GOODMAN Furnace/Heater, Gas Manual L0806733

User Manual: GOODMAN GOODMAN Furnace/Heater, Gas Manual GOODMAN Furnace/Heater, Gas Owner's Manual, GOODMAN Furnace/Heater, Gas installation guides

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GMS8, GHS8, GDS8

GAS-FIRED WARM AIR FURNACE

SINGLE STAGE

INSTALLATION INSTRUCTIONS

Installer. Affix all manuals adjacent to the unit.

(CATEGORY 1)

These furnaces comply with requirements

embodied in the American National

Standard /National Standard of Canada

ANSI Z21.47.CSA-2.3 Gas Fired Central

Furnaces.

_lb 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 itwell 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 distributor

or our website for the applicable product data book

referred to in this manual.

Goodman Manufacturing Comapny, L.R

2550 North Loop West, Suite 400, Houston, TX 77092

www.goodmanmfg.com

@2006 Goodman Manufacturing Company, L.R

IO-294A 8/06

Table of Contents

I. GENERAL INFORMATION ................................................................................................................................................ 4

To THEOWNER............................................................................................................................................................. 4

To THEINSTALLER.......................................................................................................................................................... 4

TRANSPORTATION DAMAGE .................................................................................................................................................. 4

I1.SAFETY ........................................................................................................................................................................... 4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................. 5

II1.PRODUCT APPLICATION ............................................................................................................................................... 5

IV. LOCATION REQUIREMENTS AND CONSIDERATIONS .................................................................................................. 6

GENERAL ....................................................................................................................................................................... 6

CLEARANCES AND ACCESSIBILITY ........................................................................................................................................ 7

HORIZONTAL INSTALLATION ................................................................................................................................................. 7

FURNACE SUSPENSION ..................................................................................................................................................... 7

EXISTING FURNACE REMOVAL ............................................................................................................................................. 7

THERMOSTAT LOCATION ..................................................................................................................................................... 8

V. COMBUSTION AND VENTILATION AIR REQUIREMENTS .............................................................................................. 8

VI. CATEGORY I VENTING (VERTICALVENTING) ............................................................................................................ 10

VII. EXTERIOR MASONRY CHIMNEYS -. ........................................................................................................................... 11

CHECKLIST SUMMARY ..................................................................................................................................................... 11

CHECK1- PROPER CHIMNEY TERMINATION ........................................................................................................................ 12

CHECK2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL .......................................................... 12

CHECK3 - CHIMNEY CROWN CONDITION ........................................................................................................................... 12

CHECK4- DEBRIS IN CLEANOUT ..................................................................................................................................... 13

CHECK 5 -LINER CONDITION .......................................................................................................................................... 13

CHECK6 - DILUTIONAIR............................................................................................................................................... 13

CHECK7-COMPLETE THE INSTALLATION ............................................................................................................................ 13

Fix I - LINERTERMINATION............................................................................................................................................. 13

Fix 2-CHANGE VENTING ARRANGEMENTS ............................................................................................................................ 14

Fix 3 - REBUILDTHECROWN.......................................................................................................................................... 14

FIX4 - RELINING.......................................................................................................................................................... 14

VIII. ELECTRICAL CONNECTIONS .................................................................................................................................... 14

WIRING HARNESS ......................................................................................................................................................... 15

115 VOLT LINE CONNECTIONS ........................................................................................................................................ 15

FOSSIL FUIEL APPLICATIONS ........................................................................................................................................... 15

JUNCTIONBOXRELOCATION ............................................................................................................................................ 15

24 VOLT THERMOSTAT WIRING ......................................................................................................................................... 16

SETTING THE HEAT ANTICIPATOR ....................................................................................................................................... 16

24VAC HUM .............................................................................................................................................................. 16

IX. GAS SUPPLYAND PIPING .......................................................................................................................................... 16

GENERAL ..................................................................................................................................................................... 17

HIGH ALTITUDE DERATE .................................................................................................................................................. 17

ALTERNATE HIGH ALTITUDE DERATE .................................................................................................................................. 17

FIRING RATE ................................................................................................................................................................. 17

PROPANE GAS CONVERSION ............................................................................................................................................ 17

GAS PIPING CONNECTIONS ............................................................................................................................................. 18

GENERAL ..................................................................................................................................................................... 18

UPFLOW INSTALLATIONS .................................................................................................................................................. 18

COUNTERFLOW INSTALLATIONS ......................................................................................................................................... 19

GAS PIPING CHECKS ..................................................................................................................................................... 19

PROPANE GAS TANKS AND PIPING.................................................................................................................................... 19

PROPANE GAS PIPING CHARTS ......................................................................................................................................... 19

X. CIRCULATING AIRAND FILTERS ................................................................................................................................. 20

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ................................................................... 20

UPRIGHT INSTALLATIONS .................................................................................................................................................. 20

CIRCULATIONAIR FILTERS .............................................................................................................................................. 20

HORIZONTAL INSTALLATIONS ............................................................................................................................................. 20

XI. SEQUENCE OF OPERATION ........................................................................................................................................ 21

POWER UP .................................................................................................................................................................. 21

NORMAL HEATING SEQUENCE ........................................................................................................................................... 21

NORMAL COOLING SEQUENCE ......................................................................................................................................... 21

Table of Contents

FAN ONLY .................................................................................................................................................................... 21

XII. START-UP PROCEDURE AND ADJUSTMENT ............................................................................................................ 21

FURNACE OPERATION ...................................................................................................................................................... 21

FURNACE START-UP ....................................................................................................................................................... 21

FURNACE SHUTDOWN .................................................................................................................................................... 22

GAS SUPPLY PRESSURE MEASUREMENT ............................................................................................................................ 22

WHITE-RODGERS36F22 GAS VALVE ....................................................................................................................... 22

WHITE-RODGERS36G22 GAS VALVE ........................................................................................................................ 22

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ................................................................................................ 23

WHITE-RODGERS36F22 GAS VALVE ........................................................................................................................ 23

WHITE-RODGERS36G22 GAS VALVE ........................................................................................................................ 23

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ......................................................................................................... 23

TEMPERATURE RISE........................................................................................................................................................ 24

CIRCULATOR BLOWER SPEED ADJUSTMENT ........................................................................................................................ 24

CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ................................................................................................................. 25

XIII. OPERATIONAL CHECKS ........................................................................................................................................... 25

BURNER FLAME ............................................................................................................................................................ 25

AUXILIARY LIMIT CONTROL .............................................................................................................................................. 25

XIV. SAFETY CIRCUIT DESCRIPTION .............................................................................................................................. 26

GENERAL ..................................................................................................................................................................... 26

INTEGRATED CONTROL MODULE ....................................................................................................................................... 26

PRIMARY LIMIT .............................................................................................................................................................. 26

AUXILIARY LIMIT ............................................................................................................................................................ 26

ROLLOUT LIMITS ........................................................................................................................................................... 26

PRESSURE SWITCHES .................................................................................................................................................... 26

FLAME SENSOR ............................................................................................................................................................. 26

XV. TROUBLESHOOTING .................................................................................................................................................. 26

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ............................................................................................................... 26

DIAGNOSTIC CHART ........................................................................................................................................................ 26

RESETTING FROM LOCKOUT ............................................................................................................................................ 26

XVI. MAINTENANCE .......................................................................................................................................................... 26

ANNUAL INSPECTION ...................................................................................................................................................... 26

FILTERS ....................................................................................................................................................................... 27

FILTER MAINTENANCE ..................................................................................................................................................... 27

FILTER REMOVAL ........................................................................................................................................................... 27

UPRIGHT FILTER REMOVAL .............................................................................................................................................. 27

INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS ........................................................................................................... 27

FLAME SENSOR (QUALIFIED SERVICER ONLY) .................................................................................................................... 27

IGNITER(QUALIFIEDSERVICERONLY)............................................................................................................................... 27

BURNERS .................................................................................................................................................................... 27

XVII. BEFORE LEAVING AN INSTALLATION .................................................................................................................... 28

XVIII. REPAIRAND REPLACEMENT PARTS .................................................................................................................... 28

TROUBLE SHOOTING CHARTS ...................................................................................................................... 29 & 30

WIRING DIAGRAM .................................................................................................................................................. 31

_. WARNING

GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.

JF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME

RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERY DAMAGE WHICH

MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR

SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

WARNING

F THE INFORMATIONIN THESEINSTRUCTIONSIS NOTFOLLOWEDEXACTLY,A

FIRE OR EXPLOSIONMAY RESULTCAUS{NGPROPERTYDAMAGE,PERSONAL

INJURY OR LOSSOFLIFE.

- Do NOTSTOREOR USEGASOLINEOR OTHERFLAMMABLEVAPORSAND

LIQUIDSIN THE VICINITYOF THIS OR ANYOTHERAPPLIANCE

- WHAT TO DO IF YOU SMELL GAS:

• DO NOT TRY TO LIGHT ANY APPLIANCE

• Do NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

PHONE IN YOUR BUILDING

• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR'S

PHONE. FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS

•IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

DEPARTMENT

- INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER

SERVICE AGENCY OR THE GAS SUPPLIER

I. GENERAL INFORMATION

AWARN,NG J

ISHOULOOVERHEAT,NGOCCURORTHEGASSOPPLYFA,LTOSHOTOFF,TORNI

iM; UALAOE ;: L,ytEXTERNALTOTHEFURNACEBEFOREI

To THE INSTALLER

Before installing this unit, please read this manual thoroughly to

familiarize yourself with specific items which must be adhered to,

including but not limited to: unit maximum external static pressure,

gas pressures, BTU input rating, proper electrical connections,

circulating air temperature rise, minimum or maximum CFM, and

motor speed connections, and venting. These furnaces are

designed for Category I venting only.

CARBON MONOXIDE POISONING HAZARD

Special Warning for Instagation 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 beater, 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 agarage, utility room or parking area and acarbon 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 ira carbon monoxide producing device continues to operate in

the enclosed area. Carbon monoxide emissions can be (re)circulated

throughout the structure if the furnace or air handler is operating in any

mode.

CO can cause serious illness including permanent brain damage or death

B10259-216

_IbWARNING

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

UALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

TO THE OWNER

it is important that you fill out the owner's registration card and

mail it today. This will assist us in contacting you should any

service or warranty information change in the future. When filling

in the registration card, be sure to include the model,

manufacturing, and serial numbers, plus the installation date.

Your warranty certificate is also supplied with the unit. Read the

warranty carefully and note what is covered. Keep the warranty

certificate in a safe location for future reference.

If additional information or operating instructions are required,

contact the dealer where the purchase was made.

Homeowner Notice:

If the residence is left unattended for an extended period of time

(i.e., 4 hours or greater), have your heating system periodically

checked to ensure proper operation. Potential circumstances

beyond our control such as power outages, gas service

interruptions, product installation, or component failures could

result in heating system operational problems.

,_ WARNING

TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,

THIS FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING

CATEGORYIII VENTING.

:PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS

)UTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF FLUE PIPE

COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.

TRANSPORTATION DAMAGE

All units are securely packed in shipping containers tested

according to international Safe Transit Association specifications.

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.

•Original or certified copy of the Bill of Lading, or indemnity

bond.

• Original paid freight bill or indemnity in lieu thereof.

• Original or certified copy of the invoice, showing trade and

other discounts or reductions.

• Copy of the inspection report issued by carrier's

representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage

and for a thorough investigation of each claim. The distributor or

manufacturer will not accept claims from dealers for transportation

damage.

Keep this literature in a safe place for future reference.

II. SAFETY

Adhere to the following warnings and cautions when installing,

adjusting, altering, servicing, or operating the furnace.

_, 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.

I_i_ WARNING

To PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

TDHUEE_LOE_ _EICcTARILCCALMSpHoONCEKNTTsH;RFoUMR _vAACTE RMUST BE LOCATED TO PROTECT

_WARNING

HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE,

INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILIDNG IN WHICH ANY

SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT

SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE

EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES

AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE

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.

ADDITIONAL SAFETY CONSIDERATIONS

•This furnace is approved for Category I Venting only.

•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.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body's static electricity before touching unit. An

electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and

servicing to protect the integrated control module from damage.

By putting the furnace, the control, and the person at the same

electrostatic potential, these steps will help avoid exposing the

integrated control module to electrostatic discharge. This

procedure is applicable to both installed and non-installed

(ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the

integrated control module or any wire connected to the

control prior to discharging your body's electrostatic

charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the

furnaces near the control Any tools held in a person's

hand during grounding will be discharged.

3. Service integrated control module or connecting wiring

following the discharge process in step 2. Use caution

not to recharge your body with 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 1through 3if

installing the control on a furnace. Return any old or new

controls to their containers before touching any ungrounded

object.

III, PRODUCT 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 installed

indoors (i.e., attic space, crawl space, or garage area provided

the garage area is enclosed with an operating door).

This furnace can be used in the following non-industrial

commercial applications:

Schools, Office buildings, Churches, Retail stores,

Nursing homes, Hotels/motels, Common or office areas

In such applications, the furnace must be installed with the

following stipulations:

•It must be installed per the installation instructions provided

and per local and national codes.

• It must be installed indoors in a building constructed on

site.

• It must be part of a ducted system and not used in a free air

delivery application.

• It must not be used as a "make-up" air unit.

• All other warranty exclusions and restrictions apply.

This furnace may be used as a construction site heater ONLY if

the following conditions are met:

• The vent system is permanently installed per these

installation instructions.

• A room thermostat is used to control the furnace. Fixed

jumpers that provide continuous heating CANNOT be used.

• Return air ducts are provided and sealed to the furnace.

• 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.

• The 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 to the

instructions under Section V, Combustion and Ventilation

Air Requirements, Section 5.3.3.

• The furnace heat exchanger, components, duct system,

air filters and evaporator coils are thoroughly cleaned

following final construction clean up.

• All furnace 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:

• Gas furnaces must be installed by a licensed plumber or

gas fitter.

• A T-handle gas cock must be used.

• If the unit is to be installed in an attic, the passageway to

and the service area around the unit must have flooring.

To ensure proper installation and operation, thoroughly read this

manual for specifics pertaining to the installation and application

of this product.

_IbWARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON

MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,

OR MAINTENANCE OF THIS PRODUCT.

I i_lb WARNIN G

To PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,v EO.cOTINSTALLTH,SFURNACEIRAMOO,LEHOME.TRA,LER.OR D ONAL

To ensure proper furnace operation, install, operate and maintain

the furnace in accordance with these installation and operation

instructions, all local building codes and ordinances. In their

absence, follow the latest edition of the National Fuel Gas Code

(NFPA 54/ANSI Z223.1 ), and/or CAN/CSA B149 Installation Codes,

local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1 ) can

be obtained from any of the following:

American National Standards Institute

1430 Broadway

NewYork, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley

Cleveland, OH 44131

A copy of the CAN/CSA B149 Installation Codes can also be

obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

The rated heating capacity of the furnace should be greater than

or equal to the total heat loss of the area to be heated. The total

heat loss should be calculated by an approved method or in

accordance with "ASHRAE Guide" or "Manual J-Load Calculations"

published by the Air Conditioning Contractors of America.

In the USA, this furnace MUST be installed in accordance with the

latest edition of the ANSI Z223.1 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 CANiCGA-B149.1

& 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

Equipment, of the National Fuel Gas Code, ANSI Z223.1, or

applicable local building and/or air conditioning codes. These

publications are available from:

National Fire Protection Association, Inc.

Batterymarch Park, Quincy, MA 02269

The G*S8X furnaces meet the California NOx emission standards

and California seasonal efficiency standards. ANNUAL

inspections of the furnace and its vent system is strongly

recommended.

IV. LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL

Model type determines which installation procedures must be

used. For GMS and GHS models, you must follow instructions for

Horizontal Left, Horizontal Right or Upflow installations only. GMS

and GHS models are not approved for Downflow installations.

For GDS models, you must follow instructions for Counterflowl

Downflow installation only. GDS models are not approved for

Horizontal or Upflow installations.

A_ WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON

MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,

OR MAINTENANCE OF THIS PRODUCT.

i_ WARN IN G

I To PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace

location. Refer also to the guidelines provided in Section V,

Combustion and Ventilation Air Requirements.

• 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.

• 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 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.

• If the furnace is installed in a residential garage, position

the furnace so that the burners and ignition source are

locatednotlessthan18inches(457mm)abovethefloor.

Protectthefurnacefromphysicaldamagebyvehicles.

• If thefurnaceisinstalledhorizontally,thefurnaceaccess

doorsmustbeverticalsothattheburnersfirehorizontally

intotheheatexchanger.Donotinstalltheunitwiththe

accessdoorsonthe"up/top"or"down/bottom"sideofthe

furnace.

• Donotconnectthisfurnacetoachimneyfluethatservesa

separateappliancedesignedtoburnsolidfuel.

• OnCounterflowinstallations,theairconditioningcoilmust

bedownstreamfromtheheatexchangerofthefurnace.

•Counterflow Installation over a noncombustible floor.

Before 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 silicone 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 Product Data Book

applicable to your model for details). A special accessory

subbase must be used for upright counterflow unit

installations over any combustible material including wood.

Refer to subbase instructions for installation details.

Follow the instructions with the subbase for proper

installation. 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.)

Vent Pipe Clearance to Combustibles-

6" using Single Wall Connector or 1"

using B-1 vent.

Side

Clearance

Front Clearance - 3"

• 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.

• 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

recommended.

VENT SIDES FRONT BACK

BI-VENT I SINGLE1" 6" 1" 3" 0"

Top clearance for horizontal configuration - 1"

TOP

(PLENUM)

HORIZONTAL INSTALLATION

Line contact to framing is permitted when installed in the horizontal

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 PROTECTION

CLEARANCE. A gas-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 prevent physical damage by vehicles.

A gas furnace must not be installed directly 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"x3i8" angle iron as shown below. The length of rod

will depend on the application and the clearances necessary.

PROVIDE 8" MINMUM CLEARANCE BETWEEN

CENTER ROB AND FURNACE CABINET

3/8" DIAMETER

HOL" tTOW

Eu::°tT

2" X 2" X3/8"

ANGLE iRON POSITION AS CLOSE AS POSSIBLE

(3PLACES)TO BLOWER BECK TO ALLOW FOR

CIRCULATOR BLOWER REMVOAL

Suspended Furnace

EXISTING FURNACE 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

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL

NOTE: When an existing furnace is removed from a venting system

serving other appliances, the venting system may be too large to

properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for

Gas-Fired Central Furnaces ANSI Z21.47-Latest Edition, 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 B149 installation Codes and these

instructions. Determine that there is no blockage or

restriction, leakage, corrosion and other deficiencies which

could cause an unsafe condition;

c. 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

appliancenotconnectedto theventingsystem.Turnon

anyexhaust 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 into operation. Adjust thermostat so appliance

shall operate continuously;

e. 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 appliance connected

to the venting system properly vents when tested as outlined

above, return doors, windows, exhaust fans, fireplace

dampers and any other gas burning appliance to their

previous conditions of use;

g. If improper venting is observed during any of the above

tests, the common venting system must be corrected.

Corrections must be in accordance with the latest edition of the

National Fuel Gas Code NFPA 54/ANSI Z223.1 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 Z223.1 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 following:

• Drafts, or dead spots behind doors, in corners, or under

cabinets.

• Hot or 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.

Thermostat Influences

Consult the instructions packaged with the thermostat for mounting

instructions and further precautions.

V. COMBUSTION AND VENTILATION AIR REQUIREMENTS

IjlLWARN'NG !

To AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, SUFFICIENT

"O'2,O°,VE,";',t,AjOE O;L , 2 MUETI

FURNACE AREA. |

Improved construction and additional insulation in buildings have

reduced heat loss by reducing air infiltration and escape around

doors and windows. These changes have helped in reducing

heating/cooling costs but have created a problem supplying

combustion and ventilation air for gas fired and other fuel burning

appliances. Appliances that pull air out of the house (clothes

dryers, exhaust fans, fireplaces, etc.) increase the problem by

starving appliances for air.

House depressurization can cause back drafting or improper

combustion of gas-fired appliances, thereby exposing building

occupants to gas combustion products that could include carbon

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 Z223.1 (Section 5.3), or CANICSA B149 Installation Codes

(Sections 7.2, 7.3, or 7.4), 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 (i.e., sealed combustion) 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.

The following information on air for combustion and ventilation is

reproduced from the National Fuel Gas Code NFPA 54/ANSI

Z223.1 Section 5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment

installed in buildings and which require air for combustion,

ventilation and dilution of flue gases from within the building.

They do not apply to (1) direct vent equipment which is

constructed and installed so that all air for combustion is

obtained from the outside atmosphere and all flue gases

are discharged to the outside atmosphere, or (2) enclosed

furnaces which incorporate an integral total enclosure and

use only outside air for combustion and dilution of flue

gases.

(b) Equipment shall be installed in a location in which the

facilities for ventilation permit satisfactory combustion of

gas, proper venting and the maintenance of ambient

temperature at safe limits under normal conditions of use.

Equipment shall be located so as not to interfere with

proper circulation of air. When normal infiltration does not

provide the necessary air, outside air shall be introduced.

be provided as required for: cooling of equipment or

material, controlling dew point, heating, drying, oxidation

or dilution, safety exhaust, odor control, and air for

compressors.

(d) In additionto air neededfor combustion,air shallbe

suppliedforventilation,includingallairrequiredforcomfort

andproperworkingconditionsforpersonnel.

(e)Whileallformsofbuildingconstructioncannotbecovered

indetail,air for combustion, ventilation and dilution of flue

gases for gas utilization equipment vented by natural draft

normally may be obtained by application of one of the

methods covered in 5.3.3 and 5.3.4.

(f) Air requirements for the operation of exhaust fans, kitchen

ventilation systems, clothes dryers, and fireplaces shall be

considered in determining the adequacy of a space to

provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings,

infiltration may be adequate to provide air for combustion

ventilation and dilution of flue gases. However, in buildings

of tight construction (for example, weather stripping, heavily

insulated, caulked, vapor barrier, etc.), additional air may

need to be provided using the methods described in 5.3.3-

b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not

less than 50 cubic feet per 1,000 BTU per hour of the

aggregate input rating of all appliances installed in that

space. Rooms communicating directly with the space in

which the appliances are installed through openings not

furnished with doors, are considered a part of the

unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) All Air from Inside the Building: The confined space shall

be provided with two permanent openings communicating

directly with an additional room(s) of sufficient volume so

that the combined volume of all spaces meets the criteria

for an unconfined space. The total input of all gas utilization

equipment installed in the combined space shall be

considered in making this determination. Each opening

shall have a minimum free area of 1 square inch per 1,000

BTU per hour of the total input rating of all gas utilization

equipment in the confined space, but not less than 100

square inches. One opening shall be within 12 inches of

the top and one within 12 inches of the bottom of the

enclosure.

NOTE: Each opening must have

afree area of not less than one

square inch per 1000 BTU of

the total input rating of all equip-

ment in the enclosure, but not

less than 100 square inches. ...................................................

Equipment Located in Confined Spaces;

All Air from Inside Building. See 5.3.3-a.

the bottom of the enclosure. The openings shall

communicate directly, or by ducts, with the outdoors or

spaces (crawl or attic) that freely communicate with the

outdoors.

1. When directly communicating with the outdoors, each

opening shall have a minimum free area of 1 square

inch per 4,000 BTU per hour of total input rating of all

equipment in the enclosure.

NOTE: The inlet and outlet air

openings must each have a free

area of not less than one square

inch per 4000 BTU of the

total input rating of all equipment

in the enclosure.

unheated rlawl space

Equipment Located in Confined Spaces; All Air from Outdoors--

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated

Attic, See 5.3.3-b

2. When communicating with the outdoors through vertical

ducts, each opening shall have aminimum free area of

1 square inch per 4,000 BTU per hour of total input

rating of all equipment in the enclosure.

_Chim ey or Gas Vent

; Venti a_ on Iouve s

f (each end of attic_

__'_ NOTE: The inlet and outlet air

openings must each have a free

Jl _ II IJ\_. _,1 area of not less than one square

IIi ] II II _ inch per 4000 BTU of the

..................l _ total input rating of all equipment

.........,o,..eoo,o.o..

Heater Inlet air ducl

[ends ft (300 ram)

ve I_r]

Equipment Located in Confined Spaces; All Air from Outdoors

Through Ventilated Attic, See 5.3.3-b.

3. When communicating with the outdoors through

horizontal ducts, each opening shall have a minimum

free area of 1 square inch per 2,000 BTU per hour of

total input rating of all equipment in the enclosure.

(b) AflAirfrem Outdoors: The confined space shall be provided

with two permanent openings, one commencing within 12

inches of the top and one commencing within 12 inches of

LI I Watel

rn_ce I rlea_er

_1_r! _

NOTE: The air duct openings

must have a free area of not

less than one square inch per

2000 BTU of the total input

rating of atl equipment in the

enclosure*.

Equipment Located in Confined Spaces; All Air from Outdoors.

See 5.3.3-b.

*If the appliance room is located against an outside wall and the

air openings communicate directly with the outdoors, each opening

shall have a free area of not less than one square inch per 4,000

BTU per hour of the total input rating of all appliances in the

enclosure.

4. When ducts are used, they shall be of the same cross-

sectional area as the free area of the openings to which

they connect. The minimum dimension of rectangular

air ducts shall not be less than 3 inches.

NOTE: The single opening must have

a free area of not less than one

square inch per 3000 BTU of

the total input rating of all equip-

ment in the enclosure,

the sum of the areas of a!l vent

connectors in the confined space.

Chimney or Gas Vent

Opening

•Altel_ate

Opening

Location

Equipment Located in Confined Spaces; All Air from Outdoors -

Single Air Opening. See 5.3.3-b.

5. One permanent opening may be permitted, provided the

equipment has clearances of at least 1" from the sides

and back and 6" from the front. The opening shall

communicate directly with the outdoors and must be

located within 12" of the top of the enclosure. The

minimum free area of the opening shall be 1 square

inch per 3,000 BTU per hour of total input rating of all

equipment in the enclosure. The minimum free area

shall not be less than the sum of the areas of all vent

connectors in the confined space.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when

special engineering, approved by the authority having

jurisdiction, provides an adequate supply of air for combustion,

ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given

to the blocking effect of louvers, grilles or screens protecting

openings. Screens used shall not be smaller than 1/4 inch

mesh. If the area through a design of louver or grille is known,

it should be used in calculating the size of opening required

to provide the free area specified. If the design and free area

is not known, it may be assumed that wood louvers will have

20-25 percent free area and metal louvers and grilles will

have 60-75 percent free area. Louvers and grilles shall be

fixed in the open position or interlocked with the equipment

so that they are opened automatically during equipment

operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or

Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers,

or fireplaces may create conditions requiring special attention

to avoid unsatisfactory operation of installed gas utilization

equipment.

Vl. CATEGORY I VENTING (VERTICAL VENTING)

I AWARN'NG

To PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,

THIS FURNACE MUST BE CATEGORY I VENTED. Do NOT VENT USING

CATEGORYIII VENTING.

Category I Venting is venting at a non-positive pressure. A furnace

vented as Category I is considered a fan-assisted appliance 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 allowing, in some instances,

common venting with natural draft appliances (i.e. water heaters).

All installations must be vented in accordance with National Fuel

Gas Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, the

furnaces must be vented in accordance with the National Standard

of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 -latest editions

and amendments.

NOTE: The vertical height of the Category I venting system must

be at least as great as the horizontal length of the venting system.

I a,WARN,NG

I To PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,

The minimum vent diameter for the Category I venting system is

as shown:

MODEL

115

140

MINIMUM VENT

UPFLOW COUNTERFLOW

4 Inch 4 Inch

5 Inch 5 Inch

Under some conditions, larger vents than those shown above

may be required or allowed. When an existing furnace is removed

from a venting system serving other appliances, the venting system

may be too large to properly vent the remaining attached

appliances.

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 for Category I venting. For horizontal installations, a

four inch single wall pipe can be used to extend the induced draft

blower outlet 1/2" beyond the furnace cabinet. Vent the furnace in

accordance with the National Fuel Gas Code NFPA 54/ANSI

Z223.1 - latest edition. In Canada, vent the furnace in accordance

with the National Standard of Canada, CAN/CSA B 149.1 and CAN/

CSA B149.2 - latest editions and amendments.

Venting

THIS FURNACE IS NOT DESIGN CERTIFIED TO BE

HORIZONTALLY VENTED.

:Supply Air

Upflow Rotated Induced Draft Blower

To rotate the induced draft blower, proceed as follows:

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 appropriate side of the

furnace.

4. Remove and save the four screws that hold the induced

draft blower to the flue collector box.

5. Turn the induced draft blower 90 degrees clockwise, or

counterclockwise. The gasket is adhered to the back

plate and will rotate with the blower assembly.

6. Reinstall the induced draft blower on the flue collector

box, using the four screws removed in Step 3. Tighten

screws to provide an airtight seal.

7. 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.

8. Remove and save the screw that holds the pressure

switch to the furnace top panel.

9. Relocate the pressure switch to the same side as the

flue outlet in the hole provided.

10. Reconnect the draft blower power leads, flue pipe, and

pressure switch tubing. Make sure that all wires and the

pressure switch tubing are at least one inch from the flue

pipe, or any other hot surfaces.

11. Restore power to the furnace.

Counterflow units are shipped with the induced draft blower

discharging from the top of the furnace. ("Top" as viewed for a

counterflow installation.) Vent the furnace in accordance with

the National Fuel Gas Code NFPA 54/ANSI Z223.1 -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.

WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON

MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY,

VII. EXTERIOR MASONRY CHIMNEYS -

CATEGORYI FURNACES ONLY

An exterior masonry chimney is defined as a "Masonry chimney

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.

Researchers 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.

_I, 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 [$COMMONVENTED

WITH A DRAFT HOOD EQUIPPED APPLIANCE OR THE CHIMNEY IS LINED WITH A

METAL LINER OR TYPE SMETAL VENT. ALL INSTALLATIONS USING MASONRY

CHIMNEYS MUST BE SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING

TABLES. IF AN 80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD

EQUIPPED APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY

STILL EXIST WITH EXTREMELY COLD CONDmONS, LONG VENT CONNECTORS,

EXTERIOR CH[MNEYS_ OR ANY COMBINATION OF THESE CONDmONS. THE

RISK OF CONDENSATION DAMAGE iS BEST AVOIDED BY USING THE MASONRY

CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR TYPE S

METAL VENT.

Crown _Wash

Roof Line

Clay Tie Size Generally _'

12" x I2" (24" Length) C_ay Tib Sze: 8' x 8" x/2"

(Each x 24' Length)

Attic Floor

i Second Floor

First Floor

Wate_ Heater

ili"*_JFA F Vent ir _L VentConnector

Fan Assisted Natural Dlaft

C can O Forced Air Wate_ Heate_

Basement Floor

Typical Multiple Flue Clay Tile Chimney

CHECKLIST SUMMARY

This checklist serves as a summary of the items to be checked

before venting an 80+ furnace into a masonry chimney. In addition,

we recommend that a qualified serviceman use this checklist to

perform a yearly inspection of the furnace venting system.

This checklist is only a summary. For detailed information on

each of the procedures mentioned, see the paragraph referenced

with each item.

This inspection is based upon a draft topical report, "Masonry

Chimney inspection and Relining", issued by the Gas Research

Institute. While not yet finalized, we believe this report represents

the best information on this subject which is currently available.

Proper Chimney

Termination?

(Check1)

Chimneychannel

free of solidand

liquid fuel

appliances?

Crownin good ileal

condition

(Check 3)

Cleanout free of

debris?

(Check 4)

Liner in good _\1

condition?

(Check 5)

Dilutionair _

available?

(Check 6)

Completethe

installation

(Check 7)

_ Line, terminate with

listed vent cap

(Fix 1)

Change venting

arrangements

(Fix 2)

Rebuild crown

(Fix 3)

and/or Reline

(Fix 4)

Reline

(Fix 4)

Reline

(Fix 4)

Reline

(Fix 4)

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 equipment 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 extend the chimney. If this will not be

practical, see Fix 1.

-10' or Less--_.

_2'%in:! 2' Min_ _ m

T===T = 31! il Min.

10' or Less

Termination 10 Feet Or Less From Ridge, Wall or Parapet

More Than 10'------1_ t

NOTE: No height

above parapet required

Wall or when distance from hi ney

Parapet walls or parapet is

more than 10 feet

Height above any

More than 10' 4_ roof surface within

/_10 feet horizontally.

_10' ----_._"

Termination More Than 10 Feet From Ridge, Wall or Parapet

CHECK2 -ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO

THIS CHIMNEY CHANNEL

Solid fuel appliances include fireplaces, wood stoves, coal

furnaces, and incinerators.

Liquid fuel appliances include oil furnaces, oil-fired boilers and

oil-fired water heaters.

Appliances which burn propane (sometimes referred to as LP

(liquefied petroleum)) gas are considered gas-fired appliances.

CHECK3- CHIMNEY CROWN CONDITION.

Damage from condensate usually shows up first in the crown. If

any of the following trouble signs are present, the condition of the

crown is not satisfactory:

a) Crown leaning

b) Bricks missing

c) Mortar missing

d) Tile liner cracked

e) No tile liner

f) Salt staining at mortar joints. (White stains, and mortar

becomes sandy and/or erodes.)

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.

CHECK4 - DEBRIS IN CLEANOUT

A cleanout (dropleg) must be present such that the upper edge

of the cleanout cover is at least 12 inches below the lower edge

of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blocked by

debris. If no cleanout is present, the chimney must be refined

(Fix 4). Remove the cleanout cover, and examine the cleanout for

debris. If significant amounts of any of the following are found:

• Fuel oil residue

• Bricks

• Mortar or sand

• Pieces of the tile liner

• Rusted pieces of the metallic liner - reline the chimney

(Fix4).

CHECK 5 -LINER CONDITION.

If a metal liner is present, it must be checked. It cannot be

assumed that all existing metal liners are correctly installed and

in good condition.

Remove the lowest existing vent connector, and examine the

inside of the elbow or tee at the base of the liner. A small amount

of soot may be considered acceptable, provided the installer

vacuums it away. If rusted pieces of the liner have collected here,

the metal liner must be removed and replaced (Fix 4).

Next, gently tap the inside of the liner with a Phillips screwdriver.

If the screwdriver perforates the liner, or if the tapping does not

sound like metal hitting metal, the liner must be removed and

replaced (Fix 4).

Remember that all appliances must be vented inside the liner.

Venting one appliance inside the liner and another appliance

outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner. B vent

must be supported so as to not come into direct contact with the

chimney walls or tile liner. If it is not, it can probably be rehung so

as to be acceptable. A thimble or fire stop may be helpful here.

Flexible liners should be hung straight or nearly straight. If 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 replaced

(Fix 4). Finally, confirm that the metal liner is the correct 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 connector

to inspect the clay tile liner. If any of the following problems are

present:

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent

connectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an

approved fire clay tile reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to do this

from the cleanout. The liner must be at least as large as the

minimum size established by the tables in National Fuel Gas

Code NFPA 54/ANSI Z223.1 - latest edition and in the National

Standard of Canada, CAN/CSA B149.1 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).

CHECK 6-DILUTION AIR.

If gas-fired appliances are to be vented into a clay tile liner, a

source of dilution air is required.

Dilution air cannot be obtained through:

• 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).

CHECK7-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 Z223.1 - latest edition and in the National

Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 -

latest editions and amendments, then the clay tile liner can

probably be used as a vent 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.)

• Exterior chimneys (The tables in National Fuel Gas Code

NFPA 54/ANSI Z223.1 - latest edition and in the National

Standard of Canada, CAN/CSA B149.1 and CANiCSA

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 caplroof

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

appliances vented outside the liner.

Alternatively, the homeowner may agree to discontinue use of

the fireplace (solid fuel appliance). If so, the tile liner must be

cleaned to remove creosote buildup. The fireplace opening must

then be permanently sealed.

If oil-fired appliance(s) are being replaced by gas-fired

appliance(s), the tile liner must first be cleaned to remove the

fuel oil residue.

If none of the above options is practical, the 80% 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. A 90%+ furnace can be vented horizontally

or vertically through PVC pipe.

FIX 3- REBUILD THE CROWN

If the chimney crown is damaged, a qualified mason must repair

it in accordance with nationally recognized building codes or

standards. One such standard which may be referenced is the

Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning

Appliances, ANSI/NFPA 211.

Fix 4-RELINING

Relining options include B vent and flexible liners.

If the chimney has diagonal offsets, B vent probably cannot be

used.

If B vent is to be used, it must be supported adequately. Supports

(such as fire stops or thimbles) must be used to prevent the B

vent from coming into direct contact with the tile liner or chimney

walls. Direct contact would result in higher heat loss, with an

increased possibility of poor venting system performance.

It is not acceptable to vent one appliance inside the B vent and

other appliances outside. The excess space between the B vent

and the chimney walls must be covered at the top of the chimney

by a weatherproof, corrosion resistant flashing.

The B vent should then be topped with a listed vent cap. The

listed vent cap will, when installed per the manufacturer's

instructions, prevent problems due to rain, birds, or wind effects.

A 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, CANiCSA B149.1 and CANiCSA

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 chlorinetfluorine compounds.

•Heavier gauge 300 and 400 series stainless steel liners

were developed for use with oil or solid fuel appliances.

They are not suitable for use with gas-fired appliances.

Flexible liners specifically intended and tested for gas

applications are listed in the UL "Gas and Oil Equipment

Directory". (UL Standard 1777).

For sizing of flexible liners, see Note 22 and the tables in the

National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition

and in the National Standard of Canada, CAN/CSA B149.1 and

CAN/CSA B149.2 - latest editions and amendments.

To install the liner, read and follow the liner manufacturer's

instructions and your local codes. Excess liner length should be

pulled out of the chimney and cut off. Use caution when doing

this, as the cut edges of flexible liners may be sharp. Do not

spiral excess liner inside of the chimney. Support the liner as

recommended by the liner 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 materials,

is no longer recommended.) insulation will need to be added to

the flexible liner if:

• It is required by the liner manufacturer's instructions.

• The previous liner was properly sized and installed, and

suffered from condensation damage.

• It is required by your local building codes.

Even if none of those three conditions exist which require

additional liner insulation, the installer may wish to consider it if:

• The local climate is very cold.

• The chimney is very tall.

• The vent connectors used are very long or have a large

number of elbows.

• Local experience indicates that flexible liners installed

without insulation are likely to have condensation

problems.

Insulation must be selected and installed in accordance with the

liner manufacturer's instructions.

Finally, cap the chimney and terminate the liner in accordance

with the liner manufacturer's instructions.

VIII. ELECTRICAL CONNECTIONS

_L, WARNING

To AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE

POLARIZED AND GROUNDED.

I ,WARN,NG

ITo AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL

_POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

i_ CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

VERIFY PROPER OPERATION AFTER SERVICING.

I _ibWARNING

ITo AVOID THE RISK OF ELECTRICAL SHOCK OR THE FURNACE

INJURY, DEATH,

, %IB2L; T:I;ALILY DAN% IH,LO:tLEtT IOR

CODE.

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field

alteration to comply with electrical codes should not be required.

Wires are color coded for identification purposes. Refer to the

wiring diagram for wire routings. If any of the original wire as

supplied with the furnace must be replaced, it must be replaced

with wiring material having a temperature rating of at least 105 ° (3.

Any replacement wiring must be a copper conductor.

115VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the

supply voltage, frequency, and phase correspond to that specified

on the unit rating plate. Power supply to the furnace must be NE(3

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 (3SA

(322.1.

Use a separate fused branch electrical circuit containing properly

sized wire, and fuse or circuit breaker. The fuse or circuit breaker

must be sized in accordance with the maximum overcurrent

protection specified on the unit rating plate. An electrical 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.

FOSSIL FUEL APPLICATIONS

This furnace can be used in conjunction with a heat pump in a

fossil fuel application. A fossil fuel application refers to a combined

gas furnace and heat pump installation which uses an outdoor

temperature sensor to determine the most cost efficient means

of heating (heat pump, gas furnace, 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 thermostat

requirements.

Strictly follow the wiring guidelines in the fossil fuel kit installation

instructions. All furnace connections must be made to the furnace

integrated control module and the FURNACE terminal strip on the

fossil fuel control board.

JUNCTIONBOX RELOCATION

_IbWARNING

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.

I _WARNING

lEDGES OF SHEET METAL HOLES MAY BE SHARP, GLOVES AS A PRE-

USE

CAUTION 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 left 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 connections. To relocate

the junction box, perform the following steps.

_IbWARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,

DISCONNECT ELECTRICAL POWER.

1. Remove both doors from the furnace.

2. Remove and save the screws holding the junction box to

the left side of the furnace.

3. Models that have the juction box located in the blower

compartment will need to rotate the junction box 180

degrees. Models that have the junction box located in the

burner compartment will need to move the juction box

directly over.

4. Attach the junction box to the right side of the furnace, using

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.

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 removal

or other maintenance.

Integrated Ignition Control

I_WARNING

ToAVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE

MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR,

INTHEIRABSENCE,WITHTHE LATESTEDITIONOF THE NATIONALELECTRIC

CODE.

To ensure proper unit grounding, the ground wire should run from

the furnace ground screw located inside the furnace junction box

all the way back to the electrical panel. NOTE: Do not use gas

piping as an electrical ground. To confirm proper unit grounding,

turn off the electrical power and perform the following check.

1. Measure resistance between the neutral (white)

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

Reconnect the yellow wire to the "piggyback" terminal on the

brown jumper and then connect the 24 VAC line of the humidifier

to the stripped end of the brown 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 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.

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

connections for a "heat only" system and "heat/cool system".

Heating Heating/Cooling

Room Thermostat Room Thermostat

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.

SETTING 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

• Wrap the "R" leg around a clip-on ammeter 10 times.

• Energize the furnace in the heat mode.

• Record the reading.

• 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.

24 VOLT HUMIDIFIER

The yellow wire connected to the I.D. Blower pressure switch is

powered anytime the pressure switch is closed and provides 24

VAC humidifier control. Remove the yellow wire and connect the

supplied brown jumper wire to the pressure switch terminal.

IX. GAS SUPPLY AND PIPING

GENERAL

The furnace rating plate includes the approved furnace gas input

rating and gas types. The furnace must be equipped to operate

on the type of gas applied. This includes any conversion kits

required for alternate fuels and/or high altitude.

_i_ CAUTION

ITo PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET

G AT: :UPLPLYNPRRE:SUuR:NMUL.CT ::tSIRSEFDEC_;IptDA:NETHEpUNIRTTRI:'iGING PLATE

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

appliances 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 IMinimum: 5.0" w.c. Maximum:10.0"w.c.

Propane Gas IMinimum: 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 altitudes, the manifold pressure must be within 0.3 inches

w.c. of that listed in the Product Data Book 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 furnace

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.

When this furnace is installed at high altitude, the appropriate

High Altitude orifice kit must be applied. The furnace is supplied

with orifices sized for natural gas at altitudes up to 4,500 feet

using a heating value of approximately 1,000 Btu/hr, and should

not normally require change. Most cases will not require a change

at altitudes up to 7,500 feet. For use at altitudes in excess of

4,500 feet, refer to the following table for maximum input rates

based on altitude. Contact your local gas utility for the heating

value of the gas. Refer to National Fuel Gas Code ANSI Z223.1

and the following section to calculate firing rates.

Altitude

(R) 140

5,000 117,000

7,500 105,000

10,000 92,400

Maximium Firing Rates AtAItitude

Model(Kbtu/hr)

45 70 90 115

39,000 58,500 78,000 97,500

35,000 52,500 70,000 87,500

34,000 51,000 88,000 77,000

Firing rates may be lower than listed in table

It is important to check and adjust the input rate of the furnace to

prevent an overfiring situation. Overfiring can cause premature

heat exchanger failure. The input is controlled by the supply

pressure, orifice size, manifold pressure and heating (calorific)

value of the gas.

The supply pressure must be measured with this and all other

gas burning appliances in operation. The supply pressure must

be adjusted to the pressure range stated on the rating plate.

Applications for altitudes in excess of 4,500 feet usually require

an orifice change.

ALTERNATE HIGH ALTITUDE DERATE

Alternately standard derate for altitude from National Fuel Gas

Code ANSI Z223.1 of 4% per 1000' may be taken. Refer to the

most recent version of ASNI Z223.1 for correct gas orifice. The

orifices must be selected using the table below. The furnace

derate is 4% for each 1,000 feet above sea level. This table is

based upon a heating value of approximately 1,000 Btu/ft 3

NAT. GAS

ALTITUDE ORIFICE SIZE

0 - 2,000 #43

3,000 #44

4,000 #44

5,000 #45

6,000 #45

7,000 #46

The input to the furnace must be checked AFTER reorificing.

For altitudes above 4,500 feet, refer to appropriate section of the

National Fuel Gas Code, ANSI Z223.1. To calculate the input of

the furnace for installations in altitudes over 7,000 feet, use the

following formula:

Corrected Input = Rating Plate input - (Altitude X .04) X (Rating

Plate input /1000)

Example:

Corrected input for a 90,000 Btu/hr. appliance installed at an

altitude of 6,000 ft. utilizing natural gas with a heating value of

1,000 Btu/ft 3 is determined by-

Corrected input = 90,000 - (6,000 X .04) X (90,000 /1,000)

Corrected input = 90,000 - (240 X 90)

Corrected input = 90,000 - 21,600

Corrected Input = 68,400

FIRING RATE

Using the orifices sized as shown in the table for 6,000 feet

(#45), a meter time of 52.6 seconds is measured. The actual

firing rate of the furnace is:

Input = 1,000 (heating value of the gas) X 3600 (constant) /52.6

(meter time for 1 ft3of gas)

Input = 3,600,000 /52.6

Input = 68,400 Btu/h

Meter Time In Minutes and Seconds For Normal Input Rating of

Furnaces Equipped For Use With Natural Gas

INPUT METER HEAT HEAT HEAT HEAT

SIZE VALUE VALUE VALUE VALUE

Btu/hr FT 3 900 1,000 1040 t.100

MiN. SEC. MiN SEC MIN SEC MiN SEC

40,000 1 1 21 1 30 1 33 1 39

10 13 30 15 00 15 36 16 30

60,000 1 0 54 1 00 1 03 1 06

10 9 00 10 10 10 24 11 00

80,000 1 0 41 0 45 0 47 0 50

10 6 45 7 30 7 48 8 15

100,000 1 0 32 0 36 0 37 0 40

10 5 24 6 00 6 14 6 36

120,000 1 0 27 0 30 0 31 0 33

10 4 30 5 00 5 12 5 30

In Canada, the rating plate input for the furnace apply to

installations up to 4,500 feet (1370m) above sea level. Canadian

certification applies to the installations of up to 4,500 feet above

sea level, installations above 4,500 feet are subject to acceptance

by the local authorities having jurisdiction.

Do not derate the furnace by adjusting the manifold pressure to

a lower pressure than specified on the furnace rating plate. The

combination of the lower air density and a lower manifold

pressure will prohibit the burner orifice from drawing the proper

amount of air into the burner. This may cause incomplete

combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in

an effort to compensate for the effects of altitude. If the gas is

artificially derated, the appropriate orifice size must be determined

based upon the BTU/ft 3content of the derated gas and the altitude.

Refer to the National Fuel Gas Code, N FPA 54/ANSI Z223.1, and

information provided by the gas supplier to determine the proper

orifice size.

Some models require a pressure switch change due to the

reduced air density above certain altitudes. Refer to the following

table to determine proper pressure switch settings for your

application.

A different pressure switch may be required at high altitude

regardless of the BTU/ft 3 content of the fuel used. Contact your

distributor for appropriate altitude ranges and pressure switch

kits.

Pressure Switch Changes

Furnace input Kbtu/hr Altitude (ft) Switch Setting (inches w.c.)

45 8000' 0.55

70 NR

90* 8000' 0.60

115 NR

140 NR

904BNA does not require a switch change

PROPANE GAS CONVERSION

_, WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF

THE CORRECT CONVERSION KITS ARE NOT INSTALLED, THE APPROPRIATE KIT=

MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL

CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE

AGENCY.

This unit is configured for natural gas. The appropriate

manufacturer's propane gas conversion kit, must be applied for

propane gas installations. Refer to the "Propane Gas and/or

High Altitude installations" section for details.

Contact your distributor for a tabular listing of appropriate

manufacturer's kits for propane gas andlor high altitude

installations. The indicated kits must be used to insure safe and

proper furnace operation. All conversions must be performed by

a qualified installer, or service agency.

GAS PIPING CONNECTIONS

GENERAL

_CAUTION

To AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE

DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF

NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE

METERITANK 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 Z223.1.

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of Nominal Black Rpe Size

Rpe in Feet 112" 314" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 980

40 63 130 245 500 760

50 56 115 215 440 670

60 50 105 195 400 610

70 46 96 180 370 560

80 43 90 170 350 530

90 40 84 160 320 490

100 38 79 150 305 460

Pressure 0.5 psig or tess and pressure drop of 0.3" WC.; Based on

060 Specific Gravity Gas)

CFH= BTUHFurnaceInput

HeatingValue of Gas (BTU/CubicFoot)

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.

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 to trap dirt and moisture before it can enter

the gas valve. The drip leg must be a minimum of three

inches long.

• install a 1/8" NPT pipe plug fitting, accessible for test gage

connection, immediately upstream of the gas supply

connection to the furnace.

• 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 VaIve

(InstalIed Ahead of _ t

Ground Joint Pipe Union)

Height Required

By Local Code

Ground Joint Pipe Union

To Be installed Ahead of n\

Gas Valve

Drip Leg m-.

Reducing Coupling _

1/2" x 1/8" with 1/8"

Pipe Plug To Measure

Line Gas Pressure

General Furnace La _ut

UPFLOW INSTALLATIONS

When the gas piping enters through the right side of the furnace,

the installer must supply the following fittings (starting from the

gas valve):

• 90 degree elbows (2).

• Close nipple.

• 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 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.

• A ground joint union, drip leg, and manual shutoff valve

must also be supplied by the installer. In some cases, the

installer may also need to supply a transition piece from 1/

2 inch to another pipe size.

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 some cases, the installer may also

need to supply a transition piece from 1/2" to another pipe size.

When the gas piping enters through the right side of the furnace,

the installer must supply the following fittings (starting at the gas

valve):

• 90 degree elbow.

• Close nipple.

• 90 degree elbow.

• Straight pipe to reach exterior of furnace.

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas

connections.

AwA..,.G t

To AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR

OPEN FLAME TO TEST FOR LEAKS.

Check for leaks using an approved chloride-free soap and water

solution, an electronic combustible gas detector, or other approved

testing methods.

_ CAUTION

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 piping

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 closing

its manual shutoff valve before pressure testing of gas supply

piping system with test pressures equal to or less than 1/2 psig

(3.48 kPa).

PROPANE GAS TANKS AND PIPING

_IbWARNING

IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED

AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDEDTO

CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING

WARNING DEVICE IN CASE OF A GAB 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 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 standards

of the National Board of Fire Underwriters, NBFU Manual 58.

For satisfactory operation, propane gas pressure must be 11 inch

WC at the furnace manifold with all gas appliances in operation.

Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid,

and "wetted surface" area of the container or containers.

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,

recommended 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 ®, Clyde's ®

or John Crane ® are satisfactory.

Refer to the following illustration for typical propane gas

installations and piping.

5to 15 PS]G

First Stage

Reg_J (20 PSIG Max') Conti11......W.C.

- 200 PSIG _ Second Stage

Maximum

! i

Propane Gas Installation (Typ.)

PROPANE GAS PIPING CHARTS

Sizing Between First and Second Stage Regulator*

Maximum Propane Capacifes listed are based on 2 psig pressure drop at 10 psJg setfng

3aciSes in 1,000 BTU/hour

Pipe or

Tubing Tubing Size, O.D. Type L Nominal Pipe Size

Length, Schedule 40

Feet 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"

10 730 1,708 3,280 5,300 8,300 3,280 7,500

28 500 1,108 2,280 3,700 5,800 2,280 4,200

38 400 920 2,080 2,900 4,700 1,880 4,000

48 370 850 1,780 2,700 4,100 1,680 3,700

58 330 770 1,580 2,400 3,700 1,580 3,400

60 300 700 1,300 2,200 3,300 1,300 310

80 260 610 1,200 1,900 2,900 1,200 2,600

100 220 540 1,000 1,700 2,800 1,000 2,300

125 200 490 900 1,400 2,300 900 2,100

150 190 430 830 1,300 2,100 830 1,900

175 170 400 780 1,200 1,900 770 1,700

200 160 380 730 1,100 1,800 720 1,500

Sizing Between Firstand Second Stage Regulator*

Maximum Propane Capacitieslisted are based on 2 psig pressure drop at10 psig setting

BTU/hour

Pipe or Tubing Size, OD. Type L Nominal Pipe Size

Tubing Schedule 46

Length,

Feet 3/8" 1/2" 5/8" 3/4" 7/8" 1-I/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

10 39 92 199 329 501 935 275 567 1.971 2,295 3,307

20 26 62 I31 216 346 630 189 393 732 1,496 2,299

30 21 59 I67 I81 277 596 152 315 590 1,212 1,858

40 19 41 96 145 233 427 129 267 504 1,039 1,559

50 18 37 79 I3I 198 376 114 237 448 91 1,417

60 16 35 72 t21 187 349 103 217 409 834 1,275

80 13 29 62 I04 155 289 89 185 346 724 1,066

100 11 26 55 99 138 255 78 162 307 630 976

125 10 24 48 81 122 224 69 I46 275 567 866

150 9 21 43 72 109 292 63 132 252 511 787

260 8 19 39 66 106 187 54 I12 209 439 665

250 8 17 36 60 93 172 48 t00 185 390 599

X. CIRCULATING AIR AND FILTERS

Ductwork - Air

I_WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON

MONOXIDE, TO ENTER THE RETURN DUCTWORK 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

recommended methods of "Air Conditioning Contractors of

America" Manual D.

A duct 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.

A closed return duct system must be used, with the return duct

connected to the furnace. NOTE: Ductwork must never be attached

to the back of the furnace. Supply and return connections to the

furnace may be made with flexible joints to reduce noise

transmission. To prevent the blower from interfering with

combustion air or draft when a central return is used, a connecting

duct must be installed between the unit and the utility room wall.

A room, closet, or alcove must not be used as a return air chamber.

When the furnace is used in connection with a cooling unit, the

furnace should be installed in parallel with or on the upstream

side of the cooling unit to avoid condensation in the heating

element. With a parallel flow arrangement, the dampers or other

means used to control the flow of air must be adequate to prevent

chilled air from entering the furnace and, if manually operated,

must be equipped with means to prevent operation of either unit

unless the damper is in the full heat or cool position.

When the furnace is installed without a cooling coil, it is

recommended that a removable access panel be provided in the

outlet air duct. This opening shall be accessible when the furnace

is installed and shall be of such a size that the heat exchanger

can be viewed for visual light inspection or such that a sampling

probe can be inserted into the airstream. The access panel must

be made to prevent air leaks when the furnace is in operation.

When the furnace is heating, the temperature of the return air

entering the furnace must be between 55°F and 100°R

When a furnace is installed so that supply ducts carry air circulated

by the furnace to areas outside the space containing the furnace,

the return air shall also be handled by a duct sealed to the furnace

casing and terminating outside the space containing the furnace.

FILTERS - READ THIS SECTION BEFORE INSTALLING THE

RETURN AIR DUCTWORK

Filters must be used with this furnace. Discuss filter maintenance

with the building owner. Filters do not ship with this furnace, but

must be provided by the installer. Filters must comply with ULg00

or CANIULCS111 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 customer preference,

differing filter arrangements can be applied. Filters can be

installed in the central return register or a side panel external filter

rack kit (upflows), or the ductwork above a counterflow furnace. As

an alternative, a media air filter or electronic air cleaner can be

used as the requested 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 premature

heat exchanger failure.

A new home may require more frequent replacement until all

construction dust and dirt is removed. Circulating air filters are to

be installed in the return air duct external to the furnace cabinet.

MINIMUM FILTER SIZES

FURNACE INPUT FILTER SIZE TYPE

45M 160 in2 permanent

70M 24! in2 permanent

90M 320 in2 permanent

115M 400 in2 permanent

140M 370 in2 permanent

45M 320 in2 disposable

70M 483 in2 disposable

90M 640 in2 disposable

115M 800 in2 disposable

140M 7_6 iiq2 disposable

PERMANENT: NOMINAL 600 FM. FACE VELOCITY

DISPOSABLE: NOMINAL 300 F.M. FACE VELOCITY

HORIZONTAL INSTALLATIONS

Filters must be installed in either the central return register or in

the return air duct work.

POWER UP

Xl. SEQUENCE OF OPERATION

(INTEGRATED IGNITION CONTROL)

115 VAC power applied to furnace.

integrated ignition control performs internal checks.

integrated ignition LED will light.

integrated ignition control monitors safety circuits

continuously.

• Furnace awaits call from thermostat.

NORMAL HEATING SEQUENCE

The normal operational sequence in heating mode 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.

• Gas valve opens at end of igniter warm up period,

delivering gas to burners and establishing flame.

• integrated control module monitors flame presence. Gas

valve will remain open only if flame is sensed.

• Circulator blower is energized on heat speed following a

fixed thirty second blower on delay.

• Furnace runs, integrated control module monitors safety

circuits continuously.

• 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.

• Circulator blower is de-energized following the heat off

delay period (fixed 150 seconds).

• Furnace awaits next call from thermostat.

NORMAL COOLING SEQUENCE

• Thermostat calls for cooling.

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized.

• Circulator blower is energized on cool speed following a

fixed five second on delay.

• Furnace circulator blower and outdoor cooling unit run,

integrated control module monitors safety circuits

continuously.

• R and Y thermostat contacts open, completing the call for

cool.

• Outdoor fan and compressor are de-energized.

• Circulator blower is de-energized following a fixed forty-

five second cool off delay period.

• Furnace awaits the next call from the thermostat.

FAN ONLY MODE

The normal operational sequence in fan only mode is as follows:

• R and G thermostat contacts close, initiating a call for fan.

• Integrated control module performs safety circuit checks.

• Circulator blower is energized on heat speed.

• Circulator blower runs, integrated control module monitors

safety circuits continuously.

• R and G thermostat contacts open, completing the call for

fan.

• Circulator blower is de-energized.

• Furnace awaits next call from thermostat.

Xll. 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 operating

properly, the control module LED will flash on and off in a factory-

programmed sequence, depending on the problem encountered.

This light can be viewed through the observation window in the

blower access door. Refer to the Troubleshooting Chartfor further

explanation of the lighting codes.

Follow the start-up and adjustment items, refer to further

information in Section XIII, Operational Checks.

FURNACE OPERATION

Purge gas lines of air prior to start-up. Do not purge lines into an

enclosed burner compartment.

Check for leaks using an approved chloride-free soap and water

solution, an electronic combustible gas detector, or other approved

method. Verify that all required kits (propane gas, high altitude,

etc.) have been appropriately installed.

NOTE: An interlock switch prevents furnace operation if the blower

door is not in place. Keep the blower access doors in place

except for inspection and maintenance.

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 Models 36F22/36G22: Push the switch to

the OFF position.

6. Wait five minutes to clear out any gas. Then smell for gas,

including near the floor.

7. 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 Models 36F22/36G22: Push 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 supply to the furnace.

11. Set the room thermostat to the desired temperature.

NOTE: There is an approximate 20 second delay between

thermostat energizing and burner firing.

FURNACE SHUTDOWN

1. Set the thermostat to lowest setting.

2. Turn off the electrical power supply to the furnace.

3. White-Rodgers Models 36F22/36G22: Push switch to the

OFF position.

4. Close manual gas shutoff valve external to the furnace.

5. Replace the door on the unit.

Gas Valve _ ....._" I, _m_(I

.5,

Selector

Switch

INLE OUTLET

Inlet Pressure Tap J

(Side of Valve) Pressure Regulator Outlet (Manifold)

Adjustment Pressure Tap

(Under Cap Screw)

White-Rodgers Model 36F22

PressureRegulator

Outlet Pressure _ Adjustment

Cap Screw)

Inlet Pressure

Tap !_Gas Valve

On/Off

Selector

Switch

White-Rodgers Model 36G22

GAS SUPPLY PRESSURE MEASUREMENT

IA CAUT,O.

To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET

PLATE

WHITE-RODGERS36F22 GAS VALVE

The line pressure supplied to the gas valve must be within the

range specified below. The supply pressure can be measured at

the gas valve inlet pressure tap or at a hose fitting installed in the

gas piping drip leg. The supply pressure must be measured with

the burners operating. To measure the gas supply pressure, use

the following procedure.

With Power and Gas Off.

1. Connect a water manometer or adequate gauge to the

"inlet pressure tap" of the gas valve.

As an alternative method, inlet gas pressure can also be

measured by removing the cap from the drip leg and

installing a predrilled cap with a hose fitting.

With Power and Gas On:

2. Put furnace into heating cycle and turn on all other gas

consuming appliances.

If operating pressures differ from the Inlet Gas Supply Pressure

table, make necessary pressure regulator adjustments, check

piping size, etc., and/or consult with local utility.

Gas [

Shutoff

Ve_ve

[

Gas Line

To Fumace

Dlip Leg Cap

With Ftt_ng

Manome,el

Measuring Inlet Gas Pressure (Alternate Method)

Inlet Gas Supply Pressure

Natural Gas IMinimum: 5.0" w.c. Maximum:10.0" w.c.

Propane Gas /Minimum: 11.0" w.c. Maximum: 13.0" w.c.

If supply pressure differs from table, make the necessary

adjustments to pressure regulator, gas piping size, etc., and/or

consult with local gas utility.

3. Turn OFF gas to furnace at the manual shutoff valve and

disconnect manometer. Reinstall plug before turning on

gas to furnace.

4. Turn OFF any unnecessary gas appliances started in step

WHITE-RODGERS36G22 GAS VALVE

The line pressure supplied to the gas valve must be within the

range specified below. The supply pressure can be measured at

the gas valve inlet pressure tap or at a hose fitting installed in the

gas piping drip leg. The supply pressure must be measured with

the burners operating. To measure inlet pressure, use the

following procedure.

Gas Valve

On/Off

Selector

Switch Inlet Pressure

=_//._/_ Tap

r/ \Out,etPresso,ePressure Regulator

Adjustment _ Tap

(UnderCap Screw)

White-Rodgers Model 36G22

1. Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

2. Using 3/32 hex wrench, loosen inlet pressure tap screw

one turn.

3. Connect a 5/16 inch hose and calibrated water manometer

to the gas valve inlet pressure tap. The hose should overlap

the tap by 3/8 inch.

4. Turn ON the gas supply and operate the furnace

5. Leak test. Using a leak detection solution or non-chlorine

soap suds, check for leaks at hose connection. Bubbles

forming indicate a leak. SHUT OFF GAS AND FIXALL LEAKS

IMMEDIATELY BEFORE PROCEEDING TO NEXT STEP!

6. Measure furnace gas supply pressure. Supply pressure

must be within the range specified in the Inlet Gas Supply

Pressure table.

If supply pressure reading differs from the table, make

necessary adjustments to pressure regulator, gas piping

size, etc., and/or consult with local gas utility.

Inlet Gas Supply Pressure I

Natural Gas Minimum: 5.0" w.c. Maximum:10.0" w.c. I

Propane Gas Minimum: 11.0" w.c. Maximum:13.0" w.c.

7. Turn OFF gas to furnace at the manual shutoff valve and

disconnect manometer and hose. Reinstall plug before

turning on gas to furnace.

8. Seal pressure port. Tighten inlet pressure tap screw

clockwise 7 in-lbs, minimum.

9. Retest for leaks. If bubbles form, shut down gas and fix

leaks immediately.

10. Turn valve switch ON.

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

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.

WHITE-RODGERS36F22 GAS VALVE

Only small variations in gas pressure should be made by adjusting

the gas valve pressure regulator. The manifold pressure must be

measured with the burners operating. To measure and adjust

the manifold pressure, use the following procedure.

1. Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

2. Connect a calibrated water manometer (or appropriate gas

pressure gauge) at the gas valve outlet pressure tap (refer

to gas valve figure in previous section).

3. Turn ON the gas supply and operate the furnace.

4. Measure gas manifold pressure with burners firing. Adjust

manifold pressure according to the Manifold Gas Pressure

table:

Manifold Gas Pressure

Gas Range Nominal

Natural 3.2 - 3.8" w.c. 3.5" w.c.

Propane 9.7 - 10.3" w.c. 10.0" w.c.

The final manifold pressure must not vary more than 0.3 " w.c.

from the above specified pressures. Any necessary major changes

in gas flow rate should be made by changing the size of the burner

orifice.

5. To adjust the gas valve pressure regulator, remove the

regulator cap.

6. Turn the adjustment screw clockwise to increase the

pressure, or counterclockwise to decrease the pressure.

7. Securely replace the regulator cap.

8. Turn OFF gas to furnace at the manual shutoff valve and

disconnect manometer.

9. Reinstall gas valve outlet pressure tap plug before turning

on gas to furnace.

WHITE-RODGERS36G22 GAS VALVE

This valve is shipped from the factory with the regulator preset

(see control label).

Consult the appliance rating plate to ensure burner manifold

pressure is as specified. If another outlet pressure is required,

follow these steps.

1. Turn OFF all electrical power to the system.

2. Using a 3/32 inch hex wrench, loosen outlet pressure tap

screw one turn. Do not remove screw.

3. Connect a calibrated water manometer and 5/16 inch hose

to the gas valve outlet pressure tap. Hose should overlap

tap by 318 inch.

4. Turn ON system power and set thermostat to a call for

heat.

5. Using a leak detection solution or non-chlorine soap suds,

check for leaks at hose connection. Bubbles forming

indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS

IMMEDIATELY!

6. Remove regulator screw cover. Turn regulator screw either

clockwise to increase pressure or counterclockwise to

decrease. Always adjust regulator to provide the correct

pressure according to the original equipment manufacturer

specifications listed on the appliance rating plate.

7. Replace regulator screw cover and finger-tighten securely.

8. Turn OFF all electrical power to the system.

9. Remove manometer and hose from outlet pressure tap.

10. Tighten outlet pressure tap clockwise 7 in-lbs minimum to

seal port.

11. Turn ON system power and set thermostat to call for heat.

12. Using a leak detection solution or non-chlorine soap suds,

check for leaks at hose connection. Bubbles forming

indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS

IMMEDIATELY!

Measure gas manifold pressure with burners firing. Adjust

manifold pressure per the Manifold Gas Pressure table.

Manifold Gas Pressure

Gas Range Nominal

Natural 3.2-3.8" w.c. 3.5"w.c.

Propane 9.7 - 10.3" w.c. 10.0" w.c.

The final manifold pressure must not vary more than _+0.3 w.c.

from specified manifold pressure.

Any necessary major changes in gas flow rate should be made by

changing the size of the burner orifice.

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)

The gas input rate to the furnace must never be greater than that

specified on the unit rating plate. To measure natural gas input

using the gas meter, use the following procedure.

1. Turn OFF the gas supply to all other gas-burning

appliances except the furnace.

2. While the furnace is operating, time and record one

complete revolution of the smallest gas meter dial.

3. Calculate the number of seconds per cubic foot (sec/ft 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: 1,0go BTU/ft 3

(Obtained from gas supplier)

Installation's seconds per cubic foot: 34 sec/ft 3

Conversion Factor (hours to seconds): 3600 sec/hr

Input = (Htg. value x 3600) + seconds per cubic foot

Input = (1 ,O00 BTUift 3 x 3600 sec/hr) + 34 sec/ft 3

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 relight 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 usually

obtained when the unit is operated at the rated input with the "as

shipped" blower speed. If the correct amount of temperature rise

is not obtained, it may be necessary to change the blower speed.

An incorrect temperature rise can cause condensing in or

overheating of the heat exchanger. Determine and adjust the

temperature rise as follows. The temperature rise must be within

the range specified on the rating plate or Product Data Book

applicable to your model. (Please contact your distributor or visit

our website for the appficable Product Data Book referred to in

this manual.)

HEAT EXCHANGER

RADIATION "LINE OF SIGHT"

_'_ iTsuP_Ly

B m

R_SE = Tsu_ _ TRETURN

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 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

_IbWARNING

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. The Product

Data Book applicable to your model provides an airflow table

showing the relationship between airflow (CFM) and external static

pressure (E.S.P.) and a table for the proper selection of heating

and cooling speeds. The cooling blower speed is shipped set on

HIGH. High heat ships on MEDIUM andlow heat is shipped on

MEDIUM-LO. These blower speeds should be adjusted by the

installer to match the installation requirements so as to provide

the correct heating temperature 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

Product Data Book applicable to your model.

3. Relocate desired motor leads to the circulator blower heat

and cool speed terminals on the integrated control module.

(Terminals are identified as HEAT and COOL (hot)). If

heating and cooling blower speeds are the same, a jumper

wire must be used between the heat and cool terminals.

4. Connect all unused blower motor leads to the "PARK"

terminals on the integrated control module. Any leads not

connected to the "PARK" terminals must be taped.

5. Turn ON power to furnace.

6. Verify proper temperature rise as outlined in Temperature

Rise section.

CIRCULATOR BLOWER FAN TIMING ADJUSTMENT

NOTE: Items in this section refer to the air circulator blower fan,

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 "heatinq fan OFF delay"

adiustment Dins or switches. It is NOT adjustable in 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 seconds after

the call for cooling ends. During normal heating operation, the

circulator fan will come on approximately 34 seconds after the

gas valve opens.

SECOND _

DELAY ZI=

t50 "{"-

SECOND

DELAY Z I=

Switches viewed in

120 _"

SECOND

DELAY ZII

0 "

180 _"

SECOND

DELAY Z I=

O "

an upflow installation.

Adjustment Switches -(Not present on all models)

XlII. OPERATIONAL CHECKS

_k, WARNING

To AVOID 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.

BURNER FLAME

The burner flames should be inspected with the burner

compartment 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 burners

without curling, floating, or lifting off. Flames must not impinge on

the sides of the heat exchanger firing tubes.

1Good adjustment

2Stable, soft and blue

3 Not curling, floating, or Jffting off

Burner Flame

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 prevent

furnace operation in case of main blower failure on horizontal and

counterfiow 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 installations.

Regardless of airflow direction, it does not need to be relocated.

_WARNING

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.

XIV. SAFETY CIRCUIT DESCRIPTION

GENERAL

A number of safety circuits are employed to ensure safe and proper

furnace operation. These circuits serve to control any potential

safety hazards and serve as inputs in the monitoring and diagnosis

of abnormal function. These circuits are continuously monitored

during furnace operation by the integrated control module.

INTEGRATED CONTROL MODULE

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

precautions and provide diagnostic information through an LED.

PRIMARY LIMIT

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 LIMIT

The auxiliary limit control is located either on or near the circulator

blower and monitors heat exchanger compartment temperatures.

The control is a temperature sensor. It guards against overheating

resulting from insufficient air passing over the heat exchanger.

ROLLOUT 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 pressure-

activated switches. They monitor the airflow (combustion air and

flue products) through the heat exchanger via pressure taps located

on the induced draft blower. 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

determine the presence or absence of flame.

XV. TROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body's static electricity before touching unit. An

electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and

servicing to protect the integrated control module from damage.

By putting the furnace, the control, and the person at the same

electrostatic potential, these steps will help avoid exposing 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 control module or any wire connected to the

control prior to discharging your body's electrostatic

charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the

furnace 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 on the following pages for

assistance in determining the source of unit operational problems.

The red diagnostic LED blinks to assist in troubleshooting the

unit. The number of blinks refer to a specific code.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve

ignition after three attempts. It is characterized by a non-functioning

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.

XVI. 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 FAILURE. ONLY A QUALIFIED SERVICER SHOULD

EVER HANDLE THE IGNITER.

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service

agency at least once per year. This check should be performed at

the beginning of the heating season. This will ensure that all

furnace components are in proper working order and that the

heating system functions appropriately. Pay particular attention to

the following items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage.

Check the outside termination and the connections at and

internal to the furnace.

• Heat exchanger. Check for corrosion and/or buildup within

the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame

sense.

• Wiring. Check electrical connections for tightness and/or

corrosion. Check wires for damage.

• Filters.

FILTERS

i_lb 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 installer will

supply filter(s) at the time of installation.

FILTER MAINTENANCE

Improper filter maintenance is the most common cause of

inadequate heating or cooling performance. Filters should be

cleaned (permanent) or replaced (disposable) every two months

or as required. When replacing a filter, it must be replaced with a

filter of the same type and size.

,_ WARNING

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

air filter or electronic air cleaner can be used as an alternate filter.

Follow the filter sizes given in the Recommended Minimum Filter

size table to ensure proper unit performance.

To remove filters from an external filter rack in an upright upfiow

installation, follow the directions provided with external filter rack

kit. Internal filters are an accessory item and are not included with

your furnace. For further details, see your distributor.

U PRIGHT FILTER REMOVAL

To remove filters from an external filter rack in an upright upfiow

installation, follow the directions provided with external filter rack

kit.

Clean, wash and dry a permanent filter. When using a permanent

filter, both sides should be sprayed with a dust adhesive as

recommended on the adhesive container. Spray adhesives for

use with permanent filters can be found at some hardware stores.

BE SUREAIRFLOW DIRECTIONARROW POINTS TOWARDS THE

BLOWER.

Inspect filter. If your dirty filter is the disposable type, replace dirty

filter with the same type and size filter. If your dirty filter is a

permanent filter, clean as follows:

• Wash, rinse, and dry the permanent filters. Both sides

should then be sprayed with a filter adhesive as is

recommended on the adhesive container. Many hardware

stores stock spray adhesives for use with permanent filters.

• if badly torn or uncleanable, these filters must be replaced

by equal size permanent, high velocity filters. Throwaway

filters must not be used as replacement for permanent

filters. Under normal use, permanent filters should last for

several years.

INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS

The bearings in the induced draft blower and circulator blower

motors are permanently lubricated by the manufacturer. No further

lubrication is required. Check motor windings for accumulation

of dust which may cause overheating. Clean as necessary.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly

invisible coating on the flame sensor. This coating acts as an

insulator causing a drop in the flame sense signal. If the flame

sense signal drops too low, the furnace will not sense flame and

will lock out. The flame sensor should be carefully cleaned by a

qualified servicer using emery cloth or steel wool. Following

cleaning, the flame sense signal should be 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 components,

the resistance of the igniter should not exceed 200 ohms. If it

does, the igniter should be replaced.

BURNERS

I_IbWARNING

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 tips. They should not be yellow. They should

extend directly outward from the burner ports without curling

downward, floating or lifting off the ports.

CLEANING (QUALIFIED SERVICER ONL Y)

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.

_[_ 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.

CAUTION

THE IGNITER IS FRAGILE AND CAN BE EASILY DAMAGED. USE EXTREME

CAUTION WHEN REMOVING THE BURNER BOX TOP.

4. Remove the screws securing the burners to the burner

bracket. Remove the burners.

5. Use bottle brush to clean burner insert and inside of burner.

6. Replace burner (opposite of removal). Ensure burners

are fully seated on burner bracket. Re-connect wiring.

_[_ CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

VERIFY PROPER OPERATION AFTER SERVICING.

7. Turn on electric power and gas supply to the furnace.

8. Check furnace for proper operation. Refer to "Operational

Checks" section to verify burner flame characteristics.

XVII. 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.

XVlll. REPAIR AND REPLACEMENT PARTS

• When ordering any of the listed functional parts, be sure to

provide the furnace model, manufacturing, and serial

numbers with the order.

• Although only functional parts are shown in the parts list,

all sheet metal parts, doors, etc. may be ordered by

description.

• Parts are available from your distributor.

Functional Parts List-

Single Stage 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

TROUBLESHOOTING CHART

• Furnace fails to operate

• Integrated control

module diagnostic LED

)rovides no signal.

Furnace fails to operate

• Furnace fails to operate

• Integrated control

module diagnostic LED

is flashing ONE (1)

flash.

• Furnace fails to operate

• Integrated control

module diagnostic LED

is flashing TWO (2)

flashes.

• Induced draft blower

runs continuously with

no further furnace

operation.

• Integrated control

module diagnostic LED

is flashing THREE (3)

flashes.

NONE • No 115 volt power

to furnace, or no 24

volt power to

integrated control

module.

• Manual disconnect switch

OFF, door switch open, or

24 volt wires improperly

connected or loose.

1 FLASH

2 FLASHES

3 FLASHES

• Blown fuse or

circuit breaker.

•Integrated control

module has an

internal fault.

• Furnace lockout due

to an excessive

number of ignition

attempts. (3 total) _

• Auxiliary Limit Open

• Pressure switch

circuit is closed.

• Induced draft

blower is not

operating.

• Pressure switch

circuit not closed.

• Induced draft

blower is operating.

• Blown fuse or circuit

breaker.

Integrated controi module

has an internal fault.

• 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.

• Loss of flame after

establishment. Cause may

be interrupted gas supply,

lazy burner flames

(improper gas pressure

or restriction in flue or

improper induced 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.

• 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.

• 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.

• 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.

• Repair short.

• Inspect pressure

switch hose. Repair,

if necessary,

• Inspect flue for

blockage, proper

length, elbows, and

termination.

• Correct pressure

switch setpoint or

contact motion.

• Tighten or correct

wiring connection.

• 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.

• Clean flame

sensor with steel

wool.

• See "Combustion

and Ventilation Air

Requirements" and

"Category I

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 I

Venting (Vertical

Venting)" section

for details.

• Replace

pressure switch

with proper

replacement part.

1 integrated control module will automatically attempt to reset from lockout after one hour.

2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

TROUBLESHOOTING CHART

•Circulator blower runs

continuously. No furnace

operation.

• Integrated control module

diagnostic LED is flashing

FOUR (4) flashes.

, Induced draft blower and

circulator blower runs

continuously. No furnace

operation.

, Integrated control module

diagnostic LED is flashing

FIVE (5) flashes.

• Furnace fails to operate.

• Integrated control module

diagnostic LED is flashing

SIX (6) flashes.

• Normal furnace

operation.

• Integrated control

module diagnostic LED

is flashing SEVEN (7)

flashes.

• Induced draft blower runs

continuously. No furnace

operation.

• Integrated control module

diagnostic LED is flashing

continuously.

4 FLASHES

5 FLASHES

6 FLASHES

7 FLASHES

CONTINUOUS

FLASHING

• Primary limit

circuit is open.

• Flame sensed

with no call

for heat.

• Rollout limit open.

Flame sense

microamp signal is

low.

• Polarity of 115

or 24 volt

power is

reversed.

• Faulty primary limit

switch.

• Insufficient conditioned

air over the heat

exchanger. Blocked

filters, restrictive

ductwork, improper

circulator blower speed,

or failed circulator

blower.

• Loose or improperly

connected wiring.

• Short to ground in flame

sense circuit.

• Flame rollout.

• MisaIigned burners,

blocked flue or failed

induced draft blower.

• Loose or improperly

connected wiring.

•Faulty rolIout limit.

• Flame sensor is coated/

oxidized.

• Flame sensor incorrectly

positioned in burner

flame.

• Lazy burner flame due to

improper gas pressure

or combustion air.

• Polarity of 115 volt AC

power to furnace or

integrated control module

is reversed.

• Red and blue wires to

transformer are

reversed.

• Poor unit ground.

• LED is steady on STEADY • Normal operation.

• 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

• Check burners for

proper alignment.

• Check flue and air inlet

piping for blockage,

proper length, elbows,

and termination.

Correct as necessary.

• Check roIIout limit.

Replace if necessary.

• Check induced draft

blower for proper

performance.

Replace, if necessary.

• Tighten or correct

wiring connection.

• Sand flame sensor.

• Inspect for proper sensor

alignment.

• Compare current gas

pressure to rating plate

info. Adjust as needed.

• Review wiring diagram to

correct polarity.

• Verify proper ground.

Correct if necessary.

• Reverse red and blue

wires connected to

transformer.

2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.

• Turn power OFF

prior to repair.

• Replace primary

limit 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.

• Replace roIIout

limit with correct

replacement part.

• Turn power OFF

prior to repair.

• Clean flame

sensor with steel

wool.

• See "Vent!Flue

Pipe" section for

piping details.

• See rating plate

for proper gas

pressure.

• Turn power OFF

prior to repair.

wn*

a. 0

_LIJ

-_nJ

WF-

.,,JZ

0., •

On,,

WIRING DIAGRAM FOR GMS8/GHS8/GDS8

PROPERLY POLARIZEDANDGROUNDED

24VAC

_UMiDIRER

_ La_

DISCONNECT PC_bLER I_ DISCONNECT

BEFORE SERVIC_NG _

WIRING TO UNIT

MUST BE [[] I i

PROPERLY L_ I I

POLARIZED II I

AND GROUNDED II

OVERCURRENT PROTECTION DEVICE

JUNCTION

_OX

ROL_O_TL_M_TS

i STEADY ON =NORMALOPERAT]ON

OFF =CONTROL FAILURE

1 FLASH =SYSTEMLOCKOUT(RETRIES/RECYCLESEXCEEDED)

2 FLASHES =PRESSURE SWITCH STUCK CLOSED

3 FLASHES = PRESSURE SWITCH STUCK OPEN

4FLASHES = OPEN H_GH LIMIT

5 FLASHES =FLAME SENSE WITHOUT GAS VALVE

6 FLASHES =OPEN ROLLQUT

7 FLASHES LOWFLAME SIGNAL

RAPID FLASHES = REVERSED 115 VAC POLARITY/VERIFY GND

TO 1I_ V_C,¸ I_0HZ

OW_CURRE_ PROT_CT_O_

LOW VOLTAGE (24V)

LOW VOLTAGE FIELD

HI VOLTAGE (115V)

HI VOLTAGE FIELD .....

JUNCTION

TERMINAL

INTERNAL TO

iNTEGRATED CONTROL

PLUG CONNECTION

COLOR CODES: PK PiNK

YL YELLOW BR BROWN

OR ORANGE WH WHITE

PU PURPLE BL BLUE

GR GREEN GY GRAY

BK BLACK RD RED

0140F00119 REV, O0

NOTES:

1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7/_MPS

2 MANUFACTURER'S SPECIFIE D 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

RATING OF AT LEAST 105C USE COPPER CONDUCTORS ON LY

4 BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION

FdEQU_REMENTS 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

EQUIPMENT GND /77

FIELD GND ±

FIELD SPLICE

SWITCH (TEMP)

IGNITER

SWITCH (PRESS) °_

OVERCURRENT

PROT DEVICE

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

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

efficiency. We have designed these units to significantly reduce the most frequent causes of product failure.

They 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 website at wwwx oodmanmfq.com or www.amana-hac.com for information on:

Products

Warranties

Customer Services

Parts

Contractor Programs and Training

Financing Options

Goodman Manufacturing Company, L.P.

2550 North Loop West, Suite 400, Houston, TX 77092

www.qoodmanmfq.com

GOODMAN Furnace/Heater, Gas Manual L0806733

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