaseeuaeeueenuneeuseesuaseeusesuaeenaeeeuuseuseseesssussesnaes 42 ias E ui led anh AN ct eh e cee Ch heer eae 42 WIRING DIAGRAMS iii S 43 MD A S 6 WIRING DIAGRAM sasas a i i a as SE A 43 GME8 WIRING 44 CU DJHG WIRING DIAGRAM lt sus a ossis sanis kub asai aa a a A a a a aa 45 SAFETY PRECAUTIONS Adhere to the following warnings and cautions when installing adjusting altering servicing or operating the furnace To ensure proper installation and operation thoroughly read this manual for specifics pertaining to the installation and application of this product WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FOR
9. and or consult with local gas utility INLET GAS SUPPLY PRESSURE Outlet Pressure Natural Gas Minimum 4 5 w c Maximum 10 0 w c Minimum 11 0 w c Maximum 13 0 w c 9 Turn OFF all electrical power and gas supply to the system 10 Remove the manometer hose from the hose barb fitting or inlet pressure boss 11 Replace inlet pressure tap a Honeywell VR8215 valve Remove the 1 8 NPT hose barb fitting from the inlet pressure tap Replace the inlet pressure boss plug and seal with a high quality thread sealer White Rodgers Model 36G22 26 b White Rodgers 36G22 valve Turn inlet pressure test screw in to seal pressure port clockwise 7 in Ib minimum 12 Retest for leaks If bubbles form shut down gas and repair leaks immediately 13 Turn ON electrical power and gas supply to the system 14 Turn valve switch ON usiNG Two STAGE GAs VALVES A caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR 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 ata hose fitting installed in the gas piping drip leg The supply pressure must b
10. 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 VoLT THERMOSTAT WIRING NOTE Wire routing must not interfere with circulator blower operation filter removal or routine maintenance Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located in the blower compartment The following figure shows con nections for a heat only system and heat cool system Heating Heating Cooling Room Room Thermostat Thermostat M 160 00000 R Remote Condensing Furnace Furnace Unit Control Control Typical Field Wiring 24 VAC Control Circuit 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 A single stage thermostat with only one heating stage can be used to control this furnace GME8 Furnace witH 2 STAGE CONDENSER FIELD WIRING The GME8 model furnaces may be used with a 2 stage outdoor ai
11. positioned in burner flame e Lazy burner flame due to improper gas pressure or combustion air Corrective Action Check primary limit Replace if necessary Check filters and ductwork for blockage Clean filters or remove obstruction Check circulator blower speed and performance Correct speed or replace blower if necessary Tighten or correct wiring connection Correct short at flame sensor or in flame sensor wiring e Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check rollout limit Replace if necessary Check induced draft blower for proper performance Replace if necessary Tighten or correct wiring connection Repair short in 24 volt AC control safety circuit s Replace integrated control module fuse 3A Sand flame sensor Inspect for proper sensor alignment Compare current gas pressure to rating plate info Adjust as needed ower to the control module is interrupted through the disconnect or door switch 38 Cautions amp Notes Turn power OFF prior to repair Replace primary switch with proper replacement part Replace blower with correct replacement part Turn power OFF prior to repair See Vent Flue Pipe section for piping details Replace induced draft blower with proper replacement part Repla
12. 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 Gas SUPPLY AND PIPING The furnace rating plate includes the approved furnace gas in put rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any conver sion kits required for alternate fuels and or high altitude Ay caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified in the following table The supply pressure must be constant and available with all other household gas fired appli ances operating The minimum gas supply pressure must be maintained to prevent unreliable ignition The maximum must not be exceeded to prevent unit overfiring INLET GAS SUPPLY PRESSURE Natural Gas Maximum 10 0 w c Minimum 11 0 w c Maximum 13 0 w c NOTE Adjusting the minimum supply pressure below the limits in the above table could lead to unreliable ignition Gas input to the burners must not exceed the rated input shown on the rating plate Overfiring of the furnace can result in premature heat exchanger failure Gas pressures in excess of 13 inches water column can also cause permanent damage to the gas valve At all alt
13. ther lubrication is required Check motor windings for accumu lation of dust which may cause overheating Clean as neces Sary FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will lock out The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool Following cleaning the flame sense signal should be 1 to 6 microamps at 115 volts IGNITER QUALIFIED SERVICER ONLY If the igniter and the surrounding air are at about 70 F and the igniter wires are not connected to any other electrical compo nents the resistance of the igniter should not exceed 75 ohms If it does the igniter should be replaced BURNERS Aywarnine TO PREVENT PERSONAL INJURY OR DEATH DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP Periodically during the heating season make a visual check of the burner flames Turn the furnace on at the thermostat Wait a few minutes since any dislodged dust will alter the normal flame appearance Flames should be stable quiet soft and blue with slightly orange ti
14. 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 Aywarnine 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 2 DANGER PELIGRO CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas Carbon monoxide producing devices such as an automobile space heater gas water heater etc should not be operated in enclosed areas such as unventilated garages utility rooms or parking areas because of the danger of 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 ser
15. C AND LOCAL CODES 6 TO RECALL THE LAST 5 FAULTS MOST RECENT TO LEAST RECENT DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY NO THERMOSTAT INPUTS 0140F00658 REV A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 44 M D H8 Wirinc DIAGRAM lt H o gt I E z D 2 z lt gt n x o gt 14 N x L m x 4 a lt o 2 o 2 MULTIPLE POWER SOURCES MAY PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH WARNING RAPID FLASHES REVERSED 115 VAC POLARITY VERIFY GND PLUG C
16. Furnace OPERATING DH8 ME8 AND MH8 moDELs ONLY This furnace is designed to operate with either a single gas input rate or with two discrete gas input rates The Mode DIP switch is used to select the single gas input rate or two discrete input rates Setting the Mode switch to 1 STG forces furnace to oper ate at the furnace s highest input rate only Operation is as described under Sequence of Operation Integrated Ignition Control Mode DIP Switch is set to 1 STG position 30 Setting the Mode switch to 2 STG allows the furnace to oper ate at the furnace s highest input AND at an input rate that is 75 of the highest input rate For this mode of operation the furnace operates at the low input rate for a pre determined time period then steps to the high input rate Operation is as described under Sequence of Operation Integrated Ignition Control Mode DIP Switch is set to 2 STG position The time period is determined by the 2 4 Stg Dly DIP switch Setting the 2 Stg Dly DIP switch to 5 minutes fixes the delay period at 5 minutes Setting the 2 Stg Dly DIP switch to Auto enables an algorithm that calculates a delay period based on the heating cycle time and the total cycle time The delay period can range from 1 minute to 12 minutes OFF ON MODE 25 6 1 sta 2 STG 5 mj AUTO OPERATIONAL CHECKS TO AVOID PERSONAL INJURY OR DEATH DO NOT REMOVE ANY INTER
17. Joint Pipe Union Height Required By Local Code Ground Joint Pipe Union To Be Installed Ahead of Gas Valve Drip Leg Reducing Coupling 1 2 x 1 8 with 1 8 Pipe Plug to Measure Line Gas Pressure General Furnace Layout UPFLOW INSTALLATIONS A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 to another pipe size When the gas piping enters through the left side of the furnace the installer must supply the following fittings starting from the gas valve Straight pipe to reach the exterior of the furnace e Aground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installer may also need to supply a transition piece from 1 2 inch to another pipe size CouNTERFLOW INSTALLATIONS When the gas piping enters through the left side of the furnace the installer must supply a straight pipe to reach the exterior of the furnace A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In most cases the installer may also need to supply a transition piece from 12 to another pipe size Gas PIPING CHECKS Before placing unit in operation leak test the unit and gas con nections Ay warnine TO AVOID THE POSSIBILITY OF EXPLOS
18. OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT USE THE PROPER SIZE OF NATURAL PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER TANK TO THE FURNACE When sizing a trunk line be sure to include all appliances which will operate simultaneously The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of the run The gas line installation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code NFPA54 ANSI 2223 1 Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH Length of Nominal Black Pipe Size C o o 5 500780 5 Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas BTUH Furnace Input Heating Value of Gas BTU Cubic Foot To connect the furnace to the building s gas piping the installer must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size 20 The following stipulations apply when connecting gas piping Use black iron or steel pipe and fittings for the building piping Use pipe joint compound on male threads only Pipe joint compound must be resistant to the action of the fuel used Use ground joint unions Install a drip leg t
19. air cleaner hot terminal is identified as EAC H and the neutral terminal is identified as NEUTRAL All field wiring must conform to applicable codes Connections should be made as shown in the following illustra tion Control Module Neutral 120 VAC lt Air Cleaner Hot 120 VAC Transformer Transformer Optional Accessories GME8 GDH8 8 A GMH8 MODELS ONLY If it is necessary for the installer to supply additional line volt age 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 electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized 18 24 Vac HUMIDIFIER The yellow wire connected to I D Blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control Remove the yellow wire and con necta field supplied jumper wire with a piggyback terminal to the pressure switch terminal Reconnect the yellow wire to the piggyback terminal on the jumper wire and then connect the 24 VAC line of the humidifier to the stripped end of the jumper wire Using a wire nut or a field supplied quick connect terminal can make this connection The wiring must conform to all local and national codes Connect the COM side of the humidifier to
20. in sequence is as follows R and W thermostat contacts close initiating a call for heat Integrated control module performs safety circuit checks Induced draft blower is energized for 15 second prepurge period causing pressure switch contacts to close Igniter warm up begins after 15 second prepurge expires Low and high stage gas valves open at end of igniter warm up period delivering gas to burners and establishing flame High stage gas valve closes after five seconds low stage gas valve remains open Integrated control module monitors flame presence Gas valve will remain open only if flame is detected Circulator blower is energized on low heat speed following a fixed thirty second blower on delay Electronic air cleaner terminals are energized with circulator blower Furnace is now operating in low stage heating mode Furnace operates integrated control module monitors safety circuits continuously If low stage delay period expires control will shift operation from low stage heating mode operation to high stage heating mode operation Control will energize circulator blower high heat speed and high stage gas valve Furnace is now operating in high stage heating mode R and W thermostat contacts open completing the call for heat Induced draft blower is de energized following a fifteen second post purge Circulator blower is de energized following a heat off delay period selectable 100 or 150 seconds factory se
21. provides no signal Blown fuse or circuit breaker Furnace fails to operate Integrated control module has an internal fault Furnace lockout due to an excessive number of ignition attempts 3 total e Furnace fails to operate Integrated control module diagnostic LED is flashing ONE 1 flash TFLASH Auxiliary Limit Open Pressure switch circuit is closed Furnace fails to operate we 2 e Integrated control module diagnostic LED is flashing TWO 2 flashes Induced draft blower gt FLASHES 15 not operating Induced draft blower runs continuously with no further furnace operation Pressure switch circuit not closed e Induced draft blower is operating Integrated control module FLASHES diagnostic LED is flashing THREE 3 flashes If installed manual reset limit switch is open on Masonry Vent Kit MVK 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 Failure to establish flame Cause may be no gas to burners bad igniter or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor e Loss of flame after establishment Cause may be interrupted gas supply lazy burner flames improper gas pressure or restriction in flue or improper indu
22. 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 3 of this manual All propane gas equipment must conform to the safety stan dards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended for both cost and efficiency 3 Pressure drop in lines between regulators and between second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appliances Complete information regarding tank sizing for vaporization rec ommended regulator settings and pipe sizing is available from most regulator manufacturers and propane gas suppliers Since propane gas will quickly dissolve white lead and most standard commercial compounds special pipe dope must be used Shellac based compounds resistant to the actions of liquefied petroleum gases such as Gasolac Stalactic
23. the furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling unit coil Premature heat exchanger failure will result if the cooling unit coil is placed ahead of the furnace For vertical upflow or downflow applications the minimum cooling coil width shall not be less than furnace width minus 1 Additionally a coil installed above an upflow furnace or under a counterflow furnace may be the same width as the furnace or may be one size larger than the furnace Example a C width coil may be installed with a width furnace For upflow applications the front of the coil and furnace must face the same direction 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 Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel For counterflow installations the air conditioning coil must be downstream from the heat exchanger of the furnace Counterflow installation over a noncombustible floor Before
24. 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 the following section for speed changing details CIRCULATOR BLOWER SPEED ADJUSTMENT A WARNING 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 PSC circulator blower motor This blower provides ease in adjusting blower speeds Refer to the Blower Performance Data in the back of the manual for proper selection of heating and cooling speeds The cooling blower speed is shipped set on HIGH High heat ships on MEDIUM and low heat is shipped on MEDIUM LO These blower speeds should be adjusted by the installer to match the instal lation requirements so as to provide the correct heating tem perature rise and the correct cooling CFM To adjust the circulator blower speed proceed as follows 1 Turn OFF power to the furnace 2 Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Specification Sheet applicable to your model Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual 3 R
25. to the instructions under Combustion and Ventilation Air Requirements Section 5 3 3 furnace heat exchanger components duct system air filters and evaporator coils are thoroughly cleaned following final construction clean up Allfurnace operating conditions including ignition input rate temperature rise and venting are verified according to these installation instructions NOTE The Commonwealth of Massachusetts requires that the following additional requirements must also be met e Gas furnaces must be installed by a licensed plumber or gas fitter AT handle gas cock must be used Ifthe unit is to be installed in an attic the passageway to and the service area around the unit must have flooring WARNING TO 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 installa tion and operation instructions all local building codes and ordinances In their absence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes of the National Fuel Gas Code NFPA 54 ANSI 2223 1 can be obtained from any of the following American National Standards Institute 1430 Broadway New York N
26. usiNG Two STAGE GAs VALVES A caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR Only small variations in gas pressure should be made by ad justing the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Turn off all electrical power to the system 3 Outlet pressure tap connections a Honeywell VR9205 valve Remove the outlet pressure boss plug Install an 1 8 NPT hose barb fitting into the outlet pressure tap b White Rodgers 36G54 valve 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 barb fitting Honeywell valve or outlet pressure boss White Rodgers valve 5 Turn ON the gas supply 6 Turn on power and close thermostat R and W1 contacts to provide a call for low stage heat 7 Measure the 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 clo
27. 0 F Note This kit is for use on Amana brand and Goodman brand 80 AFUE 33 tall and S model furnaces installed in the upflow position only 11 NOTE The vertical height of the Category venting system must be at least as great as the horizontal length of the venting system Ay WARNING TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION COMMON VENTING WITH OTHER MANUFACTURER S INDUCED DRAFT APPLIANCES IS NOT ALLOWED The minimum vent diameter for the Category I venting system is as shown MINIMUM VENT 6 4inch MODEL Under some conditions larger vents than those shown above may be required or allowed When an existing furnace is re moved from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appliances Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace Top is as viewed for an upflow installation The induced draft blower can be rotated 90 degrees with the 0270F01119 chimney transi tion bottom kit for Category venting For horizontal installa tions a four inch single wall pipe can be used to extend the induced draft blower outlet 1 2 beyond the furnace cabinet THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCK WISE INDUCED DRAFT BLOWER ROTATION Vent the furnace in accordance with the National Fuel Gas Code NFPA 54 ANSI 2223
28. 0 Gas Manifold 3 FluePipe Connection 11 Inshot Burner 4 Induced Draft Blower 12 Transformer 5 Gas Line Entrance 13 Integrated Control Module 6 Gas Valve 14 Blower Door Interlock Switch 7 Rollout Limit 15 Circulator Blower 8 Junction Box 16 Gas Line Entrance Alternate 35 Component ID 4 Inshot Burner 7 Rollout Limit Gas Manifold 4 Induced Draft Blower Gas Line Entrance Alternate N 8 Junction Box 9 Wiring Harness Grommet 2 Pressure Switch 2 Transformer Pressure Switch Gas Line Entrance Gas Valve Rollout Limit Junction Box Tubular Heat Exchanger Flue Pipe Connection Induced Draft Blower 1 Tubular Heat Exchanger L 22 5 Gas Line 15 Flue Pipe Connection 0 Chimney Transition Top Shipped Loose 3 Integrated Cantrol Module k Blower Blower Door Interlock Switch 9 Wiring Harness Grommet 10 Gas Manifold 11 Inshot Burner 12 Transformer 13 Integrated Control Module 14 Blower Door Interlock Switch 15 Circulator Blower 16 Gas Line Entrance Alternate 36 TROUBLESHOOTING CHART Fault Description s Associated LED Code Symptoms of Abnormal Operation Furnace fails to operate No 115 volt power to furnace or no 24 volt power to integrated control module Integrated control module diagnostic LED
29. 1 latest edition In Canada vent the furnace in accordance with the National Standard of Canada CAN CSA B149 1 and CAN CSA B149 2 latest editions and amendments Venting Furnace Installed in Horizontal Position THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI ZONTALLY VENTED THROUGH AN EXTERIOR SIDE WALL The following describes an optional venting procedure when the furnace is installed in the horizontal left discharge position To rotate the induced draft blower clockwise you will need to purchase one 0270F01119 chimney transition bottom kit 1 Disconnect electrical power from the furnace 2 Disconnect the induced draft blower power leads flue pipe and pressure switch tubing 3 Remove the round cutout from the right side of the wrapper 4 Remove and save the four screws that fasten the induced draft blower to the flue collector box 5 Remove and save the three screws that hold the chimney assembly to the induced draft blower 6 Remove and save the four screws that fasten the chimney top to the chimney bottom 7 Remove the chimney transition bottom from the transition bottom kit 8 Install the chimney top with the four screws retained from step 6 onto the new chimney transition bottom from the transition bottom kit 9 Remove the induced draft blower and install the new chimney assembly to it using the three screws retained from step 5 Rotate the induced draft blower 90 degrees to the right feed the f
30. 32 DIAGNOSTIC GHART ccataceakcuanvaieiwescudscusazucccatesaunsitenacicaacecnuneslavcaatacaanessacaniealasassencavseicussaensaganiensaeiwosi res 32 FAULT RECALL E 32 RESETTING FROM LOCKOUT 32 Table of Contents IMAINTEK ANG Da ai i a i i Sri A ia a a eee Gace 32 NNIUALINSPECTION E E tide i D aa ai kd EDEL E a La i a aa 32 in si ai i i i a a a i a a e i a 33 FILTER MAINTENANCE sias ei ia a Taa i ie o e ai aa L iii a ass as ais a i DL 33 BIETER PREMOVA L si iii a a i ia i i a a a i a A a e a Las a 33 INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS s ssssceseecusecusecnseeecuseeuseeuaeeneeeueeeeaseenneeuseenasseessnees 33 FLAME SENSOR QUALIFIED SERVICER ONLY 33 IGNITER QUALIFIED SERVICER ONLY ias ai aa Gas iii ien aka kenkia iais 33 cae i i ede Aa a i a ice i a e a S a 33 CLEANING QUALIFIED SERVICER ONLY 22 a asa a s ana aka nas asi s ke a ss E a E a Eu m EASA LSS 33 BEFORE LEAVING AN INSTALLATION Lis asikik ia i nnn Di i i i i i k k i e k i ai 34 PARTS a danai Gai Ei Lado a Eni ou Gia 34 COMPONENT aidai aa salia Laidai sa aidas Ls sa Ca Vas aka an ie i a inia a ata Edin A 35 COMPONENT LD
31. 34 REPAIR AND REPLACEMENT PARTS e When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and serial numbers with the order e Although only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description e Parts are available from your distributor Functional Parts List Gas Valve Natural Gas Orifice Propane Gas Orifice Burner Hot Surface Igniter Flame Sensor Gas Manifold Ignition Control Blower Mounting Bracket Pressure Switch Pressure Switch Hose Induced Draft Blower Collector Box Blower Collector Box Gasket Primary Limit Switch Rollout Limit Switch Auxiliary Limit Switch Heat Exchanger Door Switch Transformer Blower Wheel Blower Housing Blower Cutoff Blower Motor Motor Mount Bracket Capacitor Component ID Tubular Heat Exchanger 2 Pressure Switch Flue Pipe Connection 4 Induced Draft Blower Chimney Transition Top Shipped Loose 5 Gas Line Entrance 6 Gas Valve 7 Rollout Limit 8 Junction Box Wiring Harness HS Grommet Gas Manifold Line Entrance Alternate Inshot Burner 2 Transformer 3 Circulator Blower 4 Blower Door Interlock Switch 3 Integrated Control Module 1 Tubular Heat Exchanger 9 Wiring Harness Grommet 2 Pressure Switch 1
32. 62 307 630 976 125 10 24 48 81 122 224 69 146 275 567 866 150 9 21 43 72 109 202 63 132 252 511 787 200 8 19 39 66 100 187 54 112 209 439 665 250 8 17 36 60 93 172 48 100 185 390 590 CIRCULATING AIR AND FILTERS Ductwork AIR FLow Aywarnine NEVER ALLOW THE PRODUCTS OF COMBUSTION INCLUDING CARBON MONOXIDE TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY 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 recom mended methods of Air Conditioning Contractors of America Manual D Aduct system must be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning Warm Air Heating and Ventilating Systems Pamphlets No 90A and 90B Aclosed return duct system must be used with the return duct connected to the furnace NOTE Ductwork must never be attached to the back of the furnace For installations requiring more than 1800 CFM use a bottom return or two sided return Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission To prevent the blower from interfering with combustion air or draft when a cen tral return is used a connecting duct must be installed be tween the unit and the utility room wall Furnace is shipped with the top flanges in the fl
33. A MEDIUM GHS806048 MEDIUM GHS80805C MEDIUM 41 BLOWER PERFORMANCE DATA GME8 CFM amp Temperature Rise vs External Static Pressure Model EXTERNAL STATIC PRESSURE Inches Water Column STATICPRESSURE Morse tos o1 o2 oa os T os fosforas 1 YELLOW T2 RED GME80603B T3 ORANGE T4 BLUE T5 BLACK 1 YELLOW 2 RED GME80805C 113 ORANGE T4 BLUE T5 BLACK 1 YELLOW T2 RED GME81005C 113 ORANGE T4 BLUE T5 BLACK Notes CFM in chart is without filter s Filters do not ship with this furnace but must be provided by the installer If the furnace requires two return filters this chart assumes both filters are installed All furnaces ship as high speed cooling and medium speed heating Installer must adjust blower cooling and heating speed as needed For most jobs about 375 400 CFM per ton when cooling is desirable INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE This chart is for information only For satisfactory operation external static pressure should not exceed value shown on the rating plate The above chart is for U S furnaces installed at 0 2000 feet At higher altitudes a properly derated unit will have approximately the same temperature rise ata particular CFM while ESP at the CFM will be lower Factory Motor Speed Setting 1 1st Stage
34. ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICER AGENCY OR THE GAS SUPPLIER Aywarnine 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 5 PHONE FOLLOW THE GAS SUPPLIER 5 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 WARNING THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM Aywarnine HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUTINE INSPECTION MAINTENANCE AND SUPERVISION IF THE BUILDING 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
35. AFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit must be applied for propane gas installations Refer to the Propane Gas and or High Altitude Installations section for details If converting to LP gas it is recommended that an LPLPO kit also be installed The use of this kit will prevent the furnace from firing when the LP gas supply pressure is too low to sup port proper combustion Models using Single Stage Gas Valves Manifold Pressure Pressure Switch NOTE In Canada gas furnaces are certified to 4500 feet NOTE GMS81405DN models utilize 43 orifices in Natural gas applications 19 Models using 2 Stage Gas Valves Manifold Pressure Pressure Manifold Pressure Pressure Orifice High Low Stage Stage Natural EEE E O 0 NOTE In Canada gas furnaces are only certified to 4500 feet NOTE GMH81405DN models utilize 43 orifices in Natural gas applications Contact your distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude instal lations The indicated kits must be used to insure safe and proper furnace operation All conversions must be performed by a gualified installer or service agency Gas PIPING CONNECTIONS A WARNING TO AVOID POSSIBLE UNSATISFACTORY
36. Canada vent the furnace in accordance with the national standard of Canada CAN CSA B149 1 and CAN CSA B149 2 latest editions and amendments Ay WARNING NEVER ALLOW THE PRODUCTS OF COMBUSTION INCLUDING CARBON MONOXIDE TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY Exterior Masonry CHivneys Carecory I Furnaces Ony An exterior masonry chimney is defined as a Masonry chim ney exposed to the outdoors on one or more sides below the roof line The ability to use a clay lined masonry chimney depends on a parameter not associated with interior chimneys This variable is the geographic location of the installation Re searchers have discovered that the winter design temperatures have a direct impact on the suitability of this type of venting In most situations the existing masonry chimneys will require a properly sized metallic liner A WARNING POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN A SINGLE FAN ASSISTED CATEGORY I APPLIANCE 80 AFUE FURNACE IS VENTED WITHOUT ADEQUATE DILUTION AIR DO NOT CONNECT AN 80 FURNACE TO A MASONRY CHIMNEY UNLESS THE FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE B METAL VENT ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES IF AN 80 FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPP
37. Clyde s or John Crane are satisfactory Refer to the following illustration for typical propane gas instal lations and piping 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C 200 PSIG Second Stage Maximum 9 Regulato Propane Gas Installation Typ PROPANE Gas PIPING CHARTS Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Pipe or gt Tubing Tubing Size O D Type L Nominal Pipe Size Schedule 40 Length Feet 5 8 7 8 3 4 7 500 4 200 4 000 3 700 3 400 310 2 600 2 300 2 100 1 900 1 700 1 500 Sizing Between Second Stage and Appliance Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Pipe or i Nominal Pipe Size Tubing Tubing Size O D Type L Schedule Length Feet 3 8 1 2 5 8 3 4 7 8 1 1 8 1 2 3 4 1 1 1 4 1 1 2 10 39 92 199 329 501 935 275 567 1 071 2 205 3 307 20 26 62 131 216 346 630 189 393 732 1 496 2 299 30 21 50 107 181 277 500 152 315 590 1 212 1 858 40 19 41 90 145 233 427 129 267 504 1 039 1 559 50 18 37 79 131 198 376 114 237 448 913 1 417 60 16 35 72 121 187 340 103 217 409 834 1 275 80 13 29 62 104 155 289 89 185 346 724 1 066 100 11 26 55 90 138 255 78 1
38. E N gt 54 BURNER COMPARTMENT JUNCTION BOX 2 DOOR E DOOR SWITCH SWITCH L Lead SWITCH LOCATED IN BLOWER a oo COMPARTMENT ON SOME MODELS 1 YSS lt WARNING 7 DISCONNECT POWER DISCONNECT ss YL SE YL BEFORE SERVICING PRIMARY LIMIT WIRING TO UNIT gt RD i MUST BE PROPERLY POLARIZED m as AND GROUNDED BK L N BR BL OVERCURRENT PROTECTION DEVICE WH BK M JUNCTION HOT Wy BOX SURFACE 2 STAGE R eel UNEN IGNITER GAS VALVE 7 2 GND HONEY WELL Nu al S 4 LINEH INDUCED DRAFT BLOWER TO 115 VAC 1 60HZ Pu POWER SUPPLY WITH FLAME OVERCURRENT PROTECTION SENSOR DEVICE ROLLOUT LIMITS SINGLE CONTROL ON SOME MODELS 07 STEADY ON NORMAL OPERATION LOW VOLTAGE 24 OFF CONTROL FAILURE 240 EQUIPMENT GND 77 1FLASH SYSTEM LOCKOUT RETRIES RECYCLES EXCEEDED LOW VOLTAGE FIELD FIELD GND L 27 2 FLASHES PRESSURE SWITCH STUCK CLOSED HI VOLTAGE 115V 3 FLASHES PRESSURE SWITCH STUCK OPEN 13 HI VOLTAGE FIELD 4 FLASHES OPEN HIGH LIMIT SWITCH TEMP 0 JUNCTION 5 5 FLASHES FLAME SENSE WITHOUT GAS VALVE IGNITER nn 6 6 FLASHES OPEN ROLLOUT OR OPEN FUSE TERMINAL O ae 7 7 FLASHES LOW FLAME SIGNAL INTERNAL TO SWITCH PRESS Be 2 INTEGRATED CONTROL OVERCURRENT 8 FLASHES CHECK IGNITER OR IMPROPER GROUND PROT DEVICE
39. E SERVICING OR b White Rodgers 36G22 valve INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY Back inlet pressure test screw inlet pressure boss BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY out one turn counterclockwise not more than one DAMAGE PERSONAL INJURY OR DEATH tum 4 Attach a hose and manometer to the outlet pressure MODELS USING SINGLE STAGE GAS VALVES barb fitting Honeywell valve or inlet pressure boss White Rodgers valve The line pressure supplied to the gas valve must be within the 5 Turn ON the gas supply range specified below The supply pressure can be measured at the gas valve inlet pressure tap or ata hose fitting installed in 6 Turn On power and close thermostat R W contacts the gas piping drip leg The supply pressure must be mea to provide a call for heat sured with the unit OFF To measure inlet pressure use the 7 Using leak detection solution or soap suds check for following procedure leaks at outlet pressure boss plug Honeywell valve or Gas Valve screw White Rodgers valve Bubbles forming indicate On Off a leak SHUT OFF GAS AND REPAIR ALL LEAKS Selector IMMEDIATELY Inlet Pressure 8 Measure the gas supply pressure with burners firing Tap Adjust supply pressure using the nlet Gas Supply Pressure table shown below If supply pressure reading differs from the table make necessary adjustments to 4 INLET pressure regulator gas piping size etc
40. ED APPLIANCE THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL EXIST WITH EXTREMELY COLD CONDITIONS LONG VENT CONNECTORS EXTERIOR CHIMNEYS OR ANY COMBINATION OF THESE CONDITIONS THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR TYPE B METAL VENT Crown Roof Line Clay Tile Size Generally 12 12 24 Length Clay Tile Size 8 x 8 x12 Each x 24 Length Attic Floor gt 1 2 to 1 Air Space Second Floor First Floor F A F Vent il Connector Fan Assisted Forced Air Fumace Typical Multiple Flue Clay Tile Chimney lt Water Heater Vent Connector Natural Draft Clean Out Water Heater Basement Floor CHECKLIST SUMMARY This checklist serves as a summary of the items to be checked before venting an 80 furnace into a masonry chimney In addi tion we recommend that a qualified serviceman use this check list to perform a yearly inspection of the furnace venting sys tem 12 This checklist is only a summary For detailed information on each of the procedures mentioned see the paragraph refer enced with each item This inspection is based upon a draft topical report Masonry Chimney Inspection and Relining issued by the Gas Research Institute While not yet finalized we believe this report repre sents the best information on this subject which is currently available
41. Gas Fired Central Furnaces ANSI Z21 47 Latest Edi tion CSA 2 3 Latest Edition Section 1 23 1 The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances connected to the venting system are not in operation a Seal any unused openings in the venting system b Inspect the venting system for proper size and horizontal pitch as required by the National Fuel Gas Code ANSI Z223 1 or the CAN CSA 149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition In so far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continuously Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each applia
42. Ht 2 2nd Stage Ht 5 Cooling Temperature rise data is based on 2nd stage heat First stage heat is 75 of rise indicated above 42 WIRING DIAGRAMS Aw NG DISCONNECT POWER BEFORE 24 HUMIDIFIER SERVICING WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED xt DIAGNOSTIC LED OR M D H S8 WiRING lt HUMIDIFIER INTEGRATED MVC 9 MV 12 INTEGRATED CONTROL MODULE OVA SL 115 VAG HOT AND PARK TERMINALS XFMR4I AUXILIARY LIMITS XFMR 3 AUXILIARY LIMIT CONTROLS CONTROL MODULE ID BLOWER PRESSURE SWITCH DIAGRAM AUTO RESET PRIMARY LIMIT CONTROL MANUALRESET ROLLOUT LIMIT CONTROL S SINGLE CONTROL ON SOME MODELS Oe o 40VA TRANSFORMER ama 15 VAC XFMR N FLAME SENSOR HOT SURFACE IGNITER MOT BINGO 1 1 HOLVINID 15 PIN PLUG ON SOME MODELS BLOWER COMPARTMENT DOOR SWITCH SWITCH LOCATED IN BLOWER COMPARTMENT ON SOME MODELS BURNER COMPARTMENT DOOR SWITCH T 24VAC HUMIDIFIER
43. ILURE ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER A NNUAL INSPECTION The furnace should be inspected by a qualified installer or ser vice agency at least once per year This check should be per formed at the beginning of the heating season This will ensure that all furnace components are in proper working order and that the heating system functions appropriately Pay particular attention to the following items Repair or service as neces sary Flue pipe system Check for blockage and or leakage Check the outside termination and the connections at and internal to the furnace 32 e Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways Burners Check for proper ignition burner flame and flame sense e Wiring Check electrical connections for tightness and or corrosion Check wires for damage e Filters FILTERS Ay WARNING TO AVOID PROPERTY DAMAGE PERSONAL INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE REMOVING FILTERS NEVER OPERATE FURNACE WITHOUT A FILTER INSTALLED BECAUSE DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY EQUIPMENT DAMAGE AND POSSIBLE FIRE A return air filter is not supplied with this furnace however there must be a means of filtering all of the return air The in staller will supply filter s at the time of installation FILTER MAINTENANCE Improper filter maintenance is the most common cause of
44. ING THE HEAT ANTICIPATOR The following method should be used in measuring the amp draw of the control circuit to assure proper adjustment of the thermostat heat anticipator 4 an Wrap the leg around a clip on ammeter 10 times Energize the furnace in the heat mode e Record the reading e Divide this reading by 10 Set the heat anticipator on the thermostat to match this reading Example If the reading on the ammeter is 4 divide this by 10 The anticipator setting will be 4 amps 115 LINE CONNECTION OF ACCESSORIES ELECTRONIC AIR CLEANER GME8 GDH8 amp A GMH8 MODELS ONLY WARNING HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field supplied electronic air cleaner The accessory load specifications are as follows Electronic Air Cleaner 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any accesso ries Follow the air cleaner manufacturers instructions for lo cating mounting grounding and controlling these accesso ries Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the furnace inte grated control module The electronic
45. INSTALLATION INSTRUCTIONS FOR M H S 8 D H S 8 HS8 GME8 Gas Furnace CATEGORY I Installer Affix all manuals adjacent to the unit These furnaces comply with requirements em bodied in the American National Standard Na tional Standard of Canada ANSI Z21 47 CSA US 2 3 Gas Fired Central Furnaces Intertek A RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual are intended as supplemental to existing practices However if there is a direct conflict between existing practices and the content of this manual the precautions listed here take precedence NOTE Please contact your
46. ION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS Check for leaks using an approved chloride free soap and wa ter solution an electronic combustible gas detector or other approved testing methods 21 TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS PRESSURE TESTING LOCATION OF SHUTOFF VALVE AND INSTALLATION OF GAS PIPING NOTE Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply pip ing system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa This unit must be isolated from the gas supply system by clos ing its manual shutoff valve before pressure testing of gas sup ply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE GAS TANKS AND PIPING WARNING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR CONFINED SPACE IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK SINCE PROPANE GAS IS HEAVIER THAN AIR ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES PROPANE GAS ODORANT MAY FADE MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE A gas detecting warning
47. LATION AIR REQUIREMENTS A warnine TO AVOID PROPERTY DAMAGE PERSONAL INJURY OR DEATH SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA 10 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 heating cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burn ing 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 combustion of gas fired appliances thereby exposing building occupants to gas combustion products that could include car bon monoxide If this furnace is to be installed in the same space with other gas appliances such as a water heater ensure there is an adequate supply of combustion and ventilation air for the other appliances Refer to the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 or CAN CSA B149 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances This furnace must use indoor air for combustion It cannot be installed as a direct vent sealed c
48. NAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP FLAME The burner flames should be inspected with the burner com partment door installed Flames should be stable quiet soft and blue dust may cause orange tips but they must not be yellow Flames should extend directly outward from the burn ers 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 31 AUXILIARY Limit CONTROL Auto reset limits are located on or near the blower To access this auxiliary limit disconnect the electrical power and remove the blower door The auxiliary limit control is designed to pre vent furnace operation in case of main blower failure on hori zontal installations It may also open if the power supply is interrupted while the furnace is firing The auxiliary limit control is suitable for both horizontal right and horizontal left installa tions Regardless of airflow direction it does not need to be relocated A warnine TO AVOID PERSONAL INJURY OR DEATH DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS
49. NTROL MODULE MANUAL RESET ROLLOUT LIMIT CONTROL S g SINGLE CONTROL ON SOME MODELS FS 4 XFMR 3 x 24 21 TEKAT 40VA 8 BL BR gt TRANSFORMER RD 8 Greed 2 XFMR H 115VAC XFMR N O c FLAME SENSOR z 2 9 5 l FP CI HOT SURFACE IGNITER XFMR H IGN IGNN 1 PARK 2 1 k 8 BORE 2 58555 8 lt 7 BK lt 3595 E IND IND N 8 2 LE 2 BK 24V 3 7 52 CIRCULATOR 2 115V r 8 E m m XFMR 55 m WH Ed BK z ELECTRONI GR 15 PIN PLUG EACH AIR CLEANER EACN ON SOME MODELS LINE H LINE N BURNER COMPARTMENT o gt 24VAC DOOR SWITCH HUMIDIFIER SWITCH SWITCH LOCATED IN BLOWER co COMPARTMENT ON SOME MODELS ha T NNN 9 4 i WARNING ka RD PRESSURE DISCONNECT POWER DISCONNECT 3 YL YL BEFORE SERVICING 1 PRIMARY LIMIT WIRING TOUNIT i RB MUST BE PROPERLY POLARIZED Lilis We AND GROUNDED 1 BK L N BR BL OVERCURRENT PROTECTION DEVICE WH BK JUNCTION HOT Wy BOX SURFACE 2 STAGE IGNITER GAS VALVE GND HONEYWELL Bui r 4 LINEH INDUCED DRAFT BLOWER 115VAC 1 60HZ PU PU POWER SUPPLY WITH FLAME OVERCURRENT PROTECTION SENSOR DEVICE ROLLOUT LIMITS SINGLE CONTROL ON
50. ONNECTION f gt WARNING DISCONNECT POWER BEFORE HUMIDIFIER INTEGRATED SERVICING WIRING TO UNIT MUST BE CONTROL MODULE PROPERLY POLARIZED AND GROUNDED SKB a es CET Ei 24 VAC I 2 HUMIDIFIER MVH 12 a ami 7 2 7 IDBLOWER Sees AUXILIARY PRESSURE 4 LIMIT CONTROLS SWITCH w Y N lt 5 O PS 10 NO EBM Tone Pso 4 150 SEC 100 SEC HEO TO 007 02 MICRO 7 NN WH 8 4 00O BL 3 HLO 1 KEJ 4 5 6 g 8 AUTO RESET FUSE Moe O 2558 PRIMARY SEE NOTE 6 95 m RO2 11 LIMIT AUXILIARY 8 Pt CONTROL BR LIMITS 2 ROW Gy INTEGRATED CONTROL MODULE MANUAL RESET ROLLOUT ay LIMIT CONTROL S ET SINGLE CONTROL ON SOME MODELS XFMR 3 24 VAC alz UI BL BR 77 TRANSFORMER RD 8 2 XFMR H 115 VAC XFMR N 5 A 4 5 FLAME SENSOR T a E L FP HOT SURFACE IGNITER XFMR H LINE H EAC H IGN IGN N PARK 9 2 28529 g IFURA 9 S gt ID t BLWR m BK 5 IND IND N 8 Q d 2 A 2 24V r 2 9 2 loo CIRCULATOR d usv A 2 2 CIR N m XFMR 58 3 7 25 WH a v BK GR 15 PIN PLUG ON SOME MODELS BLOWER COMPARTMENT LINE H LIN
51. RAFT BLOWER 115 1 60HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE LOW VOLTAGE 24V LOW VOLTAGE FIELD HI VOLTAGE 115V HI VOLTAGE FIELD JUNCTION TERMINAL INTERNAL TO INTEGRATED CONTROL PLUG CONNECTION SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS BR BROWN WH WHITE BL BLUE GY GRAY BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION RD RED 2 MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY EQUIPMENT GND FIELD GND FIELD SPLICE SWITCH IGNITER SWITCH PRESS TOYLNOD OVERCURRENT PROT DEVICE REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE CORRECT COOLING CFM SEE SPEC SHEET FOR AIR FLOW CHART 43 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO AND LOCAL CODES GME8 WiRING DIAGRAM lt H gt x MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY _ CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH E z D 2 z a lt n 14 2 gt 14 N a L m x z a lt o 2 o 2
52. SOME MODELS 0 STEADY ON NORMAL OPERATION OFF CONTROL FAILURE LOW VOLTAGE 24V EQUIPMENT GND 75 1FLASH SYSTEM LOCKOUT RETRIES RECYCLES EXCEEDED LOW VOLTAGE FIELD FIELD GND 4 2 2 FLASHES PRESSURE SWITCH STUCK CLOSED HI VOLTAGE 115V 3 FLASHES PRESSURE SWITCH STUCK OPEN a SPLICE 07 HI VOLTAGE FIELD 4 FLASHES OPEN HIGH LIMIT SWITCH TEMP 5 2 JUNCTION eo 15 5 FLASHES FLAME SENSE WITHOUT GAS VALVE IGNITER _ 67 6 FLASHES OPEN ROLLOUT OR OPEN FUSE TERMINAL 7 7 FLASHES LOW FLAME SIGNAL INTERNAL TO ____ SWITCH PRESS 9 59 8 8 FLASHES CHECK IGNITER OR IMPROPER GROUND INTEGRATED CONTROL SEG BENGE PLUG CONNECTION F RAPID FLASHES REVERSED 115VAC POLARITY VERIFY GND NOTES COLOR CODES PK PINK 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS YL YELLOW BR BROWN 2 MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH OR ORANGE WH WHITE WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY PU PURPLE BL BLUE 4 BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS SO AS TO GR GREEN GY GRAY PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE CORRECT COOLING CFM SEE SPEC SHEET FOR AIR FLOW CHART BK BLACK RD RED 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E
53. Transit Association specifica tions The carton 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 delivery receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 With concealed damage carrier must be notified as soon as possible preferably within five days 4 File the claim with the following support documents within a nine month statute of limitations e Original or certified copy of the Bill of Lading or indemnity bond e Original paid freight bill or indemnity in lieu thereof e Original or certified copy of the invoice showing trade and other discounts or reductions 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 dam age and for a thorough investigation of each claim The distribu tor or manufacturer will not accept claims from dealers for trans portation damage Keep this literature in a safe place for future reference ELectrostatic DiscHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely
54. Y 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 A copy of the CAN CSA B149 Installation Codes can also be obtained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 The rated heating capacity of the furnace should be greater than or 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 Cal culations published by the Air Conditioning Contractors of America In the USA this furnace MUST be installed in accordance with the latest edition of the ANSI 2223 1 booklet entitled National Fuel Gas Code NFPA 54 and the requirements or codes of the local utility or other authority having jurisdiction In Canada this furnace must be installed in accordance with the current CAN CGA B149 1 amp 2 Gas Installation Codes local plumbing or waste water codes and other applicable codes Additional helpful publications available from the NFPA are NFPA 90A Installation of Air Conditioning and Ventilating System and NFPA 90B Warm Air Heating and Air Conditioning System All venting shall be in accordance with PART 7 Venting of Equip ment of the National Fuel Gas Code ANSI 2223 1 or appli cable local building and or air conditioning codes These pub lications are available from N
55. a i a a i i a As 29 CIRCULATOR BLOWER SPEED ADJUSTMENT 30 CIRCULATOR BLOWER FAN TIMING ADJUSTMENT 30 SETTING Furnace OPERATING DH8 ME8 AND MODELS ONLY 30 OPERATIONAL a kan k a pas et ai aa aa k ai cass o a Ia a a E A 31 BURNER FLAME Zaki tect as 31 AUXILIARY CONTROL aaa 31 DAFETY CIRCUIT DESCRIPTION vase ai ai i i EE i E a i i S 31 GENERAL ahah oneal Da A E i Dai D Aa ni Nite iai S aa a i T D D Du aa as 31 INTEGRATED CONTROL MODULE iais ie aa a a a i K i i E i i i 31 PRIMARY LAIM ii aina i ia i a a O i E L ai Eolas Gral aa ia D 31 ai a a a ai iai a i i a E a i i a ceca aa a LS 31 OUT IMIES k Ais dia inkai o i E Dia a ks ai ia Das A a ana as 31 PRESSURE OWITCHES es nuvi nates a aa ia a ii V e a ds a ai a a i 32 FRAME SENSOR a a a G aa SU i a aa a i a i a D Salia IIS 32 TROUBLESHOOTING sis kas iai asa ia a sakos ku ia ais ak kak aka aaa a a aa TTA 32 ELECTROSTATIC DISCHARGE ESD
56. a si ad ais das Oda kas koda sa i iais 14 CHECK 7 COMPLETE THE INSTALLATION scssccesecceeccesecseeuseenusecuseeuceeenaeeeaeeeuseeueeeuseeuaeeenasenasesaeseaessags 15 Fix 1 LINER TERMINATION 15 Fix 2 CHANGE VENTING ARRANGEMENTS ccscccsseceseecueeccasecsecuseenaeeeusseeuaeeueeeeaueeueeeueeeeseeeaneeuaesnasssuesenaees 15 Fix REBUILD THE CROWN 15 Fix 4 RELINING 15 ELECTRICAL GONNEC HONG aa acces esta ia ua a i wel G a a a a a a E i 16 WVIRING EI ARNESS i sai i i a a e i i a a a a a ak 16 115 VoLT LINE CONNECTIONS giai a sai a ae ai a E d ae Ei e Gas a Ua i aa ao i a E a 16 FOSSIL FUEL APPLICATIONS asirai iii S ri i k e i a e S a i i i I i a i ia 16 JUNCTION Box RELOCATION Si sa sia ieee a ai sa a ko ais i aa Ga a des Ga ais ieskai 17 24 VOLT THERMOSTAT WIRING Ls vneeaidennuntviausdcesadecndaubcevsdivedusunasauseieaisasieaceks 17 GME8 Furnace 2 STAGE CONDENSER FIELD WIRING 17 SETTING THE HEAT NTICIPATOR La sai i Ta Dai ai E i a e i e i a se 18 115 LINE CONNECTION OF ACCESSORIES scesecceeccnsecceeccusecusecuneeensecuseeuaeenuceeueeecaseesneneaseeasssessnees 18 ELECTRONIC AIR CLEANER i ii i i des ia ace ean ei i eee cee 18 24 VAC PLUMIDIFIER T E GTI S Chat tats B a La L Sa ad c
57. ad EDI an ai 19 GAS SUPPLY AND PIPING 20 ceeeceeecceeeceecceeeceeeuseeuseeeusecuueeeeasenuseeuaeeneeeuseeuaeenaseeeuseeuaeecaseeeeeuaeseusesesssseees 19 HIGH ALTITUDE DERATE 19 PROPANE GAS CONVERSION ccscccssecesecseccuseceecuseeenuseeuseeuaeenaseeuseeuaeenaneeeseeeueeeuseeuseenaeseuseeuseeeassessesnass 19 GAS PIPING CONNECTIONS 20 UPFLOW INSTALLATIONS sscceseccsseccuseceeccesecseeuseeuaeeesuneeuaeeuaeenaneeuseuaeenauseeuaeecaeeeuneeuseeeaseeasseeuseseasssaeees 21 COUNTERFLOW INSTALLATIONS 21 GAS PIPING CHECKS asas ais ai aidas aidu E dis aa as ki E aaa ska E Ua Ei EE S ease iui sios Aina a des aisiais 21 PROPANE GAS TANKS AND PIPING 020sc0eccceeecneecuseccessecueeeueeeeseeuseeesenusseeuaeeuasenesseuseeeuseeusesesessnaseseessnees 21 Table of Contents CRCULATING AND PIETERS ane sauce a nace i asin Ga D i ia is as GA 22 DUCTWORK AIR FEOW E i i O se Aika E i ia i i a i ii Dandi a 22 CHECKING S T TO iii ai a i i d i i i o a i i a a i 23 FILTERS READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK 23 UPRIGHT INSTALLATIONS LL
58. affect electrical com ponents Use the following precautions during furnace installation and servicing to protect the integrated control module from dam age By putting the furnace the control and the person at the same electrostatic potential these steps will help avoid expos ing the integrated control module to electrostatic discharge This procedure is applicable to both installed and non installed ungrounded furnaces Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnaces near the control Any tools held ina person s hand during grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an 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 To THE INSTALLER Before installing this unit please read this manual thoroughly to familiarize yoursel
59. aks using an approved chloride free soap and wa ter solution an electronic combustible gas detector or other approved method Verify that all required kits propane gas high altitude etc have been appropriately installed NOTE An interlock switch prevents furnace operation if the blower door is notin place Keep the blower access doors in place except for inspection and maintenance FURNACE START UP 1 Close the manual gas shutoff valve external to the furnace 2 Turn off the electrical power to the furnace 3 Set the room thermostat to the lowest possible setting 4 Remove the burner compartment door NOTE This furnace is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 White Rodgers Model 36G22 or 36G54 Push the switch to the OFF position Honeywell VR8215 or VR9205 Slide the switch to the OFF position 6 Wait five minutes to clear out any gas Then smell for gas including near the floor If gas can be smelled following the five minute waiting period in Step 6 immediately follow the instructions on Page 3 of this manual If you do not smell gas after five minutes White Rodgers Model 36G22 or 36G54 Push the switch to the ON position Honeywell VR8215 or VR9205 Slide the switch to the ON position 8 Replace the door on the front of the furnace 9 Open the manual gas valve external to the furnace 10 Turn on the electrical power su
60. appliances They are not suitable for use with gas fired appliances Flexible liners specifically intended and tested for gas applications are listed in the UL Gas and Oil Equipment Directory UL Standard 1777 15 For sizing of flexible liners see Note 22 and the tables in the National Fuel Gas Code NFPA 54 ANSI Z223 1 latest edition and in the National Standard of Canada CAN CSAB149 1 and CAN CSA B149 2 latest editions and amendments To install the liner read and follow the liner manufacturer s in structions and your local codes Excess liner length should be pulled out of the chimney and cut off Use caution when doing this as the cut edges of flexible liners may be sharp Do not spiral excess liner inside of the chimney Support the liner as recommended by the liner manufacturer Some manufacturers of flexible liners offer an insulation sleeve designed to be added to the liner before it is installed in the chimney Poured insulation either vermiculite or other materi als is no longer recommended Insulation will need to be added to the flexible liner if e Itis required by the liner manufacturer s instructions previous liner was properly sized and installed and suffered from condensation damage e ltis required by your local building codes Even if none of those three conditions exist which require addi tional liner insulation the installer may wish to consider it if The local climate is v
61. at position Before installing a coil or ducts the flanges must be bent 90 A room closet or alcove must not be used as a return air chamber When the furnace is used in connection with a cooling unit the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and if manually operated must be 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 rec ommended that a removable access panel be provided in the outlet air duct This opening shall be accessible when the fur nace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream The ac cess panel must be made to prevent air leaks when the furnace is in operation NOTE In a horizontal installation the air conditioning coil must be adequately supported by proper brackets and supports Inadequate coil support can result in furnace cabinet distortion and air leakage 22 When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F When a furnace is installed so t
62. ational Fire Protection Association Inc 1 Batterymarch Park Quincy MA 02269 NOTE Furnaces with NOx screens meet the California NOx emission standards and California seasonal efficiency stan dards ANNUAL inspections of the furnace and its vent system is strongly recommended LOCATION REQUIREMENTS AND CONSIDERATIONS Your unit model type determines which installation procedures must be used For MH8 and GHS8 models you must follow instructions for Horizontal Left Horizontal Right or Up flow installations only These furnaces are not approved for Downflow installations Downflow models GD H S ARE NOT APPROVED FOR HORI ZONTAL OR UPFLOW INSTALLATIONS For these models use only the instructions for downflow installation only Ay WARNING TO PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT Follow the instructions listed below when selecting a furnace location Refer also to the guidelines provided in Section V Combustion and Ventilation Air Requirements e Centrally locate the furnace with respect to the proposed or existing air distribution system Ensure the temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable an optional sound reducti
63. ce integrated control module fuse with 3A automotive fuse Read precautions in Electrostatic Discharge section of manual Replace rollout limit with correct replacement part Turn power OFF prior to repair e Clean flame sensor with steel wool See Vent Flue Pipe section for piping details See rating plate for proper gas pressure TROUBLESHOOTING CHART i Fault i Symptoms of Associated p Possible Causes Corrective Action Cautions Abnormal Operation LED Code Description s amp Notes Furnace not operating Problem with Improperly connected e Check and correct wiring Turn power OFF igniter circuit igniter from integrated control prior to repair Integrated control module module to igniter diagnostic LED is flashing EIGHT 8 flashes Bad igniter Replace bad igniter Replace igniter 8 FLASHES with proper replacement part Poor unit ground Check and correct unit Read precautions Poor burner ground ground wiring in Electrostatic Discharge Faulty integrated control Replace bad integrated section of manual module control module Induced draft blower runs 2 e Polarity of 115 e Polarity of 115 volt AC Review wiring diagram to Turn power OFF power to furnace or correct polarity j i continuously No furnace T or 24 volt integrated control module y prior to repair operation power Is is reversed e Verify proper gr
64. ced draft blower performance Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower Induced draft blower pressure switch contacts sticking Shorts in pressure switch circuit e Pressure switch hose blocked pinched or connected improperly Blocked flue or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning switch contacts Loose or improperly connected wiring Blockage in flue or chimney 1 Integrated control module will automatically attempt to reset from lockout after one hour 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 Locate and correct gas interruption Replace or realign igniter Check flame sense signal Sand sensor if coated and or oxidized Check flue piping for blockage proper length elbows and termination e Verify proper induced draft blower performance Check circulator blower speed and performance Correct speed or replace blower if necessary Replace induced draft blower pressure switch e Repair short e Inspect pressure switch hose Repair if neces sary Ins
65. ckwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw 9 Close thermostat and W2 contacts to provide a call for high stage heat Remove regulator cover screw from the high HI outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw 11 Turn off all electrical power and gas supply to the system 12 Remove the manometer hose from the hose barb fitting or outlet pressure boss 13 Replace outlet pressure tap a Honeywell VR9205 valve Remove the 1 8 NPT hose barb fitting from the outlet pressure tap Replace the outlet pressure boss plug and seal with a high quality thread sealer b White Rodgers 36G54 valve Turn outlet pressure test screw to seal pressure port clockwise 7 in Ib minimum 14 Turn on electrical power and gas supply to the system 15 Close thermostat contacts and W1 W2 to energize the valve Using a leak detection solution or soap suds check for leaks at outlet pressure boss plug Honeywell valve or screw White Rodgers valve Bubbles forming indicate a leak SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY NOTE For gas to gas conversion consult your dealer for appropriate conversion eas Range Nominal tra Tow Sage 16 27 TS ME 6 Ow iC 10 0 w c Low Stage 33 10 3 w c T Hi
66. d 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 e Furnace fails to operate Integrated control module diagnostic LED is flashing SIX 6 flashes No furnace operation Normal furnace operation Integrated control module diagnostic LED is flashing SEVEN 7 flashes 2 LED Flash code will cease if p Associated Fault LED Code Description s lt Primary limit gt circuit is open eye A 4 FLASHES Flame sensed with no call for 5 FLASHES lt Rollout limit open 6 5 lt Integrated control module fuse is 6FLASHES blown e Flame sense microamp signal is low 7 FLASHES Possible Causes Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower Faulty primary limit switch Loose or improperly connected wiring Short to ground in flame sense circuit Flame rollout Misaligned burners blocked flue and or air inlet pipe or failed induced draft blower Loose or improperly connected wiring Short in 24 volt AC control circuits or safety circuits Faulty rollout limit Flame sensor is coated oxidized Flame sensor incorrectly
67. distributor or our website listed below for the applicable Specification Sheet referred to in this manual Ay warnine GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT 5151 San Felipe Suite 500 Houston TX 77056 10 417B www goodmanmfg com www amana hac com 10 2012 2011 2012 Goodman Manufacturing Company L P Table of Contents SAFETY PRECAUTIONS LL Li ai aina a na i ia S a i A 5 ADDITIONAL SAFETY CONSIDERATIONS 6 SHIPPING INSPECTION teat aa Gia Elkis S I adis i pecs 6 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS ssseeeeeeeeeeeeeeeeeeeeeeeeeeeneneeneeeeeneeneeeeeeeeeeeeeeeeeeeeeeeeeees 6 amp iis S Ai ais Dia Aa ii a ie ais S abs a 6 IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY 6 PRODUCT APPLICATION sccccssecccssecenceeeeeeeeeececeeeuuueeeuaueueueuseeuuusueeuuueueuaueeeuuueeeuauseeegaueueuaueseuaueeeuueeseueeesenaueenags 7 LOCATION REQUIREMENTS AND CONSIDERATIONS 02scc
68. e mea sured with the burners operating To measure the gas supply pressure use the following procedure Fe INLET gt gt b OUTLET Gas Valve On Off Selector Switch White Rodgers Model 36G54 Two Stage Open to Manometer Atmosphere Hose High Fire Regulator Outlet N g Adjust Pressure Boss Regulator Vent a 3 el ING S gt 7 we Low Fire Alene m Regulator iia 6 hive Adjust Pressure Boss High Fire Coll Coaxial Coil Manometer Terminal HI Terminal M On Off Switch Common Terminal C White Rodgers Model 36G54 Connected to Manometer High Fire Regulator Regulator Adjust Ce o JA o ar 6 Gas Valve On Off Selector Switch Regul Adjust Honeywell Model VR9205 Two Stage Common Terminal C High Fire Coil Terminal HI Low Fire Coil Terminal LO Open to Manometer Atmosphere Hose Inlet Pressure 1 8 NPT N gt Manometer
69. easuring Inlet Gas Pressure Alt Method regulator and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace Gas ManiFo_p PRESSURE MEASUREMENT AND ADJUSTMENT regulator cover screw 10 Turn OFF all electrical power and gas supply to the Ay caution system 11 Remove the manometer hose from the hose barb fitting TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE or outlet pressure boss GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING 12 Replace outlet pressure tap THE GAS VALVE PRESSURE REGULATOR a Honeywell VR8215 valve Remove the 1 8 NPT hose barb fitting from the outlet pressure tap Replace the outlet pressure boss plug A WARNING and seal with a high quality thread sealer b White Rodgers 36G22 valve Turn outlet pressure test screw in to seal pressure port clockwise 7 in lb HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY minimum BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY 13 Turn ON electrical power and gas supply to the system DAMAGE PERSONAL INJURY OR DEATH 14 Close thermostat contacts to provide a call for heat 15 Retest for leaks If bubbles form SHUT OFF GAS AND MoDELS USING SINGLE STAGE Gas VALVES REPAIRALL LEAKS IMMEDIATELY This valve is shipped from the factory with the regulator preset see control label 28
70. elocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module Terminals are identified as LO HEAT HI HEAT and COOL hot for M D H8 models and HEAT and COOL for M H D S8 models If a heating speed and the cooling speed are the same a jumper wire must be used between the heat and cool terminals 4 Connect all unused blower motor leads to the PARK terminals on the integrated control module Any leads not connected to the PARK terminals must be taped 5 Turn ON power to furnace Verify proper temperature rise as outlined in Temperature Rise section D CIRCULATOR BLOWER FAN TIMING ADJUSTMENT NOTE Items in this section refer to the air circulator blower fan the M D H8 models NOT to the induced draft blower The induced draft blower timing sequence is not adjustable The circulator blower fan timing is adjustable only on models with optional heating fan OFF delay adjustment pins or switches It is NOT adjustable any other circumstances As shipped the circulator blower fan will remain on for 150 seconds after the gas valve closes When a call for cooling occurs the circulator fan comes on and remains on for 45 sec onds after the call for cooling ends During normal heating op eration the circulator fan will come on approximately 34 sec onds after the gas valve opens Switch viewed in an upflow installation Adjustment Switch SETTING
71. ent for the gas appliances However the installer must keep in mind the following factors which may render the tile liner unsuitable for use as a vent Extremely cold weather Long vent connectors Masonry chimneys with no air gap between the liner and the bricks In practice this can be difficult to detect e Exterior chimneys The tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and in the National Standard of Canada CAN CSAB149 1 and CAN CSA B149 2 latest editions and amendments assume interior chimneys If in the judgment of the local gas utility installer and or local codes one or more of the above factors is likely to present a problem the chimney must be relined Fix 4 Fix 1 LINER TERMINATION Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use The liner and cap roof assembly must then terminate above the roof in accordance with the manufacturer s instructions In some cases a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney For further information on relining see Fix 4 Fix 2 CHANGE VENTING ARRANGEMENTS If the masonry chimney has more than one channel it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance s into another channel s Do not vent an 80 Furnace inside of a metal liner with other appli ances vented ou
72. ent physical damage by vehicles A gas furnace must not be installed di rectly on carpeting tile or other combustible materials other than wood flooring FURNACE SUSPENSION If suspending the furnace from rafters or joist use 3 8 threaded rod and 2 x2 x3 8 angle iron as shown below The length of rod will depend on the application and the clearances neces sary PROVIDE 8 MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL 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 3 8 DIAMETER THREADED ROD 6 PLACES HOLD DOWN NUTS SUPPORT NUTS NOTE IN A HORIZONTAL INSTALLATION THE AIR CONDITIONING COIL MUST BE ADEQUATELY SUPPORTED BY PROPER BRACKETS AND SUPPORTS INADEQUATE COIL SUPPORT CAN RESULT IN FURNACE CABINET DISTORTION AND AIR LEAKAGE 2 x 2 x 3 8 ANGLE IRON 3 PLACES POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMOVAL TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL Suspended Furnace ExisTING 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
73. ery cold The chimney is very tall e The vent connectors used are very long or have a large number of elbows Local experience indicates that flexible liners installed without insulation are likely to have condensation problems Insulation must be selected and installed in accordance with the liner manufacturer s instructions Finally cap the chimney and terminate the liner in accordance with the liner manufacturer s instructions ELECTRICAL CONNECTIONS Aywarnine HIGH VOLTAGE TO AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED Ay warnine HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING Ay caution LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Aywarnine HIGH VOLTAGE 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 CODE Wirinc HARNESS The wiring harness is an integral part of this furnace Field alteration to comply with electrical codes should not be re quired Wires are color coded for identification purposes Re fer to the wiring diagram for wire routings If any of the origi
74. eseccnseecueeeusecceeecueeeuseecnseeeceeuseeuuseeuseeuaeenassesuseeuaesnaesesesnaees 8 CLEARANCES AND CCESSIBILITY Lilui cee ias i i i wat a i i i i a i i a a a a 9 NSTALLATION POSITIONS sd asi d aa a a i e Sa D a a Dinas a S E aa aaa Ia 9 HORIZONTAL INSTALLATION i nels i i a i i a 9 FURNACE SUSPENSION sK ini aki kia ino ia iai a Lasa akos Lada ai Gai aaa 10 EXISTING FURNACE REMOVAL ia iai ai a a i i a a i a a i i 10 THERMOSTAT ZOCATION Lai ana sai iai ai i i a a i i a i a a i LS Od 10 COMBUSTION AND VENTILATION AIR REQUIREMENTS 10 CATEGORY VENTING VERTICAL VENTING 11 EXTERIOR MASONRY CHIMNEYS CATEGORY FURNACES 12 CHECKLIST SUMMARY csscceeeccnseccueecsecuseecececuseeusneenseeuseeuseeuaeeeaeseuseeenaeeeuseeuseseusenasseusesuassenuessusesnaeesas 12 CHECK 1 PROPER CHIMNEY TERMINATION csscceeecccsecceeecseceneecseeueeeuaceecuseeuseecaseeuseeuaeeuaneeeusseuaeenanseneeens 13 CHECK 2 ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL 14 CHECK CHIMNEY CROWN CONDITION 14 CHECK 4 DEBRIS IN CLEANOUT 14 CHECK 5 LINER CONDITION 14 CHECK 6 DILUTION AIRS a saskaitos koa iai ia Lisas aa d
75. f with specific items which must be ad hered to including but not limited to unit maximum external static pressure gas pressures BTU input rating proper elec trical connections circulating air temperature rise minimum or maximum CFM and motor speed connections and venting These furnaces are designed for Category venting only Aywarnine TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE IMPORTANT NOTE To THE OWNER REGARDING PRODUCT WARRANTY Your warranty certificate is supplied as a separate document with the unit installed by your contractor Read the limited war ranty certificate carefully to determine what is and is not cov ered and keep the warranty certificate in a safe place If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service 877 254 4729 to obtain a copy IMPORTANT To receive the Lifetime Heat Exchanger Limited Warranty good for as long as you own your home and the 10 year Parts Limited Warranty online registration must be com pleted within 60 days of installation Online registration is not required in California or Quebec Complete warranty details available from your local dealer or for Goodman brand prod ucts visit www goodmanmfg com and for Amana brand prod ucts visit www amana hac com To register your Goodman brand unit g
76. gh Stage_ 7 Gas INPUT MEASUREMENT NATURAL Gas ONLY The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas burning appliances except the furnace 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 3 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 installation s gas heating value multiplied by a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating HTG value 1 000 BTU ft Obtained from gas supplier Installation s seconds per cubic foot 34 sec ft3 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 This measured input must not be greater than the input indicated on the unit rating plate 5 Turn ON gas and rel
77. hat supply ducts carry air cir culated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct sealed to the furnace casing and terminating outside the space con taining the furnace Duct Static Refer to your furnace rating plate for the maximum ESP exter nal duct static rating Total external static refers to everything external to the furnace cabinet Cooling coils filters ducts grilles registers must all be considered when reading your total external static pres sure The supply duct pressure must be read between the fur nace and the cooling coil This reading is usually taken by removing the A shaped block off plate from the end on the coil drilling a test hole in it and reinstalling the block off plate Take a duct static reading at the test hole Tape up the test hole after your test is complete The negative pressure must be read between the filter and the furnace blower Too much external static pressure will result in insufficient air that can cause excessive temperature rise This can cause limit switch tripping and heat exchanger failure To determine total external duct static pressure proceed as follows 1 With clean filters in the furnace use a draft gauge inclined manometer to measure the static pressure of the return duct at the inlet of the furnace Negative Pressure 2 Measure the static pressure of the supply duct Posi
78. hools Office buildings Churches Retail stores Nursing homes Hotels motels Common or office areas In such applications the furnace must be installed with the following stipulations t 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 free air delivery application lt must not be used as a make up air unit All other warranty exclusions and restrictions apply This furnace may be used as a construction site heater ONLY if the following conditions are met e The vent system is permanently installed per these installation instructions Aroom thermostat is used to control the furnace Fixed jumpers that provide continuous heating CANNOT be used e Return air ducts are provided and sealed to the furnace e A return air temperature range between 60 F 16 C and 80 F 27 C is maintained Air filters are installed in the system and maintained during construction replaced as appropriate during construction and upon completion of construction are replaced input rate and temperature rise are set per the furnace rating plate 100 outside air is provided for combustion air requirements during construction Temporary ducting can be used NOTE Do not connect the temporary duct directly to the furnace The duct must be sized according
79. ight appliances turned off in step 1 Ensure all the appliances are functioning properly and that all pilot burners are operating TEMPERATURE RISE Air temperature rise is the temperature difference between supply and return air The proper amount of temperature rise is usu ally obtained when the unit is operated at the rated input with the as shipped blower speed If the correct amount of tem perature rise is not obtained it may be necessary to change the blower speed 29 An incorrect temperature rise can cause condensing in or over heating of the heat exchanger Determine and adjust the tem perature rise as follows The temperature rise must be within the range specified on the rating plate or Specification Sheet applicable to your model Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual HEAT EXCHANGER RADIATION LINE OF SIGHT SUPPLY D gt AIR SUPPLY e SUPPLY TRETURN Saag RETURN AIR Temperature Rise Measurement 1 Operate furnace with burners firing approximately 15 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 3 Subtract
80. in adequate heating or cooling performance Filters should be cleaned permanent 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 Ay warnine HIGH VOLTAGE TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER TO THE FURNACE BEFORE REMOVING THE FILTER OR PERFORMING ANY OTHER MAINTENANCE Become familiar with filter location and procedures for removal cleaning and replacing them If help is needed contact the installer of the furnace or a qualified servicer 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 alter nate filter Follow the filter sizes given in the Recommended Minimum Filter size table or instruction provided by the media or electronic air cleaner manufacturer 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 For further details see your distributor INDUCED DRAFT AND CIRCULATOR BLOWER Motors The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer No fur
81. ious illness including permanent brain damage or death B10259 216 Aywarnine 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 Aywarnine POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSATION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT A WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FOR ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICER AGENCY OR THE GAS SUPPLIER Ay WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION THIS FURNACE MUST BE CATEGORY VENTED DO NOT VENT USING CATEGORY III VENTING PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS OUTDOORS THROUGH A PROPER VENTING SYSTEM THE LENGTH OF FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE ADDITIONAL SAFETY CONSIDERATIONS This furnace is approved for Category Venting only e Provisions must be made for venting combustion products outdoors through a proper venting system The length of flue pipe could be a limiting factor in locating the furnace SHIPPING INSPECTION All units are securely packed in shipping containers tested according to International Safe
82. itudes the manifold pressure must be within 0 3 inches w c of that listed in the Specification Sheet applicable to your model for the fuel used At all altitudes and with either fuel the air temperature rise must be within the range listed on the fur nace nameplate Should this appliance be converted to LP refer to the instructions included in the factory authorized LP conversion kit HiGH ALTITUDE DERATE IMPORTANT NOTE The furnace will naturally derate itself with altitude Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure This can cause poor combustion and equipment failure High altitude installations may require both a pressure switch and an orifice change These changes are necessary to com pensate 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 distribu tor for required kit s Contact the distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude instal lations 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 PROPANE GAS CONVERSION Aywarnine POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE S
83. lue pipe through the round cutout from the outside of the wrapper and fit onto the chimney top assembly Secure the pipe to the chimney top from the front top and bottom using 3 screws and rotating the induced draft blower to properly orient the assembly NOTE If the pipe section is less than 18 then attach it directly to the chimney top on 3 sides and feed it through the round cutout from the inside of the wrapper 11 Reattach the induced draft blower using the 4 screws retained from step 3 Ensure the gasket located between the induced draft blower and collector box is rotated accordingly Reconnect the induced draft blower power leads NOTE If the wires are not long enough pull extra wire from the wire bundle in the blower compartment Reconnect the remaining flue pipe and the pressure switch tubing Ensure that all wires and the pressure switch tubing is at least one inch from the flue pipe or any other hot surface 14 Restore power to furnace NOTE In a horizontal installation the air conditioning coil must be adequately supported by proper brackets and supports Inadequate coil support can result in furnace cabinet distortion and air leakage 12 13 Counterflow units are shipped with the induced draft blower discharging from the top of the furnace Top as viewed fora counterflow installation Vent the furnace in accordance with the National Fuel Gas Code NFPA54 ANSI Z223 1 latest edition In
84. nal 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 a copper con ductor 115 LINE CONNECTIONS Before proceeding with electrical connections ensure that the supply voltage frequency and phase correspond to that speci fied on the unit rating plate Power supply to the furnace must be NEC Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with 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 prop erly sized wire and fuse or circuit breaker The fuse or circuit breaker must be sized in accordance with the maximum over current protection specified on the unit rating plate An electri cal disconnect must be provided at the furnace location Line voltage wiring must enter into the junction box provided with the furnace NOTE Line polarity must be observed when making field connections Fossit FuEL APPLICATIONS This furnace can be used in conjunction with a heat pump ina fossil fuel application A fossil fuel application refers to a com bined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost effi cient means of heating heat pump gas f
85. nce connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use 9 Ifimproper venting is observed during any of the above tests the common venting system must be corrected Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54 ANSI 2223 1 and or CAN CSA B149 Installation Codes If resizing is required on any portion of the venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI 2223 1 and or CAN CSA B149 Installation Codes THERMOSTAT LOCATION In an area having good air circulation locate the thermostat about five feet high on a vibration free inside wall Do not install the thermostat where it may be influenced by any of the follow ing Drafts or dead spots behind doors in corners or under cabinets Hotor cold air from registers Radiant heat from the sun Light fixtures or other appliances Radiant heat from a fireplace Concealed hot or cold water pipes or chimneys Unconditioned areas behind the thermostat such as an outside wall DRAFTS OR DEAD SPOTS BEHIND DOORS CORNERS UNDER CABINETS Thermostat Influences Consult the instructions packaged with the thermostat for mount ing instructions and further precautions COMBUSTION AND VENTI
86. nce inside the B vent and other appliances outside The excess space between the B vent and the chimney walls must be covered at the top of the chimney by a weatherproof corrosion resistant flashing The B vent should then be topped with a listed vent cap The listed vent cap will when installed per the manufacturer s in structions prevent problems due to rain birds or wind effects B vent installed as described in this section is considered to be an enclosed vent system and the sizing tables in National Fuel Gas Code NFPA 54 ANSI Z223 1 latest edition and in the National Standard of Canada CAN CSA B149 1 CAN CSA B149 2 latest editions and amendments may be used If a flexible liner is to be used it must be made of the proper materials For most residential applications an aluminum liner should be acceptable If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine a liner of AL 29 4C stainless steel should be used Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine bleaches paint strippers adhesives paints varnishes sealers waxes which are not yet dried and solvents used during construction and remodeling Various commercial and industrial processes may also be sources of chlorine fluorine compounds e Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel
87. nd the chimney If this will not be practical see Fix 1 10 or Less gt 2 Min 1 2 Min Wall or Parapet Chimney L 10 or Less lt gt 2 Min Ridge 4 Chimney KS Termination 10 Feet Or Less From Ridge Wall or Parapet than 10 4 3 Min NOTE No Height above parapet required when distance Chimney Wall or from walls or parapet is Parapet more than 10 feet lt More than 10 gt Height above any roof surface within 10 p 10 feet horizontally Ridge 2 Min iit Ea Chimney S Termination More Than 10 Feet From Ridge Wall or Parapet CHECK 2 ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL Solid fuel appliances include fireplaces wood stoves coal fur naces and incinerators Liquid fuel appliances include oil furnaces oil fired boilers and oil fired water heaters Appliances which burn propane sometimes referred to as LP liquefied petroleum gas are considered gas fired appliances CHEcK 3 CHIMNEY CROWN CONDITION Damage from condensate usually shows up first in the crown If any of the following trouble signs are present the condition of the crown is not satisfactory Crown leaning Bricks missing Mortar missing Tile liner cracked No tile liner Salt staining at mortar joints White stains and mortar becomes sandy and or erodes
88. o to www goodmanmfg com and click Warranty Registration Complete the registration as prompted To register your Amana brand unit go to www amana hac com and click Warranty Registration Complete the registration as prompted Product limited warranty certificates for models currently in pro duction can be viewed at www goodmanmfg com or www amana hac com If your model is not currently in production or does not appear on the website please contact your installing con tractor or contact customer service 877 254 4729 to obtain a copy of your warranty certificate Each product overview page contains a Product Warranty link by clicking on it you will be able to view the limited warranty coverage for that specific product To view warranty registration information click on the Product Warranty text on the left navi gation panel on the home page of each website The Online Product Registration pages are located in this same section APPLICATION This furnace is primarily designed for residential home heating applications It is NOT designed or certified for use in mobile homes trailers or recreational vehicles Neither is it designed or certified for outdoor applications The furnace must be in stalled 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 com mercial applications Sc
89. o trap dirt and moisture before it can enter the gas valve The drip leg must be aminimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace Use two pipe wrenches when making connection to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped from the factory Install a manual shutoff valve between the gas meter and unit within six feet of the unit If a union is installed the union must be downstream of the manual shutoff valve between the shutoff valve and the furnace Tighten all joints securely Connect the furnace to the building piping by one of the following methods Rigid metallic pipe and fittings Semi rigid metallic tubing and metallic fittings Aluminum alloy tubing must not be used in exterior locations Use listed gas appliance connectors in accordance with their instructions Connectors must be fully in the same room as the furnace Protect connectors and semi rigid tubing against physical and thermal damage when installed Ensure aluminum alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry plaster or insulation or subjected to repeated wetting by liquids such as water except rain water detergents or sewage Location of Manual Valve Installed Ahead of r Ground
90. ol 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 away from 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 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 DIAGNosTic CHART Refer to the troubleshooting chart in the Appendix for assis tance in determining the source of unit operational problems The red diagnostic LED blinks to assist in troubleshooting the unit The number of blinks refer to a specific code NOTE To clear all alarm codes depress the push button for 6 seconds RECALL The ignition control is equipped with a momentary push button switch that can be used to display on the diagnostic LED the last five faults detected by the control The control must be in Standby Mode no thermostat inputs to use the feature De press the
91. ombustion furnace 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 CATEGORY I VENTING VERTICAL VENTING Ay warnine TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION THIS FURNACE MUST BE CATEGORY I VENTED DO NOT VENT USING CATEGORY III VENTING Category Venting is venting at a non positive pressure A furnace vented as Category is considered a fan assisted ap pliance and the vent system does not have to be gas tight NOTE Single stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allow ing in some instances common venting with natural draft ap pliances i e water heaters All installations must be vented in accordance with National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition In Canada the furnaces must be vented in ac cordance with the National Standard of Canada CAN CSA B149 1 and CAN CSA B149 2 latest editions and amendments NOTE Masonry vent kit MVK 01 and MVK 02 is to only be used on interior masonry chimneys or qualifying exterior masonry chimney applications identified in the MVK kit installation instructions To ensure safe and reliable operation use only the kit listed for your model Input KBTU Range Limit Setting MVK 01 40 100 250 F MV K 02 120 140 29
92. on kit is available Consult your local distributor for more details Provisions must be made for venting combustion products outdoors through a proper venting system The length of flue pipe could be a limiting factor in locating the furnace 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 The furnace must be level If the furnace is to be set on a floor that may become wet or damp at times the furnace should be supported above the floor on a concrete base sized approximately 1 1 2 larger than the base of the furnace Ensure upflow or horizontal furnaces are not installed directly on carpeting or any other combustible material The only combustible material allowed is wood 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 If
93. ouT Limits The rollout limit controls are mounted on the burner manifold assembly and monitor the burner flame They are manual reset temperature sensors This limit guards against burner flames not being properly drawn into the heat exchanger PRESSURE SWITCHES The pressure switches are normally open negative air pres sure activated switches They monitor the airflow combustion air and flue products through the heat exchanger via pressure taps located on the induced draft blower These switches guard against insufficient airflow combustion air and flue products through the heat exchanger FLAME SENSOR The flame sensor is a probe mounted to the burner manifold assembly which uses the principle of flame rectification to de termine the presence or absence of flame TROUBLESHOOTING ELectrostatic DiscHARGE ESD PRECAUTIONS NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and servicing to protect the integrated control module from dam age By putting the furnace the control and the person at the same electrostatic potential these steps will help avoid expos ing the integrated control module to electrostatic discharge This procedure is applicable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated contr
94. ound reversed Correct if necessary Integrated control module diagnostic LED is flashing CONTINUOUS and blue wires to Reverse red and blue FLASHING transformer are reversed wires connected to continuously transformer Poor unit ground 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch 39 BLOWER PERFORMANCE DATA M H S 8 CFM amp Temperature Rise vs External Static Pressure Model Heating Speed As Shipped M H S 80403A MEDIUM M H S 80603A MEDIUM M H S 80604B MEDIUM M H S 80803B MEDIUM M H S 80804B MEDIUM M H S 80805C MEDIUM M H S 81005C MEDIUM M H S 81205D MEDIUM M H S 81405D MEDIUM Tons AC at 0 5 0 1 ESP CFM RISE 26 31 38 31 40 48 21 27 31 39 37 51 63 EXTERNAL STATIC PRESSURE Inches Water Column f os Tos 3 2 4 2 4 6 8 7 3 7 1 8 0 53 7 1 1 39 4 4 4 4 8 6 2 8 9 0 9 7 7 3 3 3 2 3 3 3 5 3 5 5 6 4 40 BLOWER PERFORMANCE DATA D H S8 CFM amp Temperature Rise vs External Static Pressure Model EXTERNAL STATIC PRESSURE Inches Water Column Heating Speed 02 03 04 05 eid GDS80403A MEDIUM GDS80603A MEDIUM GDS80804B MEDIUM GDS81005C MEDIUM Model Heating Speed As Shipped GHS80403
95. pect flue for blockage proper length elbows and termination e Correct pressure switch setpoint or contact motion e Tighten or correct wiring connection Inspect masonry chimney and flue remove blockage 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch 37 Cautions amp Notes Turn power OFF prior to repair Replace integrated control module fuse with 3A automotive fuse Turn power OFF prior to repair Read precautions in Electrostatic Discharge section of manual Turn power OFF prior to repair Igniter is fragile handle with care e Clean flame sensor with steel wool See Combustion and Ventilation Air Requirements and Category Venting Vertical Venting section for details See Product Data Bulletin for allowable rise range and proper circulator speed Turn power OFF prior to repair Replace pressure switch with proper replacement part Turn power OFF prior to repair See Combustion and Ventilation Air Requirements and Category Venting Vertical Venting section for details Replace pressure switch with proper replacement part Replace masonry vent kit limit switch with correct replacement part TROUBLESHOOTING CHART Symptoms of Abnormal Operation Circulator blower runs continuously No furnace operation Integrate
96. pply to the furnace 11 Set the room thermostat to the desired temperature NOTE There is an approximate 30 second delay between ther mostat energizing and burner firing FURNACE SHUTDOWN 1 Set the thermostat to lowest setting 2 Turn off the electrical power supply to the furnace 3 Set the room thermostat to the lowest possible setting 25 4 Remove the burner compartment door Pressure Regulator d 5 White Rodgers Model 36654 Push switch to the OFF Lae EAS ee position Tap E a Honeywell VR8215 or VR9205 Slide the switch to the i OFF position 6 Close manual gas shutoff valve external to the furnace INLET S E OUTLET 7 Replace the door on the unit Gas SuppLy PRESSURE MEASUREMENT Gas Valve On Off Ay caution Selector Switch TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE Honeywell Model VR8215 Single Stage INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT 1 Turn OFF gas to furnace at the manual gas shutoff valve RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES external to the furnace OPERATING 2 Turn OFF all electrical power to the system 3 Inlet pressure tap connections Awarninc a Honeywell MRD Valve Remove the inlet pressure boss plug Install 1 8 HIGH VOLTAGE NPT hose barb fitting into the outlet pressure tap DISCONNECT ALL POWER BEFOR
97. ps They should not be yellow They should extend directly outward from the burner ports without curling downward floating or lifting off the ports CLEANING QUALIFIED SERVICER ONLY 1 Shut off electric power and gas supply to the furnace 2 Disconnect the rollout limit wires flame sensor wire and disconnect the igniter plug Ay caution LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 3 Remove four 4 screws securing the burner box top Ay caution THE IGNITER IS FRAGILE AND CAN BE EASILY DAMAGED USE EXTREME CAUTION WHEN REMOVING THE BURNER BOX TOP 33 Remove the screws securing the burners to the burner bracket Remove the burners Use bottle brush to clean burner insert and inside of burner Replace burner opposite of removal Ensure burners are fully seated on burner bracket and are properly aligned Replace burner box top Reconnect wiring Turn on electric power and gas supply to the furnace Check furnace for proper operation Refer to Operational Checks section to verify burner flame characteristics 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
98. pushbutton switch for approximately 2 seconds Re lease the switch when the LED is turned off The diagnostic LED will then display the flash codes associated with the last five detected faults The order of display is the most recent fault to the least recent fault RESETTING FRom Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts It is characterized by a non func tioning furnace and a one flash diagnostic LED code from the red LED If the furnace is in lockout it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace for 1 20 seconds 3 Manual thermostat cycle Lower the thermostat so that there is no longer a call for heat for 1 20 seconds then reset to previous setting NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to the Diagnostic Chart for aid in determining the cause MAINTENANCE WARNING TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE IF YOU MUST HANDLE THE IGNITER HANDLE WITH CARE TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREMATURE FA
99. r conditioner A two stage cooling single stage gas heat thermostat is required in addition to a field supplied relay The relay must have a 24VAC coil and contacts rated for up to 1 horse power at 125VAC 17 1 Install the field supplied relay on the control mount ing panel near the furnace ignition control The relay should be installed such that the motor leads will reach the relay contact terminals 2 Connect the Y2 high stage cool thermostat terminal to one coil terminal of the field supplied relay Connect the other field supplied relay coil terminal to the terminal on the furnace ignition control Typical 18AWG thermostat wire may be used 3 Connect the common terminal of the field supplied relay to the LINE H terminal on the furnace ignition control Use wiring having copper conductors only and a temperature rating of at least 105 C 4 Using the GME8 airflow tables in this manual determine the motor speed tap needed to deliver the required high stage cooling airflow Connect the selected motor speed tap to the normally open terminal on the field supplied relay Use wiring having copper conductors only and a temperature rating of at least 105 C 5 See the wiring schematic below ECO TECH MOTOR Furnace Field Control Supplied Relay J Heating Cooling Room Thermostat Remote Condensing Unit Field Wiring for GME8 Furnace with 2 Stage Condenser SETT
100. rcuit checks e Circulator blower is energized on low heat speed Electronic air cleaner terminals are energized e Circulator blower runs integrated control module monitors safety circuits continuously e Rand G thermostat contacts open completing the call for fan e Circulator blower is de energized Electronic air cleaner terminals are de energized Furnace awaits the next call from thermostat START UP PROCEDURE AND ADJUSTMENT Furnace must have a 115 VAC power supply properly connected and grounded Proper polarity must be maintained for correct operation An interlock switch prevents furnace operation if the blower door is not in place Keep the blower access door in place except for inspection and maintenance This furnace is also equipped with a self diagnosing electronic control module In the event a furnace component is not operat ing properly the control module LED will flash on and off ina factory programmed sequence depending on the problem en countered This light can be viewed through the observation window in the blower access door Refer to the Troubleshoot ing Chart for further explanation of the lighting codes Follow the start up and adjustment items refer to further infor mation in Section XIII Operational Checks see table of con tents pages 2 3 for page number FURNACE OPERATION Purge gas lines of air prior to start up Do not purge lines into an enclosed burner compartment Check for le
101. rs Mortar protruding from between tile sections Use of sewer pipe or drainage pipe rather than approved fire clay tile reline the chimney Fix 4 Next measure the size of the liner It may be possible to do this from the cleanout The liner must be at least as large as the minimum size established by the tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and the National Standard of Canada CAN CSAB149 1 and CAN CSA B149 2 latest editions and amendments If the liner is too small or too large then the chimney must be relined Fix 4 6 DILUTION AIR If gas fired appliances are to be vented into a clay tile liner a source of dilution air is required Dilution air cannot be obtained through Induced draft appliances Natural draft appliances with vent dampers Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance s vent connector does not include a vent damper If dilution air will not be available the chimney must be relined Fix 4 14 CHECK 7 COMPLETE THE INSTALLATION If Checks 1 through 6 have been satisfactory and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54 ANSI 2223 1 latest edition and the National Standard of Canada CAN CSAB149 1 and CAN CSA B149 2 latest editions and amendments then the clay tile liner can probably be used as a v
102. sausus i es ia a i i i i i i i a i 23 CIRCULATIONAIRFLTERS i ii L ak E E a a Dia Da Gia kai aid 23 FIGRIZONTAL INSTALLATIONS L aster aiski iii iii ia ii i ia a i i i k 24 SEQUENCE OF OPERATION INTEGRATED IGNITION CONTROL 24 POWER UP i AA Aa A 24 MODE eis ao a a Ana LAS ADEO En uo LE Lakis aa Ss 24 Mope DIP Is SET 1 STG 24 DIP Switcu Is SET TO 2 STG POSITION 24 COOLING MODE Gai ais aaa aa Saias Aaaa aaa os ana ina A Eos aa aki e 25 FaN MODE S 25 START UP PROCEDURE AND ADJUSTMENT 0s ccseccesecnsecceeecseecueeenaeecuseeuseeeaseeusecuuseenseeuuseuseseseeuseeuaseseesseesseeees 25 FURNACE OPERATION La i ai e i a i a i i i a i k a O a a 25 FURNAGE START UP i a DI a I ae i ai a E a En Da 25 FURNACE SHUTDOWN 20 i i ia i as os a a i e i a i i i 25 Gas SupPLy PRESSURE MEASUREMENT ssccsecceseeceseccueeeseeuseenaeeeuneeueeenusesuseeuseeceeeuseeuaeeuaeeeuseeseaeseasssaes 26 Gas MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT 20sccssccesecceecceeecesscuseeceseesseeuseenaeenseeeeeseasssaes 28 Gas INPUT MEASUREMENT NATURAL GAS ONLY 29 TEMPERATURE RISE rales ais ia ce ca id
103. setting the furnace over the plenum opening ensure the surface around the opening is smooth and level A tight seal should be made between the furnace base and floor by using a silicon rubber caulking compound or cement grout Counterflow installation over a combustible floor If installation over a combustible floor becomes necessary use an accessory subbase see Specification Sheet applicable to your model for details A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood Follow the instructions with the subbase for proper installations Do not install the furnace directly on carpeting tile or other combustible material other than wood flooring NOTE The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor Return air ducts must be completely sealed to the furnace and terminate outside the enclosure surfaces CLEARANCES AND ACCESSIBILITY Unobstructed front clearance of 24 for servicing is recom mended VENT TOP B1 VENT SINGLE SIDES FRONT BAGA PLENUM Top clearance for horizontal configuration 1 INSTALLATION POSITIONS An upflow 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 vertically installed upflow furnaces return air ductwork ma
104. t at 150 seconds If the furnace is operating in the low stage heating mode when thermostat contacts open circulator remains at low heat speed for the selected delay off period If the furnace is operating in high stage heating mode when the thermostat contacts open the circulator blower remains at high heat speed for the selected heat off delay period Furnace awaits the next call from thermostat Coone The normal operational seguence in cooling mode is as fol lows Rand Y thermostat contacts close initiating a call for cool Integrated control module performs safety circuit checks Outdoor fan and compressor are energized e Circulator blower is energized on cool speed following a fixed five second on delay Electronic air cleaner terminals are energized with circulator blower Furnace circulator blower and outdoor cooling unit run integrated control module monitors safety circuits continuously Rand Y thermostat contacts open completing the call for cool e Outdoor fan and compressor are de energized e Circulator blower is de energized following a fixed forty five second cool off delay period Electronic air cleaner terminals are de energized Furnace awaits the next call from thermostat FAN OnLy The normal operational sequence in fan only mode is as fol lows e Rand thermostat contacts close initiating a call for fan Integrated control module performs safety ci
105. t be re moved and replaced Fix 4 Remember that all appliances must be vented inside the liner Venting one appliance inside the liner and another appliance outside the liner is not acceptable Next use a flashlight and small mirror to sight up the liner B vent must be supported so as to not come into direct contact with the chimney walls or tile liner If it is not it can probably be rehung so as to be acceptable A thimble or fire stop may be helpful here Flexible liners should be hung straight or nearly straight If it is spiraled in the chimney and in good condition it should be rehung To do this break the top seal pull up and cut off the excess liner length and refit the top seal Use caution when doing this as the cut edges of flexible liners may be sharp The surfaces of the liner must be physically sound If gaps or holes are present the metal liner must be removed and re placed Fix 4 Finally confirm that the metal liner is the cor rect size for the appliances to be installed Use the GAMA tables and rules If a metal liner is not present a clay tile liner must be present or the chimney must be lined Fix 4 Use a flashlight and small mirror at the cleanout or vent con nector to inspect the clay tile liner If any of the following prob lems are present e Tile sections misaligned e Tile sections missing Gaps between tile sections Signs of condensate drainage at the cleanout or vent connecto
106. ted ignition LED will light Integrated ignition control monitors safety circuits continuously Furnace awaits call from thermostat HEATING DIP 15 set To 1 STG Position The normal operational sequence in heating mode is as fol lows R and W thermostat contacts close initiating a call for heat Integrated control module performs safety circuit checks Induced draft blower is energized for 15 second pre purge period causing pressure switch contacts to close Igniter warm up begins after 15 second prepurge expires Low and high stage gas valves open 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 Circulator blower is energized on high heat speed following a fixed thirty second blower on delay Electronic air cleaner terminals are energized with circulator blower Furnace operates integrated control module monitors safety circuits continuously 24 R and W 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 The circulator blower remains on high speed for the selected heat off delay period Furnace awaits the next call from thermostat DIP Swircu 15 set To 2 STG Position The normal operational sequence
107. the screws removed in step 2 5 Check the location of the wiring Confirm that it will not be damaged by heat from the burners or by the rotation of the fan Also confirm that wiring location will not interfere with filter removal or other maintenance After the junction box is in the desired location use washers to connect field supplied conduit to the junction box in accordance with NEC and local codes Connect hot neutral and ground wires as shown in the furnace wiring diagram The wires and ground screw are located in the furnace junction box NOTE In downflow applications the power leads should be routed through the supplied wire tabs when rotating junction box to the left side Low voltage wires may be connected to the terminal strip IMPORTANT NOTE To avoid possible equipment malfunction route the low voltage wires to avoid interference with filter re moval or other maintenance Aywarnine HIGH VOLTAGE 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 CODE n To ensure proper unit grounding the ground wire should run from the furnace ground screw located inside the furnace junc tion 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
108. tive Pressure 3 The difference between the two numbers is 4 w c Example static reading from return duct 1 w c static reading from supply duct 3 w c total external static pressure on this system 4 w c NOTE Both readings may be taken simultaneously and read directly on the manometer if so desired If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace the readings must also include theses components as shown in the following drawing 4 Consult proper tables for the quantity of air If the total external static pressure exceeds the maximum listed on the furnace rating plate check for closed dampers regis ters undersized and or oversized poorly laid out duct work SUPPLY AIR A CUTAWAY OF DUCTWORK _ TO EXPOSE COIL NBA INCLINED MANOMETER RETURN AIR Checking Static Pressure 80 Furnace Shown 90 Similar FiLTERS READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DucTworK Filters must be used with this furnace Discuss filter mainte nance with the building owner Filters do not ship with this furnace but must be provided by the installer Filters must com ply with UL900 or CAN ULCS111 standards If the furnace is installed without filters the warranty will be voided NOTE An undersized opening will cause reduced airflow The bottom return is set up as a knock out UPRIGHT INSTALLATIONS Depending on the installation and or c
109. tside the liner Alternatively the homeowner may agree to discontinue use of the fireplace solid fuel appliance If so the tile liner must be cleaned to remove creosote buildup The fireplace opening must then be permanently sealed If oil fired appliance s are being replaced by gas fired appliance s the tile liner must first be cleaned to remove the fuel oil residue If none of the above options is practical the furnace may need to be vented vertically with a B Vent Under some conditions a 90 furnace could be installed rather than an 80 furnace The 90 furnace can be vented hori zontally or vertically through PVC pipe Fix 3 REBUILD THE CROWN If the chimney crown is damaged a qualified mason must re pair it in accordance with nationally recognized building codes or standards One such standard which may be referenced is the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 Fix 4 RELINING Relining options include B vent and flexible liners If the chimney has diagonal offsets B vent probably cannot be used If B vent is to be used it must be supported adequately Sup ports such as fire stops or thimbles must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls Direct contact would result in higher heat loss with an increased possibility of poor venting system perfor mance It is not acceptable to vent one applia
110. ure differs from table make the necessary ad a Honeywell VR8215 valve justments 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 Minimum 11 0 Remove the outlet pressure boss plug Install an 1 8 NPT hose barb fitting into the outlet pressure tap b White Rodgers 36G22 valve Back outlet pressure test screw outlet pressure boss out one turn counterclockwise not more than one turn 4 Attach a hose and manometer to the outlet pressure barb fitting Honeywell valve or outlet pressure boss White Rodgers valve 5 Turn ON the gas supply 6 Turn ON power and close thermostat and contacts to provide a call for heat 7 Using a leak detection solution or soap suds check for Gas Line leaks at outlet pressure boss plug Honeywell valve or PAS screw White Rodgers valve Bubbles forming indicate a leak SHUT OFF GAS AND REPAIR ALL LEAKS Open To IMMEDIATELY 8 Measure the gas manifold pressure with burners firing Adjust manifold pressure using the Manifold Gas Pressure table shown below ST kose Manifold Gas Pressure Gas Line Drip Leg Cap With Fitting LT Natural Gas 10 0 Manometer 9 Remove regulator cover screw from the outlet pressure M
111. urnace or both A heat pump thermostat with two stages of heat is required to properly use a furnace in conjunction with a heat pump Refer to the fossil fuel kit installation instructions for additional ther mostat requirements 16 Strictly follow the wiring guidelines in the fossil fuel kit installa tion instructions All furnace connections must be made to the furnace integrated control module and the FURNACE terminal strip on the fossil fuel control board JUNCTION Box RELOCATION A WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a right side electrical connection To make electrical connections through the opposite side of the furnace the junction box must be relocated to the left side prior to making electrical connec tions To relocate the junction box perform the following steps WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT 1 Remove both doors from the furnace 2 Remove and save the screws holding the junction box to the right side of the furnace 3 Models that have the junction box located in the burner compartment will need to move the junction box directly over 4 Attach the junction box to the left side of the furnace using
112. ustomer preference dif fering filter arrangements can be applied Filters can be in stalled in the central return register or a side panel external filter rack kit upflows or the ductwork above a downflow fur nace As alternative a media air filter or electronic air cleaner can be used as the primary filter CIRCULATION AIR FILTERS One of the most common causes of a problem in a forced air heating system is a blocked or dirty filter Circulating air filters must be inspected monthly for dirt accumulation and replaced if necessary Failure to maintain clean filters can cause prema ture heat exchanger failure A new home may require more frequent replacement until all construction dust and dirtis removed Circulating air filters are to be installed in the return air duct external to the furnace cabinet 23 MINIMUM FILTER SIZES for DISPOSABLE FILTERS POM po OM Ti 00 DISPOSABLE NOMINAL 300 FACE VELOCITY 40M 60M 80M 100M 120M 140M HORIZONTAL INSTALLATIONS Filters must be installed in either the central return register or in the return air duct work SEQUENCE OF OPERATION INTEGRATED IGniTION CONTROL Refer to Timing Charts for sequencing NOTE Dip switch positions referenced in this section applies to M D H8 models only Power Up 115 VAC power applied to furnace Integrated ignition control performs internal checks Integra
113. y are simple to service and forgiving to operate We use quality materials and components Finally every unit is run tested before it leaves the factory That s why we know There s No Better Quality Visit our websites at www goodmanmfg com or www amana hac com for information on Products Warranties Customer Services Parts Contractor Programs and Training Financing Options 2011 2012 Goodman Manufacturing Company L P 48
114. y be attached to the side panel s and or basepan For horizontally installed upflow furnaces return air ductwork must be attached to the basepan For counterflow furnaces return ductwork must be attached to the top end of the blower compartment NOTE Ductwork must never be attached to the back of the furnace HORIZONTAL INSTALLATION Vent Pipe Clearance to Combustibles 6 using Single Wall Connector or 1 using B 1 vent Doce ji Front Clearance 3 eee ES _ Adequate combustion ventilation air must be supplied to the closet Furnace must be completely sealed to floor or base Combustion ventilation air supply pipes must terminate 12 from top of closet and 12 from floor of closet DO NOT remove solid base plate for side return Clearance For S horizontal installations insert the x 8 5 8 screw from the literature package Line contact to framing is permitted when installed in the hori zontal configuration Line contact is defined as the portion of the cabinet that is formed by the intersection of the top and side ACCESSIBILITY CLEARANCE WHERE GREATER SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PRO TECTION CLEARANCE Agas fired furnace for installation in a residential garage must be installed so that the ignition source and burners are located not less than eighteen inches 18 above the floor and is protected or located to prev

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