INSTALLATION INSTRUCTIONS FOR *M(H,S)8 / *D(H,S)8 / *HS8 / GME8 GAS FURNACE
(CATEGORY I )
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements em-
bodied in theAmerican National Standard / Na-
®
tional Standard of Canada ANSI Z21.47·CSA-
2.3 Gas Fired Central Furnaces.
US
C
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer, you have an obligation to know the product better than the customer.
This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself
in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough
to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting.
Most dealers have a list of specific, good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices.
However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
NOTE: Please contact your distributor or our website listed below
for the applicable Specification Sheet referred to in this manual.
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY
DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME
RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE
WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO
INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
5151 San Felipe Suite 500 • Houston, TX 77056
© 2011 Goodman Manufacturing Company, L.P.
IO-417A
11/2011
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Table of Contents
CIRCULATING AIR AND FILTERS .................................................................................................................... 22
DUCTWORK -AIR FLOW ...................................................................................................................... 22
CHECKING DUCT STATIC ..................................................................................................................... 22
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ............................................ 23
UPRIGHT INSTALLATIONS ..................................................................................................................... 23
CIRCULATION AIR FILTERS ................................................................................................................... 23
HORIZONTAL INSTALLATIONS ................................................................................................................ 23
SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL) ................................................................................ 23
POWER UP ...................................................................................................................................... 23
HEATING MODE ................................................................................................................................. 24
(MODE DIP SWITCH IS SET TO “1 STG” POSITION).................................................................................. 24
(MODE DIP SWITCH IS SET TO “2 STG” POSITION) ................................................................................. 24
COOLING MODE ................................................................................................................................ 24
FAN ONLY MODE .............................................................................................................................. 25
START-UP PROCEDURE AND ADJUSTMENT ....................................................................................................... 25
FURNACE OPERATION .......................................................................................................................... 25
FURNACE START-UP ........................................................................................................................... 25
FURNACE SHUTDOWN ......................................................................................................................... 25
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. 25
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... 28
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................ 29
TEMPERATURE RISE ........................................................................................................................... 29
CIRCULATOR BLOWER SPEED ADJUSTMENT ............................................................................................. 30
CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ...................................................................................... 30
SETTING FURNACE OPERATING MODE (*DH8, *ME8, AND *MH8 MODELS ONLY) ............................................ 30
OPERATIONAL CHECKS .............................................................................................................................. 31
BURNER FLAME ................................................................................................................................ 31
AUXILIARY LIMIT CONTROL ................................................................................................................. 31
SAFETY CIRCUIT DESCRIPTION .................................................................................................................... 31
GENERAL ......................................................................................................................................... 31
INTEGRATED CONTROL MODULE ............................................................................................................. 31
PRIMARY LIMIT ................................................................................................................................ 31
AUXILIARY LIMIT ............................................................................................................................... 31
ROLLOUT LIMITS .............................................................................................................................. 32
PRESSURE SWITCHES ......................................................................................................................... 32
FLAME SENSOR ................................................................................................................................ 32
TROUBLESHOOTING ................................................................................................................................... 32
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... 32
DIAGNOSTIC CHART........................................................................................................................... 32
FAULT RECALL ................................................................................................................................ 32
RESETTING FROM LOCKOUT ................................................................................................................ 32
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Table of Contents
MAINTENANCE ......................................................................................................................................... 32
ANNUAL INSPECTION ........................................................................................................................... 33
FILTERS .......................................................................................................................................... 33
FILTER MAINTENANCE ......................................................................................................................... 33
FILTER REMOVAL .............................................................................................................................. 33
INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS ................................................................................. 33
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... 33
IGNITER (QUALIFIED SERVICER ONLY) ..................................................................................................... 33
BURNERS ......................................................................................................................................... 33
CLEANING (QUALIFIED SERVICER ONLY) ........................................................................................................ 34
BEFORE LEAVING AN INSTALLATION ............................................................................................................... 34
REPAIR AND REPLACEMENT PARTS .............................................................................................................. 34
COMPONENT IDENTIFICATION ................................................................................................................. 35 - 36
APPENDIX......................................................................................................................................... 37
TROUBLESHOOTING CHART .................................................................................................................. 37
BLOWER PERFORMANCE DATA ............................................................................................................. 40
*M(H/S)8................................................................................................................................. 40
*(D/H)S8 ................................................................................................................................. 41
GME8 ..................................................................................................................................... 42
*(M, D, H)S8 WIRING DIAGRAM .................................................................................................. 43
GME8 WIRING DIAGRAM ............................................................................................................ 44
*(M,D)H* WIRING DIAGRAM......................................................................................................................45
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SAFETY PRECAUTIONS
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure
proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this
product.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER.
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
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.
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
DEPARTMENT.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
CO can cause serious illness including permanent brain damage or death.
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.
B10259-216
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
WARNING
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE,
ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE
BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT,
CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED,
MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING
MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT,
ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD
BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE
EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
WARNING
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT
SOURCES SHOULD BE UTILIZED.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
THE GAS SUPPLIER.
WARNING
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO
PROTECT THE ELECTRICAL COMPONENTS FROM WATER.
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SAFETY PRECAUTIONS
ing 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 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS
FURNACE MUST BE CATEGORY
CATEGORY III VENTING.
I
VENTED. DO NOT VENT USING
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.
ADDITIONALSAFETY 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.
SHIPPINGINSPECTION
All units are securely packed in shipping containers tested
according to International Safe Transit Association specifica-
tions. The carton must be checked upon arrival for external
damage. If damage is found, a request for inspection by carrier’s
agent must be made in writing immediately.
TOTHE INSTALLER
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.
Before installing this unit, please read this manual thoroughly
to familiarize yourself with specific items which must be ad-
hered to, including but not limited to: unit maximum external
static pressure, gas pressures, BTU input rating, proper elec-
trical connections, circulating air temperature rise, minimum or
maximum CFM, and motor speed connections, and venting.
These furnaces are designed for Category I venting only.
4. File the claim with the following support documents within
a nine month statute of limitations.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECREATIONAL VEHICLE.
•
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.
IMPORTANTNOTE TOTHE OWNER REGARDING PRODUCT
WARRANTY
•
Your warranty certificate is supplied as a separate document
with the unit installed by your contractor. Read the limited war-
ranty certificate carefully to determine what is and is not cov-
ered and keep the warranty certificate in a safe place. If you are
unable to locate the warranty certificate please contact your
installing contractor or contact customer service (877-254-4729)
to obtain a copy.
The carrier is responsible for making prompt inspection of dam-
age and for a thorough investigation of each claim. The distribu-
tor or manufacturer will not accept claims from dealers for trans-
portation damage.
Keep this literature in a safe place for future reference.
IMPORTANT: To receive the Lifetime Heat Exchanger Limited
Warranty (good for as long as you own your home) and the 10-
year Parts Limited Warranty, online registration must be com-
pleted within 60 days of installation. Online registration is not
required in California or Quebec. Complete warranty details
available from your local dealer or, for Goodman® brand prod-
ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical com-
ponents.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos-
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PRODUCT APPLICATION
To register your Goodman® brand unit, go to
Complete the registration as prompted.
•
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 Combustion and Ventilation Air
Requirements, Section 5.3.3.
To register yourAmana® brand unit, go to www.amana-hac.com
and click “Warranty Registration”. Complete the registration
as prompted.
•
•
Product limited warranty certificates for models currently in pro-
hac.com. If your model is not currently in production or does
not appear on the website, please contact your installing con-
tractor or contact customer service (877-254-4729) to obtain a
copy of your warranty certificate.
•
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.
Each product overview page contains a Product Warranty link;
by clicking on it you will be able to view the limited warranty
coverage for that specific product. To view warranty registration
information, click on the Product Warranty text on the left navi-
gation panel on the home page of each website. The Online
Product Registration pages are located in this same section.
•
NOTE: The Commonwealth of Massachusetts requires that the
following additional requirements must also be met:
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 in-
stalled indoors (i.e., attic space, crawl space, or garage area
provided the garage area is enclosed with an operating door).
•
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.
•
•
This furnace can be used in the following non-industrial com-
mercial applications:
WARNING
Schools,Officebuildings,Churches,Retailstores,
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR
RECREATIONAL VEHICLE.
Nursinghomes,Hotels/motels,Commonorofficeareas
In such applications , the furnace must be installed with the
following stipulations:
To ensure proper furnace operation, install, operate and
maintain the furnace in accordance with these installa-
tion and operation instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CSA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
•
•
•
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.
Acopy of the National Fuel Gas Code (NFPA54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
1430 Broadway
This furnace may be used as a construction site heater ONLY
if the following conditions are met:
•
New York, NY 10018
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 60ºF (16ºC)
and 80ºF (27ºC) is maintained.
National Fire Protection Association
1 Batterymarch Park
•
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
•
•
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LOCATION REQUIREMENTS AND CONSIDERATIONS
A copy of the CAN/CSA B149 Installation Codes can also be
obtained from:
•
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W 1R3
•
If the furnace is installed in an application where the
typical operating sound level of a furnace is deemed
objectionable, an optional sound reduction kit is
available. Consult your local distributor for more details.
Provisions must be made for venting combustion
products outdoors through a proper venting system.
The length of flue pipe could be a limiting factor in
locating the furnace.
Ensure adequate combustion air is available for the
furnace. Improper or insufficient combustion air can
expose building occupants to gas combustion products
that could include carbon monoxide. Refer to Section
V, Combustion and Ventilation Air Requirements.
The furnace must be level. If the furnace is to be set
on a floor that may become wet or damp at times, the
furnace should be supported above the floor on a
concrete base sized approximately 1-1/2" larger than
the base of the furnace.
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible
material. The only combustible material allowed is
wood.
Exposure to contaminated combustion air will result
in safety and performance-related problems. Do not
install the furnace where the combustion air is exposed
to the following substances:
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved method
or in accordance with “ASHRAE Guide” or “Manual J-Load Cal-
culations” published by the Air Conditioning Contractors of
America.
•
•
In the USA, this furnace MUST be installed in accordance with
the latest edition of theANSI Z223.1 booklet entitled “National
Fuel Gas Code” (NFPA54), and the requirements or codes of
the local utility or other authority having jurisdiction. In Canada,
this furnace must be installed in accordance with the current
CAN/CGA-B149.1 & 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 ofAir Conditioning and Ventilating System and NFPA
90B - Warm Air Heating and Air Conditioning System.
•
•
•
All venting shall be in accordance with PART 7, Venting of Equip-
ment, of the National Fuel Gas Code, ANSI Z223.1, or appli-
cable local building and/or air conditioning codes. These pub-
lications are available from:
National Fire Protection Association, Inc.
1 Batterymarch Park, Quincy, MA 02269
NOTE: Furnaces with NOx screens meet the California NOx
emission standards and California seasonal efficiency stan-
dards.ANNUAL inspections of the furnace and its vent system
is strongly recommended.
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
LOCATION REQUIREMENTS AND CONSIDERATIONS
Your unit model type determines which installation procedures
must be used. For *MH8, *MS8, and GHS8 models, you must
follow instructions for Horizontal Left, Horizontal Right or Up-
flow installations only. These furnaces are not approved for
Downflow installations.
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 located not less than 18 inches (457 mm)
above the floor. Protect the furnace from physical
damage by vehicles.
If the furnace is installed horizontally, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace.
Downflow models GD(H,S) ARE NOT APPROVED FOR HORI-
ZONTAL OR UPFLOW INSTALLATIONS. For these models,
use only the instructions for downflow installation only.
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WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THIS UNIT.
Follow the instructions listed below when selecting a furnace
location. Refer also to the guidelines provided in Section V,
Combustion and Ventilation Air Requirements.
•
Centrally locate the furnace with respect to the
proposed or existing air distribution system.
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LOCATION REQUIREMENTS AND CONSIDERATIONS
VENT
B1-VENT SINGLE
TOP
(PLENUM)
•
•
•
Do not connect this furnace to a chimney flue that
serves a separate appliance designed to burn solid
fuel.
For counterflow installations, the air conditioning coil
must be downstream from the heat exchanger of the
furnace.
SIDES
1"
FRONT
3"
BACK
0"
1"
6"
1"
Top clearance for horizontal configuration - 1"
INSTALLATION POSITIONS
An upflow furnace may be installed in an upright position or
horizontal on either the left or right side panel. Do not install
this furnace on its back. For vertically installed upflow furnaces,
return air ductwork may be attached to the side panel(s) and/
or basepan. For horizontally installed upflow furnaces, return
air ductwork must be attached to the basepan. For counterflow
furnaces, return ductwork must be attached to the top end of
the blower compartment.
Counterflow installation over a noncombustible floor.
Before setting the furnace over the plenum opening,
ensure the surface around the opening is smooth and
level.Atight seal should be made between the furnace
base and floor by using a silicon rubber caulking
compound or cement grout.
Counterflow installation over a combustible floor. If
installation over a combustible floor becomes
necessary, use an accessory subbase (see
Specification Sheet applicable to your model for details).
A special accessory subbase must be used for upright
counterflow unit installations over any combustible
material including wood. Follow the instructions with
the subbase for proper installations. Do not install the
furnace directly on carpeting, tile, or other combustible
material other than wood flooring. (NOTE: The subbase
will not be required if an air conditioning coil is installed
between the supply air opening on the furnace and the
floor.
•
NOTE: Ductwork must never be attached to the back of the
furnace.
HORIZONTALINSTALLATION
Line contact to framing is permitted when installed in the hori-
zontal configuration. Line contact is defined as the portion of
the cabinet that is formed by the intersection of the top and
side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PRO-
TECTION CLEARANCE. Agas-fired furnace for installation in
a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed di-
rectly on carpeting, tile, or other combustible materials other
than wood flooring.
Vent Pipe Clearance to Combustibles-
6" using Single Wall Connector or 1"
using B-1 vent.
Top - 1"
Back - 0"
FURNACESUSPENSION
Side
Clearance - 1"
If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances neces-
sary.
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.
•
Suspended Furnace
CLEARANCES AND ACCESSIBILITY
Unobstructed front clearance of 24" for servicing is recom-
mended.
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COMBUSTION & VENTILATION CATEGORY I VENTING AIR REQUIREMENTS
•
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.
EXISTING FURNACE REMOVAL
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be
too large to properly vent the remaining attached appliances.
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•
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•
•
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 Edi-
tion, CSA-2.3-Latest Edition Section 1.23.1. The following
steps shall be followed with each appliance connected to the
venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and
horizontal pitch, as required by the National Fuel Gas
Code,ANSI Z223.1 or the CAN/CSAB149 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 appliance not connected to
the venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they shall
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers;
HOT
COLD
Thermostat Influences
Consult the instructions packaged with the thermostat for mount-
ing instructions and further precautions.
d. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so
appliance shall operate continuously;
e. Test for draft hood equipped 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.
COMBUSTION AND VENTILATION AIR REQUIREMENTS
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF
FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE
SUPPLIED INTO THE FURNACE AREA.
Improved construction and additional insulation in buildings have
reduced heat loss by reducing air infiltration and escape around
doors and windows. These changes have helped in reducing
heating/cooling costs but have created a problem supplying
combustion and ventilation air for gas fired and other fuel burn-
ing appliances. Appliances that pull air out of the house (clothes
dryers, exhaust fans, fireplaces, etc.) increase the problem by
starving appliances for air.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA54/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.
House depressurization can cause back drafting or improper
combustion of gas-fired appliances, thereby exposing building
occupants to gas combustion products that could include car-
bon monoxide.
THERMOSTAT LOCATION
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
In an area having good air circulation, locate the thermostat
about five feet high on a vibration-free inside wall. Do not install
the thermostat where it may be influenced by any of the follow-
ing:
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation Under some conditions, larger vents than those shown above
Codes or applicable provisions of the local building codes for may be required or allowed. When an existing furnace is re-
determining the combustion air requirements for the appliances. moved from a venting system serving other appliances, the
venting system may be too large to properly vent the remaining
This furnace must use indoor air for combustion. It cannot be
installed as a direct vent (i.e., sealed combustion) furnace.
attached appliances.
Upflow or Horizontal units are shipped with the induced draft
Most homes will require outside air be supplied to the furnace
blower discharging from the top of the furnace. (“Top” is as
area by means of ventilation grilles or ducts connecting directly
viewed for an upflow installation.) The induced draft blower can
to the outdoors or spaces open to the outdoors such as attics
be rotated 90 degrees with the (0270F01119) chimney transi-
or crawl spaces.
tion bottom kit for Category I venting. For horizontal installa-
tions, a four inch single wall pipe can be used to extend the
induced draft blower outlet 1/2” beyond the furnace cabinet.
CATEGORY I VENTING (VERTICAL VENTING)
THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCK-
WISE INDUCED DRAFT BLOWER ROTATION.
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO
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.
ASPHYXIATION, THIS FURNACE MUST BE CATEGORY
I
VENTED. DO NOT
VENT USING CATEGORY III VENTING.
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted ap-
pliance and the vent system does not have to be “gas tight.”
NOTE: Single stage gas furnaces with induced draft blowers
draw products of combustion through a heat exchanger allow-
ing, in some instances, common venting with natural draft ap-
pliances (i.e. water heaters).All installations must be vented in
accordance with National Fuel Gas Code NFPA54/ANSI Z223.1
- latest edition. In Canada, the furnaces must be vented in ac-
cordance with the National Standard of Canada, CAN/CSA
B149.1 and CAN/CSA B149.2 - latest editions and amendments.
Venting - Furnace Installed in Horizontal Position
THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI-
ZONTALLY VENTED THROUGHAN EXTERIOR SIDE WALL.
The following describes an optional venting procedure when the
furnace is installed in the horizontal left discharge position.
To rotate the induced draft blower clockwise, you will need to
purchase one (0270F01119) chimney transition bottom kit.
1. Disconnect electrical power from the furnace.
2. Disconnect the induced draft blower power leads, flue
pipe, and pressure switch tubing.
3. Remove the round cutout from the right side of the wrapper.
4. Remove and save the four screws that fasten the induced
draft blower to the flue collector box.
NOTE: Masonry vent kit (MVK-01 and MVK-02) is to only be
used on interior masonry chimneys or qualifying exterior
masonry chimney applications identified in the MVK kit
installation instructions. To ensure safe and reliable operation,
use only the kit listed for your model.
5. Remove and save the three screws that hold the chimney
assembly to the induced draft blower.
6. Remove and save the four screws that fasten the chimney
top to the chimney bottom.
7. Remove the chimney transition bottom from the transition
bottom kit.
8. Install the chimney top with the four screws retained
from step 6 onto the new chimney transition bottom from
the transition bottom kit.
NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the venting
system.
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO
ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER’S
INDUCED DRAFT APPLIANCES IS NOT ALLOWED.
The minimum vent diameter for the Category I venting system
is as shown:
9. Remove the induced draft blower and install the new
chimney assembly to it using the three screws retained
from step 5.
10. Rotate the induced draft blower 90 degrees to the right,
feed the flue pipe through the round cutout from the outside
of the wrapper, and fit onto the chimney top assembly.
Secure the pipe to the chimney top from the front, top,
and bottom using (3) screws and rotating the induced
MINIMUM VENT
MODEL
UPFLOW
4 Inch
4 Inch
4 Inch
5 Inch
5 Inch
5 Inch
COUNTERFLOW
4 Inch
40
60
4 Inch
80
4 Inch
5 Inch
100
120
140
N/A
N/A
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
draft blower to properly orient the assembly. NOTE: If
the pipe section is less than 18”, then attach it directly
WARNING
to the chimney top on 3 sides and feed it through the
round cutout from the inside of the wrapper.
POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS
WHEN A SINGLE FAN‐ASSISTED CATEGORY
11. Reattach the induced draft blower using the (4) screws
retained from step 3. Ensure the gasket located between
the induced draft blower and collector box is rotated
accordingly.
12. 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.
13. Reconnect the remaining flue pipe, and the pressure
switch tubing. Ensure that all wires and the pressure
switch tubing is at least one inch from the flue pipe, or
any other hot surface.
I
APPLIANCE (80% AFUE
FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR. DO NOT
CONNECT AN 80% FURNACE TO A MASONRY CHIMNEY UNLESS THE
FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED
APPLIANCE OR THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE
B
METAL VENT. ALL INSTALLATIONS USING MASONRY CHIMNEYS MUST BE
SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTING TABLES. IF AN
80% FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPED
APPLIANCE, THE POTENTIAL FOR CONDENSATION DAMAGE MAY STILL
EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS,
EXTERIOR CHIMNEYS, OR ANY COMBINATION OF THESE CONDITIONS.
THE RISK OF CONDENSATION DAMAGE IS BEST AVOIDED BY USING
MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER
14. Restore power to furnace.
NOTE: In a horizontal installation the air conditioning coil
must be adequately supported by proper brackets and
supports. Inadequate coil support can result in furnace cabinet
distortion and air leakage.
OR TYPE
B
METAL VENT.
Wash
Roof Line
Counterflow units are shipped with the induced draft blower
discharging from the top of the furnace. (“Top” as viewed for a
counterflow installation.)
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Attic Floor
Vent the furnace in accordance with the National Fuel Gas
Code NFPA54/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.
1/2" to 1" Air Space
Second Floor
Throat
Damper
WARNING
First Floor
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR
SUPPLY.
Water Heater
Vent Connector
F.A.F. Vent
Connector
Breech
Natural Draft
Water Heater
Fan Assisted
Forced Air
Furnace
Clean Out
Basement Floor
EXTERIORMASONRYCHIMNEYS (CATEGORYIFURNACESONLY)
Typical Multiple Flue Clay Tile Chimney
CHECKLIST SUMMARY
An exterior masonry chimney is defined as a “Masonry” chim-
ney exposed to the outdoors on one or more sides below the
roof line.” The ability to use a clay lined masonry chimney
depends on a parameter not associated with interior chimneys.
This variable is the geographic location of the installation. Re-
searchers have discovered that the winter design temperatures
have a direct impact on the suitability of this type of venting. In
most situations, the existing masonry chimneys will require a
properly sized metallic liner.
This checklist serves as a summary of the items to be checked
before venting an 80+ furnace into a masonry chimney. In addi-
tion, we recommend that a qualified serviceman use this check-
list to perform a yearly inspection of the furnace venting sys-
tem.
This checklist is only a summary. For detailed information on
each of the procedures mentioned, see the paragraph refer-
enced with each item.
This inspection is based upon a draft topical report, “Masonry
Chimney Inspection and Relining”, issued by the Gas Research
Institute. While not yet finalized, we believe this report repre-
sents the best information on this subject which is currently
available.
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
If the chimney does not meet these termination requirements,
Proper Chimney
Termination?
(Check 1)
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' Min.
2' Min.
3' Min.
Chimney channel
free of solid and
liquid fuel
Change venting
arrangements
(Fix 2)
appliances?
(Check 2)
Wall or
Parapet
Chimney
10' or Less
Rebuild crown
(Fix 3)
and/or Reline
(Fix 4)
Crown in good
condition
(Check 3)
2' Min.
3' Min.
Cleanout free of
debris?
Reline
(Fix 4)
Chimney
(Check 4)
Termination 10 Feet Or Less From Ridge, Wall or Parapet
More than 10’
Liner in good
condition?
(Check 5)
Reline
(Fix 4)
3’ Min.
NOTE: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
Chimney
Wall or
Parapet
Dilution air
available?
(Check 6)
Reline
(Fix 4)
More than 10’
10’
Height above any
roof surface within
10 feet horizontally.
Ridge
Complete the
installation.
(Check 7)
2” Min.
3’ Min.
CHECK 1 -PROPER CHIMNEY TERMINATION.
Chimney
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
Termination More Than 10 Feet From Ridge, Wall or Parapet
than any portion of a building within a horizontal distance of 10 CHECK 2-ANY SOLID OR LIQUID FUEL APPLIANCES VENTED
feet. In addition, the chimney must terminate at least 3 feet
above any forced air inlet located within 10 feet. The chimney
must extend at least five feet above the highest connected equip-
ment draft hood outlet or flue collar.
INTO THISCHIMNEY CHANNEL
Solid fuel appliances include fireplaces, wood stoves, coal fur-
naces, and incinerators.
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
Liquid fuel appliances include oil furnaces, oil-fired boilers and Next, use a flashlight and small mirror to sight up the liner. B
oil-fired water heaters.
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.
Appliances which burn propane (sometimes referred to as LP
(liquefied petroleum)) gas are considered gas-fired appliances.
CHECK 3-CHIMNEY CROWN CONDITION.
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.
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.)
The surfaces of the liner must be physically sound. If gaps or
holes are present, the metal liner must be removed and re-
placed (Fix 4). Finally, confirm that the metal liner is the cor-
rect size for the appliances to be installed. Use the GAMA
tables and rules.
If a metal liner is not present, a clay tile liner must be present,
or the chimney must be lined (Fix 4).
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.
Use a flashlight and small mirror at the cleanout or vent con-
nector to inspect the clay tile liner. If any of the following prob-
lems are present:
CHECK 4-DEBRIS IN CLEANOUT
•
•
•
•
Tile sections misaligned
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.
Tile sections missing
Gaps between tile sections
Signs of condensate drainage at the cleanout or vent
connectors
A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be re-
lined (Fix 4). Remove the cleanout cover, and examine the
cleanout for debris. If significant amounts of any of the following
are found:
•
•
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).
•
•
•
•
•
Fuel oil residue
Bricks
Mortar or sand
Pieces of the tile liner
Rusted pieces of the metallic liner - 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/CSAB149.1 and CAN/CSA
B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).
CHECK 5-LINER CONDITION.
CHECK 6-DILUTION AIR.
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.
If gas-fired appliances are to be vented into a clay tile liner, a
source of dilution air is required.
Remove the lowest existing vent connector, and examine the
inside of the elbow or tee at the base of the liner.Asmall amount
of soot may be considered acceptable, provided the installer
vacuums it away. If rusted pieces of the liner have collected
here, the metal liner must be removed and replaced (Fix 4).
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).
Next, gently tap the inside of the liner with a Phillips screw-
driver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be re-
moved and replaced (Fix 4).
Remember that all appliances must be vented inside the liner.
Venting one appliance inside the liner and another appliance
outside the liner is not acceptable.
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EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
CHECK 7-COMPLETE THE INSTALLATION.
FIX 3-REBUILD THE CROWN
If Checks 1 through 6 have been satisfactory, and the liner is an If the chimney crown is damaged, a qualified mason must re-
acceptable size as determined by the tables in National Fuel pair it in accordance with nationally recognized building codes
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the or standards. One such standard which may be referenced is
National Standard of Canada, CAN/CSAB149.1 and CAN/CSA the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel
B149.2 - latest editions and amendments, then the clay tile BurningAppliances,ANSI/NFPA211.
liner can probably be used as a vent for the gas appliances.
FIX 4-RELINING
However, the installer must keep in mind the following factors
which may render the tile liner unsuitable for use as a vent:
Relining options include B vent and flexible liners.
•
•
•
Extremely cold weather
Long vent connectors
If the chimney has diagonal offsets, B vent probably cannot be
used.
Masonry chimneys with no air gap between the liner
and the bricks. (In practice, this can be difficult to
detect.)
If B vent is to be used, it must be supported adequately. Sup-
ports (such as fire stops or thimbles) must be used to prevent
the B vent from coming into direct contact with the tile liner or
chimney walls. Direct contact would result in higher heat loss,
with an increased possibility of poor venting system perfor-
mance.
•
Exterior chimneys (The tables in National Fuel Gas
Code NFPA54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CSAB149.1 and
CAN/CSA B149.2 - latest editions and amendments
assume interior chimneys.)
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.
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).
The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s in-
structions, prevent problems due to rain, birds, or wind effects.
FIX 1-LINER TERMINATION
Any cap or roof assembly used with a liner must be approved
by the liner manufacturer for such use. The liner and cap/roof
assembly must then terminate above the roof in accordance
with the manufacturer’s instructions.
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, CAN/CSAB149.1 and CAN/
CSA B149.2 - latest editions and amendments may be used.
In some cases, a shorter extension above the roof may be
possible with a liner than would be required with a masonry
chimney.
If a flexible liner is to be used, it must be made of the proper
materials:
For further information on relining, see Fix 4.
•
For most residential applications, an aluminum liner
should be acceptable.
FIX 2-CHANGEVENTING ARRANGEMENTS
•
If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
fluorine, a liner of AL 29-4C stainless steel should be
used. Common sources of chlorine and fluorine
compounds include indoor swimming pools and
chlorine bleaches, paint strippers, adhesives, paints,
varnishes, sealers, waxes (which are not yet dried)
and solvents used during construction and remodeling.
Various commercial and industrial processes may also
be sources of chlorine/fluorine compounds.
If the masonry chimney has more than one channel, it may be
possible to vent the gas appliances into one channel and vent
the solid or liquid fuel appliance(s) into another channel(s). Do
not vent an 80+ Furnace inside of a metal liner with other appli-
ances vented 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.
•
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).
If oil-fired appliance(s) are being replaced by gas-fired
appliance(s), the tile liner must first be cleaned to remove the
fuel oil residue.
If none of the above options is practical, the furnace may need
to be vented vertically with a B Vent.
Under some conditions, a 90%+ furnace could be installed rather
than an 80% furnace. The 90%+ furnace can be vented hori-
zontally or vertically through PVC pipe.
15
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ELECTRICAL CONNECTIONS
For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFPA54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CSAB149.1 and
CAN/CSA B149.2 - latest editions and amendments.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
To install the liner, read and follow the liner manufacturer’s in-
structions and your local codes. Excess liner length should be
pulled out of the chimney and cut off. Use caution when doing
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney. Support the liner as
recommended by the liner manufacturer.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
Some manufacturers of flexible liners offer an insulation sleeve
designed to be added to the liner before it is installed in the
chimney. (Poured insulation, either vermiculite or other materi-
als, is no longer recommended.) Insulation will need to be added
to the flexible liner if:
WIRINGHARNESS
•
It is required by the liner manufacturer’s instructions.
The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be re-
quired. Wires are color coded for identification purposes. Re-
fer to the wiring diagram for wire routings. If any of the original
wire as supplied with the furnace must be replaced, it must be
replaced with wiring material having a temperature rating of at
least 105° C. Any replacement wiring must be a copper con-
ductor.
•
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 addi-
tional 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.
115VOLT LINE CONNECTIONS
•
Local experience indicates that flexible liners installed
without insulation are likely to have condensation
problems.
Before proceeding with electrical connections, ensure that the
supply voltage, frequency, and phase correspond to that speci-
fied on the unit rating plate. Power supply to the furnace must
be NEC Class 1, and must comply with all applicable codes.
The furnace must be electrically grounded in accordance with
local codes or, in their absence, with the latest edition of The
National Electric Code, ANSI NFPA 70 and/or The Canadian
Electric Code CSA C22.1.
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.
Use a separate fused branch electrical circuit containing prop-
erly sized wire, and fuse or circuit breaker. The fuse or circuit
breaker must be sized in accordance with the maximum over-
current protection specified on the unit rating plate. An electri-
cal disconnect must be provided at the furnace location.
ELECTRICAL CONNECTIONS
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO
THE UNIT MUST BE POLARIZED AND GROUNDED.
Line voltage wiring must enter into the junction box provided
with the furnace.
NOTE: Line polarity must be observed when making field
connections.
WARNING
HIGH VOLTAGE !
FOSSIL FUEL APPLICATIONS
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
This furnace can be used in conjunction with a heat pump in a
fossil fuel application. Afossil fuel application refers to a com-
bined gas furnace and heat pump installation which uses an
outdoor temperature sensor to determine the most cost effi-
cient means of heating (heat pump, gas furnace, or both).
16
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ELECTRICAL CONNECTIONS
A heat pump thermostat with two stages of heat is required to
properly use a furnace in conjunction with a heat pump. Refer
to the fossil fuel kit installation instructions for additional ther-
mostat requirements.
WARNING
HIGH VOLTAGE !
TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
Strictly follow the wiring guidelines in the fossil fuel kit installa-
tion instructions. All furnace connections must be made to the
furnace integrated control module and the FURNACE terminal
strip on the fossil fuel control board.
JUNCTION BOX RELOCATION
To ensure proper unit grounding, the ground wire should run
from the furnace ground screw located inside the furnace junc-
tion box all the way back to the electrical panel. NOTE: Do
not use gas piping as an electrical ground. To confirm proper
unit grounding, turn off the electrical power and perform the
following check.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A
PRECAUTION WHEN REMOVING HOLE PLUGS.
1. Measure resistance between the neutral (white)
connection and one of the burners.
2. Resistance should measure 10 ohms or less.
Line voltage connections can be made through either the right
or left side panel. The furnace is shipped configured for a right
side electrical connection. To make electrical connections
through the opposite side of the furnace, the junction box must
be relocated to the left side prior to making electrical connec-
tions. To relocate the junction box, perform the following steps.
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.
24VOLT THERMOSTAT WIRING
WARNING
NOTE: Wire routing must not interfere with circulator blower
operation, filter removal, or routine maintenance.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,
DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS
UNIT.
Low voltage connections can be made through either the right
or left side panel. Thermostat wiring entrance holes are located
in the blower compartment. The following figure shows con-
nections for a “heat only” system and “heat/cool system”.
1. Remove both doors from the furnace.
2. Remove and save the screws holding the junction box to
the right side of the furnace.
3. Models that have the junction box located in the burner
compartment will need to move the junction box directly
over.
Heating
Room
Thermostat
Heating/Cooling
Room Thermostat
W
W
4. Attach the junction box to the left side of the furnace,
using the screws removed in step 2.
Remote
Condensing
Unit
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.
Furnace
Control
Furnace
Control
Typical Field Wiring (24 VAC Control Circuit)
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.
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.
NOTE: In downflow applications the power leads should be
routed through the supplied wire tabs when rotating junction
box to the left side.
GME8FURNACE WITH2-STAGE CONDENSERFIELD WIRING
Low voltage wires may be connected to the terminal strip.
The GME8 model furnaces may be used with a 2-stage
outdoor air conditioner. A two stage cooling/single stage gas
heat thermostat is required, in addition to a field supplied
relay. The relay must have a 24VAC coil and contacts rated
for up to 1 horse power at 125VAC.
IMPORTANT NOTE: To avoid possible equipment malfunction,
route the low voltage wires to avoid interference with filter re-
moval or other maintenance.
17
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GAS SUPPLY AND PIPING
1. Install the field supplied relay on the control mount-
ing panel near the furnace ignition control. The relay
should be installed such that the motor leads will
reach the relay contact terminals.
•
•
•
Record the reading.
Divide this reading by 10.
Set the heat anticipator on the thermostat to match
this reading.
2. Connect the “Y2” (high stage cool) thermostat
terminal to one coil terminal of the field supplied
relay. Connect the other field supplied relay coil
terminal to the “C” terminal on the furnace ignition
control. Typical 18AWG thermostat wire may be
used.
Example: If the reading on the ammeter is “4”, divide this by
10. The anticipator setting will be .4 amps.
115VOLT LINE CONNECTION OF ACCESSORIES
(ELECTRONIC AIR CLEANER)
3. Connect the common terminal of the field supplied
relay to the “LINE-H” terminal on the furnace ignition
control. Use wiring having copper conductors only
and a temperature rating of at least 105°C.
4. Using the GME8 airflow tables in this manual,
determine the motor speed tap needed to deliver the
required high stage cooling airflow. Connect the
selected motor speed tap to the normally open
terminal on the field supplied relay. Use wiring
having copper conductors only and a temperature
rating of at least 105°C.
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE SERVICING OR CHANGING ANY ELECTRICAL
WIRING.
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
field-supplied electronic air cleaner.
5. See the wiring schematic below.
The accessory load specifications are as follows:
ECO-TECH
MOTOR
Electronic Air Cleaner
1.0 Amp maximum at 120 VAC
T5
T3
Turn OFF power to the furnace before installing any accesso-
ries. Follow the air cleaner manufacturers’ instructions for lo-
cating, mounting, grounding, and controlling these accesso-
ries. Accessory wiring connections are to be made through
the 1/4" quick connect terminals provided on the furnace inte-
grated control module. The electronic air cleaner hot terminal
is identified as EAC-H and the neutral terminal is identified as
NEUTRAL. All field wiring must conform to applicable codes.
Connections should be made as shown in the following illustra-
tion.
T4
T2
Field
Furnace
Control
Supplied
Relay
Y
Heating/Cooling
Room Thermostat
Y1
Y1
Y2
Y2
Control Module
Neutral 120 VAC
Hot 120 VAC
Remote Condensing Unit
Field Wiring for GME8 Furnace with 2-Stage Condenser
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
Air Cleaner
Optional
Accessories
If it is necessary for the installer to supply additional line volt-
age wiring to the inside of the furnace, the wiring must conform
to all local codes, and have a minimum temperature rating of
105°C. All line voltage wire splices must be made inside the
furnace junction box.
The integrated control module electronic air cleaner terminals
(EAC) are energized with 115 volts whenever the circulator blower
is energized.
•
•
Wrap the “R” leg around a clip-on ammeter 10 times.
Energize the furnace in the heat mode.
18
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GAS SUPPLY AND PIPING
High altitude installations may require both a pressure switch
and an orifice change. These changes are necessary to com-
pensate for the natural reduction in the density of both the gas
fuel and the combustion air at higher altitude.
24VAC 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. 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.
For installations above 7000 feet, please refer to your distribu-
tor for required kit(s).
Contact the distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude instal-
lations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
PROPANEGAS CONVERSION
GAS SUPPLY AND PIPING
WARNING
The furnace rating plate includes the approved furnace gas in-
put rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conver-
sion kits required for alternate fuels and/or high altitude.
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY
OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE
APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER
FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A
QUALIFIED INSTALLER OR SERVICE AGENCY.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
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.
Models using Single Stage Gas Valves
Inlet gas supply pressures must be maintained within the ranges
specified in the following table. The supply pressure must be
constant and available with all other household gas fired appli-
ances operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overfiring.
Manifold
Pressure
Pressure
Switch
Altitude
Gas
Kit
Orifice
Natural
None
#45
3.5" w.c.
Inlet Gas Supply Pressure
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
0-7000
None
Propane
LPT-03
#55
10.0" 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.
In Canada, gas furnaces are certified to 4500 feet.
NOTE:
NOTE:
GMS81405DN** models utilize #43 orifices in Natural gas
applications.
Models using 2-Stage Gas Valves
At all altitudes, the manifold pressure must be within 0.3 inches
w.c. of that listed in the Specification Sheet applicable to your
model for the fuel used. At all altitudes and with either fuel, the
air temperature rise must be within the range listed on the fur-
nace nameplate. Should this appliance be converted to LP,
refer to the instructions included in the factory authorized LP
conversion kit.
Manifold Pressure
Pressure
Switch
Change
Gas
Altitude
Kit
Orifice
High
Low
Stage
Stage
Natural
None
#45
3.5" w.c. 1.9" w.c.
None
None
0-7000
Propane
LPM-06
#55 10.0" w.c. 6.0" w.c.
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.
In Canada, gas furnaces are only certified to 4500 feet.
GMH81405DN** models utilize #43 orifices in Natural gas
applications.
NOTE:
NOTE:
19
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GAS SUPPLY AND PIPING
Contact your distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude instal-
lations. The indicated kits must be used to insure safe and
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency.
•
•
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.
GAS PIPING CONNECTIONS
•
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.
WARNING
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT
DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE
OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM
THE METER/TANK TO THE FURNACE.
•
•
Connect the furnace to the building piping by one of
the following methods:
When sizing a trunk line, be sure to include all appliances
which will operate simultaneously.
– Rigid metallic pipe and fittings.
– Semi-rigid metallic tubing and metallic fittings.
The gas piping supplying the furnace must be properly sized
based on the gas flow required, specific gravity of the gas, and
length of 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.
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.
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
– Protect connectors and semi-rigid tubing against
Length of
Nominal Black Pipe Size
Pipe in Feet
1/2"
132
92
73
63
56
50
46
43
40
38
3/4"
1"
1 1/4"
1 1/2"
1600
1100
980
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.
10
20
30
40
50
60
70
80
90
100
278
190
152
130
115
105
96
520
350
285
245
215
195
180
170
160
150
1050
730
590
500
440
400
370
350
320
305
760
670
610
560
Location of Manual Valve
(Installed Ahead of
Ground Joint Pipe Union)
90
84
530
490
79
460
Height Required
By Local Code
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
0.60 Specific Gravity Gas)
BTUH Furnace Input
CFH =
Ground Joint Pipe Union
To Be Installed Ahead of
Gas Valve
Heating Value of Gas (BTU/Cubic Foot)
To connect the furnace to the building’s gas piping, the installer
must supply a ground joint union, drip leg, manual shutoff valve,
and line and fittings to connect to gas valve. In some cases,
the installer may also need to supply a transition piece from 1/
2" pipe to a larger pipe size.
``
Drip Leg
Reducing Coupling
1/2” x 1/8” with 1/8”
Pipe Plug to Measure
Line Gas Pressure
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.
General Furnace Layout
UPFLOW INSTALLATIONS
•
•
Use ground joint unions.
When the gas piping enters through the right side of the fur-
nace, the installer must supply the following fittings (starting
from the gas valve):
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.
•
•
•
90 degree elbows (2).
Close nipple.
Straight pipe to reach the exterior of the furnace .
20
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GAS SUPPLY AND PIPING
A ground joint union, drip leg, and manual shutoff valve must This unit must be isolated from the gas supply system by clos-
also be supplied by the installer. In some cases, the installer ing its manual shutoff valve before pressure testing of gas sup-
may also need to supply a transition piece from 1/2" to another ply piping system with test pressures equal to or less than 1/2
pipe size.
psig (3.48 kPa).
When the gas piping enters through the left side of the furnace,
the installer must supply the following fittings (starting from the
gas valve):
PROPANE GAS TANKS AND PIPING
WARNING
•
•
Straight pipe to reach the exterior of the furnace.
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING
DEVICE IN CASE OF A GAS LEAK.
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.
•
SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
COUNTERFLOWINSTALLATIONS
•
PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE.
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 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.
A ground joint union, drip leg and manual shutoff valve must
also be supplied by the installer. In most cases, the installer
may also need to supply a transition piece from ½” to another
pipe size. When the gas piping enters through the right side of
the furnace, the installer must supply the following fittings (start-
ing at the gas valve):
•
•
•
•
All propane gas equipment must conform to the safety stan-
dards of the National Board of Fire Underwriters, NBFU Manual
58.
90 Degree Elbow
Close Nipple
90 Degree Elbow
Straight Pipe to Reach Exterior of Furnace.
For satisfactory operation, propane gas pressure must be 10
inch WC at the furnace manifold with all gas appliances in
operation. Maintaining proper gas pressure depends on three
main factors:
GAS PIPING CHECKS
Before placing unit in operation, leak test the unit and gas con-
nections.
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).
WARNING
TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
OR OPEN FLAME TO TEST FOR LEAKS.
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.
Check for leaks using an approved chloride-free soap and wa-
ter solution, an electronic combustible gas detector, or other
approved testing methods.
Complete information regarding tank sizing for vaporization, rec-
ommended regulator settings, and pipe sizing is available from
most regulator manufacturers and propane gas suppliers.
Since propane gas will quickly dissolve white lead and most
standard commercial compounds, special pipe dope must be
used. Shellac-based compounds resistant to the actions of
liquefied petroleum gases such as Gasolac®, Stalactic®,
Clyde’s® or John Crane® are satisfactory.
NOTE: Never exceed specified pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overfiring, resulting in heat exchanger failure.
Refer to the following illustration for typical propane gas instal-
lations and piping.
Disconnect this unit and shutoff valve from the gas supply pip-
ing system before pressure testing the supply piping system
with pressures in excess of 1/2 psig (3.48 kPa).
21
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CIRCULATING AIR AND FILTERS
Aduct system must be installed in accordance with Standards
of the National Board of Fire Underwriters for the Installation of
Air Conditioning, Warm Air Heating and Ventilating Systems.
Pamphlets No. 90A and 90B.
5 to 15 PSIG
First Stage
(20 PSIG Max.)
Regulator
Continuous
11" W.C.
200 PSIG
Maximum
Second Stage
Regulator
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. For installations requiring
more than 1800 CFM, use a bottom return or two sided return.
Supply and return connections to the furnace may be made
with flexible joints to reduce noise transmission. To prevent the
blower from interfering with combustion air or draft when a cen-
tral return is used, a connecting duct must be installed be-
tween the unit and the utility room wall. Furnace is shipped
with the top flanges in the flat position. Before installing a coil
or ducts, the flanges must be bent 90°. A room, closet, or
alcove must not be used as a return air chamber.
Propane Gas Installation (Typ.)
PROPANE GAS PIPING CHARTS
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
Pipe or
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
Tubing
Length,
Feet
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.
3/8"
1/2"
5/8"
3/4"
7/8"
1/2"
3/4"
10
20
30
40
50
730
500
400
370
330
300
260
220
200
190
170
160
1,700
1,100
920
850
770
700
610
540
490
430
400
380
3,200
2,200
2,000
1,700
1,500
1,300
1,200
1,000
900
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
7,500
4,200
4,000
3,700
3,400
310
2,600
2,300
2,100
1,900
1,700
1,500
60
80
100
125
150
175
200
830
780
730
830
770
720
When the furnace is installed without a cooling coil, it is rec-
ommended that a removable access panel be provided in the
outlet air duct. This opening shall be accessible when the fur-
nace is installed and shall be of such a size that the heat
exchanger can be viewed for visual light inspection or such that
a sampling probe can be inserted into the airstream. The ac-
cess panel must be made to prevent air leaks when the furnace
is in operation.
Sizing Between Second Stage and Appliance Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length,
Feet
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
3/8"
1/2"
5/8"
3/4"
7/8" 1-1/8" 1/2"
3/4"
1"
1-1/4" 1-1/2"
10
20
30
40
50
39
26
21
19
18
16
13
11
10
9
92
62
50
41
37
35
29
26
24
21
19
17
199
131
107
90
329
216
181
145
131
121
104
90
501
346
277
233
198
187
155
138
122
109
100
93
935
630
500
427
376
340
289
255
224
202
187
172
275
189
152
129
114
103
89
78
69
63
54
567
393
315
267
237
217
185
162
146
132
112
100
1,071 2,205 3,307
732
590
504
448
409
346
307
275
252
209
185
1,496 2,299
1,212 1,858
1,039 1,559
79
72
62
55
48
43
39
36
913
834
724
630
567
511
439
390
1,417
1,275
1,066
976
866
787
NOTE: In a horizontal installation the air conditioning coil
must be adequately supported by proper brackets and
supports. Inadequate coil support can result in furnace cabinet
distortion and air leakage.
60
80
100
125
150
200
250
81
72
66
60
8
8
665
590
48
When the furnace is heating, the temperature of the return air
entering the furnace must be between 55°F and 100°F.
CIRCULATING AIR AND FILTERS
DUCTWORK -AIR FLOW
WARNING
When a furnace is installed so that supply ducts carry air cir-
culated by the furnace to areas outside the space containing
the furnace, the return air shall also be handled by a duct sealed
to the furnace casing and terminating outside the space con-
taining the furnace.
NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR
SUPPLY.
CHECKING DUCT STATIC
Refer to your furnace rating plate for the maximum ESP (exter-
nal duct static) rating.
Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace.
Ductwork should be designed in accordance with the recom-
mended methods of “Air Conditioning Contractors ofAmerica”
Manual D.
Total external static refers to everything external to the furnace
cabinet. Cooling coils, filters, ducts, grilles, registers must all
be considered when reading your total external static pres-
sure. The supply duct pressure must be read between the fur-
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START-UP PROCEDURE AND ADJUSTMENT
nace and the cooling coil. This reading is usually taken by
removing the “A” shaped block off plate from the end on the
coil; drilling a test hole in it and reinstalling the block off plate.
FILTERS -READ THISSECTION BEFORE INSTALLING THE
RETURNAIR DUCTWORK
Take a duct static reading at the test hole. Tape up the test Filters must be used with this furnace. Discuss filter mainte-
hole after your test is complete. The negative pressure must be nance with the building owner. Filters do not ship with this
read between the filter and the furnace blower.
furnace, but must be provided by the installer. Filters must com-
ply with UL900 or CAN/ULCS111 standards. If the furnace is
installed without filters, the warranty will be voided.
Too much external static pressure will result in insufficient air
that can cause excessive temperature rise. This can cause
limit switch tripping and heat exchanger failure.
NOTE:An undersized opening will cause reduced airflow. The
bottom return is set up as a knock out.
To determine total external duct static pressure, proceed as
follows;
UPRIGHT INSTALLATIONS
1. With clean filters in the furnace, use a draft gauge
(inclined manometer) to measure the static pressure of
the return duct at the inlet of the furnace. (Negative
Pressure)
2. Measure the static pressure of the supply duct. (Positive
Pressure)
Depending on the installation and/or customer preference, dif-
fering filter arrangements can be applied. Filters can be in-
stalled in the central return register or a side panel external
filter rack kit (upflows), or the ductwork above a downflow fur-
nace. As an alternative, a media air filter or electronic air cleaner
can be used as the primary filter.
3. The difference between the two numbers is .4” w.c.
Example:
CIRCULATION AIR FILTERS
static reading from return duct = -.1" w.c.
static reading from supply duct = .3" w.c.
total external static pressure on this system = .4" w.c.
One of the most common causes of a problem in a forced air
heating system is a blocked or dirty filter. Circulating air filters
must be inspected monthly for dirt accumulation and replaced
if necessary. Failure to maintain clean filters can cause prema-
ture heat exchanger failure.
NOTE: Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
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.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the maximum listed
on the furnace rating plate, check for closed dampers, regis-
ters, undersized and/or oversized poorly laid out duct work.
MINIMUM FILTER SIZES for DISPOSABLE FILTERS
FURNACE INPUT
FILTER SIZE
320 in2
483 in2
640 in2
800 in2
738 in2
738 in2
40M
60M
80M
100M
120M
140M
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.
SEQUENCE OF OPERATION (INTEGRATED IGNITION CONTROL)
Refer to Timing Charts for sequencing.
NOTE: Dip switch positions referenced in this section applies
to *(M,D)H8 models only.
POWER UP
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
•
•
•
115 VAC power applied to furnace.
Integrated ignition control performs internal checks.
Integrated ignition LED will light.
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START-UP PROCEDURE AND ADJUSTMENT
•
•
Integrated ignition control monitors safety circuits
continuously.
•
Circulator blower is energized on low heat speed following
a fixed thirty second blower on delay. Electronic air
cleaner terminals are energized with circulator blower.
Furnace awaits call from thermostat.
•
•
Furnace is now operating in low-stage heating mode.
HEATINGMODE
Furnace operates; integrated control module monitors
safety circuits continuously.
(MODE DIP SWITCH IS SET TO “1 STG” POSITION)
•
If low-stage delay period expires, control will shift
operation from low-stage heating mode operation to high-
stage heating mode operation. Control will energize
circulator blower high heat speed and high stage gas
valve.
The normal operational sequence in heating mode is as fol-
lows:
•
R and W thermostat contacts close, initiating a call for
heat.
•
•
Integrated control module performs safety circuit checks.
•
•
Furnace is now operating in high-stage heating mode.
Induced draft blower is energized for 15 second pre-purge
period causing pressure switch contacts to close.
R and W thermostat contacts open, completing the call
for heat.
•
•
Igniter warm up begins after 15 second prepurge expires.
•
•
Induced draft blower is de-energized following a fifteen
second post purge.
Low and high-stage gas valves open at end of igniter
warm up period, delivering gas to burners and establishing
flame.
Circulator blower is de-energized following a heat off delay
period (selectable 100 or 150 seconds; factory set at
150 seconds).
If the furnace is operating in the low-stage heating mode
when thermostat contacts open, circulator remains at
low heat speed for the selected delay off period.
If the furnace is operating in high-stage heating mode
when the thermostat contacts open, the circulator blower
remains at high heat speed for the selected heat off delay
period.
•
•
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
Circulator blower is energized on high heat speed following
a fixed thirty second blower on delay. Electronic air
cleaner terminals are energized with circulator blower.
•
•
Furnace operates; integrated control module monitors
safety circuits continuously.
R and W thermostat contacts open, completing the call
for heat.
•
Furnace awaits the next call from thermostat.
COOLING MODE
•
•
Gas valve closes, extinguishing flame.
Induced draft blower is de-energized following a fifteen
second post purge.
The normal operational sequence in cooling mode is as fol-
lows:
•
The circulator blower remains on high speed for the
selected heat off delay period.
•
R and Y thermostat contacts close, initiating a call for
cool.
•
Furnace awaits the next call from thermostat.
•
•
•
Integrated control module performs safety circuit checks.
Outdoor fan and compressor are energized.
(MODE DIP SWITCH IS SET TO “2 STG” POSITION)
Circulator blower is energized on cool speed following a
fixed five second on delay. Electronic air cleaner
terminals are energized with circulator blower.
The normal operational sequence in sequence is as follows:
•
R and W thermostat contacts close, initiating a call for
heat.
•
•
Furnace circulator blower and outdoor cooling unit run,
integrated control module monitors safety circuits
continuously.
•
•
Integrated control module performs safety circuit checks.
Induced draft blower is energized for 15 second prepurge
period causing pressure switch contacts to close.
R and Y thermostat contacts open, completing the call
for cool.
•
•
Igniter warm up begins after 15 second prepurge expires.
•
•
Outdoor fan and compressor are de-energized.
Low and high-stage gas valves open at end of igniter
warm up period, delivering gas to burners and establishing
flame.
Circulator blower is de-energized following a fixed forty
five second cool off delay period. Electronic air cleaner
terminals are de-energized.
•
•
High-stage gas valve closes after five seconds; low-stage
gas valve remains open.
•
Furnace awaits the next call from thermostat.
Integrated control module monitors flame presence. Gas
valve will remain open only if flame is detected.
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START-UP PROCEDURE AND ADJUSTMENT
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
FANONLY MODE
The normal operational sequence in fan only mode is as fol-
lows:
NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by
hand.
•
R and G thermostat contacts close, initiating a call for
fan.
5. White-Rodgers Model 36G22 or 36G54: Push the switch
•
•
Integrated control module performs safety circuit checks.
to the OFF position.
Circulator blower is energized on low heat speed.
Electronic air cleaner terminals are energized.
Honeywell VR8215 or VR9205: Slide the switch to the
OFF position.
•
•
•
•
Circulator blower runs, integrated control module
monitors safety circuits continuously.
6. Wait five minutes to clear out any gas. Then smell for
gas, including near the floor.
R and G thermostat contacts open, completing the call
for fan.
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:
Circulator blower is de-energized. Electronic air cleaner
terminals are de-energized.
Furnace awaits the next call from thermostat.
White-Rodgers Model 36G22 or 36G54: Push the switch
to the ON position.
START-UP PROCEDURE AND ADJUSTMENT
Honeywell VR8215 or VR9205: Slide the switch to the
ON position.
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.
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.
This furnace is also equipped with a self-diagnosing electronic
control module. In the event a furnace component is not operat-
ing properly, the control module LED will flash on and off in a
factory-programmed sequence, depending on the problem en-
countered. This light can be viewed through the observation
window in the blower access door. Refer to the Troubleshoot-
ing Chart for further explanation of the lighting codes.
NOTE: There is an approximate 30 second delay between ther-
mostat energizing and burner firing.
FURNACESHUTDOWN
1. Set the thermostat to lowest setting.
2. Turn off the electrical power supply to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
Follow the start-up and adjustment items, refer to further infor-
mation in Section XIII, Operational Checks (see table of con-
tents, pages 2-3 for page number)..
5. White-Rodgers Model 36G54: Push switch to the OFF
FURNACEOPERATION
position.
Purge gas lines of air prior to start-up. Do not purge lines into
an enclosed burner compartment.
Honeywell VR8215 or VR9205: Slide the switch to the
OFF position.
Check for leaks using an approved chloride-free soap and wa-
ter solution, an electronic combustible gas detector, or other
approved method. Verify that all required kits (propane gas,
high altitude, etc.) have been appropriately installed.
6. Close manual gas shutoff valve external to the furnace.
7. Replace the door on the unit.
GASSUPPLYPRESSUREMEASUREMENT
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.
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
FURNACE START-UP
1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
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START-UP PROCEDURE AND ADJUSTMENT
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or inlet pressure boss (White-
Rodgers valve).
5. Turn ON the gas supply.
6. Turn On power and close thermostat “R” and “W” contacts
to provide a call for heat.
7. Using a leak detection solution or soap suds, check for
leaks at outlet pressure boss plug (Honeywell valve) or
screw (White-Rodgers valve). Bubbles forming indicate
a leak. SHUT OFF GAS AND REPAIR ALL LEAKS
IMMEDIATELY!
8. Measure the gas supply pressure with burners firing.
Adjust supply pressure using the Inlet Gas Supply
Pressure table shown below. 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.
WARNING
HIGH VOLTAGE !
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
MODELS USING SINGLE STAGE GAS VALVES
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 mea-
sured with the unit OFF. To measure inlet pressure, use the
following procedure.
Gas Valve
On/Off
Selector
Inlet Gas Supply Pressure
Inlet Pressure
Switch
Natural Gas
Minimum:5.0" W.C. Maximum :10.0" W.C.
Tap
Propane Gas Minimum:11.0" W.C. Maximum :13.0" W.C.
9. Turn OFF all electrical power and gas supply to the
system.
10. Remove the manometer hose from the hose barb fitting
or inlet pressure boss.
INLET
OUTLET
11. Replace inlet pressure tap:
a. Honeywell VR8215 valve:
Pressure Regulator
Adjustment
(Under Cap Screw)
Outlet Pressure
Tap
Remove the 1/8” NPT hose barb fitting from the inlet
pressure tap. Replace the inlet pressure boss plug
and seal with a high quality thread sealer.
b. White-Rodgers 36G22 valve:
Turn inlet pressure test screw in to seal pressure port
(clockwise, 7 in-lb minimum).
12. Retest for leaks. If bubbles form, shut down gas and
repair leaks immediately.
White-Rodgers Model 36G22
Pressure Regulator
(under cap screw)
Inlet
Pressure
Tap
Outlet
Pressure
Tap
13. Turn ON electrical power and gas supply to the system.
14. Turn valve switch ON.
MODELS USING TWO STAGE GAS VALVES
CAUTION
Gas Valve On/Off
Selector Switch
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.
Honeywell Model VR8215 (Single-Stage)
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Turn OFF all electrical power to the system.
3. Inlet pressure tap connections:
The line pressure supplied to the gas valve must be within the
range specified below. The supply pressure can be measured
at the gas valve inlet pressure boss or at a hose fitting installed
in the gas piping drip leg. The supply pressure must be mea-
sured with the burners operating. To measure the gas supply
pressure, use the following procedure.
a. Honeywell VR8215 Valve:
Remove the inlet pressure boss plug. Install an 1/8”
NPT hose barb fitting into the outlet pressure tap.
b. White-Rodgers 36G22 valve:
Back inlet pressure test screw (inlet pressure boss)
out one turn (counterclockwise, not more than one
turn).
26
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START-UP PROCEDURE AND ADJUSTMENT
Common
Terminal(C)
meter
Mano
en to
Op
Atmo
High Fire Coil
Terminal (HI)
e
Hos
sphere
INLET
OUTLET
Low Fire Coil
Terminal (LO)
i
Gas Valve On/Off
Selector Switch
Inlet Pressure Tap
1/8 NPT
White-Rodgers Model 36G54 (Two-Stage)
ter
Manome
ter
anome
Hose
M
Open to
Atmosphere
High Fire Regulator
Adjust
Outlet
Pressure Boss
Regulator
Vent
Outlet Pressure Tap
1/8 NPT
Honeywell Model VR9205 Connected to Manometer
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
Low Fire
Regulator
Adjust
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
boss or the gas piping drip leg. See Honeywell VR9205
gas valve figure or White-Rodgers 36G54 gas valve figure
for location of inlet pressure boss.
Inlet
Pressure
Boss
High Fire Coil
inal (HI)
Coaxial Coil
Manometer
Term
Switch
inal (M)
Term
Common
Terminal(C)
On/Off
NOTE: If measuring gas pressure at the drip leg or Honeywell
VR9205 gas valve, a field-supplied hose barb fitting must be
installed prior to making the hose connection. If using the inlet
pressure boss on the White-Rodgers 36G54 gas valve, then
use the 36G Valve Pressure Check Kit, Goodman Part No.
0151K00000S.
White-Rodgers Model 36G54 Connected to Manometer
High Fire
Regulator
Regulator
Adjust
Vent
3. Turn ON the gas supply and operate the furnace and all
other gas consuming appliances on the same gas supply
line.
4. Measure furnace gas supply pressure with burners firing.
Supply pressure must be within the range specified in
the Inlet Gas Supply Pressure table.
Gas Valve On/Off
Low Fire
Inlet Gas Supply Pressure
Selector Switch
Regulator
Adjust
Natural Gas
Propane Gas
Minimum: 5.0" w.c. Maximum:10.0" w.c.
Minimum: 11.0" w.c. Maximum:13.0" w.c.
Honeywell Model VR9205 (Two-Stage)
If supply pressure differs from table, make the necessary ad-
justments to pressure regulator, gas piping size, etc., and/or
consult with local gas utility.
5. Turn OFF gas to furnace at the manual shutoff valve and
disconnect manometer. Reinstall plug before turning on
gas to furnace.
6. Turn OFF any unnecessary gas appliances stated in
step 3.
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START-UP PROCEDURE AND ADJUSTMENT
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
Gas Line
Gas
Shutoff
Valve
5. Turn ON the gas supply.
6. Turn ON power and close thermostat “R” and “W”
contacts to provide a call for heat.
Gas Line
To Furnace
7. Using a leak detection solution or soap suds, check for
leaks at outlet pressure boss plug (Honeywell valve) or
screw (White-Rodgers valve). Bubbles forming indicate
a leak. SHUT OFF GAS AND REPAIR ALL LEAKS
IMMEDIATELY!
Drip Leg Cap
With Fitting
8. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
Manometer Hose
Manifold Gas Pressure
Natural Gas
3.5" w.c.
Propane Gas
10.0" w.c.
Measuring Inlet Gas Pressure (Alt. Method)
GASMANIFOLDPRESSUREMEASUREMENTANDADJUSTMENT
CAUTION
9. Remove regulator cover screw from the outlet pressure
regulator and turn screw clockwise to increase pressure
or counterclockwise to decrease pressure. Replace
regulator cover screw.
10. Turn OFF all electrical power and gas supply to the
system.
11. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
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.
12. Replace outlet pressure tap:
a. Honeywell VR8215 valve:
WARNING
Remove the 1/8” NPT hose barb fitting from the outlet
pressure tap. Replace the outlet pressure boss plug
and seal with a high quality thread sealer.
b. White-Rodgers 36G22 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
13. Turn ON electrical power and gas supply to the system.
14. Close thermostat contacts to provide a call for heat.
15. Retest for leaks. If bubbles form, SHUT OFF GASAND
REPAIRALLLEAKS IMMEDIATELY!
HIGH VOLTAGE !
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
MODELS USING SINGLE STAGE GAS VALVES
This valve is shipped from the factory with the regulator preset
(see control label).
MODELS USING TWO STAGE GAS VALVES
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 gas to furnace at the manual gas shutoff valve
external to the furnace.
2. Turn OFF all electrical power to the system.
3. Outlet pressure tap connections:
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING
PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING
THE GAS VALVE PRESSURE REGULATOR.
Only small variations in gas pressure should be made by ad-
justing the gas valve pressure regulator. The manifold pressure
must be measured with the burners operating. To measure
and adjust the manifold pressure, use the following procedure.
1. Turn OFF gas to furnace at the manual gas shutoff valve
external to the furnace.
a. Honeywell VR8215 valve:
Remove the outlet pressure boss plug. Install an 1/8”
NPT hose barb fitting into the outlet pressure tap.
b. White-Rodgers 36G22 valve:
Back outlet pressure test screw (outlet pressure boss)
out one turn (counterclockwise, not more than one
turn).
2. Turn off all electrical power to the system.
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START-UP PROCEDURE AND ADJUSTMENT
3. Outlet pressure tap connections:
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY)
a. Honeywell VR9205 valve: Remove the outlet pressure
boss plug. Install an 1/8" NPT hose barb fitting into
the outlet pressure tap.
b. White-Rodgers 36G54 valve: Back outlet pressure test
screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure
barb fitting (Honeywell valve) or outlet pressure boss
(White-Rodgers valve).
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/ ft3)
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.
5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
7. Measure the gas manifold pressure with burners firing.
Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
8. Remove regulator cover screw from the low (LO) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
9. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.
10. Remove regulator cover screw from the high (HI) outlet
pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier)
Installation’s seconds per cubic foot: 34 sec/ ft3
Conversion Factor (hours to seconds): 3600 sec/hr
Input = (Htg. value x 3600) ÷ seconds per cubic foot
Input = (1,000 BTU/ft3 x 3600 sec/hr) ÷ 34 sec/ ft3
Input = 106,000 BTU/hr
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
This measured input must not be greater than the input
indicated on the unit rating plate.
13. Replace outlet pressure tap:
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.
a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
thread sealer.
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
14. Turn on electrical power and gas supply to the system.
15. Close thermostat contacts “R” and “W1/W2” to energize
the valve.
TEMPERATURERISE
Air temperature rise is the temperature difference between supply
and return air. The proper amount of temperature rise is usu-
ally obtained when the unit is operated at the rated input with
the “as shipped” blower speed. If the correct amount of tem-
perature rise is not obtained, it may be necessary to change
the blower speed.
Using a leak detection solution or soap suds, check for leaks
at outlet pressure boss plug (Honeywell valve) or screw (White-
Rodgers valve). Bubbles forming indicate a leak. SHUT OFF
GASAND REPAIRALL LEAKS IMMEDIATELY!
NOTE: For gas to gas conversion, consult your dealer for
appropriate conversion.
An incorrect temperature rise can cause condensing in or over-
heating of the heat exchanger. Determine and adjust the tem-
perature rise as follows. The temperature rise must be within
the range specified on the rating plate or Specification Sheet
applicable to your model. (Please contact your distributor or
our website for the applicable Specification Sheet referred to
in this manual.)
Manifold Gas Pressure
Gas
Range
Nominal
1.9" w .c.
3.5" w .c.
6.0" w .c.
Natural
Low Stage 1.6 - 2.2" w .c.
High Stage 3.2 - 3.8" w .c.
Low Stage 5.7 - 6.3" w .c.
Propane
High Stage 9.7 - 10.3" w .c. 10.0" w .c.
29
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START-UP PROCEDURE AND ADJUSTMENT
3. Relocate desired motor leads to the circulator blower
heat and cool speed terminals on the integrated control
module. (Terminals are identified as LO HEAT, HI HEAT
and COOL (hot)) for *(M,D)H8 models and HEAT and
COOL for *(M,H,D)S8 models). If a heating speed and
the cooling speed are the same, a jumper wire must be
used between the heat and cool terminals.
SUPPLY
AIR
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.
RETURN
AIR
6. Verify proper temperature rise as outlined in Temperature
Rise section.
CIRCULATOR BLOWER FAN TIMING ADJUSTMENT
Temperature Rise Measurement
NOTE: Items in this section refer to the air circulator blower
fan in the *(M,D)H8 models, NOT to the induced draft blower.
The induced draft blower timing sequence is not adjustable.
The circulator blower fan timing is adjustable only on models
with optional “heating fan OFF delay” adjustment pins or
switches. It is NOT adjustable in any other circumstances.
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.
As shipped, the circulator blower fan will remain on for 150
seconds after the gas valve closes. When a call for cooling
occurs, the circulator fan comes on and remains on for 45 sec-
onds after the call for cooling ends. During normal heating op-
eration, the circulator fan will come on approximately 34 sec-
onds after the gas valve opens.
150
100
SECOND
DELAY
SECOND
DELAY
CIRCULATOR BLOWER SPEEDADJUSTMENT
WARNING
Switch viewed in an upflow installation.
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,
TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS.
AdjustmentSwitch
SETTING FURNACE OPERATING MODE(*DH8,*ME8,AND
*MH8MODELS ONLY)
This furnace is designed to operate with either a single gas
input rate or with two discrete gas input rates. The Mode
DIP switch is used to select the single gas input rate or two
discrete input rates.
This furnace is equipped with a PSC circulator blower motor.
This blower provides ease in adjusting blower speeds. Refer to
the Blower Performance Data in the back of the manual for
proper selection of heating and cooling speeds. The cooling
blower speed is shipped set on HIGH. High heat ships on
MEDIUM and low heat is shipped on MEDIUM-LO. These blower
speeds should be adjusted by the installer to match the instal-
lation requirements so as to provide the correct heating tem-
perature rise and the correct cooling CFM.
Setting the Mode switch to “1 STG” forces the furnace to
operate at the furnace’s highest input rate only. Operation is
as described under Sequence of Operation (Integrated
Ignition Control) – Mode DIP Switch is set to “1 STG”
position.
To adjust the circulator blower speed, proceed as follows:
1. Turn OFF power to the furnace.
2. Select the heating and cooling blower speeds that match
the installation requirements from the airflow table in the
Specification Sheet applicable to your model. (Please
contact your distributor or our website for the applicable
Specification Sheet referred to in this manual.)
30
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START-UP PROCEDURE AND ADJUSTMENT
Setting the Mode switch to “2 STG” allows the furnace to
operate at the furnace’s highest input AND at an input rate
that is 75% of the highest input rate. For this mode of
operation, the furnace operates at the low input rate for a
pre-determined time period then steps to the high input rate.
Operation is as described under Sequence of Operation
(Integrated Ignition Control) – Mode DIP Switch is set to “2
STG” position.
AUXILIARY LIMIT CONTROL
Auto reset limits are located on or near the blower. To access
this auxiliary limit, disconnect the electrical power and remove
the blower door. The auxiliary limit control is designed to pre-
vent furnace operation in case of main blower failure on hori-
zontal installations. It may also open if the power supply is
interrupted while the furnace is firing. The auxiliary limit control
is suitable for both horizontal right and horizontal left installa-
tions. Regardless of airflow direction, it does not need to be
relocated.
The time period is determined by the 2nd Stg Dly DIP switch.
Setting the 2nd Stg Dly DIP switch to 5 minutes fixes the
delay period at 5 minutes. Setting the 2nd Stg Dly DIP
switch to Auto enables an algorithm that calculates a delay
period based on the heating cycle time and the total cycle
time. The delay period can range from 1 minute to 12
minutes.
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.
ON
OFF
M
2 STG
5 MIN
1 STG
AUTO
2ND STG DLY
SAFETY CIRCUIT DESCRIPTION
GENERAL
OPERATIONAL CHECKS
A number of safety circuits are employed to ensure safe and
proper furnace operation. These circuits serve to control any
potential safety hazards and serve as inputs in the monitoring
and diagnosis of abnormal function. These circuits are con-
tinuously monitored during furnace operation by the integrated
control module.
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.
INTEGRATED CONTROLMODULE
The integrated control module is an electronic device which
controls all furnace operations. Responding to the thermostat,
the module initiates and controls normal furnace operation, and
monitors and addresses all safety circuits. If a potential safety
concern is detected, the module will take the necessary pre-
cautions and provide diagnostic information through an LED.
BURNER FLAME
The burner flames should be inspected with the burner com-
partment door installed. Flames should be stable, quiet, soft,
and blue (dust may cause orange tips but they must not be
yellow). Flames should extend directly outward from the burn-
ers without curling, floating, or lifting off. Flames must not
impinge on the sides of the heat exchanger firing tubes.
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.
Check the burner flames for:
1. Good adjustment
2. Stable, soft and blue
AUXILIARY LIMIT
3. Not curling, floating, or lifting off.
The auxiliary limit control is located either on or near the circu-
lator blower and monitors heat exchanger compartment tem-
peratures. The control is an automatic reset, temperature
sensor. It guards against overheating resulting from insufficient
air passing over the heat exchanger.
Burner Flame
31
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OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
ROLLOUT LIMITS
DIAGNOSTIC CHART
The rollout limit controls are mounted on the burner/manifold Refer to the troubleshooting chart in the Appendix for assis-
assembly and monitor the burner flame. They are manual- tance in determining the source of unit operational problems.
reset, temperature sensors. This limit guards against burner The red diagnostic LED blinks to assist in troubleshooting the
flames not being properly drawn into the heat exchanger.
unit. The number of blinks refer to a specific code.
NOTE: To clear all alarm codes, depress the push button for 6
seconds.
PRESSURE SWITCHES
The pressure switches are normally-open, negative air pres-
sure-activated switches. They monitor the airflow (combustion
FAULT RECALL
air and flue products) through the heat exchanger via pressure The ignition control is equipped with a momentary push button
taps located on the induced draft blower. These switches guard switch that can be used to display on the diagnostic LED the
against insufficient airflow (combustion air and flue products) last five faults detected by the control. The control must be in
through the heat exchanger.
Standby Mode (no thermostat inputs) to use the feature. De-
press the pushbutton switch for approximately 2 seconds. Re-
lease the switch when the LED is turned off. The diagnostic
LED will then display the flash codes associated with the last
five detected faults. The order of display is the most recent fault
to the least recent fault.
FLAME SENSOR
The flame sensor is a probe mounted to the burner/manifold
assembly which uses the principle of flame rectification to de-
termine the presence or absence of flame.
RESETTINGFROM LOCKOUT
TROUBLESHOOTING
Furnace lockout results when a furnace is unable to achieve
ignition after three attempts. It is characterized by a non-func-
tioning furnace and a one flash diagnostic LED code from the
red LED. If the furnace is in “lockout”, it will (or can be) reset in
any of the following ways.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
2. Manual power interruption. Interrupt 115 volt power to
the furnace for 1 - 20 seconds.
ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
age. By putting the furnace, the control, and the person at the
same electrostatic potential, these steps will help avoid expos-
ing the integrated control module to electrostatic discharge.
This procedure is applicable to both installed and uninstalled
(ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
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.
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.
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.
32
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TROUBLESHOOTING & MAINTENANCE
ANNUALINSPECTION
FILTER REMOVAL
The furnace should be inspected by a qualified installer, or ser- Depending on the installation, differing filter arrangements can
vice agency at least once per year. This check should be per- be applied. Filters can be installed in either the central return
formed at the beginning of the heating season. This will ensure register or a side panel external filter rack (upflow only). A
that all furnace components are in proper working order and media air filter or electronic air cleaner can be used as an alter-
that the heating system functions appropriately. Pay particular nate filter. Follow the filter sizes given in the Recommended
attention to the following items. Repair or service as neces- Minimum Filter size table or instruction provided by the media
sary.
•
or electronic air cleaner manufacturer to ensure proper unit
performance.
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.
To remove filters from an external filter rack in an upright upflow
installation, follow the directions provided with external filter
rack kit. For further details, see your distributor.
•
•
•
•
INDUCED DRAFTAND CIRCULATORBLOWER MOTORS
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No fur-
ther lubrication is required. Check motor windings for accumu-
lation of dust which may cause overheating. Clean as neces-
sary.
FILTERS
FLAME SENSOR (QUALIFIED SERVICER ONLY)
WARNING
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.
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
DISCONNECT ELECTRICAL POWER BEFORE REMOVING FILTERS. NEVER
OPERATE FURNACE WITHOUT A FILTER INSTALLED BECAUSE DUST AND
LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF
EFFICIENCY, EQUIPMENT DAMAGE AND POSSIBLE FIRE.
A return air filter is not supplied with this furnace; however,
there must be a means of filtering all of the return air. The in-
staller will supply filter(s) at the time of installation.
IGNITER (QUALIFIEDSERVICER ONLY)
FILTERMAINTENANCE
If the igniter and the surrounding air are at about 70°F and the
igniter wires are not connected to any other electrical compo-
nents, the resistance of the igniter should not exceed 75 ohms.
If it does, the igniter should be replaced.
Improper filter maintenance is the most common cause of in-
adequate heating or cooling performance. Filters should be
cleaned (permanent) or replaced (disposable) every two months
or as required. When replacing a filter, it must be replaced with
a filter of the same type and size.
BURNERS
WARNING
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.
HIGH VOLTAGE!
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT
ELECTRICAL POWER TO THE FURNACE BEFORE
REMOVING THE FILTER OR PERFORMING ANY OTHER
MAINTENANCE.
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.
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.
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TROUBLESHOOTING & MAINTENANCE
CLEANING (QUALIFIED SERVICER ONLY)
REPAIR AND REPLACEMENT PARTS
1. Shut off electric power and gas supply to the furnace.
•
•
•
When ordering any of the listed functional parts, be sure
to provide the furnace model, manufacturing, and serial
numbers with the order.
2. Disconnect the rollout limit wires, flame sensor wire, and
disconnect the igniter plug.
Although only functional parts are shown in the parts
list, all sheet metal parts, doors, etc. may be ordered by
description.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Parts are available from your distributor.
Functional Parts List-
Gas Valve
Blower/Collector Box Gasket
Primary Limit Switch
Rollout Limit Switch
Auxiliary Limit Switch
Heat Exchanger
3. Remove four (4) screws securing the burner box top.
Natural Gas Orifice
Propane Gas Orifice
Burner
Hot Surface Igniter
Flame Sensor
Gas Manifold
CAUTION
THE IGNITER IS FRAGILE AND CAN BE EASILY DAMAGED. USE EXTREME
CAUTION WHEN REMOVING THE BURNER BOX TOP.
Door Switch
Transformer
4. Remove the screws securing the burners to the burner
bracket. Remove the burners.
Ignition Control
Blower Wheel
5. Use bottle brush to clean burner insert and inside of
burner.
Blower Mounting Bracket Blower Housing
Pressure Switch
Blower Cutoff
Blower Motor
Motor Mount Bracket
Capacitor
6. Replace burner (opposite of removal). Ensure burners
are fully seated on burner bracket and are properly
aligned. Replace burner box top. Reconnect wiring.
Pressure Switch Hose
Induced Draft Blower
Collector Box
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.
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.
34
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COMPONENT IDENTIFICATION
Tubular Heat Exchanger
1
2 Pressure Switch
Flue Pipe Connection
Induced Draft Blower
3
4
(Chimney Transition Top Shipped Loose)
躀
Gas Line
Entrance
5
6
Gas Valve
7
Rollout Limit
8
Junction Box
Wiring Harness
Grommet
9
Gas Manifold
Inshot Burner
Gas Line Entrance
(Alternate)
Transformer
Circulator Blower
Blower Door
Interlock Switch
Integrated Control Module
1
2
3
4
5
6
7
8
Tubular Heat Exchanger
Pressure Switch
Flue Pipe Connection
Induced Draft Blower
Gas Line Entrance
Gas Valve
9 Wiring Harness Grommet
10 Gas Manifold
11 Inshot Burner
12 Transformer
13 Integrated Control Module
14 Blower Door Interlock Switch
15 Circulator Blower
Rollout Limit
Junction Box
16 Gas Line Entrance (Alternate)
35
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COMPONENT IDENTIFICATION
Inshot Burner
Tubular Heat Exchanger
1
7
4
Rollout Limit
Gas Manifold
Induced Draft Blower
6
5
Gas Valve
Gas Line Entrance
(Alternate)
8
9
Junction Box
Wiring Harness
Grommet
Gas Line
Entrance
3
Flue Pipe Connection
(Chimney Transition Top Shipped Loose)
2
Pressure Switch
Transformer
Integrated Control Module
Circulator Blower
Blower Door
Interlock Switch
1
Tubular Heat Exchanger
Pressure Switch
Flue Pipe Connection
Induced Draft Blower
Gas Line Entrance
Gas Valve
9 Wiring Harness Grommet
10 Gas Manifold
11 Inshot Burner
12 Transformer
13 Integrated Control Module
14 Blower Door Interlock Switch
15 Circulator Blower
2
3
4
5
6
7
8
Rollout Limit
Junction Box
16 Gas Line Entrance (Alternate)
36
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TROUBLESHOOTING CHART
Fault
Description(s)
Associated
LED Code2
Symptoms of
Abnormal Operation
Corrective
Action
Cautions
& Notes
Possible
Causes
• Turn power OFF
prior to repair.
NONE
• Assure 115 and 24 volt
power to furnace
integrated control
module.
• Furnace fails to operate.
• No 115 volt power to • Manual disconnect switch
furnace, or no 24
volt power to
integrated control
module.
OFF, door switch open, or
24 volt wires improperly
connected or loose.
• Integrated control module
diagnostic LED provides
no signal.
• Replace integrated
control module
fuse with 3A
• Check integrated control
module fuse (3A).
Replace if necessary.
• Blown fuse or circuit
• Blown fuse or circuit breaker.
breaker.
automotive fuse.
• Check for possible
shorts in 115 and 24 volt
circuits. Repair as
necessary.
• Turn power OFF
prior to repair.
• Read precautions
in “Electrostatic
Discharge” section
of manual.
• Furnace fails to operate.
• Furnace fails to operate.
• Integrated control
module has an
internal fault.
• Integrated control module
has an internal fault.
• Replace bad integrated
control module.
• Locate and correct
gas interruption.
• Furnace lockout due
to an excessive
• Failure to establish flame.
Cause may be no gas to
burners, bad igniter or
igniter alignment, improper
orifices, or coated/
• Turn power OFF
prior to repair.
1
• Integrated control module
diagnostic LED is
flashing ONE (1) flash.
number of ignition
• Replace or realign
igniter.
attempts. (3 total)1
• Igniter is fragile,
handle with care.
1 FLASH
• Check flame sense
signal. Sand sensor
if coated and/or
oxidized.
• Auxiliary Limit Open
oxidized or improperly
connected flame sensor.
• Clean flame sensor
with steel wool.
• Loss of flame after
• See “Combustion
and Ventilation Air
Requirements” and
“Category I Venting
(Vertical Venting)”
section for details.
establishment. Cause may
be interrupted gas supply,
lazy burner flames
(improper gas pressure or
restriction in flue or
• Check flue piping for
blockage, proper
length, elbows, and
termination.
• Verify proper
induced draft blower
performance.
improper induced draft
blower performance.
• See Product Data
Bulletin for
allowable rise
range and proper
circulator speed.
• Insufficient conditioned air
over the heat exchanger.
Blocked filters, restrictive
ductwork, improper
circulator blower speed,
or failed circulator blower.
• Check circulator
blower speed and
performance.
Correct speed or
replace blower if
necessary.
• Turn power OFF
prior to repair.
• Furnace fails to operate.
• Pressure switch
circuit is closed.
• Induced draft blower
pressure switch contacts
sticking.
• Replace induced
draft blower
pressure switch.
2
• Integrated control module
diagnostic LED is
flashing TWO (2)
flashes.
• Replace pressure
switch with proper
replacement part.
• Induced draft blower
is not operating.
• Shorts in pressure switch
circuit.
• Repair short.
2 FLASHES
• Inspect pressure switch
hose. Repair, if neces-
sary,
• Turn power OFF
prior to repair.
• Induced draft blower
runs continuously with
no further furnace
operation.
• Pressure switch hose
blocked, pinched or
connected improperly.
• Pressure switch
circuit not closed.
3
• See “Combustion
and Ventilation Air
Requirements” and
“Category I Venting
(Vertical Venting)”
section for details.
• Induced draft blower
is operating.
• Inspect flue for blockage,
proper length, elbows,
and termination.
• Blocked flue or weak
induced draft blower.
• Integrated control module
diagnostic LED is
flashing THREE (3)
flashes.
3 FLASHES
• If installed, manual
reset limit switch is
open on Masonry
Vent Kit (MVK).
• Incorrect pressure switch
setpoint or malfunctioning
switch contacts.
• Correct pressure switch
setpoint or contact
motion.
• Replace pressure
switch with proper
replacement part.
• Tighten or correct wiring
connection.
• Loose or improperly
connected wiring.
• Replace masonry
vent kit limit switch
with correct
• Inspect masonry
chimney and flue; remove
blockage.
• Blockage in flue or
chimney.
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.
37
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TROUBLESHOOTING CHART
Associated
LED Code2
Fault
Description(s)
Symptoms of
Abnormal Operation
Cautions
& Notes
Corrective Action
Possible Causes
• Check primary limit.
Replace if necessary.
• Insufficient conditioned air
over the heat exchanger.
Blocked filters, restrictive
ductwork, improper
circulator blower speed, or
failed circulator blower.
• Turn power OFF
prior to repair.
• Circulator blower runs
continuously. No furnace
operation.
• Primary limit
circuit is open.
4
• Check filters and
ductwork for blockage.
Clean filters or remove
obstruction.
• Replace primary
switch with proper
replacement part.
• Integrated control module
diagnostic LED is flashing
FOUR (4) flashes.
4 FLASHES
• Faulty primary limit switch.
• Check circulator blower
speed and performance.
Correct speed or replace
blower if necessary.
• Tighten or correct wiring
connection.
• Replace blower
with correct
replacement part.
• Loose or improperly
connected wiring.
• Induced draft blower and
circulator blower runs
continuously. No furnace
operation.
• Short to ground in flame
sense circuit.
• Flame sensed
with no call for
heat.
• Turn power OFF
prior to repair.
• Correct short at flame
sensor or in flame
sensor wiring.
5
5 FLASHES
• Integrated control module
diagnostic LED is flashing
FIVE (5) flashes.
• Check burners for proper • See “Vent/Flue Pipe”
• Flame rollout.
• Furnace fails to operate.
• Rollout limit open.
alignment.
section for piping
details.
6
• Integrated control module
diagnostic LED is flashing
SIX (6) flashes.
• Integrated control
module fuse is
blown.
• Check flue and air inlet
piping for blockage,
proper length, elbows,
and termination. Correct
as necessary.
• Misaligned burners,
blocked flue and/or air
inlet pipe, or failed
• Replace induced
draft blower with
proper replacement
part.
6 FLASHES
• No furnace operation.
induced draft blower.
• Check rollout limit. Replace
if necessary.
• Replace integrated
control module fuse
with 3A automotive
fuse.
• Read precautions in
“Electrostatic
• Loose or improperly
connected wiring.
• Check induced draft
blower for proper
performance. Replace, if
necessary.
• Short in 24 volt AC
control circuits or safety
circuits.
• Tighten or correct wiring
connection.
Discharge” section
of manual.
• Repair short in 24 volt AC
control/safety circuit(s).
• Replace rollout limit
with correct
replacement part.
• Replace integrated control
module fuse (3A).
• Faulty rollout limit.
• Turn power OFF
prior to repair.
• Sand flame sensor.
• Flame sense
microamp signal is
low.
• Flame sensor is coated/
oxidized.
• Normal furnace
operation.
7
• Clean flame sensor
with steel wool.
• Inspect for proper sensor
alignment.
• Flame sensor incorrectly
positioned in burner
flame.
• Lazy burner flame due to
improper gas pressure or
combustion air.
• Integrated control module
diagnostic LED is
flashing SEVEN (7)
flashes.
7 FLASHES
• See “Vent/Flue
Pipe” section for
piping details.
• Compare current gas
pressure to rating plate
info. Adjust as needed.
• See rating plate for
proper gas
pressure.
2
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
38
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TROUBLESHOOTING CHART
Fault
Description(s)
Symptoms of
Abnormal Operation
Cautions
& Notes
Associated
Corrective Action
Possible Causes
LED Code2
• Improperly connected
igniter.
• Furnace not operating.
• Problem with
igniter circuit.
• Check and correct wiring • Turn power OFF
from integrated control
module to igniter.
prior to repair.
• Integrated control module
diagnostic LED is
flashing EIGHT (8)
flashes.
• Bad igniter.
• Replace igniter
with proper
• Replace bad igniter.
8 FLASHES
replacement part.
• Read precautions
in “Electrostatic
Discharge”
• Check and correct unit
ground wiring.
• Poor unit ground.
• Poor burner ground.
section of manual.
• Faulty integrated control
module.
• Replace bad integrated
control module.
• Polarity of 115 volt AC
power to furnace or
integrated control module
is reversed.
• Review wiring diagram to
correct polarity.
• Polarity of 115
or 24 volt
power is
• Turn power OFF
prior to repair.
• Induced draft blower runs
continuously. No furnace
operation.
C
• Verify proper ground.
Correct if necessary.
reversed.
• Integrated control module
diagnostic LED is flashing
continuously.
• Red and blue wires to
transformer are reversed.
CONTINUOUS
FLASHING
• Reverse red and blue
wires connected to
transformer.
• Poor unit ground.
• Normal operation.
• LED is steady on
STEADY
2
LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch.
39
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BLOWER PERFORMANCE DATA
*M(H/S)8
(CFM & Temperature Rise vs. External Static Pressure)
EXTERNAL STATIC PRESSURE (Inches Water Column)
0.2 0.3 0.4 0.5
Model
Tons AC
at 0.5"
ESP
3.0
2.5
2.0
1.5
3.0
2.5
2.0
1.5
4.0
3.5
3.0
2.5
3.0
2.5
2.0
1.5
4.0
3.5
3.0
2.5
5.0
4.0
3.5
3.0
5.0
4.0
3.5
3.0
5.0
4.0
3.5
3.0
5.0
4.0
3.5
3.0
Motor
Speed
0.1
0.6
0.7
0.8
Heating Speed
As Shipped
CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
1521 ---- 1466 ---- 1414 ---- 1373 ---- 1298 ---- 1243 1164 1075
HIGH
MED
*M(H/S)80403A***
(MEDIUM)
1160 26
1160 26 1132 26 1121 26 1082 27 1042 997 925
MED-LO
LOW
961
781
31
38
955
785
31
38
948
781
31
38
932
773
32
38
913
761
33
32
882 821 803
745 716 668
HIGH
MED
1422 31
1098 40
1352 33 1307 34 1197 37 1157 38 1092 1075 983
*M(H/S)80603A***
(MEDIUM)
1081 41 1051 42 1039 43 1021 44
983 924 868
818 792 728
677 649 626
MED-LO
LOW
919
758
48
913
741
49
892
741
50
847
733
----
----
829
699
----
----
----
----
----
HIGH
MED
2134 21
1668 27
1419 31
1134 39
1607 37
1159 51
2100 21 2042 22 1975 23 1883 24 1786 1700 1601
1663 27 1656 27 1645 27 1616 28 1549 1492 1391
1426 31 1426 31 1432 31 1419 31 1378 1328 1261
1145 39 1166 38 1171 38 1160 38 1144 1111 1071
1572 38 1547 39 1498 40 1448 41 1390 1302 1222
1156 51 1145 52 1127 53 1108 53 1075 1033 957
*M(H/S)80604B***
(MEDIUM)
MED-LO
LOW
HIGH
MED
*M(H/S)80803B***
(MEDIUM)
MED-LO
LOW
938
785
63
916
766
65
916
743
65
900
730
----
----
889
709
----
----
865 829 785
683 666 604
----
----
----
HIGH
MED
2051 ---- 1983 ---- 1895 ---- 1812 ---- 1725 ---- 1627 1530 1439
1736 ---- 1708 35 1652 36 1611 37 1540 38 1475 1394 1307
*M(H/S)80804B***
(MEDIUM)
MED-LO
LOW
1693 35
1200 49
1668 36 1459 41 1429 41 1389 43 1339 1274 1204
1185 50 1180 50 1173 51 1158 51 1125 1125 1080
HIGH
MED
2290 ---- 2229 ---- 2155 ---- 2047 ---- 1960 ---- 1837 1712 1584
1852 ---- 1820 ---- 1777 ---- 1719 --- 1641 36 1567 1469 1382
*M(H/S)80805C***
(MEDIUM)
MED-LO
LOW
1615 37
1290 46
1592 37 1556 38 1516 39 1470 40 1405 1346 1235
1285 46 1265 47 1235 48 1214 49 1174 1044 904
HIGH
MED
2323 ---- 2225 ---- 2120 35 2040 36 1974 38 1801 1688 1577
*M(H/S)81005C***
(MEDIUM)
1858 40
1596 46
1291 57
1847 40 1799 41 1744 42 1674 44 1577 1493 1399
1587 47 1571 47 1552 48 1493 50 1397 1326 1217
1272 58 1261 59 1257 59 1205 61 1168 1118 1060
MED-LO
LOW
HIGH
MED
2469 ---- 2389 ---- 2300 ---- 2223 40 2131 42 2027 1902 1786
*M(H/S)81205D***
(MEDIUM)
1575 56
1402 63
1558 57 1545 58 1513 59 1500 59 1419 1354 1271
1380 64 1343 66 1319 67 1296 69 1245 1183 1106
MED-LO
LOW
1200 ---- 1186 ---- 1161 ---- 1127 ---- 1082 ---- 1042 995 926
HIGH
MED
2469 42
1575 66
2389 43 2300 45 2223 47 2131 49 2027 1902 1786
1558 67 1545 67 1513 69 1500 69 1419 1354 1271
*M(H/S)81405D***
(MEDIUM)
MED-LO
LOW
1402 ---- 1380 ---- 1343 ---- 1319 ---- 1296 ---- 1245 1183 1106
1200 ---- 1186 ---- 1161 ---- 1127 ---- 1082 ---- 1042 995 926
40
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BLOWER PERFORMANCE DATA
*(D/H)S8
(CFM & Temperature Rise vs. External Static Pressure)
Model
EXTERNAL STATIC PRESSURE (Inches Water Column)
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Tons AC
at 0.5"
Motor
Speed
0.1
Heating Speed
As Shipped
ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
HIGH
MED
3.0
2.5
2.0
1.5
3.0
2.5
2.0
1.5
4.0
3.5
3.0
2.5
5.0
4.0
3.5
3.0
1353 ---- 1290 ---- 1246 ---- 1199 25 1149 26 1116 1116 1099
1183 25 1113 27 1098 27 1052 28 1039 29 1006 1012 969
GDS80403A***
(MEDIUM)
MED-LO
LOW
980
778
30
38
946
762
31
39
920
738
32
40
900
746
33
40
896
738
33
40
885 855 804
717 696 678
HIGH
1290 34 1236 36 1194 37 1166 38 1176 38 1166 1108 1029
1139 39 1090 41 1035 43 1063 42 1063 42 1020 962 895
GDS80603A***
(MEDIUM)
MED
MED-LO
LOW
962
787
46
56
927
776
48
57
925
763
48
58
941
744
47
60
909
723
49
877 834 779
690 641 581
----
HIGH
2128 ---- 2063 ---- 2001 ---- 1927 ---- 1824 ---- 1726 1628 1529
1840 ---- 1788 ---- 1745 ---- 1689 35 1625 36 1550 1470 1364
1602 37 1558 38 1543 38 1493 40 1455 41 1402 1328 1239
1277 46 1252 47 1244 48 1229 48 1214 49 1179 1141 1079
2405 ---- 2361 ---- 2250 ---- 2161 ----- 2037 36 1937 1808 1689
1880 39 1838 40 1794 41 1734 43 1677 44 1568 1510 1401
1659 45 1630 45 1587 47 1537 48 1492 50 1445 1368 1287
1472 50 1454 51 1404 53 1366 54 1326 56 1300 1228 1139
GDS80804B***
(MEDIUM)
MED
MED-LO
LOW
HIGH
GDS81005C***
(MEDIUM)
MED
MED-LO
LOW
(CFM & Temperature Rise vs. External Static Pressure)
Model
EXTERNAL STATIC PRESSURE (Inches Water Column)
0.3 0.4 0.5 0.6
ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE
Tons AC
Motor
Speed
at 0.5"
0.1
0.2
0.7
0.8
Heating Speed
As Shipped
HIGH
MED
3.0
2.5
2.0
1.5
4.0
3.5
3.0
3.0
5.0
4.0
3.5
3.0
1739 ---- 1656 ---- 1601 ---- 1551 ---- 1513 20 1460 22.8 1413 23.6 1353 24.6
GHS80403A***
(MEDIUM)
1422 21
1207 25
1399 21 1378 22 1350 22 1305 23 1275 26.1 1220 27.3 1178 28.3
1213 24 1197 25 1169 25 1158 26 1131 29.5 1103 30.2 1068 31.2
MED-LO
LOW
991
30
980
30
958
31
950
31
937
32
924 36.1 910 36.6 874 38.1
HIGH
MED
2097 21
1596 28
1380 32
1239 36
2068 21 2012 22 1939 23 1869 24 1795 28.9 1718 30.2 1631 31.8
1566 28 1534 29 1492 30 1445 31 1401 37 1354 38.3 1288 40.3
1356 33 1328 33 1303 34 1274 35 1239 41.8 1192 43.5 1127 46
1191 37 1165 37 1133 39 1104 40 1082 47.9 1040 49.9 996 52.1
GHS80604B***
(MEDIUM)
MED-LO
LOW
HIGH
MED
2382 ---- 2315 ---- 2234 ---- 2158 ---- 2078 ---- 1971 33.8 1866 35.7 1762 37.8
GHS80805C***
(MEDIUM)
1622 37
1436 41
1240 48
1603 37 1583 37 1556 38 1516 39 1482 45 1422 46.9 1359 49.1
1391 43 1387 41 1356 44 1325 45 1279 52.1 1239 53.8 1180 56.5
1214 49 1191 50 1157 51 1120 53 1083 61.6 1052 63.4 1025 65
MED-LO
LOW
41
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BLOWER PERFORMANCE DATA
GME8
(CFM & Temperature Rise vs. External Static Pressure)
Model
EXTERNAL STATIC PRESSURE (Inches Water Column)
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Tons AC
at 0.5"
Motor Speed
0.1
Heating Speed
As Shipped
ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM
T1 - YELLOW
T2 - RED
1.5
2.0
2.5
3.0
3.5
2.5
3.0
3.5
4.0
5.0
3.0
3.5
4.0
4.0
5.0
875
----
793
965
----
46
736
914
----
49
674
861
----
----
592
810
----
----
556 509 460
756 712 659
964 918 877
1032 43
GME80603B*** T3 - ORANGE
T4 - BLUE
1217 37 1153 39 1098 40 1051 42 1009 44
1365 33 1313 34 1268 35 1221 36 1172 38 1129 1086 1054
1549 29 1505 30 1460 30 1420 31 1378 32 1350 1305 1268
T5 - BLACK
T1 - YELLOW
1268 47 1198 49 1151 51 1092 54 1041 57
988 932 883
T2 - RED
1362 44 1305 45 1261 47 1212 49 1170 51 1121 1074 1021
1576 38 1519 39 1473 40 1426 42 1398 42 1341 1290 1252
1755 ---- 1711 35 1657 36 1627 36 1579 38 1548 1502 1463
2183 ---- 2128 ---- 2094 ---- 2060 ---- 2014 ---- 1992 1944 1847
1466 51 1415 52 1357 55 1306 57 1248 59 1202 1144 1088
1642 45 1596 46 1552 48 1499 49 1449 51 1388 1352 1306
1750 42 1750 42 1707 43 1667 44 1610 46 1574 1531 1486
1870 40 1805 41 1782 42 1737 43 1701 44 1656 1606 1571
2297 ---- 2297 ---- 2224 ---- 2106 35 2014 37 1896 1813 1669
GME80805C***
GME81005C***
T3 - ORANGE
T4 - BLUE
T5 - BLACK
T1 - YELLOW
T2 - RED
T3 - ORANGE
T4 - BLUE
T5 - BLACK
Notes:
• CFM in chart is without filter(s). Filters do not ship with this furnace, but must be provided by the installer. If the furnace requires two
return filters, this chart assumes both filters are installed.
• All furnaces ship as high-speed cooling and medium-speed heating. Installer must adjust blower cooling and heating speed as needed.
• For most jobs, about 375 - 400 CFM per ton when cooling is desirable.
• INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.
should
• This chart is for information only. For satisfactory operation, external static pressure
not exceed value shown on the rating plate.
• The above chart is for U.S. furnaces installed at 0-2000 feet. At higher altitudes, a properly derated unit will have approximately the same
temperature rise at a particular CFM, while ESP at the CFM will be lower.
• Factory Motor Speed Setting: T1 = 1st Stage Ht, T2 = 2nd Stage Ht, T5 = Cooling.
• Temperature rise data is based on 2nd-stage heat. First-stage heat is 75% of rise indicated above.
42
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*(M, D, H)S8 WIRING DIAGRAM
BOX
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
43
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GME8 WIRING DIAGRAM
INTEGRATED
CONTROLMODULE
HUMIDIFIER
XFMR(6)
WARNING:DISCONNECTPOWERBEFORE
SERVICING.WIRINGTOUNITMUSTBE
PROPERLYPOLARIZEDANDGROUNDED.
GND
GND(8)
MVC(9)
24VAC
HUMIDIFIER
C2
HI
GAS
VALVE
MVH(12)
MVL(2)
M1
C
IDBLOWER
PRESSURE
SWITCH
AUXILIARY
LIMITCONTROLS
C
G
R
W
Y
G
Y
NO
PS(10)
PSO(4)
C
AUTO
1STG
150SEC
5MIN
2STG
MODE
H
T
TO
100SEC
O
F
F
MICRO HLI(7)
D
10 11 12
L
Y
WH
W
7
4
1
8
5
2
9
6
3
BL
HLO(1)
AUTORESET
PRIMARY
LIMIT
FUSE
R
RO2(11)
RO1(5)
SEENOTE6
BR
CONTROL
AUXILIARY
LIMITS
INTEGRATED
CONTROLMODULE
MANUALRESETROLLOUT
LIMITCONTROL(S)
(SINGLECONTROLONSOMEMODELS)
XFMR(3)
FS
24VAC
40VA
TRANSFORMER
BR
BL
RD
XFMR-H
XFMR-N
115VAC
FLAMESENSOR
2
1
FP
HOTSURFACE
IGNITER
XFMR-H LINE-H EAC-H
IGN
IND
IGN-N
PARK
ID
BLWR
BK
IND-N
L
H
O
E
A
T
-
BK
24V
H
COOL-H
I
CIRCULATOR
BLWR
115V
CIR-N
H
E
H
-
XFMR
T
A
H
WH
BK
ELECTRONIC
AIRCLEANER
15PINPLUG
ONSOMEMODELS
EAC-H
LINE-H
GR
EAC-N
BLOWERCOMPARTMENT
LINE-N
JUNCTIONBOX
BURNERCOMPARTMENT
DOOR
SWITCH
24VAC
HUMIDIFIER
DOORSWITCH
SWITCHLOCATEDINBLOWER
COMPARTMENTONSOMEMODELS
NO
C
WARNING:
RD
RD
DISCONNECTPOWER
BEFORESERVICING.
WIRINGTOUNIT
MUSTBE
PROPERLY
POLARIZED
DISCONNECT
PRESSURE
SWITCH
YL
YL
PRIMARYLIMIT
YL
RD
YL
WH
BK
ANDGROUNDED.
L
GND
N
BR
BL
OVERCURRENTPROTECTIONDEVICE
WH
BK
PM
1
C
3
HI
2
JUNCTION
BOX
HOT
SURFACE
IGNITER
2STAGE
GASVALVE
(HONEYWELL)
LINE-N
GND
LINEH
PU
INDUCEDDRAFT
BLOWER
TO115VAC/1/60HZ
POWERSUPPLYWITH
OVERCURRENTPROTECTION
DEVICE
PU
PU
FLAME
SENSOR
ROLLOUTLIMITS
(SINGLECONTROLONSOMEMODELS)
0
STEADYON=NORMALOPERATION
LOWVOLTAGE(24V)
LOWVOLTAGEFIELD
HIVOLTAGE(115V)
HIVOLTAGEFIELD
EQUIPMENTGND
FIELDGND
OFF
=CONTROLFAILURE
1
2
3
4
5
6
1FLASH
=
SYSTEMLOCKOUT(RETRIES/RECYCLESEXCEEDED)
2FLASHES=PRESSURESWITCHSTUCKCLOSED
3FLASHES=PRESSURESWITCHSTUCKOPEN
4FLASHES=OPENHIGHLIMIT
FIELDSPLICE
SWITCH(TEMP.)
IGNITER
JUNCTION
TERMINAL
INTERNALTO
5FLASHES=FLAMESENSEWITHOUTGASVALVE
6FLASHES=
OPENROLLOUTOROPENFUSE
SWITCH(PRESS.)
7FLASHES=LOWFLAMESIGNAL
7
8
INTEGRATEDCONTROL
OVERCURRENT
PROT.DEVICE
8FLASHES=CHECKIGNITERORIMPROPERGROUND
RAPIDFLASHES=REVERSED115VACPOLARITY/VERIFYGND
PLUGCONNECTION
C
NOTES:
1.SETHEATANTICIPATORONROOMTHERMOSTATAT0.7AMPS.
2.MANUFACTURER'SSPECIFIEDREPLACEMENTPARTSMUSTBEUSEDWHENSERVICING.
3.IFANYOFTHEORIGINALWIREASSUPPLIEDWITHTHEFURNACEMUSTBEREPLACED,ITMUSTBEREPLACEDWITH
WIRINGMATERIALHAVINGATEMPERATURERATINGOFATLEAST105°C.USECOPPER CONDUCTORSONLY.
4.BLOWERSPEEDSSHOULDBEADJUSTEDBYINSTALLERTOMATCHTHEINSTALLATIONREQUIREMENTSSOASTO
PROVIDETHECORRECTHEATINGTEMPERATURERISEANDTHECORRECTCOOLINGCFM.(SEESPECSHEETFORAIR
FLOWCHART)
5.UNITMUSTBEPERMANENTLYGROUNDEDANDCONFORMTON.E.C.ANDLOCALCODES.
6.TORECALLTHELAST5FAULTS,MOSTRECENTTOLEASTRECENT,DEPRESSSWITCHFORMORETHAN2SECONDS
PKPINK
COLORCODES:
YL YELLOW
OR ORANGE
PUPURPLE
GRGREEN
BRBROWN
WH WHITE
BLBLUE
GYGRAY
RD RED
BKBLACK
WHILEINSTANDBY(NOTHERMOSTATINPUTS).
0140F00658 REV.A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
44
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*(M,D)H8 WIRING DIAGRAM
INTEGRATED
CONTROL MODULE
HUMIDIFIER
XFMR (6)
WARNING:DISCONNECT POWER BEFORE
SERVICING.WIRING TO UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
GND
GND (8)
MVC (9)
24 VAC
HUMIDIFIER
C2
HI
GAS
VALVE
MVH (12)
MVL (2)
M1
C
ID BLOWER
PRESSURE
SWITCH
AUXILIARY
LIMIT CONTROLS
C
G
R
W
Y
G
Y
NO
PS (10)
PSO (4)
C
AUTO
5 MIN
1 STG
2 STG MODE
H
TO
150 SEC
100 SEC
T
O
F
F
MICRO HLI (7)
D
10 11 12
L
Y
WH
W
7
4
1
8
5
2
9
6
3
BL
HLO (1)
AUTO RESET
PRIMARY
LIMIT
FUSE
R
RO2 (11)
RO1 (5)
SEE NOTE 6
BR
CONTROL
AUXILIARY
LIMITS
INTEGRATED
CONTROL MODULE
MANUAL RESET ROLLOUT
LIMIT CONTROL(S)
(SINGLE CONTROL ON SOME MODELS)
XFMR (3)
FS
24 VAC
40 VA
TRANSFORMER
BR
BL
RD
XFMR-H
XFMR-N
115 VAC
FLAME SENSOR
2
1
FP
HOT SURFACE
IGNITER
XFMR-H LINE-H EAC-H
IGN
IND
IGN-N
PARK
ID
BLWR
BK
IND-N
L
H
O
E
A
T
-
BK
24V
H
COOL-H
CIRCULATOR
BLWR
115V
CIR-N
XFMR
WH
BK
ELECTRONIC
AIR CLEANER
15 PIN PLUG
ON SOME MODELS
EAC-H
LINE-H
GR
EAC-N
BLOWER COMPARTMENT
LINE-N
JUNCTION BOX
BURNER COMPARTMENT
DOOR
SWITCH
24 VAC
HUMIDIFIER
DOOR SWITCH
SWITCH LOCATED IN BLOWER
COMPARTMENT ON SOME MODELS
NO
C
WARNING:
RD
RD
DISCONNECT POWER
BEFORE SERVICING.
WIRING TO UNIT
MUST BE
PROPERLY
POLARIZED
DISCONNECT
PRESSURE
SWITCH
YL
YL
PRIMARY LIMIT
YL
RD
YL
WH
BK
AND GROUNDED.
L
GND
N
BR
BL
OVERCURRENT PROTECTION DEVICE
WH
BK
PM
1
C
3
HI
2
JUNCTION
BOX
HOT
SURFACE
IGNITER
2 STAGE
GAS VALVE
(HONEY WELL)
LINE-N
GND
LINE H
PU
INDUCED DRAFT
BLOWER
TO 115 VAC/ 1/60HZ
POWER SUPPLY WITH
OVERCURRENT PROTECTION
DEVICE
PU
PU
FLAME
SENSOR
ROLLOUT LIMITS
(SINGLE CONTROL ON SOME MODELS)
0
STEADY ON = NORMAL OPERATION
LOW VOLTAGE (24V)
LOW VOLTAGE FIELD
HI VOLTAGE (115V)
HI VOLTAGE FIELD
EQUIPMENT GND
FIELD GND
OFF
= CONTROL FAILURE
1
2
3
4
5
6
1 FLASH
=
SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED)
2 FLASHES = PRESSURE SWITCH STUCK CLOSED
3 FLASHES = PRESSURE SWITCH STUCK OPEN
4 FLASHES = OPEN HIGH LIMIT
FIELD SPLICE
SWITCH (TEMP.)
IGNITER
JUNCTION
TERMINAL
INTERNAL TO
5 FLASHES = FLAME SENSE WITHOUT GAS VALVE
6 FLASHES =
OPEN ROLLOUT OR OPEN FUSE
SWITCH (PRESS.)
7 FLASHES = LOW FLAME SIGNAL
7
8
INTEGRATED CONTROL
OVERCURRENT
PROT. DEVICE
8 FLASHES = CHECK IGNITER OR IMPROPER GROUND
RAPID FLASHES = REVERSED 115 VAC POLARITY/VERIFY GND
PLUG CONNECTION
C
NOTES:
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS.
PK PINK
COLOR CODES:
YL YELLOW
OR ORANGE
PU PURPLE
GR GREEN
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING.
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE
RATING OF AT LEAST 105 °C. USE COPPER CONDUCTORS ONLY.
4. BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION
REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE
CORRECT COOLING CFM. (SEE SPEC SHEET FOR AIR FLOW CHART)
BR BROWN
WH WHITE
BL BLUE
GY GRAY
RD RED
BK BLACK
5. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. AND LOCAL CODES.
6. TO RECALL THE LAST 5 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH
FOR MORE THAN 2 SECONDS WHILE IN STANDBY(NO THERMOSTAT INPUTS).
0140F00662 REV. A
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Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
© 2009-2010 Goodman Manufacturing Company, L.P.
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