GOODMAN GMSS960603BNAA (01) PDF MANUAL

GOODMAN GMSS960603BNAA (01) PDF SUMMARY:

What should you do if you smell gas?

• Do NOT try to light any appliance.
• Do NOT touch any electrical switch.
• Do NOT use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.

Should overheating occur or the gas supply fail to shut off, what should you do?

Turn off the manual gas shutoff valve external to the furnace before turning off the electrical supply.

This unit should not be connected to, or used in conjunction with, any devices that are not design certified for use with this unit or have not been tested and approved by Goodman.

Serious property damage or personal injury, reduced unit performance and/or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman.

Who should perform installation and repair of this unit?

Installation and repair of this unit should be performed only by individuals meeting the requirements of an Entry Level Technician, at a minimum, as specified by the Air Conditioning, Heating, and Refrigeration Institute (AHRI).

What may result from attempting to install or repair this unit without the proper background?

Attempting to install or repair this unit without such background may result in product damage, personal injury, or death.

What may happen if the information in the instructions is not followed exactly?

A fire or explosion may result causing property damage, personal injury or loss of life.

What should you NOT do in the vicinity of this or any other appliance?

Do NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

What should you do if you smell gas?

• Do NOT try to light any appliance.
• Do NOT touch any electrical switch; DO NOT use any phone in your building.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

Installation and service must be performed by whom?

A qualified installer, service agency, or the gas supplier.

What special warning is there for the installation of furnaces or air handling units in enclosed areas, such as garages, utility rooms, or parking areas?

Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms, or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room, or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation. This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.

What could happen if someone does not follow the instructions in the manual?

Anyone who does not follow the instructions in this manual exactly risks triggering a fire or explosion resulting in material damage, bodily injury or loss of life.

Does this appliance have a pilot light?

No. This appliance does not have a pilot light. It is equipped with an ignition device which automatically lights the burner. Do not attempt to light the burner manually.

How should the gas inlet lever be operated?

Only use your hand to push or turn the gas inlet lever; never use a tool for this purpose. If the lever gets stuck, do not try to repair it; call a qualified technician. Anyone who tries to force the lever or repair it may trigger an explosion or fire.

What should you do if the appliance has been immersed in water?

Do not use this appliance if it has been immersed in water, completely or partially. Call a qualified technician to inspect the appliance and replace any part of the control system and any control that have been immersed in water.

What are the operating instructions?

1. STOP! Read the safety instructions on the upper portion of this label.
2. Set the thermostat to the lowest temperature.
3. Turn off the power to the appliance.
4. This household appliance is equipped with an automatic ignition system, do not try to light the burner manually.
5. Push the gas control lever to the “OFF / STOP” position.
6. Wait five (5) minutes to allow all the gas to escape. Sniff all around the appliance, including near the floor, to detect any smell of gas. If this is the case, STOP! Go to step B of the safety instructions on the upper portion of this label. If there is no smell of gas, proceed to the next step.
7. Push the gas control lever to the “ON / START” position.
8. Replace the access panel.
9. Turn on the power to the appliance.
10. Set the thermostat to the desired temperature.
11. If the appliance does not start, follow the instructions entitled: How to shut off the gas supply to the appliance and call a qualified technician or the gas supplier.

What should you do to turn off the gas to the appliance?

1. Set the thermostat to the lowest temperature.
2. Turn off the power to the appliance if maintenance is to be carried out.
3. Push the gas control lever to the “OFF / STOP” position. Do not force.
4. Replace the access panel.

What should you do before operating the appliance?

Before operating, smell all around the appliance to detect any smell of gas. Smell near the floor, because some gases are heavier than air and may accumulate at floor level.

What should you do if you smell gas?

• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.

Does this appliance have a pilot?

No, this appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

What should you do before operating the appliance?

Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

How should you operate the gas control lever?

Use only your hand to push in or turn the gas control lever. Never use tools. If the lever will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

What should you do if any part of the appliance has been underwater?

Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater.

What are the operating instructions?

1. STOP! Read the safety information above on this label.
2. Set the thermostat to the lowest setting.
3. Turn off all power to the appliance.
4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. Push the gas control lever to “OFF” Position. Do not force.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.
7. Push gas control lever to “ON”.
8. Replace access panel.
9. Turn on all electric power to the appliance.
10. Set thermostat to desired setting.
11. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas company.

How do you turn off the gas to the appliance?

1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Push the gas control lever to “OFF” Position. Do not force.
4. Replace control access panel.

What may happen if you do not follow these instructions?

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Does this appliance have a pilot?

No, this appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

How do you turn off the gas to the appliance?

1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Push the gas control lever to “OFF” Position. Do not force.
4. Replace control access panel.

What may happen if you do not follow these instructions?

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

What should you do if you smell gas?

• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.

What should you do before operating the appliance?

Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

Does this appliance have a pilot?

No. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

What should you do before operating the appliance?

Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

What should you do if you smell gas?

• Do not try to light any appliance.
• Do not touch any electric switch; do not use any telephone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

What are the operating instructions?

1. STOP! Read the safety information above on this label.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an automatic ignition system which automatically lights the burners. Do not try to light the burners by hand.
5. Remove control access panel.
6. Move the gas control switch or knob to “OFF”.

What should you do for your safety?

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

How do you turn off the gas to the appliance?

1. Set the thermostat to its lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove control access panel.
4. Move the gas control switch or knob to “OFF”.

What could this product expose you to?

This product contains fiberglass insulation. This product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the State of California to cause cancer, birth defects or other reproductive harm. Fiberglass insulation contains a chemical known by the State of California to cause cancer.

What should you do if any part of the appliance has been underwater?

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

How should you operate the gas control switch or knob?

Use only your hand to move the gas control switch or knob. Never use tools. If the gas control switch or knob will not operate, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

What may happen if you do not follow these instructions exactly?

A fire or explosion may result causing property damage, personal injury or loss of life.

What are the operating instructions?

1. STOP! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. Push the gas control lever to “OFF” Position. Do not force.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.
7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.
8. Move the gas control switch or knob to “ON”.
9. Replace control access panel.
10. Turn on all electric power to the appliance.
11. Set the thermostat to the desired setting.
12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

How should this furnace be installed?

This furnace must be installed in accordance with the manufacturer’s instructions and local codes. In the absence of local codes, follow the National Fuel Gas Code, ANSI Z223.1.

What can improper installation, adjustment, alteration, service or maintenance cause?

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage.

What should you refer to for additional information?

Refer to the user’s information manual provided with this furnace.

What are the model and manufacturing number used for?

The model and manufacturing number are used for positive identification of component parts used in manufacturing.

When should you use these numbers?

Use these numbers when requesting service or parts information.

What does the brand minor revision “A” indicate?

Amana®

What does the brand minor revision “G” indicate?

Goodman®

What does the brand minor revision “A” indicate?

Initial release

What does the brand minor revision “B” indicate?

1st Revision

What does the configuration “M” indicate?

Upflow/Horizontal

What does the configuration “C” indicate?

Downflow/Horizontal

What does the configuration “K” indicate?

Dedicated Upflow

What does the configuration “D” indicate?

Dedicated Downflow

What does the NOx airflow “N” indicate?

Natural Gas

What does the NOx airflow “X” indicate?

Low NOx

What does the airflow “C” indicate?

Variable Speed/ComfortNet

What does the airflow “E” indicate?

High Efficiency

What does the airflow “S” indicate?

Single Speed

What does the cabinet width “A” indicate?

14"

What does the cabinet width “B” indicate?

17.5"

What does the cabinet width “C” indicate?

21"

What does the cabinet width “D” indicate?

24.5"

What does the gas valve stages “M” indicate?

Modulating

What does the gas valve stages “V” indicate?

2 Stage

What does the gas valve stages “H” indicate?

Convertible 2 Stage

What does the gas valve stages “S” indicate?

Single Stage

What does the maximum CFM “3” indicate?

1200 CFM

What does the maximum CFM “4” indicate?

1600 CFM

What does the AFUE “97” indicate?

97% AFUE

What does the maximum CFM “5” indicate?

2000 CFM

What does the AFUE “80” indicate?

80% AFUE

What does the BTU/h “040” indicate?

40,000

What does the BTU/h “060” indicate?

60,000

What does the BTU/h “080” indicate?

80,000

What does the BTU/h “100” indicate?

100,000

What does the BTU/h “120” indicate?

120,000

What is the description for the GMSS92 model?

Goodman® Brand 92% Single Stage Gas Furnace. 34.5" tall, Upflow/Horizontal Installation, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features an aluminized steel tubular heat exchanger. Available cabinet widths are 17.5", 21", and 24.5" wide.

What is the description for the GCSS92 model?

Goodman® Brand 92% Single Stage Gas Furnace. 34.5" tall, Downflow/Horizontal Installation, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features an aluminized steel tubular heat exchanger. Available cabinet widths are 17.5" and 21" wide.

What is the description for the GMSS96 model?

Goodman® Brand 96% Single Stage Gas Furnace. 34.5" tall, Upflow/Horizontal Installation, 1-stage gas valve induced draft. PSC motor. 120 volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features an aluminized steel tubular heat exchanger. Available cabinet widths are 17.5" 21" and 24.5" wide.

What is the description for the GCSS96 model?

Goodman® Brand 96% Single Stage Gas Furnace. 34.5" tall, Downflow/Horizontal Installation, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features an aluminized steel tubular heat exchanger. Available cabinet widths are 17.5", 21", and 24.5" wide.

What is the description for the AMSS92 model?

Amana® Brand 92% Single Stage Gas Furnace. Upflow/Horizontal Installation, 34.5" tall, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features a stainless steel tubular heat exchanger. Available cabinet widths are 17.5", 21", and 24.5" wide.

What is the description for the ACSS92 model?

Amana® Brand 92% Single Stage Gas Furnace. Downflow/Horizontal Installation, 34.5" tall, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features a stainless steel tubular heat exchanger. Available cabinet widths are 17.5" and 21" wide.

What is the description for the AMSS96 model?

Amana® Brand 96% Single Stage Gas Furnace. Upflow/Horizontal Installation, 34.5" tall, 1-stage gas valve induced draft. PSC motor. 120-volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features a stainless steel tubular heat exchanger. Available cabinet widths are 17.5" 21" & 24.5 wide.

What is the description for the ACSS96 model?

Amana® Brand 96% Single Stage Gas Furnace. Downflow/Horizontal Installation, 34.5" tall, 1-stage gas valve induced draft. PSC motor. 120- volt silicon carbide 17-second hot surface ignition. Left or right gas pipe entry. The furnace also features a stainless steel tubular heat exchanger. Available cabinet widths are 17.5", 21", and 24.5" wide.

What is the AFE18-60A control designed for?

The AFE18-60A control is designed for use where the indoor coil is located above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pumps and single and two-stage furnaces. The AFE18-60A control will turn the heat pump unit off when the furnace is turned on.

What is the anti-short cycle feature?

An anti-short cycle feature initiates a 3 minute timed off delay when the compressor goes off.

What is the Electronic Air Cleaner designed to do?

The High-Efficiency Electronic Air Cleaner is designed to remove air contaminants down to .01 microns.

What do the dual indicator lights on the Electronic Air Cleaner show?

Dual indicator lights show unit operation at a glance.

What does the electronic proving switch on the Electronic Air Cleaner do?

Electronic proving switch cycles the air cleaner On/Off with the system fan.

What is the Counterflow Subbase Kit used for?

For use with 34.5" downflow furnace models.

What furnace widths are available for the Counterflow Subbase Kit?

These kits are available for the following furnace widths: 17.5" wide (CFSB17), 21" wide (CFSB21) and 24.5" wide (CFSB24).

Why must the Counterflow Subbase Kits be used?

The kits must be used to prevent excessive temperature from reaching combustible materials, if the furnace is installed on a combustible floor.

What does the subbase do?

This subbase effectively separates the furnace base and plenum from combustible materials.

Where should the counterflow floor base not be installed?

To ensure safe installation, do not install the counterflow floor base directly on carpeting, tile, or other combustible material other than wood flooring.

What is the Media Air Cleaner?

A high-efficiency air filtration device designed to remove dirt, dust, pollen and other microscopic particles from the air passing through it.

What is the capacity of the Media Air Cleaner?

Flexible performance range up to 2,000 CFM capacity.

Where should the Media Air Cleaner be installed?

The air cleaner should be installed in the system so that all the system air is circulated through the air cleaner.

What will the Media Air Cleaner remove?

The air cleaner will only remove the airborne contaminants delivered to it.

When is maximum performance obtained with the Media Air Cleaner?

Maximum performance is obtained when the system blower is set for continuous operation.

What is the Concentric Vent Kit designed to do?

This kit is designed to allow terminations of a direct vent furnace to be “concentrically” vented through a wall or roof.

What does the Concentric Vent Kit allow?

This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intake pipe.

What is the External Filter Rack Kit used for?

For use with 34.5" up flow gas furnaces.

What is the External Filter Rack Kit intended to provide?

This kit is intended to provide a location, external to the furnace casing for installation of a permanent filter.

Where is the rack mounted?

The rack is mounted over the indoor air blower compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

What is the Side Wall Only Concentric Vent Kit to be used with?

This kit is to be used with 2" – 3" vent systems.

Where must the Side Wall Only Concentric Vent Kit terminate?

The vent kit must terminate outside the structure.

What is the Side Wall Only Concentric Vent Kit not intended for?

This kit is NOT intended for use with single pipe (indirect vent) installations.

What is the LP Gas Low Pressure Kit designed for?

Designed for use with furnaces converted to LP gas.

What does the LP Gas Low Pressure Kit do?

The kit monitors gas line pressure with a pressure switch and will open the circuit to the gas valve if the LP tank pressure gets low.

What does the LP Conversion Kit convert?

Converts a 34.5" single stage furnace to operate on L.P. gas.

What does the LP Conversion Kit contain?

The kit contains an L.P. gas valve and a set of six L.P. orifices.

What is the Drain Coupling Kit used for?

For use when the drain/vent elbow has been removed in a horizontal left installation.

What does the Drain Coupling Kit prevent and do?

This kit prevents condensate from getting in the inducer and routes the condensate to a drain.

To prevent personal injury or death due to improper installation, adjustment, alteration, service or maintenance, what should you do?

Refer to this manual.

For additional assistance or information, who should you consult?

Consult a qualified installer, service agency or the gas supplier.

To prevent possible property damage, personal injury or death due to electrical shock, where must the furnace be located?

The furnace must be located to protect the electrical components from water.

When should you discharge your body’s static electricity?

NOTE: Discharge body’s static electricity before touching unit.

Why should you discharge your body’s static electricity before touching the unit?

An electrostatic discharge can adversely affect electrical components.

What precautions should you use during furnace installation and servicing?

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage.

What will the steps help avoid?

By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge.

When is this procedure applicable?

This procedure is applicable to both installed and uninstalled (ungrounded) furnaces.

What is the first step in discharging your body’s electrostatic charge to ground?

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.

What is the second step in discharging your body’s electrostatic charge to ground?

2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

What is the third step in discharging your body’s electrostatic charge to ground?

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.

What is the fourth step in discharging your body’s electrostatic charge to ground?

4. Discharge any static electricity from 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.

What is this product designed for?

This product is designed for use as a residential home gas furnace.

What is this product not designed or certified for?

It is not designed or certified for use in mobile home, trailer, or recreational vehicle applications.

Where can this furnace be used?

This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches, Retail stores, Nursing homes, Hotels/motels, Common or office areas.

How must the furnace be installed?

In all applications, the furnace must be installed per the installation instructions.

What are the Goodman® brand G*SS9* and Amana® brand A*SS9* furnaces certified as?

Goodman® brand G*SS9* and Amana® brand A*SS9* furnaces are ETL certified.

What are all furnaces built for use with?

All furnaces are built for use with Natural gas but can be converted for use with LP gas.

What is required if using propane gas?

(NOTE: If using propane gas, a propane conversion kit is required).

What are the Goodman® brand G*SS9* and Amana® brand A*SS9* high-efficiency furnaces?

Goodman® brand G*SS9* and Amana® brand A*SS9* high-efficiency furnaces are dual certified.

What does dual certification mean?

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as:

• Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or
• Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in this manual and the installation instructions.

To ensure proper installation, operation and servicing, what should you read thoroughly?

To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and application of this product.

To prevent property damage, personal injury or death due to fire, where should you not install this furnace?

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, how should the furnace be installed, operated, maintained and serviced?

To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building codes and ordinances.

What should be followed in the absence of 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/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

Where can a copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) be obtained?

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

• American National Standards Institute 1430 Broadway New York, NY 10018
• National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269
• CSA International 8501 East Pleasant Valley Cleveland, OH 44131

Where can a copy of the CAN/CGA B149 Installation Codes be obtained?

A copy of the CAN/CGA B149 Installation Codes can be obtained from:

• CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W, 1R3

What should the rated heating capacity of the furnace be?

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.

How should the total heat loss be calculated?

The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.

What should be followed when selecting a furnace location?

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

Where should the furnace be located with respect to the proposed or existing air distribution system?

Centrally locate the furnace with respect to the proposed or existing air distribution system.

What should the temperature of the return air entering the furnace be?

Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

What is available if the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable?

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.

Who should you consult for more details about the sound reduction kit?

Consult your local distributor for more details.

What provisions should be made for venting combustion products outdoors?

Provide provisions for venting combustion products outdoors through a proper venting system.

What should be given special consideration to?

Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.

Where can you refer to for appropriate termination locations for 90% Furnaces?

90% Furnaces: Refer to the Vent/Flue Pipe and Combustion Air Pipe -Termination Locations section in this manual or the installation instructions for appropriate termination locations.

What can the length of flue and/or combustion air piping be?

NOTE: The length of flue and/or combustion air piping can be a limiting factor.

Where should the 90% furnace be located?

Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to the drain.

Where should the furnace or its condensate drainage system not be located?

Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection.

Where can you refer to for further details on Condensate Drain Lines and Trap?

Refer to the Condensate Drain Lines and Trap section in this manual or the installation instructions for further details.

Where should the 90% furnace be set?

Set the 90% furnace on a level floor to enable proper condensate drainage.

What should you do if the floor becomes wet or damp at times?

If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace.

Where can you refer to for leveling of horizontal furnaces?

Refer to the Horizontal Applications and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.

Where should upflow or horizontal furnaces not be installed?

Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

When must a special accessory subbase be used?

A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood).

Where can you refer to for installation details on the subbase?

Refer to subbase instructions for installation details.

When is a subbase not required?

(NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor).

What will result from exposure to contaminated combustion air?

Exposure to contaminated combustion air will result in safety and performance-related problems.

Where should you not install the furnace?

Do not install the furnace where the combustion air is exposed to the following substances:

• chlorinated waxes or cleaners
• chlorine-based swimming pool chemicals
• water softening chemicals
• deicing salts or chemicals
• carbon tetrachloride
• halogen type refrigerants
• cleaning solutions (such as perchloroethylene)
• printing inks
• paint removers
• varnishes
• hydrochloric acid
• cements and glues
• antistatic fabric softeners for clothes dryers and
• masonry acid washing materials

How should a nondirect furnace be isolated?

Isolate a nondirect furnace from an area contaminated by any of the above substances.

Why should a nondirect furnace be isolated?

This protects the non-direct vent furnace from airborne contaminants.

To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, where should you vent from?

To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors.

Where can you refer to for details on Combustion and Ventilation Air Requirements?

Refer to the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

Where should the furnace be installed if it is used in connection with a cooling unit?

If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil.

What will happen if the cooling unit coil is placed ahead of the furnace?

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, how should it be positioned?

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.

How should the furnace be protected if it is installed in a residential garage?

Protect the furnace from physical damage by vehicles.

If the furnace is installed horizontally, how must the furnace access doors be positioned?

If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger.

How should you not install the furnace?

Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.

What must installations adhere to?

Installations must adhere to the clearances to combustible materials to which this furnace has been design certified.

Where is the minimum clearance information for this furnace provided?

The minimum clearance information for this furnace is provided on the unit’s clearance label.

How must these clearances be maintained?

These clearances must be permanently maintained.

Where can you refer to for minimum clearances to combustible materials?

Refer to Specification Sheet for minimum clearances to combustible materials.

What must clearances also accommodate?

Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections.

If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, what must be provided?

If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, additional clearances must be provided to accommodate these connections.

Where can you refer to for details on Vent Flue Pipe and Combustion Air Pipe?

Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the installation instructions for details.

What minimum service clearance must be available in front of the unit?

NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

What must a furnace installed in a confined space have?

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating.

Where must one of the ventilation openings be?

One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space.

In a typical construction, what is usually adequate to satisfy this ventilation requirement?

In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

If suspending the furnace from rafters or joists, what should you use?

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following figure.

How should the furnace be installed if it is installed in a crawl space?

If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad.

Where should you never install the furnace?

Never install the furnace on the ground or allow it to be exposed to water.

What will the length of the rod depend on?

The length of rod will depend on the application and the clearances necessary.

What should be ensured when an existing furnace is removed from a venting system serving other appliances?

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.

Where is the following vent testing procedure reproduced from?

The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, latest edition, CSA-2.3b, latest edition Section 1.23.1.

What steps shall be followed with each appliance connected to the venting system?

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:

What is the first step for testing the venting system?

a. Seal any unused openings in the venting system;

What is the second step for testing the venting system?

b. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

What is the third step for testing the venting system?

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;

What is the fourth step for testing the venting system?

d. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously;

What is the fifth step for testing the venting system?

e. Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;

What is the sixth step for testing the venting system?

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;

What is the seventh step for testing the venting system?

g. If improper venting is observed during any of the above tests, the common venting system must be corrected.

How must corrections be made to the venting system?

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.

What should be used if resizing is required on any portion of the venting system?

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes.

What kind of thermostat is recommended to control the G*SS9* and A*SS9* furnace?

A high-quality single-stage thermostat with a “C” terminal is recommended to control the G*SS9* and A*SS9* furnace.

Where should the thermostat be located?

In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall.

Where should the thermostat not be installed?

Do not install the thermostat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under cabinets.
• Hot or cold air from registers.
• Radiant heat from the sun.
• Light fixtures or other appliances.
• Radiant heat from a fireplace.
• Concealed hot or cold water pipes, or chimneys.
• Unconditioned areas behind the thermostat and dehumidistat, such as an outside wall.

When may property damage, personal injury, or death occur?

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES.

Why do most homes require outside air to be supplied to the furnace area?

MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

What have improved construction and additional insulation in buildings done?

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows.

What have these changes helped in reducing?

These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas-fired and other fuel-burning appliances.

What do appliances that pull air out of the house do?

Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

When the furnace is installed as a direct vent (2-pipe) furnace, what is not required?

When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required.

If the furnace is to be installed in the same space with other gas appliances, such as a water heater, what should you ensure?

However, 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.

Where can you refer to for determining the combustion air requirements for the appliances?

Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

How do most homes get outside air supplied to the furnace area?

Most homes will require outside air to be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

Where is the following information on air for combustion and ventilation reproduced from?

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section 9.3.

How shall air for combustion, ventilation, and dilution of flue gases for appliances installed in buildings be obtained?

9.3 Air for Combustion and Ventilation. 9.3.1 General. 9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through 9.3.6.

Where the requirements of 9.3.2 are not met, how shall outdoor air be introduced?

Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.

What is exception No. 1 to 9.3.1.1?

Exception No. 1: This provision shall not apply to direct vent appliances.

How shall appliances of other than natural draft design and other than Category 1 vented appliances be provided with combustion, ventilation, and dilution air?

9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s instructions.

How shall appliances be located?

9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

Where shall a draft hood or a barometric draft regulator be installed?

9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.

What shall be considered in determining the adequacy of a space to provide combustion air requirements?

9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

How shall the required volume of indoor air be determined?

9.3.2 Indoor Combustion Air. The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 except that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used.

What shall the total required volume be?

The total required volume shall be the sum of the required volume calculated for all appliances located within the space.

What are considered a part of the required volume?

Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.

What is the minimum required volume?

9.3.2.1 Standard Method. The minimum required volume shall be 50 ft3 per 1,000/Btu/hour (4.8m3/kW).

Where the air infiltration rate of a structure is known, how shall the minimum required volume be determined?

9.3.2.2 Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be determined as follows:

How do you calculate the required volume for appliances other than fan-assisted?

(1) For appliances other than fan-assisted, calculate using the following equation:

Required Volume other = 21 ft3 * I other / (1000 Btu/hr * ACH)

How do you calculate the required volume for fan-assisted appliances?

(2) For fan-assisted appliances, calculate using the following equation:

Required Volume fan = 15 ft3 * I fan / (1000 Btu/hr * ACH)

What do the variables in the required volume equations stand for?

where:

• I other = all appliances other than fan-assisted input in Btu per hour
• I fan = fan-assisted appliances input in Btu per hour
• ACH = air change per hour (percent of volume of space exchanged per hour, expressed as a decimal)

What infiltration rate shall not be used in the equations?

(3) For purposes of this calculation, an infiltration rate greater than 0.60 ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.2.2(2).

How shall openings used to connect indoor spaces be sized and located?

9.3.2.3 Indoor Opening Size and Location. Openings used to connect indoor spaces shall be sized and located in accordance with the following:

What is required for combining spaces on the same story?

(1) Combining spaces on the same story. Each opening shall have a minimum free area of 1 in.2/1000Btu/hr (2200 mm2/kW) of the total input rating of all appliances in the space but not less than 100 in.2 (0.60m2).

Where shall one opening commence?

One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)].

What shall the minimum dimension of air openings be?

The minimum dimension of air openings shall be not less than 3 in. (80 mm).

What are the requirements for combining spaces in different stories?

(2) Combining spaces in different stories. The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW) of total input rating of all appliances.

How shall outdoor combustion air be provided?

9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods in 9.3.3.1 or 9.3.3.2.

What shall the minimum dimension of air openings be?

The minimum dimension of air openings shall not be less than 3 in. (80 mm).

What is the Two Permanent Openings Method?

9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided.

Where shall the openings communicate?

The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

Where shall each opening have a minimum free area?

(1) Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of the total input rating of all appliances in the enclosure.

Where shall each opening have a minimum free area?

(2) Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100 min2/kW) of the total input rating of all appliances in the enclosure.

What precautions should be taken to prevent condensate from freezing?

It is recommended that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should be insulated with 1/2” thick closed cell foam. Also, all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) should be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.

Where must all vent/flue pipe and combustion air intake pipe (when applicable) terminations be located?

All terminations must be located at least 12 inches above ground level or the anticipated snow level.

Where must vent terminations terminate in relation to a forced air inlet?

Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet. NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.

Where must the vent termination of a non-direct vent application terminate in relation to a door, window, or gravity air inlet?

The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.

Where must the vent termination of a direct vent application terminate in relation to an opening through which flue gasses may enter a building?

The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

Where must the vent termination of a vent pipe run vertically through a roof terminate?

The vent termination of a vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

Where shall a vent termination not terminate?

A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

Where should the combustion air intake termination of a direct vent application not terminate?

The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

What takes precedence over the preceding termination restrictions in Canada?

In Canada, the B149 Fuel Gas Code takes precedence over the preceding termination restrictions.

How do you secure the combustion air intake pipe on upflow units?

On upflow units, secure the combustion air intake pipe directly to the air intake coupling.

How do you secure the combustion air intake pipe on counterflow units?

On counterflow units, secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit.

What does the counterflow rubber coupling allow?

The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment.

Where can the combustion air intake pipe be secured?

The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

What must be installed on the combustion air intake “coupling” on non-direct vent installations?

A minimum of one 90° elbow must be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

What are the applicable lengths, elbows, and pipe diameters for construction of the vent/flue pipe system of a non-direct vent installation?

Refer to the following tables for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct vent installation. In addition to the vent/flue pipe, a single 90° elbow must be secured to the combustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

Model	Pipe Size	1	2	3	4	5	6	7	8
MSS9*1205DNA*	3"	238	231	224	217	210	203	196	189

Model	Pipe Size	1	2	3	4	5	6	7	8
CSS9*1205DNA*	3"	238	231	224	217	210	203	196	189

What are the maximum allowable lengths of vent/flue pipe & combustion air pipe?

Model	Pipe Size	1	2	3	4	5	6	7	8
MSS9*0402BNA*	2"	145	140	135	130	125	120	115	110
	3"	238	231	224	217	210	203	196	189
MSS9*0603BNA*	2"	220	215	210	205	200	195	190	185
	3"	224	217	210	203	196	189	182	175
MSS9*0803BNA*	2"	95	90	85	80	75	70	65	60
	3"	238	231	224	217	210	203	196	189
MSS9*0804CNA*	2"	95	90	85	80	75	70	65	60
	3"	238	231	224	217	210	203	196	189
MSS9*/*CSS9 Direct Vent (2-Pipe)	2"	45	40	35	30	25	20	15	10
& Non-Direct Vent (1-Pipe) (6)	3"	217	210	203	196	189	182	175	168

What are the maximum allowable lengths of vent/flue pipe and combustion air pipe (cont.)?

Model	Pipe Size	1	2	3	4	5	6	7	8
CSS9*0402BNA*	2"	145	140	135	130	125	120	115	110
	3"	238	231	224	217	210	203	196	189
CSS9*0603BNA*	2"	120	115	110	105	100	95	90	85
	3"	224	217	210	203	196	189	182	175
CSS9*0804CNA*	2"	95	90	85	80	75	70	65	60
	3"	238	231	224	217	210	203	196	189
CSS9*1005CNA*	2"	25	20	15	10	5	n/a	n/a	n/a
	3"	238	231	224	217	210	203	196	189

What are the maximum allowable limits listed on individual lengths for inlet and flue?

Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination.

What is the minimum requirement for each vent pipe in length and elbow/tee?

Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee.

What must be included when determining the number of elbows in the piping system?

Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

What size pipe can be used in place of 2” diameter pipe?

2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.

What should be considered equivalent to one 90 deg. elbow?

Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.

What should be secured to the combustion air intake connection?

One 90° elbow should be secured to the combustion air intake connection.

What are the applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a non-direct vent (single pipe) installation?

Refer to the preceding table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a non-direct vent (single pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

When may insulation of the combustion air pipe be required?

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required.

How may the vent/flue pipe terminate?

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

How should vertical vent/flue pipe terminations be?

Vertical vent/flue pipe termination should be as shown in the following figures. Refer to Vent/Flue Pipe and Combustion Air Pipe – Termination Locations section in this manual or the installation instructions for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

Where should both pipes terminate?

Terminate both pipes in the same pressure zone (same side of roof, no major obstacles between pipes, etc.).

How should horizontal vent/flue pipe terminations be?

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe – Termination Locations section in this manual or the installation instructions for details concerning location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe.

How do you secure the pipe passing through the wall and prohibit damage to piping connections?

To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall.

How should the wall penetration be sealed?

The wall penetration should be sealed with silicone caulking material.

How can the vent/flue pipe be run in a basement installation?

In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

What do direct vent installations require?

Direct vent installations require both a combustion air intake and a vent/flue pipe.

How may the pipes be run?

The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building.

Can the pipes be run through an existing unused chimney?

The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather-tight, corrosion-resistant flashing.

Where must both the combustion air intake and vent/flue pipe terminations be?

Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone.

What are the DCVK-20 and DCVK-30 kits designed to allow?

The DCVK-20 and DCVK-30 kit is designed to allow the terminations of a direct vent furnace to be “concentrically” vented through a wall or roof. This kit allows a single penetration to support terminations for both the vent/flue pipe and the combustion air intake pipe.

How do you determine termination locations based on clearances specified in furnace installation instructions?

Follow the steps as shown in Figures 1, 3, 6, 7, 8 and 9.

Where must the vent termination be located?

The vent termination must be located at least 12” above ground or normally expected snow accumulation levels.

Where should you NOT terminate the vent?

Do NOT terminate over public walkways. Avoid areas where condensate may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

Where shall the vent termination be located in relation to an electric meter, gas meter, regulator, and any relief equipment?

The vent termination shall be located at least 4’ horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY to U.S. Installations.

Where shall the vent termination be located in relation to a forced air inlet and combustion air intake of another appliance?

The vent termination shall be located at least 3’ above any forced air inlet located within 10’; and at least 10’ from a combustion air intake of another appliance, except another direct vent furnace intake.

What takes precedence over the preceding termination instructions in Canada?

In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination instructions.

What are the DCVK-20 and DCVK-30 kits for?

These kits are for vertical or horizontal termination of the combustion air inlet and the exhaust vent pipes on Category IV gas-fired condensing furnaces. The DCVK-30 kit can be used for 3” diameter pipe systems. The DCVK-20 kit can be used for the 2” diameter pipe system. For the correct pipe size for the furnace, both the combustion air inlet and the exhaust vent pipes must attach to the termination kit.

Where must the termination kit terminate?

The termination kit must terminate outside the structure and must be installed per the instructions outlined below for vertical or horizontal termination. Vertical termination is preferred. Field-supplied pipe and fittings are required to complete the installation.

How do you determine the best location for the termination kit?

1. Determine the best location for the termination kit. Roof termination is preferred since it is less susceptible to damage, has reduced intake contaminants and less visible vent vapors.
2. For side termination, consideration should be given to:
   • Possible damage from the vapors to plants/shrubs, other equipment and building materials
   • Possible damage to the terminal from foreign objects
   • Wind effects that may cause recirculation of flue products, debris or light snow
   • Visible vent vapors.

Why should the furnace not be operated with the rain cap removed?

DO NOT OPERATE THE FURNACE WITH THE RAIN CAP REMOVED AS RECIRUCLATION OF THE FLUE GASES MAY OCCUR. WATER MAY ALSO COLLECT INSIDE THE LARGER COMBUSTIN AIR PIPE AND FLOW TO THE BURNER ENCLOSURE. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN PROPERTY DAMAGE, EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH.

When is the Concentric Sidewall Vent Kit (0170K00000S) to be used?

This (sidewall only) vent kit is to be used with 2” – 3” vent systems.

Where must the vent kit terminate?

The vent kit must terminate outside the structure.

How may the intake and exhaust pipes be installed?

The intake and exhaust pipes may be installed located side-by-side or with one pipe above the other.

Is this kit intended for use with single pipe (non-direct vent) installations?

This kit is NOT intended for use with single pipe (non-direct vent) installations.

What precautions must be taken if the drain line is routed through an area which may see temperatures near or below freezing?

If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.

Can a common drain be used if an air conditioning coil is installed with the furnace?

If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.

What must horizontal installations require to accommodate the drain trap?

Horizontal installations require 5.5" under the furnace to accommodate the drain trap.

How must the horizontal furnace be installed?

The horizontal furnace must be installed with ¾" slope from back to front to permit condensate flow towards the front of the furnace.

What are the options for connecting the vent pipe to the furnace when installing a MSS9* horizontally with the left side down?

When installing a MSS9 horizontally with the left side down, there are two options for connecting the vent pipe to the furnace.

Option 1: Venting may be connected to the furnace vent pipe fitting on the original top (now the end) of the furnace.

Option 2: The internal vent pipe and elbow may be removed from the furnace to permit the vent to exit the top (original side) of the furnace. If this option is used, an RF000142 Vent-Drain coupling must be used to keep condensate from collecting in the inducer assembly.

To install the drain, what are the instructions?

To install the drain, refer to the following instructions and illustration.

1. Remove screws from vent flange.
2. Remove internal elbow and vent pipe.
3. Cut pipe 2 1/2" from flange.
4. Remove cabinet plug adjacent to inducer outlet and install an original cabinet vent hole.
5. Install RF000142 coupling on inducer outlet.
6. Install flanged vent section removed in step 2 and secure with clamps.
7. Secure flange to cabinet using screws removed in step 1.

What does the furnace rating plate include?

The furnace rating plate includes the approved furnace gas input rating and gas types.

How must the furnace be equipped to operate?

The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.

What must the inlet gas supply pressure be?

Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas-fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

What are the inlet gas supply pressure minimums and maximums for Natural Gas and Propane Gas?

INLET GAS SUPPLY PRESSURE

Gas Type	Minimum	Maximum
Natural Gas	4.5" w.c.	10.0" w.c.
Propane Gas	11.0" w.c.	13.0" w.c.

What must be applied when the furnace is installed at high altitude?

When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied.

Why is the High Altitude orifice kit required?

This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

How are high altitude kits purchased?

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/ or Pressure Switch) kits.

How should you not derate the furnace?

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

What may the gas supplier do in some areas?

In some areas, the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude.

What must be done if the gas is artificially derated?

If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

What may be required at high altitude regardless of the BTU/ft3 content of the fuel used?

A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

For what is the unit configured?

This unit is configured for natural gas.

What must be applied for propane gas installations?

The appropriate manufacturer’s propane gas conversion kit must be applied for propane gas installations.

What LP Conversion Kit do SS9* models using a White-Rodgers 36J22 single stage valve use?

SS9* models using a White-Rodgers 36J22 single stage valve use LPM-07 LP Conversion Kit.

What is the unit equipped with?

This unit is equipped with a 24-volt gas valve controlled during furnace operation by the integrated control module.

For what is the valve configured as shipped?

As shipped, the valve is configured for natural gas.

How is the valve field convertible for use with propane gas?

The valve is field convertible for use with propane gas by using the appropriate propane gas conversion kit.

What are provided on the valve?

Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

How can the gas supply pressure on White-Rodgers “J” model gas valve, used on single stage furnaces, be checked?

The gas supply pressure on White-Rodgers “J” model gas valve, used on single stage furnaces, can be checked with a gas pressure test kit (Part #0151K00000S) available through our authorized distributors.

What does the gas valve have?

The gas valve has a manual ON/OFF control located on the valve itself.

To what position may this control be set?

This control may be set only to the “ON” or “OFF” position.

Where can you refer for use of this control during start-up and shut down periods?

Refer to the Lighting Instructions Label or the “Putting the Furnace Into Operation” section of this manual or the installation instructions for use of this control during start up and shut down periods.

How must the gas piping supplying the furnace be sized?

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.

With what must the gas line installation comply?

The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

What is the natural gas capacity of pipe in cubic feet of gas per hour (CFH)?

Length of Pipe in Feet	1/2"	3/4"	1"	1 1/4"	1 1/2"
10	132	278	520	1050	1600
20	92	190	350	730	1100
30	73	152	285	590	980
40	63	130	245	500	760
50	56	115	215	440	670
60	50	105	195	400	610
70	46	96	180	370	560
80	43	90	170	350	530
90	40	84	160	320	490
100	38	79	150	305	460

CFH = (BTUH Furnace Input) / (Heating Value of Gas (BTU/Cubic Foot))

What must the installer supply to connect the furnace to the building’s gas piping?

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 the gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.

What stipulations apply when connecting gas piping?

The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.

1. Use black iron or steel pipe and fittings for the building piping.
2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.
5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.
6. 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.
7. 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.
8. Tighten all joints securely.

What should be done before placing the unit in operation?

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

How should leaks be checked?

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

What pressures should never be exceeded for testing?

Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure.

When should the unit and shutoff valve be disconnected from the gas supply piping system?

Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa).

When should the unit be isolated from the gas supply piping system?

Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing the supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).

What is the only reliable way to detect a propane gas leak?

A gas-detecting warning system is the only reliable way to detect a propane gas leak.

What can iron oxide (rust) do to propane gas?

Iron oxide (rust) can reduce the level of odorant in propane gas.

What should you do if you suspect the presence of gas?

If the presence of gas is suspected, follow the instructions on this page.

To what must all propane gas equipment conform?

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

What must the propane gas pressure be for satisfactory operation?

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 what three main factors?

Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on the temperature of the liquid, and “wetted surface” area of the container or containers.
2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).
3. Pressure drop in lines between regulators, and between the second stage regulator and the appliance. Pipe size will depend on the length of pipe run and the total load of all appliances.

Where is complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing available?

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

What should you use on pipe threads?

Use pipe dope approved for use with L.P. gas.

Who should be contacted to install a gas detecting warning device if the gas furnace is installed in a basement, an excavated area or a confined space?

IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

Why is a gas detecting warning device recommended?

• SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
• PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE.

What should you do if you smell gas?

• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

Who must perform installation and service?

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

What are the installation considerations for the media air cleaner?

The media air cleaner must be readily accessible for periodic inspection and replacement of the media air cleaner (AMU and GMU) filter cartridge (3 per carton) M0-1056, M1-1056, M2-1056, M8-1056, to maintain maximum efficiency and trouble-free operation. Carbon Filters 1156-3 and 1856-3 (set of 3) are also available.

What is the normal sequence of operation for power up?

1. 115 VAC power applied to furnace.
2. Integrated ignition control module performs internal checks.
3. Integrated ignition control module LED will light.
4. Integrated ignition control monitors safety circuits continuously.
5. Furnace awaits call from thermostat.

What is the normal heating sequence?

1. R and W thermostat contacts close, initiating a call for heat.
2. Integrated control module performs safety circuit checks.
3. The induced draft blower is energized causing pressure switch contacts to close. Induced draft blower remains energized for pre-purge period.
4. Ignitor warm up begins after pre-purge is completed. The ignition control has a WARM UP PERIOD OF 17 SECONDS.
5. Gas valve opens at end of ignitor warm up period, delivering gas to burners to establish flame.
6. The control checks for a signal from the flame sensor within seven (4) seconds after the gas valve is energized. Gas will only continue to flow if a flame signal is present.
7. Circulator blower is energized on heat speed following a fixed thirty (30) second blower on delay.
8. Furnace runs, integrated control module monitors safety circuits continuously.
9. R and W thermostat contacts open, allowing the gas valve to cycle off.
10. Induced draft blower is de-energized following a fifteen (15) -second post purge.
11. Circulator blower is de-energized following heat off delay period.
12. Furnace awaits next call from thermostat.

What is the normal operational sequence in cooling mode?

1. R and Y thermostat contacts close, initiating a call for cool.
2. Integrated control module performs safety circuit checks.
3. Outdoor fan and compressor are energized.
4. Circulator blower is energized on cool speed following a fixed five (5) second on delay.
5. Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously.
6. R and Y thermostat contacts open, completing the call for cool.
7. Outdoor fan and compressor are de-energized.
8. Circulator blower is de-energized following a fixed forty five (45) second cool off delay period.
9. Furnace awaits next call from thermostat.

What is the normal operational sequence in fan only mode?

1. R and G thermostat contacts close, initiating a call for fan.
2. Integrated control module performs safety circuit checks.
3. Circulator blower is energized on heat speed. Electronic air cleaner terminals are energized.
4. Circulator blower runs, integrated control module monitors safety circuits continuously.
5. R and G thermostat contacts open, completing the call for fan.
6. Furnace awaits next call from thermostat.
7. Furnace awaits next call from thermostat.

What are the abnormal operations that can occur during heating and how to fix them?

1. Internal Control Failure with Integrated Ignition* Control. Check for voltage to the furnace and low voltage at the control board. Check for blown fuse on the control board. If the control determines it has an internal fault, it enters a locked-out state. Any of the situations mentioned will cause the diagnostic LED to provide no signal. The control board should only be replaced after all other checks from the Troubleshooting Chart have been verified.
2. System Lockout. If a flame is not sensed during the first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated. The gas valve will then be energized. If flame is not sensed in seven (4) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off for more than (5) seconds and less than (20) seconds and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for a minimum of 5 seconds. Note: The control board will automatically reset one hour after lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected.
3. Pressure Switch Stuck Closed. If the control senses the pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic light code for this problem is 2 flashes. The probable cause is either a faulty pressure switch or wiring.
4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close within 5 minutes, the control will go into a 1-hour lockout. The control will automatically reset from lock-out and restart the ignition sequence. The diagnostic light code for this problem is three short flashes followed by a pause. The probable causes are either disconnected hose to the pressure switch, faulty pressure switch or wiring, or restricted air intake or flue piping.
5. Open Primary or Auxiliary Limit. If the limit control opens, the air circulator blower will be turned on until the limit closes. The induced draft blower will turn off for 5 seconds then turn off. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, or blower speed set to low.
6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation. The diagnostic flash code for this is a five flashes. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.
7. Open Rollout Limit. If the rollout control opens, the air circulator blower will be energized all the time. The diagnostic light code for this problem is six flashes followed by a pause. The probable cause is either restricted flue piping or improper air requirements.
8. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level, the diagnostic light code for this problem will be seven flashes followed by a pause. The probable cause is either a coated/oxidized sensor, incorrectly positioned sensor in burner flame or lazy burner flame due to improper gas pressure or combustion air.
9. Igniter circuit or poor ground. Improperly connected igniter, bad igniter or poor ground to the equipment. The diagnostic light code for this problem is eight flashes.

What are the factors that affect combustion quality?

Combustion quality can be affected by several factors. Major factors are venting and draining.

What should the venting system be planned and installed with?

The venting system should be planned and installed with the following in mind:

• Should not be longer than necessary
• Use 45°elbows rather than 90° elbows when possible
• Must not sag or otherwise trap condensate
• Use longest radius fittings possible
• If using 3" venting, make the transition from 2" to 3" as close as practically possible
• Make sure there is no flue gas recirculation into the combustion air pipe

How can furnace combustion be affected?

Furnace combustion can be affected if a furnace is holding condensate. Check for proper connections of drain hoses, make sure furnace condensate trap is clean. Make sure furnace is not improperly sloped. Make sure air conditioning coil drain is not interfering with furnace drain.

What are the other causes of combustion problems?

1. Manifold Gas Pressure must be set for the gas being used, Natural or L.P., high and low firing rates. If converted to L.P. gas, check size of all orifices
2. Remove Draft Inducer, Check the integrity of the gasket between the inducer and the collector box cover, any air leak here will have a negative effect on combustion. Check the orifice hole in the collector box, it must be free of burrs on both sides
3. Make sure burners are clean, not out of position and line up correctly with exchanger tubes, including the heat exchanger orifice plate between the burners and the heat exchanger tubes, make sure it is not loose, missing a screw or hanging down between the burners and heat exchangers causing flame impingement.
4. Make sure the field installed gas line is not binding and causing distortion of burner assembly
5. If the furnace is installed as a one pipe system; make sure the surrounding area and structure are adequate to provide combustion air
6. Make sure there are no cabinet air leaks allowing supply air to affect combustion
7. If heat exchanger integrity is uncertain, follow procedures in Service Bulletin SF-041

What is Side Wall Vent Kit (0170K00000S) used for?

This side wall only vent kit #0170K00000S is to be used with 2” – 3” vent systems. This kit is NOT intended for use with single pipe (indirect vent) installations. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other.

What is Side Wall Vent Kit (0170K00001S) used for?

This side wall only vent kit #0170K00001S is to be used with 2” vent systems. This kit is NOT intended for use with single pipe (indirect vent) installations. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other.

What is the EFR02 External Filter Rack Kit used on?

90% Upflow Model Furnaces

What is the minimum clearance for the concentric vent conversion kit above the highest anticipated snow level?

Maintain 12" (18" for Canada) minimum clearance above highest anticipated snow level. Maximum of 24" above roof.

What are the CVENT-2 (DCVK-20) (2") or the CVENT-3 (DCVK-30) (3")?

The CVENT-2 (DCVK-20) (2") or the CVENT-3 (DCVK-30) (3") is a concentric vent kit approved with furnaces listed in this manual. This concentric vent kit allows for vertical or horizontal vent termination.

What altitude is the external filter rack required above?

7,000 Ft

What should you do before servicing or installing this unit?

Disconnect all power before servicing or installing this unit. Multiple power sources may be present.

What does the furnace twining kit FTK 03A (Johnson Control Board) use?

80% or 90% single-stage furnaces

What color wires are used for the GMH, AMH, GDH, GCH hybrid furnaces and what do they correspond to?

Black – High Blue – Med./High Orange – Med./Low Red – Low

What is the Furnace Twining Kit – FTK04 (UTEC Control Board) used for?

80% or 90% Single-Stage Furnaces

What is the Furnace Twining Kit – FTK04 (UTEC Control Board) not compatible with?

PCBBF112 Control Boards

What are the service numbers and their descriptions?

• S-1 CHECKING VOLTAGE
• S-2 CHECKING WIRING
• S-3A THERMOSTAT AND WIRING
• S-3B HEATING ANTICIPATOR
• S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT
• S-10B CAPACITANCE CHECK
• S-15 CHECKING CAPACITOR
• S-15A RESISTANCE CHECK
• S-16A CHECKING AIR CIRCULATOR BLOWER MOTOR (PSC)
• S-200 CHECKING DUCT STATIC
• S-201 CHECKING TEMPERATURE RISE
• S-300 CHECKING PRIMARY LIMIT CONTROL
• S-302 CHECKING FLAME ROLLOUT CONTROL
• S-303 INDUCED DRAFT BLOWER MOTOR
• S-304 CHECKING GAS VALVE (REDUNDANT)
• S-305 CHECKING MAIN BURNERS
• S-306 CHECKING ORIFICES
• S-307 CHECKING GAS PRESSURE
• S-308 CHECKING HOT SURFACE IGNITOR
• S-309 CHECKING FOR FLASHBACK
• S-310 CHECKING PRESSURE SWITCH
• S-311 HIGH ALTITUDE APPLICATION (USA)
• S-312 CHECKING FOR DELAYED IGNITION
• S-313 CHECKING INTEGRATED IGNITION CONTROL BOARDS
• S-314 CHECKING FLAME SENSOR

How do you check for polarization and phasing?

As more electronics are introduced to the Heating Trade, polarization of incoming power and phasing of the primary to secondary voltage on transformers becomes more important. Some electronic boards used today with flame rectification will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers. Polarization has been apparent in the Appliance industry since the introduction of the three-prong plug; however, the Heating Industry does not use a plug for incoming power, but is hard wired.

Checking for polarization and phasing should become a habit in servicing.

1. Use a volt/ohm meter to check for polarization. Place one probe on the “hot” leg of incoming power and the other on the common or neutral leg. The meter should read 120 volts. Reverse the leads. The meter should read 0 volts.
2. Wire these to the furnace accordingly.
3. To check for phasing, use a volt/ohm meter to measure the voltage across the “hot” leg of incoming power and the “R” terminal on the secondary side of the transformer.
4. If the meter reads approximately 96 volts, the primary to secondary are in phase. If the meter reads approximately 144 volts, they are out of phase. Reverse the low voltage wires to correct this.

NOTE: For flame rectification, the common side of the secondary voltage (24V) is cabinet grounded. If bench testing a transformer, the primary neutral and secondary common must be connected together for testing purposes.

Some transformers will display phasing symbols to assist in determining proper transformer phasing.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 10 seconds?

1 Million: 90 cubic feet per hour. 100 Thousand: 36 cubic feet per hour. 10 Thousand: 11 cubic feet per hour. 1 Thousand: 3.7 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 10 seconds?

1 Million: 180 cubic feet per hour. 100 Thousand: 72 cubic feet per hour. 10 Thousand: 22 cubic feet per hour. 1 Thousand: 7.5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 10 seconds?

1 Million: 360 cubic feet per hour. 100 Thousand: 144 cubic feet per hour. 10 Thousand: 45 cubic feet per hour. 1 Thousand: 15 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 10 seconds?

1 Million: 720 cubic feet per hour. 100 Thousand: 288 cubic feet per hour. 10 Thousand: 90 cubic feet per hour. 1 Thousand: 30 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 10 seconds?

1 Million: 1800 cubic feet per hour. 100 Thousand: 720 cubic feet per hour. 10 Thousand: 225 cubic feet per hour. 1 Thousand: 75 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 90 seconds?

1 Million: 10 cubic feet per hour. 100 Thousand: 4 cubic feet per hour. 10 Thousand: 1.2 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 90 seconds?

1 Million: 20 cubic feet per hour. 100 Thousand: 8 cubic feet per hour. 10 Thousand: 2.3 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 90 seconds?

1 Million: 40 cubic feet per hour. 100 Thousand: 16 cubic feet per hour. 10 Thousand: 4.7 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 90 seconds?

1 Million: 80 cubic feet per hour. 100 Thousand: 32 cubic feet per hour. 10 Thousand: 9.5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 90 seconds?

1 Million: 200 cubic feet per hour. 100 Thousand: 80 cubic feet per hour. 10 Thousand: 23.8 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 180 seconds?

100 Thousand: 2 cubic feet per hour. 10 Thousand: .6 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 180 seconds?

100 Thousand: 4 cubic feet per hour. 10 Thousand: 1.1 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 180 seconds?

100 Thousand: 8 cubic feet per hour. 10 Thousand: 2.2 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 180 seconds?

100 Thousand: 16 cubic feet per hour. 10 Thousand: 4.5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 180 seconds?

100 Thousand: 40 cubic feet per hour. 10 Thousand: 11.3 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 360 seconds?

10 Thousand: .3 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 360 seconds?

10 Thousand: .5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 360 seconds?

10 Thousand: 1.1 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 360 seconds?

10 Thousand: 2.1 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 360 seconds?

10 Thousand: 5.3 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 720 seconds?

1 Thousand: .5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 720 seconds?

1 Thousand: 1 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 720 seconds?

1 Thousand: 2 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 720 seconds?

1 Thousand: 4 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 720 seconds?

1 Thousand: 10 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/4 cu/ft with a one revolution time of 1800 seconds?

1 Thousand: .2 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1/2 cu/ft with a one revolution time of 1800 seconds?

1 Thousand: .5 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 1 cu/ft with a one revolution time of 1800 seconds?

1 Thousand: 1 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 2 cu/ft with a one revolution time of 1800 seconds?

1 Thousand: 2 cubic feet per hour.

What is the gas rate in cubic feet per hour for a test dial size of 5 cu/ft with a one revolution time of 1800 seconds?

1 Thousand: 5 cubic feet per hour.

What are the possible causes of and remedies for no heat or unsatisfactory heat?

Service Problem	Possible Cause	Test Method	Remedy
No Heat	Power Failure	Test Voltage	See Service Procedure Reference
	Blown Fuse	Test Voltage	See Service Procedure Reference
	Loose Connection	Check Wiring	See Service Procedure Reference
	Shorted or Broken Wires	Check Wiring	See Service Procedure Reference
	No Low Voltage	Check Transformer	See Service Procedure Reference
	Faulty Thermostat	Check Thermostat	See Service Procedure Reference
	Faulty Transformer	Check Transformer	See Service Procedure Reference
	Poor or High Resistance Ground	Measure Ground Resistance	See Service Procedure Reference
Unsatisfactory Heat	Improper Heat Anticipator Setting	Adjust Heat Anticipator Setting	See Service Procedure Reference
	Improper Thermostat Location	Relocate Thermostat	See Service Procedure Reference
	Faulty Limit or Roll Out Switch	Test Control	See Service Procedure Reference
	Faulty Flame Sensor	Test Flame Sensor	See Service Procedure Reference
System Will Not Start	Faulty Ignition Control	Test Control	See Service Procedure Reference
	Gas Valve or Gas Supply Shut Off	Turn Valves to On Position	See Service Procedure Reference
	Faulty Induced Draft Blower	Test Induced Draft Motor	See Service Procedure Reference
	Faulty Blower Motor (PSC)	Test Blower Motor (PSC)	See Service Procedure Reference
	Broken or Shorted Ignitor	Test Ignitor	See Service Procedure Reference
	Dirty Flame Sensor, Low UA	Clean Flame Sensor	See Service Procedure Reference
Burner Won’t Ignite	Stuck Gas Valve	Replace Gas Valve	See Service Procedure Reference
	Faulty Gas Valve	Replace Gas Valve	See Service Procedure Reference
	Open Auxiliary Limit	Reset Control	See Service Procedure Reference
Burner Ignites – Locks Out	Improper Air Flow or Distribution	Check Duct Static	See Service Procedure Reference
	Cycling on Limit	Check Controls & Temperature Rise	See Service Procedure Reference
Burner Shuts Off…	Delayed Ignition	Test for Delayed Ignition	See Service Procedure Reference
…Prior to T’stat…	Flashback	Test for Flashback	See Service Procedure Reference
…Being Satisfied	Orifice Size	Check Orifices	See Service Procedure Reference
	Gas Pressure	Check Gas Pressure	See Service Procedure Reference
	Cracked Heat Exchanger	Check Burner Flames	See Service Procedure Reference
Short Cycles	Furnace Undersized	Replace with Proper Size Furnace	See Service Procedure Reference
Long Cycles	Furnace Oversized	Replace with Proper Size Furnace	See Service Procedure Reference
	Faulty Pressure Switch	Test Pressure Switch	See Service Procedure Reference
	Blocked or Restricted Flue	Check Flue/Drawdown Pressure	See Service Procedure Reference
	Open Roll Out Switch	Test Flame Roll Out Control	See Service Procedure Reference
	Bouncing On Pressure Switch	Test Negative Pressure	See Service Procedure Reference
Soot and/or Fumes	Improper gas/air mixture. Make sure manifold pressure is correct. Inspect burner orifices and vent system for restrictions. Replace parts as necessary.	Check Gas Pressure & Check Duct Static
Too Much Heat	Return air restricted. Check filters, return-air grilles, ductwork and dampers for obstructions.	Check Duct Static	See Service Procedure Reference
	Blower speed set too low. Increase speed to get more airflow through the system to carry heat away.	Check Controls & Temperature Rise	Refer to Circulator Blower Speed section in the Product Design section of this manual for speed changing details. Temperature rise…
	Supply air restricted. Check registers, ductwork and dampers for obstructions.	Check Duct Static	See Service Procedure Reference
Not Enough Heat	Return air pulling in from an unconditioned area such as an attic or crawl space. Seal all leaks where unconditioned air can enter the return-air system.	Check Duct Static	See Service Procedure Reference
	Blower speed set too high. Decrease speed to allow more time for heat exchange into the air.	Check Controls & Temperature Rise	Refer to Circulator Blower Speed section in the Product Design section of this manual for speed changing details. Temperature rise…
	Supply air leaking out in an unconditioned space. Seal all leaks where conditioned air can leak out of the supply-air system.	Check Duct Static	See Service Procedure Reference

NOTES:

• The integrated control module will automatically attempt to reset from lockout after one hour.
• The LED flash code will cease if power to the control module is interrupted through the disconnect or door switch.

What should you do if the furnace locks out due to an excessive number of ignition “retries”?

• The integrated control module will automatically attempt to reset from lockout after one hour.
• Locate and correct gas interruption.
• Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.

What does it mean when the furnace fails to operate and the integrated control module diagnostic LED is flashing ONE (1) flash?

The furnace fails to establish flame. Cause may be:

• no gas to burners,
• front cover pressure switch stuck open,
• bad igniter or igniter alignment,
• improper orifices,
• coated/oxidized or improperly connected flame sensor.

OR

Loss of flame after establishment. Cause may be:

• interrupted gas supply,
• lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping),
• front cover pressure switch opening,
• improper induced draft blower performance.

The pressure switch circuit is closed.

What should you do?

• Turn power OFF prior to repair.
• Igniter is fragile, handle with care.
• Sand flame sensor with emery cloth.
• See “Vent/ Flue Pipe” section for piping details.

What does it mean when the furnace fails to operate and the integrated control module diagnostic LED is flashing TWO (2) flashes?

• Induced draft blower pressure switch contacts sticking.
• Shorts in pressure switch circuit.

What should you do?

• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Inspect pressure switch hose. Repair, if necessary.
• Inspect flue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.

What does it mean when the induced draft blower runs continuously with no further furnace operation and the integrated control module diagnostic LED is flashing THREE (3) flashes?

• Pressure switch hose blocked, pinched or connected improperly.
• Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.
• Incorrect pressure switch setpoint or malfunctioning switch contacts.
• Loose or improperly connected wiring.

The pressure switch circuit is not closed. The induced draft blower is operating.

What should you do?

• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.

What does CONTINUOUS ON for the LED code mean?

Normal Operation

What does it mean when the furnace fails to operate, the circulator blower runs continuously, and the integrated control module diagnostic LED provides no signal?

• No 115 volt power to furnace, or no 24 volt power to integrated control module.
• Blown fuse or circuit breaker.
• Integrated control module has an internal fault.
• Manual disconnect switch OFF, door switch open, or 24 volt wires improperly connected or loose.

What should you do?

• Assure 115 and 24 volt power to furnace integrated control module.
• Check integrated control module fuse (3A). Replace if necessary.
• Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.
• Replace a bad integrated control module.
• Turn power OFF prior to repair.
• Replace integrated control module fuse with 3A automotive fuse.
• Read precautions in “Electrostatic Discharge” section of manual.

What does it mean when the LED is Steady On and the circulator blower runs continuously but there is no furnace operation?

Normal Operation

What does it mean when the furnace fails to operate and the integrated control module diagnostic LED is flashing FOUR (4) flashes?

• Primary or auxiliary limit circuit is open.
• Faulty primary or auxiliary limit switch.
• Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.
• Loose or improperly connected wiring.

What should you do?

• Check primary/auxiliary limit. Replace if necessary.
• Check filters and ductwork for blockage. Clean filters or remove obstruction.
• Check circulator blower speed and performance. Correct speed or replace blower if necessary.
• Tighten or correct wiring connection.
• Turn power OFF prior to repair.
• Replace primary/ auxiliary limit with proper replacement part.
• Replace blower with correct replacement part.

What does it mean when the induced draft blower and circulation blower run continuously with no furnace operation and the integrated control module diagnostic LED is flashing FIVE (5) flashes?

• Flame sensed with no call for heat.
• Short to ground in flame sense circuit.

What should you do?

• Correct short at flame sensor or in flame sensor wiring.
• Turn power OFF prior to repair.

What does it mean when the circulator blower runs continuously with no furnace operation and the integrated control module diagnostic LED is flashing SIX (6) flashes?

• Rollout limit circuit is open.
• Flame rollout.
• Misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.
• Loose or improperly connected wiring.
• Faulty rollout limit.

What should you do?

• Check burners for proper alignment.
• Check flue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.
• Check rollout limit. Replace if necessary.
• Check induced draft blower for proper performance. Replace, if necessary.
• Tighten or correct wiring connection.
• Turn power OFF prior to repair.
• See “Vent/Flue Pipe” section for piping details.
• Replace rollout limit with correct replacement part.
• Replace induced draft blower with correct replacement part.

What does it mean when there is normal furnace operation and the integrated control module diagnostic LED is flashing SEVEN (7) flashes?

• Flame sense microamp signal is low.
• Flame sensor is coated/ oxidized.
• Flame sensor incorrectly positioned in burner flame.
• Lazy burner flame due to improper gas pressure or combustion air.

What should you do?

• Sand flame sensor if coated/oxidized.
• Inspect for proper sensor alignment.
• Check inlet air piping for blockage, proper length, elbows, and termination.
• Compare current gas pressure to rating plate info. Adjust as needed.
• Turn power OFF prior to repair.
• Sand flame sensor with emery clot.
• See “Vent/Flue Pipe” section for piping details.
• See rating plate for proper gas pressure.

What does it mean when the furnace fails to operate and the integrated control module diagnostic LED is flashing continuously?

• Polarity of 115 or 24 volt power is reversed.
• Polarity of 115 volt AC power to furnace or integrated control module is reversed.
• Orange and gray wires to transformer are reversed.
• Poor unit ground.

What should you do?

• Review wiring diagram to correct polarity.
• Reverse orange and gray wires going to transformer.
• Verify proper ground. Correct if necessary.
• Turn power OFF prior to repair.

How do you check the voltage?

WARNING

HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. Remove the burner door on furnaces to gain entry to the Junction Box.
2. Remove cover from the Junction Box and gain access to incoming power lines.

WARNING

LINE VOLTAGE NOW PRESENT

1. Using a voltmeter, measure the voltage across the hot and neutral connections.
2. NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point.
3. No reading indicates open wiring, open fuse, no power, or a faulty Door Interlock Switch from the unit to fused disconnect service. Repair as needed.
4. With ample voltage at line voltage connectors, energize the furnace blower motor by jumpering terminals R to G on the integrated ignition control.
5. With the blower motor in operation, the voltage should be 115 volts ± 10 percent.
6. If the reading falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If the wire size is adequate, notify the local power company of the condition.
7. After completing the check and/or repair, replace the Junction Box cover and reinstall the service panel doors.
8. Turn on electrical power and verify proper unit operation.

How do you check the wiring?

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Check wiring visually for signs of overheating, damaged insulation, and loose connections.
2. Use an ohmmeter to check the continuity of any suspected open wires.
3. If any wires must be replaced, replace them with AWM, 105°C. 2/64 thick insulation of the same gauge or its equivalent.

How do you check the thermostat, wiring, and anticipator?

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals.
2. Remove the thermostat low voltage wires at the furnace control panel terminal board.
3. Jumper terminals R to W (or W1 and W2 for two-stage models) on the integrated ignition control.

WARNING

LINE VOLTAGE NOW PRESENT

1. Induced Draft Motor must run and pull in pressure switch.
2. If the hot surface ignitor heats and at the end of the ignitor warm-up period the gas valve opens and the burners ignite, the trouble is in the thermostat or wiring.
3. With power off, check the continuity of the thermostat and wiring. Repair or replace as necessary.
4. If checking the furnace in the air conditioning mode, proceed as follows.
5. With power off, Jumper terminals R to Y to G.
6. Turn on the power.
7. If the furnace blower motor starts and the condensing unit runs, then the trouble is in the thermostat or wiring. Repair or replace as necessary.
8. After completing the check and/or repair of wiring and check and/or replacement of the thermostat, reinstall the blower compartment door.
9. Turn on electrical power and verify proper unit operation.

On older thermostats, the heating anticipator is a wire-wound adjustable heater that is energized during the “ON” cycle to help prevent overheating of the conditioned space. The anticipator is a part of the thermostat, and if it should fail for any reason, the thermostat must be replaced. Modern thermostats do not have this type of heat anticipator. Many have a selector switch to adjust the number of cycles per hour.

The cooling anticipator is a small heater (resistor) in the thermostat. During the “OFF” cycle it heats the bimetal element helping the thermostat call for the next cooling cycle. This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degrees. The anticipator is fixed in the subbase and is not to be replaced. If the anticipator should fail for any reason, the subbase must be changed.

How do you check the transformer and control circuit?

A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation.

WARNING

HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module.
2. Remove the thermostat low voltage wires at the furnace integrated control module terminals.

WARNING

LINE VOLTAGE NOW PRESENT

1. Use a voltmeter, check voltage across terminals R and C. Must read 24 VAC.
2. No voltage indicates a faulty transformer, open fuse, bad wiring, bad splice, or open door interlock switch.
3. Check the transformer primary voltage at incoming line voltage connections, fuse, splices, and blower door interlock switch.
4. If line voltage is available to the primary side of the transformer and not at the secondary side, the transformer is inoperative. Replace.
5. After completing the check and/or replacement of the transformer and check and/or repair of the control circuit, reinstall the blower compartment door.
6. Turn on electrical power and verify proper unit operation.

How do you check the capacitor?

The direct drive motors are of the permanent split capacitor design. A run capacitor is wired across the auxiliary and a portion of the main windings. The capacitor’s primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two-phase operation when connected to a single-phase circuit. The capacitor also reduces the line current to the motor by improving the power factor to the load.

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING.

Two quick ways to test a capacitor are a resistance and a capacitance check.

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.

How do you check the Flame Rollout Switch?

a. If no voltage is measured on either side of control it indicates ignition control or wiring to control prob-lem. b. If voltage is measured on one side of the control and not the other it indicates the control is open. c. If voltage is measured on both sides of the control the wiring to gas valve or valve is at fault. 3. After check and/or replacement of rollout switch, rein-stall burner compartment door and verify proper unit op-eration.

How do you service the S-303 Induced Draft Blower Motor?

1. Remove burner compartment door to gain access to the induced draft blower motor.
2. Disconnect the motor wire leads from its connection point at the induced draft motor.
3. Using a ohmmeter, test for continuity between each of the motor leads.
4. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead. If the windings do not test continuous or a reading is obtained to ground, replace the motor.
5. If the windings have a continuity reading, reconnect wires. Turn power on to the furnace and turn the thermostat on in the heating mode. Check voltage for 115V at the induced draft motor terminals during the trial for ignition. If you have 115V and the motor does not run, replace the induced draft motor.
6. After completing check and/or replacement of in-duced draft motor, reinstall burner compartment door.
7. Turn on electrical power and verify proper unit opera-

What is the S-304 Checking Gas Valve (Redundant)?

A combination redundant operator type gas valve which pro-vides all manual and automatic control functions required for gas fired heating equipment is used. The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.

How do you service the S-304 single stage gas valves?

Single stage gas valves should be tested on the furnace with 24 VAC connected to the gas valve and manometers reading supply line and manifold pressures.

What are the S-305 Checking Main Burners?

The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger. Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners. Burners have been redesigned for 34.5" chassis furnaces. Overall length and width dimensions remain the same as 40" model burners. The burners used 34.5" models have burner head insert with larger diameter center hole and a larger number of surrounding holes.

How do you check the S-305 main burners?

In checking main burners, look for signs of rust, oversized and undersized carry over ports restricted with foreign ma-terial, etc, refer to previous drawing. Burner cross-over slots should not be altered in size.

How do you service the S-306 Checking Orifices?

1. Check orifice visually for distortion and/or burrs.
2. Check orifice size with orifice sizing drills.
3. If resizing is required, a new orifice of the same physical size and angle with proper drill size opening should be installed.

How do you measure the S-307 gas supply pressure?

1. After turning off gas to furnace at the manual gas shut-off valve external to the furnace, remove burner com-partment door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pres-sure tap or the gas piping drip leg as shown in the fol-lowing figures. NOTE: At either location, a hose fitting must be installed prior to making the hose connection. NOTE: Use adapter kit #0151K00000S to measure gas pressure on White-Rodgers 36G22 gas valves.
3. Turn ON the gas and electrical power supply and oper-ate the furnace and all other gas consuming appliances on the same gas supply line.
4. Measure furnace gas supply pressure with burners fir-ing. Supply pressure must be within the range speci-fied in the following table.

What is the Natural Gas Minimum and Maximum?

Minimum: 4.5" w.c. Maximum: 10.0" w.c.

What is the Propane Gas Minimum and Maximum?

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

What happens if the supply pressure differs from above?

If supply pressure differs from above, make necessary ad-justments to pressure regulator, gas piping size, etc., and/ or consult with local gas utility.

What do you do after disconnecting the manometer?

5.Disconnect manometer after turning off gas at manual shutoff valve. Reinstall plug before turning on gas to fur-nace. 6.Turn OFF any unnecessary gas appliances started in step 3. 7.Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door. 8.Turn on electrical power and verify proper unit opera-tion.

How do you measure and adjust the Gas Manifold Pressure Measurement and Adjust-ment?

NOTE: Use adapter kit #0151K00000S to measure gas pres-sure on White-Rodgers 36J22 gas valves. Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pres-sure must be measured with the burners operating. To mea-sure and adjust the manifold pressure, use the following procedure. 1.After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compart-ment door to gain access to the gas valve. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to Measuring Gas Pressure: Single Stage Valves figure for single stage valve outlet pressure tap connections. 3.Turn ON the gas and electrical power supply and oper-ate the furnace. 4.Measure gas manifold pressure with burners firing. Ad-just manifold pressure using the table below.

What is the Manifold Gas Pressure for Natural Gas?

3.5" w.c.

What is the Manifold Gas Pressure for Propane Gas?

10.0" w.c.

What happens if the final manifold pressure varies?

The final manifold pressure must not vary more than ± 0.3 “ w.c. from the above specified pressures. Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice.

How do you adjust the White-Rodgers 36J22 Valves?

a.Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn). b.Attach a hose and manometer to the outlet pressure outlet pressure boss. c.Turn ON the gas supply. d.Turn on power and close thermostat “R” and “W1” contacts to provide a call for heat. e.Measure the gas manifold pressure with burners fir-ing. Adjust manifold pressure using the Manifold Gas Pressure table shown below. f.Remove regulator cover screw from the outlet pres-sure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. i.Turn off all electrical power and gas supply to the sys-tem. j.Remove the manometer hose from the hose barb fit-ting or outlet pressure boss. k.Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).

How do you adjust the Honeywell VR8215 Valve?

a.Remove the outlet pressure boss plug. Install an 1/8" NPT hose barb fitting into the outlet pressure tap. b. Attach a hose and manometer to the outlet pressure barb fitting. c.Turn ON the gas supply. d.Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat. e.Measure the gas manifold pressure with burners fir-ing. Adjust manifold pressure using the Manifold Gas Pressure table shown below. f. Remove regulator cover screw from the outlet pres-sure regulator adjust tower and turn screw clock-wise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. i. Turn off all electrical power and gas supply to the system. j. Remove the manometer hose from the hose barb fitting or outlet pressure boss. k. Remove the 1/8" NPT hose barb fitting from the out-let pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread sealer.

What is the Manifold Gas Pressure for the White-Rodgers Model 36J22 (Single-Stage) Gas Rate Range?

Nominal High Stage 9.7 to 10.3" w.c. 10.0" w.c. Low Stage 5.7 to 6.3" w.c. 6.0" w.c.

How do you service the S-308 Checking Hot Surface Ignitor?

1. Remove burner compartment door to gain access to the ignitor.
2. Ignitor cool – approximately 70 – 77°F.
3. Disconnect the ignitor from the Ignition Control.
4. Using an ohmmeter measure the resistance of the igni-tor: -at room temperature a normal reading will be 37 -68 ohms.
5. Reconnect ignitor.
6. Place unit in heating cycle, measure current draw of ig-nitor during preheat cycle.

How do you check the S-309 for Flashback?

If flashback should occur, check for the following:

1. Improper gas pressure – adjust to proper pressure (See S-307 CHECKING GAS PRESSURE)…
2. Check burner for proper alignment and/or replace burner.
3. Improper orifice size – check orifice for obstruction.

How do you service the S-310 Checking Pressure Switch?

1. Remove burner compartment door to gain access to pres-sure switch(es).
2. Remove wires from the pressure switch(es) electrical terminals.
3. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures. With a call for heat and the inducer running, check across the pressure switch contacts with an ohm meter. If the contacts are not closed, compare the negative reading on the inclined manometer with the rating on the pressure switch to determine whether the switch is defective or if the nega-tive pressure is inadequate to close the switch.

How do you service the S-312 Checking For Delayed Ignition?

If delayed ignition should occur, the following should be checked:

1. Improper gas pressure – adjust to proper pressure (See S-307 CHECKING GAS PRESSURE).
2. Improper burner positioning – burners should be in locat-ing slots, level front to rear and left to right.
3. Carry over (lighter tube or cross lighter) obstructed – clean.
4. Main burner orifice(s) deformed, or out of alignment to burner – replace.

How do you service the S-313 Checking Integrated Ignition Control Boards?

NOTE: Failure to earth ground the furnace, reversing the neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame. The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring re-sistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than 2 ohms. The ignition control is a combination electronic and elec-tromechanical device and is not field repairable. Complete unit must be replaced. These tests must be completed within a given time frame due to the operation of the ignition control. The ignition control is capable of diagnosing many furnace failures to help in troubleshooting. The trial for ignition pe-riod is 4 seconds. The indicator light/display may be viewed by looking through the sight glass in the blower compartment door. If the blower compartment door is removed, failure to hold the door switch closed while removing the blower compartment door will result in the loss of the stored failure code. In most cases recycling the ignition control will result in the same failure code originally displayed.

What do the flashes on the Integrated Control Module mean?

=CONTROL FAIU-‘IE 1 FLASH = SY8TEM lOCK0UT (RETRIES EXCEEDED) 2 FLASHES =PRESSURE SWITCH STUCK CLOSED 3 FLASHES =PRESSURE SWITCH STUCK OPEN 4 FLASHES =OPEN HIGH LIMIT 5 FLASHES =FLAME SENSE WITHOLIT GAS VALVE e FLASHES = OPEN Ra.LOUT 7 FLASHES = 7 FLASHES =LOW FLAME SIGNAL 8 FLASHES = 8 FLASHES =CHECK IGNITER OR IMPROPER GROUNDING CONTINUOUS/RAPID FLASHES •REVERSED 115 VAC POLARITY

How do you service the Integrated Ignition controls?

These tests must be completed within a given time frame due to the operation of the ignition control.

1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity.
2. Check for 24 volts from W to C terminal on the ignition control. No voltage. Check transformer, room thermo-stat, and wiring. If you have 24 volts coming off the transformer but re-ceive approximately 13 volts on the terminal board be-tween © and ®, check for blown fuse. 3.Check for 120 volts to the induced draft blower by mea-suring voltage between Pin 1 (on the 2-pin connector) and Line (Neutral) on the control board. No voltage, re-place ignition control. 4.If voltage is present in Steps 1 through 3 and the in-duced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage between Pin 2 (on the 2-pin connector) and Line (Neu-tral) on the control board. No voltage, check pressure switch. 5.After the ignitor warm-up time, begin checking for 24 volts to the gas valve. Voltage will be present for seven seconds only if proof of flame has been established.

How do you service the S-314CHECKING FLAME SENSOR?

1.Connect a micro-amp meter in series with this wire and the sensor terminal. 2.Be sure the positive side of the meter is to the sensor (depending on the model) and the negative side of the meter is to sensor terminal. 3.Place the unit into a heating cycle. 4.As soon as flame is established a micro-amp reading should be evident once proof of flame (micro-amp read-ing) is established, the hot surface ignitor will be de-energized. 5.The Integrated Ignition controls will have 1 to 4 micro-amps. If the micro-amp reading is less than the mini-mum specified, check for high resistance wiring con-nections, sensor to burner gap, dirty flame sensor, or poor grounding. 6.If absolutely no reading, check for continuity on all com-ponents and if good – replace ignition control module. NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool.

What is the Annual Inspection?

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper work-ing order and that the heating system functions appropri-ately. Pay particular attention to the following items. Repair or service as necessary.

What are the items to pay attention to during the annual inspection?

• Flue pipe system. Check for blockage and/or leak-age. Check the outside termination and the connec-tions at and internal to the furnace.
• Combustion air intake pipe system (where applicable). Check for blockage and/or leakage. Check the out-side termination and the connection at the furnace.
• Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.
• Burners. Check for proper ignition, burner flame, and flame sense.
• Drainage system. Check for blockage and/or leak-age. Check hose connections at and internal to fur-nace.
• Wiring. Check electrical connections for tightness and/or corrosion. Check wires for damage.
• Filters.

What is the warning about Air Filters?

NEVER OPERATE FURNACE WIHTOUT A FILTER INSTALLED AS DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE. Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for proper furnace operation. Remember that dirty filters are the most common cause of inadequate heating or cooling performance.

What is the Maintenance for the air filters?

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. It is the owner’s responsibility to keep air filters clean. When replacing a filter, it must be replaced with a filter of the same type and size.

What is the Filter Removal procedure?

Depending on the installation, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflow only), a side panel external filter rack kit (upflow only), or the ductwork above a counterflow furnace. A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be fol-lowed to ensure proper unit performance. Refer to the fol-lowing information for removal and installation of filters.

What is the procedure for Media Air Filter or Electronic Air Cleaner Removal?

Follow the manufacturer’s directions for service.

What is the procedure for Horizontal Unit Filter Removal?

Filters in horizontal installations are located in the central return register.

What is the maintenance procedure for the INDUCED DRAFT AND CIRCULATION BLOWERS?

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufac-turer. No further lubrication is required. Check motor wind-ings for accumulation of dust which may cause overheat-ing. Clean as necessary.

What is the maintenance procedure for the CONDENSATE DRAINAGE SYSTEM (QUALIFIED SERVICER ONLY)?

The drain tubes, standpipe, and field supplied drain line must be checked annually and cleaned as often as nec-essary to ensure proper condensate drainage.

What is the maintenance procedure for the FLAME SENSOR (QUALIFIED SERVICER ONLY)?

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal. If this occurs, a qualified servicer must carefully clean the flame sensor with steel wool. After cleaning, the flame sensor output should be as listed on the specifica-tion sheet.

What is the BURNERS maintenance procedure?

Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermo-stat. 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 lift-ing off the ports.

What should you check the burner flames for?

1. Stable, soft and blue
2. Not curling, floating, or lifting off.

What is the TEST EQUIPMENT for servicing this product?

Proper test equipment for accurate diagnosis is as essen-tial as regular hand tools. The following is a must for every service technician and service shop.

1. Dial type thermometers or thermocouple meter (op-tional) – to measure dry bulb temperature.
2. Amprobe – to measure amperage and voltage.
3. Volt-Ohm Meter – testing continuity, capacitors, and motor windings.
4. Inclined Manometer – to measure static pressure, pressure drop across coils, filters, and draft.
5. Water Manometer (12") – to test gas inlet and mani-fold pressure. Other recording type instruments can be essential in solv-ing abnormal problems, however, in many instances they may be rented from local sources. Proper equipment promotes faster, more efficient service and accurate repairs resulting in fewer call backs.

How do you perform the HEATING PERFORMANCE TEST?

Before attempting to diagnose an operating fault, run a heat-ing performance test and apply the results to the Service Problem Analysis Guide. To conduct a heating performance test, the BTU input to the furnace must be calculated. After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked. To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.) EXAMPLE: It is found by the gas meter, that it takes forty (40) seconds for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the furnace. Take this information and locate it on the gas rate chart. Observe the forty (40) seconds, locate and read across to the one (1) cubic foot dial column. There we find the number 90, which shows that ninety (90) cubic feet of gas will be consumed in one (1) hour. Let’s assume the local gas utility has stated that the calo-rific value of the gas is 1,025 BTU per cubic foot. Multiplying the ninety (90) cubic feet by 1,025 BTU per cu-bic foot gives us an input of 92,250 BTUH. Checking the BTU input on the rating plate of the furnace being tested.

What is an example of a HEATING PERFORMANCE TEST?

INPUT:92,000 BTU/HR OUTPUT CAP:84,000

What should you do if the figure you calculated does not fall within five (5) per-cent of the nameplate rating of the unit?

Should the figure you calculated not fall within five (5) per-cent of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices.

How do you adjust the pressure regulator on the gas valve?

To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (coun-terclockwise) to decrease pressure and input.

How do you adjust the propane gas?

Since normally propane gas is not installed with a gas meter, clocking will be virtually impossible. The gas orifices used with propane are calculated for 2500 BTU per cubic foot gas and with proper inlet pressures and correct piping size, full capacity will be obtained. With propane gas, no unit gas valve regulator is used; how-ever, the second stage supply line pressure regulator should be adjusted to give 10" water column with all other gas con-suming appliances running.

What controls the dissipation of the heat transferred to the heat exchanger?

The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface. The amount (CFM) of air circulated is governed by the exter-nal static pressure in inches of water column of duct work, cooling coil, registers, etc., applied externally to the unit versus the motor speed tap (direct drive) or pulley adjust-ments of the motor and blower (belt drive). A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cy-cling of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for temperature rise limitation.

What should you set the HEAT ANTICIPATOR on the ROOM THERMOSTAT at?

0.7 AMPS

What parts must be used when servicing this product?

MAM.FACTUR’8 SPECIFIED REPUCe:IENT PARTS

What happens if any of the original wire is supplied with the furnace and must be replaced?

If any of the original wire is supplied with the furnace and must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C. Use copper conductors only.

How should the blower speeds be adjusted?

Blower speeds should be adjusted by the installer to match installation requirements so as to provide the correct heating temperature rise and the correct cooling CFM.

How should the unit be grounded?

Unit must be permanently grounded and conform to N.E.C. and local codes.