12342567btn11fr6147b155n1667HeatingAir Conditioning - PDF document

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5;\f-\b\n\f\n\n\n\n\n7\f\f\b\t\f\t\n"8\n0\n\b4\f\n\b\n\f\f\b\n\t\t\f\t\n\n\n\n7\f\f\b\t\f\t\n\n\t\n\f4\n\b\n\t\f\f\n\n\b\n3\n\b\n\t\n\n\t\n" '(6,*1 &(57,),(' &(57,),(' Table of ContentsI. Component Identification..........................................................................................................................................5II. Safety..........................................................................................................................................................................6ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS....................................................................................................................................6III. Product Application..................................................................................................................................................6IV. Location Requirements and Considerations..........................................................................................................7GENERAL.............................................................................................................................................................................................................7CLEARANCES AND ACCESSIBILITY.................................................................................................................................................................8FURNACE SUSPENSION..................................

4 ........................................
..................................................................................................................................................8EXISTING FURNACE REMOVAL........................................................................................................................................................................8THERMOSTAT LOCATION...................................................................................................................................................................................9V. Combustion and Ventilation Air Requirements.......................................................................................................9VI. Installation Positions.............................................................................................................................................12VII. Horizontal Applications and Considerations......................................................................................................12GENERAL...........................................................................................................................................................................................................12DRAIN TRAP AND LINES...................................................................................................................................................................................12LEVELING...........................................................................................................................................................................................................12ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS.............................................................................................................12ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS..........................................................................................................................13DRAIN PAN...........................................................................................................................................................

5 ........................................
..............................................13FREEZE PROTECTION.....................................................................................................................................................................................13FURNACE SUSPENSION..................................................................................................................................................................................13VIII. Propane Gas and/or High Altitude Installations.................................................................................................13IX. Vent/Flue Pipe and Combustion Air Pipe.............................................................................................................13GENERAL...........................................................................................................................................................................................................13DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT....................................................................................................................................13MATERIALS AND JOINING METHODS............................................................................................................................................................14PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES...........................................................................................................14TERMINATION LOCATIONS..............................................................................................................................................................................14CANADIAN VENTING REQUIREMENTS..........................................................................................................................................................15STANDARD FURNACE CONNECTIONS..........................................................................................................................................................15Vent/Flue Pipe...............................................................

6 ........................................
..............................................................................................................................15Combustion Air Pipe...................................................................................................................................................................................15Direct Vent Installations..............................................................................................................................................................................15Non-Direct Vent Installations......................................................................................................................................................................15ALTERNATE FURNACE CONNECTIONS.........................................................................................................................................................15Alternate Vent/Flue Location......................................................................................................................................................................16Alternate Combustion Air Intake Location..................................................................................................................................................17NON-DIRECT VENT (SINGLE PIPE) PIPING...................................................................................................................................................18Vent/Flue Pipe Lengths and Diameters......................................................................................................................................................18Vent/Flue Pipe Terminations.......................................................................................................................................................................18DIRECT VENT (DUAL PIPE) PIPING................................................................................................................................................................19Vent/Flue and Combustion Air Pipe Lengths and Diameters...................

7 ........................................
..................................................................................................19Vent/Flue and Combustion Air Pipe Terminations......................................................................................................................................19VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES..............................................................20CONCENTRIC VENT TERMINATION................................................................................................................................................................21X. Condensate Drain Lines and Drain Trap...............................................................................................................21GENERAL...........................................................................................................................................................................................................21UPRIGHT INSTALLATIONS...............................................................................................................................................................................21Standard Right or Left Side Drain Hose Connections................................................................................................................................21Alternate Vent/Flue Drain Hose Connections.............................................................................................................................................22Upright Drain Trap Mounting (Left or Right Side Panel).............................................................................................................................22HORIZONTAL INSTALLATIONS.........................................................................................................................................................................23Right Side Down.........................................................................................................................................................................................23Left Side Down

8 ........................................
............................................................................................................................................................................................23Horizontal Drain Trap Mounting (Left or Right Side Panel)........................................................................................................................24XI. Electrical Connections...........................................................................................................................................24WIRING HARNESS............................................................................................................................................................................................24115 VOLT LINE CONNECTIONS.......................................................................................................................................................................2424 VOLT THERMOSTAT WIRING......................................................................................................................................................................25115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)....................................................27 XII. Gas Supply and Piping.........................................................................................................................................27GENERAL...........................................................................................................................................................................................................27High Altitude Derate....................................................................................................................................................................................27Propane Gas Conversion............................................................................................................................................................................28Gas Valve...................................................................................

9 ........................................
.................................................................................................................28GAS PIPING CONNECTIONS............................................................................................................................................................................28General........................................................................................................................................................................................................28Direct/Standard Inlet Piping........................................................................................................................................................................29Propane Gas Piping Charts........................................................................................................................................................................29Indirect/Alternate Inlet Piping......................................................................................................................................................................29Gas Piping Checks.....................................................................................................................................................................................29Propane Gas Tanks and Piping..................................................................................................................................................................30XIII. Circulating Air and Filters....................................................................................................................................30DUCTWORK - AIR FLOW..................................................................................................................................................................................30FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK..........................................................................31UPRIGHT INSTALLATIONS.............................................................................................

10 ........................................
..................................................................................31HORIZONTAL INSTALLATIONS.........................................................................................................................................................................31XIV. Startup Procedure and.........................................................................................................................................31Adjustment...................................................................................................................................................................31HEAT ANTICIPATOR SETTING.........................................................................................................................................................................31DRAIN TRAP PRIMING......................................................................................................................................................................................31FURNACE OPERATION.....................................................................................................................................................................................31Furnace Startup..........................................................................................................................................................................................32Furnace Shutdown......................................................................................................................................................................................32GAS SUPPLY PRESSURE MEASUREMENT...................................................................................................................................................32GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT............................................................................................................34GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY).........................................................................................................................34TEMP

11 ERATURE RISE............................
ERATURE RISE........................................................................................................................................................................................34CIRCULATOR BLOWER SPEEDS.....................................................................................................................................................................35BLOWER HEAT OFF DELAY TIMINGS.............................................................................................................................................................35XV. Normal Sequence of Operation............................................................................................................................35POWER UP.........................................................................................................................................................................................................35HEATING MODE.................................................................................................................................................................................................36COOLING MODE................................................................................................................................................................................................36FAN ONLY MODE...............................................................................................................................................................................................36XVI. Operational Checks.............................................................................................................................................36BURNER FLAME................................................................................................................................................................................................36PRIMARY LIMIT...................................................................................................................................................................................

12 ...............36XVII. Safety Circuit De
...............36XVII. Safety Circuit Description..................................................................................................................................37GENERAL...........................................................................................................................................................................................................37INTEGRATED CONTROL MODULE..................................................................................................................................................................37PRIMARY LIMIT..................................................................................................................................................................................................37AUXILIARY LIMIT...............................................................................................................................................................................................37ROLLOUT LIMIT.................................................................................................................................................................................................37PRESSURE SWITCHES....................................................................................................................................................................................37FLAME SENSOR................................................................................................................................................................................................37XVIII. Troubleshooting.................................................................................................................................................37ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS..................................................................................................................................37DIAGNOSTIC CHART...............................................................................................................................................................

13 ..........................37RESETTING FR
..........................37RESETTING FROM LOCKOUT.........................................................................................................................................................................40XIX. Maintenance.........................................................................................................................................................40ANNUAL INSPECTION.......................................................................................................................................................................................40FILTERS..............................................................................................................................................................................................................40Maintenance................................................................................................................................................................................................40Filter Removal.............................................................................................................................................................................................40UPRIGHT UPFLOW FILTER REMOVAL...............................................................................................................................................40MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL......................................................................................................41UPRIGHT COUNTERFLOW FILTER REMOVAL..................................................................................................................................41HORIZONTAL UNIT FILTER REMOVAL................................................................................................................................................41BURNERS...........................................................................................................................................................................................................41INDUCED DRAFT AND CIRCULATOR

14 BLOWERS................................
BLOWERS...........................................................................................................................................41CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY)...............................................................................................41FLAME SENSOR (QUALIFIED SERVICER ONLY)...........................................................................................................................................41FLUE PASSAGES (QUALIFIED SERVICER ONLY).........................................................................................................................................41XX. Before Leaving an Installation.............................................................................................................................42XXI. Repair and Replacement Parts...........................................................................................................................42Table of Contents 4 WARNING –Do not store or use gasoline or other–What to do if you smell gas:-Do not try to light any appliance.-Do not touch any electrical switch; do-Immediately call your gas supplier froma neighbor’s phone. Follow the gas-If you cannot reach your gas supplier,–Installation and service must be WARNING 1.Make a notation on delivery receipt of any visible2.Notify carrier promptly and request an inspection.3.With concealed damage, carrier must be notified as4.File the claim with the following support documents 5 1Gas Valve2Gas Line Entrance (Alternate)3Pressure Switch4Gas Manifold5Combustion Air Intake Connection / “Coupling”6Hot Surface Igniter7Rollout Limit8Burners9Flame Sensor10Flue Pipe Connection / “Coupling”11Flue Pipe (Internal)12Combustion Air Intake (Alternate)13Primary Limit14Gas Line Entrance15Flue Pipe Connection (Alternate)16Rubber Elbow17Induced Draft Blower18Electrical Connection Inlets (Alternate)19Coil Front Cover Pressure Tap20Coil Front Cover Drain Port21Drain Line Penetrations22Drain Trap23Blower Door Interlock Switch24Capacitor25Integrated Control Modul

15 e2624-Volt Thermostat Connections27Trans
e2624-Volt Thermostat Connections27Transformer (40 VA)28Circulator Blower29Bottom Return Filter Retainer30Auxiliary Limit31Junction Box32Electrical Connection Inlets33Coil Front Cover34Combustion Air Inlet PipeUpflow /Horizontal (GUCA Models)Counterflow /Horizontal (GCCA Models) BLOWER COMPARTMENTBURNER COMPARTMENT 5 6 7 8 7 9 1011 3 12 13 14 1516171819 20 222423 30 25 262728 31 3221 20 19 1833 29 OFFTWOSINGLESTATIntell-Ignition87 87 T FORDEHUMCUSCFM1011 ****** BURNER COMPARTMENTBLOWER COMPARTMENT 1 97874 6 13 1423212019 33325 24 263452728103031615 17121920212 11 18 31 32 6 II. SafetyPlease adhere to the following warnings and cautions wheninstalling, adjusting, altering, servicing, or operating the WARNING To prevent personal injury or death due toimproper installation, adjustment,alteration, service or maintenance, refer tothis manual. For additional assistance or WARNING This product contains or produces achemical or chemicals which may causeserious illness or death and which areharm. WARNING To prevent possible death, personal injurythe furnace must be located to protect the CAUTION 1.Disconnect all power to the furnace. Do not touch the2.Firmly touch a clean, unpainted, metal surface of the3.Service integrated control module or connecting wiring4.Discharge your body to ground before removing a newcontrol from its container. Follow steps 1 through 3 ifIII. Product Applicationhome-heating applications. It is NOT designed or certified•It must be installed per the installation instructions•It must be installed indoors in a building constructed•It must be part of a ducted system and not used in a•It must not be used as a “make-up” air unit.•It must be installed with two-pipe systems for com-•All other warranty exclusions and restrictions apply 7 IV. Location Requirements and WARNING •Centrally locate the furnace with respect to the pro-•Ensure the temperature of the return air entering the•Provide provisions for venting combustion products•Locate the furnaceso that the condensate can be•Set the furnace on a level floor to e

16 nable proper•Ensure upflow or horiz
nable proper•Ensure upflow or horizontal furnaces are not installed•A special accessory subbase must be used for up-instructions for installation details. (NOTE: A sub- WARNING Possible death, personal injury or propertydamage due to fire, explosion, smoke, soot,condensation, electrical shock or carbonmonoxide may result from improper WARNING National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or •Exposure to contaminated combustion air will result•Seal off a •If the furnace is used in connection with a cooling unit,•If the furnace is installed in a residential garage,•If the furnace is installed horizontally, the furnace TOPBOTTOMSIDESIDESIDETOPBOTTOM T I L T O U T W A R D T O A L L O W F O R D O O R A N D C I R C U L A T O R B L O W E R R E M O V A L 3 / 8 " D I A M E T E R T H R E A D E D R O D ( 6 P L A C E S ) P R O V I D E 8 " M I N M U M C L E A R A N C E B E T W E E N C E N T E R R O D A N D F U R N A C E C A B I N E T T O A L L O W F O R C I R C U L A T O R B L O W E R R E M O V A L ASSURE FURNACE IS LEVEL FROMEND TO END AND HAS A SLIGHTFORWARD TILT WITH THE FRONTOF THE FURNACE 0"-3/4" BELOW THE BACK OF THE FURNACE P O S I T I O N A S C L O S E A S P O S S I B L E T O B L O W E R D E C K T O A L L O W F O R C I R C U L A T O R B L O W E R R E M V O A L 2 " X 2 " X 1 / 8 " A N G L E I R O N ( 3 P L A C E S ) H O L D D O W N N U T S S U P P O R T N U T S a.Seal any unused openings in the venting system; 9 COLD DRAFTS OR DEAD SPOTS-BEHIND DOORS -IN CORNERS -UNDER CABINETSV. Combustion and Ventilation AirRequirements WARNING b.Inspect the venting system for proper size and horizontal pitch,c.In so far as practical, close all building doors and windows andd.Follow the lighting instructions. Place the appliance beinge.Test for draft hood equipped spillage at the draft hood relieff.After it has been determined that each appliance connected tog.If improper venting is observed during any of the above tests,of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 10The follo

17 wing information on air for combustion a
wing information on air for combustion and ventilationis reproduced from the National Fuel Gas CodeNFPA 54/ANSI Z223.1 Section 5.3.5.3.1 General:(a) The provisions of 5.3 apply to gas utilization equipment in-stalled in buildings and which require air for combustion,ventilation and dilution of flue gases from within the building.(b) Equipment shall be installed in a location in which the facilitiesfor ventilation permit satisfactory combustion of gas, proper(c) In addition to air needed for combustion, process air shall beprovided as required for: cooling of equipment or material,(d) In addition to air needed for combustion, air shall be supplied forventilation, including all air required for comfort and proper(e) While all forms of building construction cannot be covered indetail, air for combustion, ventilation and dilution of flue gases(f) Air requirements for the operation of exhaust fans, kitchenventilation systems, clothes dryers, and fireplaces shall be5.3.2 Equipment Located in Unconfined Spaces: In unconfined spaces (see definition below) in buildings, infiltrationmay be adequate to provide air for combustion ventilation anddilution of flue gases. However, in buildings of tight constructionSpace, Unconfined. For purposes of this Code, a space whose volume is not less than 50cubic feet per 1,000 BTU per hour of the aggregate input rating ofall appliances installed in that space. Rooms communicating di-5.3.3 Equipment Located in Confined Spaces: (a) All Air from Inside the Building: The confined space shall beprovided with two permanent openings communicating directlyinches of the top and one within 12 inches of the bottom of the Furnace Water Heater Opening Chimney or Gas Vent Opening NOTE: Each opening must havea free area of not less than one square inch per 1000 BTU of the total input rating of all equip-ment in the enclosure, but notless than 100 square inches. Furnace Water Heater Outlet Air Chimney or Gas Vent NOTE: The inlet and outlet airopenings must each have a freearea of not less than one squareinch per 4000 BTU of thetotal input rating of all equipmentin the enclos

18 ure. Inlet Air Ventilation louvers forun
ure. Inlet Air Ventilation louvers forunheated crawl spaceAlternateair inlet Ventilation louvers(each end of attic) Equipment Located in Confined Spaces; AllAir from Outdoors—Inlet Air from VentilatedCrawl Space and Outlet Air to VentilatedAttic. See 5.3.3-b2. When communicating with the outdoors through verticalducts, each opening shall have a minimum free area of 1square inch per 4,000 BTU per hour of total input rating of 11 Furnace Water HeaterOutlet Air Chimney or Gas Vent NOTE: The inlet and outlet airopenings must each have a freearea of not less than one squareinch per 4000 BTU of thetotal input rating of all equipmentin the enclosure.Inlet air duct[ends 1 ft (300 mm)above floor] Ventilation louvers(each end of attic) Equipment Located in Confined Spaces; AllAir from Outdoors Through Ventilated Attic.See 5.3.3-b.3. When communicating with the outdoors through horizontalducts, each opening shall have a minimum free area of 1square inch per 2,000 BTU per hour of total input rating of Furnace Water Heater Chimney or Gas Vent NOTE: The air duct openingsmust have a free area of notless than one square inch per2000 BTU of the total inputrating of all equipment in theenclosure*. Outlet air ductInlet air duct Furnace Water Heater Opening Chimney or Gas Vent NOTE: The single opening must havea free area of not less than one square inch per 3000 BTU of the total input rating of all equip-ment in the enclosure, but not less than the sum of the areas of all ventconnectors in the confined space. AlternateOpeningLocation 12 VI. Installation Positionsment). NOTE: Ductwork must never be attached to the back of the furnace. Refer to the product SpecificationsVII. Horizontal Applications and ALTERNATE VENT/FLUE AND COMBUSTION AIRINTAKE LOCATIONS F U R N A C E M U S T B E L E V E L F R O M E N D T O E N D F U R N A C E M U S T B E L E V E L O R S L I G H T L Y T I L T E D F O R W A R D W I T H T H E D O O R S 0 " - 3 / 4 " B E L O W T H E B A C K P A N E L D R A I N L I N E W I T H 1 / 4 " P E R F O O T D O W N W A R D S L O P E 3 6 "

19 M I N I M U M S E R V I C E C L E A R
M I N I M U M S E R V I C E C L E A R A N C E R E Q U I R E D F U R N A C E M U S T B E S U P P O R T E D A T B O T H E N D S A N D M I D D L E DRAIN PAN G A S L I N E W I T H D R I P L E G ( 3 " M I N I M U M ) 4 3 / 4 " M I N I M U M D R A I N T R A P C L E A R A N C E Horizontal FurnaceDRAIN TRAP AND LINESIn horizontal applications the condensate drain trap issecured to the furnace side panel, suspending it below theSection X,Condensate Drain Trap and Lines for further details. If thedrain trap and drain line will be exposed to temperaturesLEVELINGLeveling ensures proper condensate drainage from theheat exchanger and induced draft blower. For proper flueend to end. The furnace should also be level from back tofront or have a slight tilt with the access doors downhillALTERNATE VENT/FLUE AND COMBUSTION AIRCONNECTIONSIn horizontal installations provisions for alternate flue andcombustion air piping are available for upflow furnaces withRefer to the “Recommended Installation Positions” figurefor further detail. The standard piping connections may alsoSection IX, Vent/FluePipe and Combustion Air Pipe for details concerning theconversion to the alternate vent/flue and combustion air AIR DISCHARGEAIR DISCHARGEAIR DISCHARGEBottom Return Duct Connection Bottom Return Duct Connection Bottom Return Duct Connection SideReturnDuct Connection SideReturnDuct ConnectionUPFLOWUPRIGHTUPFLOW HORIZONTALRIGHT AIR DISCHARGEUPFLOW HORIZONTALLEFT AIR DISCHARGEALTERNATE FLUE ANDCOMBUSTION AIR PIPELOCATIONS ALTERNATE FLUE ANDCOMBUSTION AIR PIPELOCATIONS AIR DISCHARGEAIR DISCHARGEAIR DISCHARGEBottom Return Duct Connection Bottom Return Duct Connection Bottom Return Duct Connection COUNTERFLOWUPRIGHTCOUNTERFLOW HORIZONTALRIGHT AIR DISCHARGECOUNTERFLOW HORIZONTALLEFT AIR DISCHARGEALTERNATE FLUE ANDCOMBUSTION AIR PIPELOCATIONS ALTERNATE FLUE ANDCOMBUSTION AIR PIPELOCATIONS Recommended Installation PositionsNOTE: Alternate “vertical” piping connections can not beused when an upflow furnace is installed with supply air 13 IX. Vent/Flue Pipe and Combustion WARNING

20 Failure to follow these instructions can
Failure to follow these instructions canresult in bodily injury or death. Carefullyread and follow all instructions given inthis section. WARNING VIII. Propane Gas and/or HighAltitude Installations WARNING Possible death, personal injury or propertydamage may occur if the correct conversionfurnace operation. All conversions mustbe performed by a qualified installer orThis furnace is shipped from the factory configured fornatural gas at standard altitude. Propane gas installationsHigh altitude installations may require both a pressureswitch and an orifice change. These changes are neces-of both the gas fuel and the combustion air at higheraltitude.Refer to the product Specification Sheet or contact anAmana distributor for a tabular listing of appropriate 14 MATERIALS AND JOINING METHODS WARNING To avoid fire, explosion, or bodily injury,solvent cements must be kept away fromflames, and excessive heat) as they arecombustible liquids. Avoid breathingTwo- or three-inch nominal diameter PVC Schedule 40 pipemeeting ASTM D1785, PVC primer meeting ASTM F656,As an alternative to PVC pipe, primer, solvent cement, andfittings, ABS materials which are in compliance with thein Canada, must be CSA listed. Solvent cement for ABS toABS joints must meet ASTM D2235 and, if used in Canada,All 90° elbows must be medium radius (1/4 bend DWV) orlong radius (Long sweep 1/4 bend DWV) types conformingand 4 9/16” minimum for 3” pipe.PROPER VENT/FLUE AND COMBUSTION AIR PIPINGPRACTICESAdhere to these instructions to ensure safe and properfurnace performance. The length, diameter, and number ofPiping must be adequately secured and supported to pro-hibit sagging, joint separation, and/or detachment from thereturn condensate to the furnace’s drain system. Allow-ances should be made for minor expansion and contractioncare must be taken to secure piping when a long run isPrecautions should be taken to prevent condensate fromfreezing inside the vent/flue pipe and/or at the vent/flue pipepiping exposed outdoors in excess of the terminationsshown in this manual (or in unheated areas) must beTERMINATION L

21 OCATIONSNOTES: Refer to Section IV, Loca
OCATIONSNOTES: Refer to Section IV, Location Requirements andConsiderations for combustion air contaminant restrictions.The following bullets and diagram describe the restrictionsNon-Direct Vent (Single Pipe) Piping and DirectVent (Dual Pipe) Piping located in this section for specificdetails on termination construction.•All terminations (flue and/or intake) must be located atleast 12 inches above ground level or the anticipatedsnow level.•Vent terminations (non-direct and direct vent) mustterminate at least 3 feet above any forced air inletNOTE: This provision does not apply to the combustionair intake termination of a direct vent application.•The vent termination of a non-direct vent applicationmust terminate at least 4 feet below, 4 feet horizontally•The vent termination of a direct vent application mustterminate at least 12 inches from any opening through•The vent termination of vent pipe run vertically throughsnow build up).•A vent termination shall not terminate over publicwalkways or over an area where condensate or vaporcould create a nuisance or hazard or could be detri-mental to the operation of regulators, relief valves, or•The combustion air intake termination of a direct ventapplication should not terminate in an area which isfrequently dusty or dirty. directly to the air intake coupling. On RUBBERCOUPLINGWITH WORMGEAR CLAMPSRUBBERCOUPLINGSWITH WORMGEAR CLAMPSCOMBUSTIONAIR PIPE(DIRECT VENT ONLY)COMBUSTIONAIR PIPE(DIRECT VENT ONLY)VENT/FLUEPIPEVENT/FLUEPIPE 90 PVCELBOW(NON-DIRECT VENT)90 PVCELBOW(NON-DIRECT VENT) STANDARD CONNECTIONS UPFLOW COUNTERFLOW ALTERNATE FURNACE CONNECTIONSIf the standard locations are undesirable for a specificinstallation, alternate side panel locations are available forA coil,or to upright counterflow installations requiring additionalpiping run vertically from the side of the cabinet.NOTE: Standard and alternate locations can be combined(i.e., an installation may use the standard combustion airintake location but use the alternate vent/flue location orNOTE: In Canada, the Canadian Fuel Gas Code takesprecedenc

22 e over the preceding termination restric
e over the preceding termination restrictions. 12" Non-Direct Vent Vent/Flue Termination No Terminations Above Walkway 12" min. 4' min. Non-Direct Vent Vent/Flue Termination Direct Vent Vent/Flue Termination 0' Forced Air Inlet Non-Direct Vent & Direct Vent Vent/Flue Terminations Grade or Highest Anticipated Snow Level 3' min. 12" min. 4' min. 12" min.corrosion-resistant flashing. 16 CAUTION 1.Remove and save the four screws securing the vent/4.Cut the vent/ flue pipe at the elbow nearest the coupling CUTELBOW N E A R E S T C O U P L I N G COUPLINGELBOWS UPFLOW5.Remove plastic plug from alternate vent/flue location.the screws removed in step 1 or with field-supplied 3/8” WARNING The rubber elbow is not designed to supporta load. When the rubber elbow is mountedcare must be taken to adequately supportfield-supplied vent/flue piping. As damageincluding carbon monoxide.7.Upflow and Counterflow units.For upright installations, externally mount the rubberelbow to the vent/flue coupling using a worm gear hoseclamp. Secure field supplied vent/flue piping to theUse of the alternate vent/flue location for upright instal-lations, requires the drain trap be installed on the same8.Upflow and Counterflow units.For horizontal installations, externally secure thefield-supplied vent/flue pipe directly to the vent/flue 17 OFFTWOTSTAIntell-Ignition 3FORWRCUS78954321 ADDITIONAL PLUGFROM DRAIN KITEXTERNALLY MOUNTRUBBER ELBOWSECURE TOID BLOWER WITHRUBBER COUPLINGAND HOSECLAMPS COUNTERFLOW/UPRIGHT(UPFLOW SIMILAR) ****** OFFONSINGLEOFFIntell-Ignition EHUWRCUS321 TWOGLEOFFTSTIntell-Ignition 4 4CUT DEHUCUSCFM1078954321 UPFLOW REMOVE4 SCREWS REMOVEPIPE DETACH RUBBERELBOW FROM ID BLOWER AND VENT/FLUEPIPE 1. REMOVE4 SCREWSDETATCH RUBBERELBOW FROM ID BLOWER AND VENT/FLUEPIPE COUNTERFLOW REMOVEPIPE REMOVEAND RELOCATE REMOVEAND RELOCATE REMOVE3 SCREWS UPFLOW/HORIZONTAL(COUNTERFLOW SIMILAR) SECURE TOID BLOWER WITHRUBBER COUPLINGAND HOSECLAMPSSECURE TOCABINET WITHSCREWS ****** OFFNGLntell-Ignitio878732T FORDEHUMWR011154321 1.Remove and save the four screws securing the com-2.Remove the

23 combustion air intake coupling and gaske
combustion air intake coupling and gasket3.Remove plastic plug from alternate combustion air CAUTION Be sure not to damage internal wiring orother components, when reinstalling5.Upflow and Counterflow units.For non-direct vent installations installed horizon-tally, a minimum of one 90° elbow must be installed onthe combustion air intake coupling to guard againstinadvertent blockage. No elbow is required on thealternate combustion air intake of upright installations,however, a minimum clearance of 2 inches is required6.Upflow and Counterflow units.For direct vent installations, secure field-suppliedcombustion air intake pipe directly to the air intakecoupling.NOTE: A PVC coupling or elbow is required oncounterflow units. ADDITIONAL PLUG FROMDRAIN KIT SECURETO CABINETUPFLOW/HORIZONTAL SHOWN(COUNTERFLOW SIMILAR)REMOVE3 SCREWSREMOVE4 SCREWSREMOVE4 SCREWSREMOVEANDRELOCATEREMOVEANDRELOCATEREMOVEAND CUTREMOVE UPFLOWCOUNTERFLOW 5 4 1 2 2 3 3 1 1 3 2" CLEARANCEREQUIRED(NON-DIRECTVENT) 5 ********* OFFTWOSINGLEOFFIntell-Ignitio2121CUT FORDEHUCUS78954321 ********* OFFTWOGLES1OFFtell-Ignition8787CUSCFM10111278954321 ********* TWONGLEOFFTSTntell-IgnitionEHUWRCUSCFM321 Alternate Combustion Air Intake Location Pipe Size (4)(inc.)234567845,00026865625956535070,00026865625956535090,000260575552504745115,000245424037353230[0 - 4,500 ft]3111107104100979390115,000225222017151210[4,500 - 11,000 ft]358555249464340Non-Direct Vent (Single Pipe)Maximum Allowable Length of Vent/Flue Pipe (ft)(1) (2)Number of Elbows (3)Unit Input(BTU) (1)One 90° elbow must be secured to the combustion air intake(2)Minimum vent length is five feet and one elbow/tee.(3)Tee used in the vent/flue termination must be included when(4)3” diameter pipe can be used in place of 2” diameter pipe. 12 " Min To Roof Or Highest Anticipated Snow Level Vertical Termination (Single Pipe) 12" Min. 90º Medium Radius Elbow penetration should be sealed with silicone caulking material. MIN. 12" FROM WALL 12" TO GROUND OR HIGHEST ANTICIPATED SNOW LEVELWALLINSIDEOUTSIDETEE 90°ELBOWTURNEDDOWNCOUPLINGELBOW ORCOUPLING Horizontal Term

24 ination (Single Pipe) 19 12" MIN. VENT/F
ination (Single Pipe) 19 12" MIN. VENT/FLUE TEE or 90° ELBOW TURNED DOWN 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL PipeSize (4)(in.)Standard268656259565350Alternate255524946434037Standard268656259565350Alternate25524946434037Standard255524946434037Alternate242393633302724Standard2262320Alternate2710Standard388878076726864Alternate374706662585450115,000Not RecommendedDirect Vent (Dual Pipe)Maximum Allowable Length of Vent/Flue & Combustion A ir Intake Pi p e ( ft ) Unit Input(Btu)Number of Elbows (1)(2)(3)115,000Not RecommendedVent/Flue/Air IntakeTermination45,00070,00090,000 (1)Elbows and/or Tees used in the terminations must be included whendetermining the number of elbows in the piping system.(2)Number of elbows tabulated are for each (Vent/Flue & Combustion airintake) pipe.(3)Minimum length of each Vent/Flue & Combustion Air Intake pipe isfive feet and one elbow/tee.(4) 3” diameter pipe can be used in place of 2” diameter pipe.Vent/Flue and Combustion Air Pipe TerminationsThe vent/flue and combustion air pipes may terminatevertically, as through a roof, or horizontally, as through anoutside wall.Vertical pipe terminations should be as shown in the follow-ing figure. Refer to Section IX, Vent/Flue Pipe and Com-bustion Pipe - Termination Locations for details concerninglocation restrictions. The penetrations through the roofmust be sealed tight with proper flashing such as is used TEE 12" MIN. 12" MIN. TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL VENT/FLUE90ºMEDIUM RADIUSELBOWS COMBUSTION AIR INTAKE 24" MAX. 3" MIN. SCREEN 2 3/8 inch diameter wall penetration is required for 2”diameter pipe while a 3 1/2 inch diameter hole is required 20 SCREEN COMBUSTION AIR INTAKE V ENT/FLUE TEE 90º MEDIUM RADIUS ELBOW 12" MIN 12" MIN 12" MIN 3" MIN 24" MAX 3" MIN 24" MAX VENT 24" MAX3" MIN 12" MIN 24" MAX AIRINTAKE 90°MEDIUM RADIUSELBOW Alternate Horizontal Vent Termination(Dual Pipe) SUPPORT STRAPS 90° MEDIUM RADIUS ELBOWS 12" MIN. VENT/FLUE TEE SCREEN COMBUSTION AIR INTAKE. 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12" MIN. ABOVE HIGHEST A

25 NTICIPATED SNOW LEVEL 3" MIN. 24" MAX.
NTICIPATED SNOW LEVEL 3" MIN. 24" MAX. Air Intake Screen 90° Medium Radius Elbow Vent 12" Min. 24" Max. 24" Max. 3" Min. 12" Min. Above Highest Anticipated Snow Level Vents24" Max.3" Min. 12" Min.Screen 24" Max. AirIntakes 90°MediumRadiusElbows 24" Max.3" Min. Min. Horizontal Venting Of Multiple Units 21 Trap WARNING •The drain trap supplied with the furnace must be•The drain line between furnace and drain location•The drain line between furnace and drain location•Do not trap the drain line in any other location than•Do not route the drain line outside where it may•If the drain line is routed through an area which•If an air conditioning coil is installed with the HOSE AQTY: 1 HOSE BQTY: 1 TUBE 1QTY: 1 TUBE 2QTY: 2 HOSE CLAMPSQTY: 2 GREENHOSE CLAMPSQTY: 31.Remove the rubber plug from the front cover drain port2.Secure Hose A to front cover drain port with a red hose DRAINTRAPFRONT COVERDRAIN PORTTUBE(S) 2GREENHOSECLAMPS ( 3 PLACES ) RIGHT SIDEPANELRUBBER ELBOW DRAIN PORTTUBE 1SIDE PANELGROMMETHOLESHOSEHOSE RUBBERELBOW RED HOSECLAMP RED HOSE CLAMP 1.Remove the rubber plug from the front cover right-side2.Secure Hose A to front cover drain port with a red hose RUBBER ELBOW (EXTERNALLY MOUNTED)TUBE 1GREEN HOSECLAMPS(3 PLACES)HOSE BTUBE(S) 2DRAIN TRAPSIDE PANELGROMMETHOLESHOSE A FRONT COVE R DRAIN PORT RUBBERELBOW DRAIN PORT RED HOSECLAMPRED HOSE CLAMP 3.Remove grommet from front right-side panel drain4.Cut 1/4 inch from the end of the drain port on the5.Insert Tube 1 into rubber elbow drain port and secure6.Cut 17 7/87.Secure remaining end of Hose B to exposed end of8.Insert short end of one Tube 2 through rear right side9.Insert short end of remaining Tube 2 into Hose B from1.Insert drain tubes into drain trap and position the drain2.Secure drain trap to side panel at the mounting holes3.Attach PVC drain line to drain trap outlet with either a LEFTSIDE PANELFRONT COVERDRAIN PORTHOSE ASIDE PANELGROMMET HOLESTUBE(S) 2DRAINTRAPGREEN HOSECLAMPS(3 PLACES)TUBE 1RUBBERELBOWHOSE B RUBBERELBOWDRAIN POR T RED HOSECLAMP RED HOSECLAMP 3.Cut and remove 1/4

26 inch from the end of the drain port4.Ins
inch from the end of the drain port4.Insert Tube 1 into rubber elbow drain port and secureCabinet Width (inches)Model GUCA & GCCA ( kBTU Tons ) 16.5045 __ 070 __ "X" Length to Cut From Long End of Hose B ( inches ) 8 inches20.524.5070__40090 __ 090__50115504 inches 6.Insert short end of each Tube 2 through side panel 1.Remove the rubber plug from the coil front cover drain2.Secure Hose A to front cover drain tap with a red hose HOSE A HOSE B SIDE PANEL GROMMET HOLES GREEN HOSE CLAMP ( 3 PLACES ) TUBE 1 RUBBER ELBOW RIGHT SIDE PANEL DRAIN TRAP TUBES 2 RUBBER ELBOW DRAIN PORT FRONT COVER DRAIN PORT FRONT COVER PRESSURE TAP RED HOSE CLAMP RED HOSE CLAMP3.Cut 1/4 inch from the end of the drain port on the rubber4.Insert Tube 1 into rubber elbow drain port and secure5.Cut 17 3/46.Secure remaining end of Hose B to exposed end of7.Cut 5 1/2 inches straight length from the long end of8.Insert approximately one inch of each Tube 2 throughSection X, Condensate Drain Lines and Drain Trap - Upright1.Remove the rubber plug from the coil front cover left3.Secure Hose A to front cover drain port with a red hose LEFT SIDE PANEL FRONT COVERDRAIN PORTSIDE PANELGROMMETHOLESDRAIN TRAPTUBE(S) 2GREEN HOSECLAMPS(3 PLACES)HOSE AHOSE BINDUCEDDRAFT BLOWERDRAIN PORT FRONTCOVERPRESSURETAP RED HOSE CLAMP Horizontal ConnectionsLeft Side Down(Upflow Shown, Counterflow Similar) 24 1.Position the drain trap against side panel with drain2.Secure drain trap to side panel at the dimples or3.Confirm that tubes reach bottom of drain trap and that4.Attach PVC drain line to drain trap outlet with either a WARNING To avoid the risk of electrical shock, wiringto the unit must be properly polarized and WARNING To avoid electrical shock, injury or death,servicing or changing any electrical wiring. CAUTION 090__50115__5011 1/4 inches"X" Length to Cut From Long End of Hose B 19 inches070__40090__4014 3/4 inchesCabinet Width (inches)Model GUCA & GCCA (kBTU Tons)045__30070__30 5.Secure short end of Hose B to induced draft blower6.Cut 5 1/2 inches straight length from the long end of each Tube 2.

27 7.Upflow Units with a 16 1/2” cabin
7.Upflow Units with a 16 1/2” cabinet width.Insert approximately one inch of cut Tube 2 through leftside panel grommet hole and secure to Hose A with ahose clamps and a short section of hose as shownbelow. NOTE: Tube must reach bottom of trap. Junction Box Tube 1 Hose B Green Hose Clamps Tube Installation with Green Hose ClampsCounterflow Units with a 16 1/2” cabinet width.Insert approximately one inch of cut Tube 2 through leftside panel grommet hole and secure to Hose A with agrommet hole and secure to Hose B with a green hoseclamp. NOTE: Tube must reach bottom of trap.All Units with a 20 1/2” and 24 1/2” cabinet width.Insert approximately one inch of each Tube 2 throughleft side panel grommet hole. Secure tubes to Hose Amust reach bottom of trap.NOTE: Ensure hoses and tubes maintain a downward slopefor proper drainage and that they are not kinked or binding.For details concerning mounting of the drain trap, refer toSection X, Condensate Drain Lines and Drain Trap - Up-right Drain Trap Mounting. 25 mum overcurrent protection specified on the unit ratingplate. An electrical disconnect must be provided at theNOTE: Line polarity must be observed when making fieldconnections. WARNING In upright upflow installations, the draintrap must be mounted on the opposite sidejunction box in the event of a blocked draincondition.Connect hot, neutral, and ground wires as shown in thewiring diagram located on the unit’s blower door. For directvent applications, the cabinet opening to the junction box Field-installed WiringLine polarity must be observed when making field connec-opposite side of the furnace, the junction box must berelocated to the other side of the blower compartment priorNOTE: Wire routing must not to interfere with circulatorblower operation, filter removal, or routine maintenance. CAUTION 1.Remove the burner compartment door.2.Remove and save the two screws securing the junction3.Relocate junction box and associated plugs and grom- ********* STANDARD J UNCTION BOXLOCATION ALTERNATE JUNCTION BOXLOCATION Junction Box Relocation WARNING 1.Measure resistance

28 between the neutral (white) con-2.Resist
between the neutral (white) con-2.Resistance should measure 10 ohms or less. W W W Y Y Y C C R R R G G W Y C R G HEATING ROOMTHERMOSTATHEATING AND COOLING ROOMTHERMOSTATFURNACEFURNACEREMOTECONDENSINGUNIT 26Gas Piping Connections ****** ****** OFFONTWOINGLS1OFFS4TATIntell-Ignition87 432187 4321CUT FORDEHUCFM0111254321 ********* MANUAL SHUT OFF VALVE(UPSTREAM FROMGROUND JOINTPIPE UNION)GROMMETIN STANDARDGAS LINE HOLE A LTERNATEGAS LINELOCATIONPLUG IN A LTERNATEGAS LINEHOLEHEIGHT REQUIRED BY LOCAL CODEGROUND JOINTPIPE UNIONDRIP LEGMANIFOLDBURNERSGAS VALVE HORIZONTAL [UPFLOW MODEL] MANUAL SHUT-OFF VALVE(UPSTREAM FROM GROUND JOINT PIPE UNION)DRIP LEGGROMMET IN STANDARD GAS LINE HOLE DRAIN TRAPALTERNATE GAS LINE LOCATIONMANIFOLDPLUG IN ALTERNATE GAS LINE HOLEGAS VALVEGROUND JOINT PIPE UNIONBURNERS ********* OFFONTWOGLES1OFFS4TSTATIntell-Ignition87 432187 4321T FORDEHUMCFM54321 GROMMETIN STANDARDGAS LINE HOLE COUNTERFLOW MANUAL SHUT OFF VALVE(UPSTREAM FROMGROUND JOINTPIPE UNION)ALTERNATEGAS LINELOCATIONPLUG INALTERNATEGAS LINEHOLEHEIGHT REQUIRED BY LOCAL CODEGROUND JOINTPIPE UNIONDRIP LEGMANIFOLDBURNERSGAS VALVE NOTESWHENGASLINETHEALTERNATE LOCATIONSWAPTHEPOSITION THEPLUGANDGROMMET 2. DRIP LEG MAY TERMINATE WITH A 1/2" X 1/8" PIPE PLUG TO ACCOMMODATE LINE GAS PRESSURE MEASUREMENT. GAS VALVE MANUAL SHUT-OFF VALVE(UPSTREAM FROM GROUNDJOINT PIPE UNION)DRIP LEGGROMMET IN STANDARD GAS LINE HOLE DRAIN TRAPALTERNATE GAS LINE LOCATIONMANIFOLDPLUG IN ALTERNATEGAS LINE HOLE BURNERSGAS VALVE HORIZONTAL[COUNTERFLOW]UPFLOW GROUND JOINT PIPE UNION 27 This furnace is equipped with a 40 VA transformer tofacilitate use with most cooling equipment. Consult the115 VOLT LINE CONNECTION OF ACCESSORIES(HUMIDIFIER AND ELECTRONIC AIR CLEANER) WARNING Humidifier1.0 Amp maximum at 120 VACElectronic Air Cleaner1.0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any acces-sories. Follow the humidifier or air cleaner manufacturers’instructions for locating, mounting, grounding, and control- ELECTRO

29 NICAIR CLEANERHUMIDIFIEROPTIONALACCESSOR
NICAIR CLEANERHUMIDIFIEROPTIONALACCESSORIES12 PINCONNECTOR120 VACNEUTRALTERMINALSHUM-NEAC-NHUM-HEAC-H120 VACHOT ANDPARKTERMINALSINTEGRATEDCONTROLMODULE CAUTION Propane GasNatural GasInlet Gas Supply PressureMinimum:5.0" W.C. Maximum :10.0" W.C.Minimum:11.0" W.C. Maximum :13.0" W.C. High Altitude DerateWhen this furnace is installed at high altitude, the appropri-ate High Altitude orifice kit must be applied. This is requiredHigh altitude kits are purchased according to the installationaltitude and usage of either natural or propane gas. Referfor a tabular listing of appropriate altitude ranges andcorresponding manufacturer’s high altitude (Natural, pro-Do not derate the furnace by adjusting the manifold pres-sure to a lower pressure than specified on the furnace ratingplate. The combination of the lower air density and a lowerIn some areas the gas supplier may artificially derate thegas in an effort to compensate for the effects of altitude. If3 content of the 28 Natural Gas Capacity of PipeIn Cubic Feet of Gas Per Hour (CFH)Length ofNominal Black Pipe SizePipe in Feet1/2"3/4"1"1 1/4"1 1/2"13227852010501600921903507301100731522855909806313024550076056115215440670501051954006104696180370560439017035053040841603204903879150305460(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on0.60 Specific Gravity Gas)CFH =BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot) To connect the furnace to the building’s gas piping, theinstaller must supply a ground joint union, drip leg, manualtransition piece from 1/2" pipe to a larger pipe size.The following stipulations apply when connecting gas pip-ing. Refer to the previous figures for typical gas lineconnections to the furnace.•Use black iron or steel pipe and fittings for the buildingpiping.•Use pipe joint compound on male threads only. Pipejoint compound must be resistant to the action of the•Use ground joint unions.•Install a drip leg to trap dirt and moisture before it canof three inches long.•Install a 1/8" NPT pipe plug fitting, accessible for testgage connection, immediately upstream o

30 f the gas•Use two pipe wrenches whe
f the gas•Use two pipe wrenches when making connection to theshipped from the factory.•Install a manual shutoff valve between the gas meterand unit within six feet of the unit. If a union is installed,valve, between the shutoff valve and the furnace.•Tighten all joints securely.•Connect the furnace to the building piping by one of the–Rigid metallic pipe and fittings.–Semi-rigid metallic tubing and metallic fittings.Aluminum alloy tubing must not be used in exteriorlocations. In order to seal the grommet cabinetpenetration, rigid pipe must be used to reach the•Use listed gas appliance connectors in accordance•Protect connectors and semirigid tubing against physi-derated gas and the altitude. Refer to the National Fuel GasCode, NFPA 54/ANSI Z223.1, and information provided byA different pressure switch may be required at high altituderegardless of the BTU/ft3 content of the fuel used. Refer tothe product Specification Sheet or an Amana distributor forsponding manufacturer’s pressure switch kits.Propane Gas Conversion WARNING Possible death, personal injury or propertydamage may occur if the correct conversionkits are not installed. The appropriate kitsbe performed by a qualified installer orservice agency.This unit is configured for natural gas. The appropriatemanufacturer’s propane gas conversion kit, must be ap-plied for propane gas installations. Refer to the “propaneGas ValveThis unit is equipped with a 24 volt gas valve controlledduring furnace operation by the integrated control module.manifold pressure are provided on the valve.The gas valve has a manual ON/OFF control located on thevalve itself. This control may be set only to the “ON” orGAS PIPING CONNECTIONSGeneral CAUTION natural/propane gas piping needed when 29 num-alloy tubing and connectors are coated to protectagainst external corrosion when in contact with ma-wetting by liquids such as water (except rain water),detergents, or sewage. CAUTION Sizing Between First and Second Stage Regulator*Maximum Propane Capacities listed are based on 2 psig pressure drop

31 at 10 psig setting. Capacities in 1,00
at 10 psig setting. Capacities in 1,000 BTU/hour.Pipe orNominal Pipe SizeTubin g Tubin g Size, O.D. T yp Schedule 40Length,3/8"1/2"5/8"3/4"7/8"1/2"3/4"Feet107301,7003,2005,3008,3003,2007,500205001,1002,2003,7005,8002,2004,200304009202,0002,9004,7001,8004,000403708501,7002,7004,1001,6003,700503307701,5002,4003,7001,5003,400603007001,3002,2003,3001,3003,100802606101,2001,9002,9001,2002,6001002205401,0001,7002,6001,0002,3001252004909001,4002,3009002,1001501904308301,3002,1008301,9001751704007801,2001,9007701,7002001603807301,1001,8007201,500To convert to capacities at 15 psig settings - multiply by 1.130To convert to capacities at 5 psig settings - multiply by 0.879 Sizing Between Single or Second Stage Regulator and Appliance*Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour.Pipe o r Nominal Pipe SizeTubingTubing Size, O.D. Type LSchedule 40Length,3/8"1/2"5/8"3/4"7/8"1-1/8"1/2"3/4"1"1-1/4"1-1/2"Feet1039921993295019352755671,0712,2053,3072026621312163466301893937321,4962,2993021501071812775001523155901,2121,858401941901452334271292675041,0391,559501837791311983761142374489131,417601635721211873401032174098341,27580132962104155289891853467241,0661001126559013825578162307630976125102448811222246914627556786615092143721092026313225251178720081939661001875411220943966525081736609317248100185390590*Data in accordance with NFPA pamphlet NO. 54 Propane Gas Piping Charts 30 WARNING To avoid the possibility of explosion or fire,never use a match or open flame to test forleaks.Check for leaks using an approved chloride-free soap andwater solution, an electronic combustible gas detector, orNOTE: Never exceed specified pressures for testing.Higher pressure may damage the gas valve and causeDisconnect this unit and shutoff valve from the gas supplypiping system before pressure testing the supply pipingIsolate this unit from the gas supply piping system byclosing its external manual gas shutoff valve before pres-Propane Gas Tanks and Piping WARNING detecting warning system. If the presence of gas is sus-1.Vaporization rate, depending

32 on temperature of the2.Proper pressure r
on temperature of the2.Proper pressure regulation. (Two-stage regulation is3.Pressure drop in lines between regulators, and be- 200 PSIGMaximum5 to 15 PSIG(20 PSIG Max.)Continuous11" W.C.Second StageRegulatorFirst StageRegulator XIII. Circulating Air and Filters Ductwork must never be attached to the back of the furnace. Supply andreturn connections to the furnace may be made with flexiblejoints to reduce noise transmission. To prevent the blowerWhen the furnace is used in connection with a cooling unit,the furnace should be installed in parallel with or on thebe adequate to prevent chilled air from entering the furnaceand, if manually operated, must be equipped with means toWhen the furnace is installed without a cooling coil, it isrecommended that a removable access panel be provided 31 When the furnace is heating, the temperature of the returnair entering the furnace must be between 55°F and 100°F.FILTERS - READ THIS SECTION BEFOREINSTALLING THE RETURN AIR DUCTWORKFilters must be used with this furnace. Discuss filter main-tenance with the building owner. Filters do not ship with thisOn upflow units, guide dimples locate the side return cutoutlocations. Use a straight edge to scribe lines connecting theNOTE: Anundersized opening will cause reduced airflow.Upflow units with an air delivery of less than 1800 CFMshould either use the bottom return or one-side return. two-side return combination or a one-sidereturn and one bottom return combination. These combi-All counterflow units must have ductwork connected to thebasepan.To ensure proper unit performance follow the filter sizesgiven in the Specifications Sheet.UPRIGHT INSTALLATIONSDepending on the installation and/or customer preference,differing filter arrangements can be applied. Filters can bethe Specifications Sheet to ensure proper unit perfor-mance. The following figures show possible filter locations. OFFTWONGLEOFFTSTIntell-Ignition 4 4CUT FORDEHUMWRCUSCFM10654321 FILTER FILTERFILTERAIR FLOW SIDE RETURN INTERNAL FILTER RETENTION (EITHER SIDE)CENTRALRETURNGRILLEBOTTOMRETURN FILTER SIDE RETURN EXTERNAL FILTER RACK KIT

33 (EITHER SIDE) POSSIBLE UPRIGHT UPFLOWFIL
(EITHER SIDE) POSSIBLE UPRIGHT UPFLOWFILTER LOCATIONS FILTER FILTER AIR FLOWFILTERACCESS DOORCENTRALRETURNGRILLERETURNDUCT ILTERFILTERSUPPORTBRACKET(PROVIDED) XIV. Startup Procedure and 32 1.Close the manual gas shut-off valve external to the2.Turn off the electrical power to the furnace.3.Set the room thermostat to the lowest possible setting.4.Remove the burner compartment door. This furnace is equipped with an ignition device5.Move the furnace gas valve manual control to the OFF6.Wait five minutes then smell for gas. Be sure check7.If you smell gas after five minutes, immediately follow8.Replace the burner compartment door.9.Open the manual gas shut-off valve external to the10.Turn on the electrical power to the furnace.11.Adjust the thermostat to a setting above room tempera-12.After the burners are lit, set the thermostat to desired1.Set the thermostat to the lowest setting.2.Remove the burner compartment door and move the3.Close the manual gas shut-off valve external to the4.Replace the burner compartment door. CAUTION 1.Turn OFF gas to furnace at the manual gas shutoff2.Connect a calibrated water manometer (or appropriate MP132COFFON Outlet (Manifold)Pressure Tap (Side of Valve) Pressure RegulatorAdjustment (Under Cap Screw) OUTLET INLET Inlet Pressure Tap (Side of Valve) Gas ValveOn/OffSelectorSwitch White-Rodgers Model 36E22 or 36E23 Gas LineGas Shutoff ValveGas Line To FurnaceDrip Leg Cap With FittingManometer Hose ManometerOpen ToAtmosphere 3.Turn ON the gas supply and operate the furnace and all4.Measure furnace gas supply pressure with burnersPropane GasNatural GasInlet Gas Supply PressureMinimum:5.0" W.C. Maximum :10.0" W.C.Minimum:11.0" W.C. Maximum :13.0" W.C. If supply pressure differs from above, make necessaryadjustments to pressure regulator, gas piping size, etc., 33Timing Chart for Normal Heating ModeTiming Chart for Normal Cooling Operation CIRCULATORBLOWERGAS VALVEIGNITERPRESSURE SWITCHCONTACTSINDUCED DRAFTBLOWERTHERMOSTATOFFOPENCLOSEDNOTE: HEATCRAFT INTEGRATED CONTROL MODULE HAS A FIXED STANDARD SEVEN-SECOND IGNITER WARM UP PERIOD (MINI IGNITER).

34 WHITE-RODGERS INTEGRATED CONTROL MO
WHITE-RODGERS INTEGRATED CONTROL MODULE HAS A VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN A 17-SECOND MAXIMUM AND A FIVE-SECOND MINIMUM.ign circ60,90,120 or180 IGNITERWARM UP PERIOD(see note)FIXED HEATON DELAY:30 SECONDS SECONDS Seconds 0 5 0 45Indoor FanOutdoor FanandCompressorThermostat OFFOFFOFF 34 5.Turn OFF gas to furnace at the manual shutoff valve6.Turn OFF any unnecessary gas appliances started in CAUTION 1.Turn OFF gas to furnace at the manual gas shutoff2.Connect a calibrated water manometer (or appropriate3.Turn ON the gas supply and operate the furnace.4.Measure gas manifold pressure with burners firing.Manifold Gas PressureNatural Gas3.5" w.c.Propane Gas10.0" w.c. than ± 0.3 “ w.c. from the above specified pressures. Any5.To adjust the gas valve pressure regulator, remove the6.Turn the adjustment screw clockwise to increase the7.Securely replace the regulator cap.8.Turn OFF gas to furnace at the manual shutoff valve9.Reinstall gas valve outlet pressure tap plug before1.Turn OFF the gas supply to all other gas-burning2.While the furnace is operating, time and record one3.Calculate the number of seconds per cubic foot (sec/4.Calculate the furnace input in BTUs per hour (BTU/hr).Installation’s gas heating (HTG) value: 1,000 BTU/ft5.Turn ON gas to and relight all other appliances turned1.Operate furnace with burners firing for approximately2.Place thermometers in the return and supply ducts as 35 RISE = SUPPLY AIRRETURN AIR HEAT EXCHANGERRADIATION "LINE OF SIGHT"RETURNSUPPLYSUPPLYRETURN3.Subtract the return air temperature from the supply air4.Adjust temperature rise by adjusting the circulator WARNING 1.Turn OFF power to the furnace.2.Select the heating and cooling blower speeds that3.Relocate desired motor leads to the circulator blower3.Connect all unused blower motor leads to the “PARK”4.Turn ON power to furnace.5.Verify proper temperature rise as outlined in Oran g eHi g Common/NeutralMedium LowCirculator Blower S p LowRedMedium BlueBlackWhite

35 SecondDelay 12 SecondDelay 21 180120120S
SecondDelay 12 SecondDelay 21 180120120SecondDelay 21 180SecondDelay 21 DIP SwitchesJumper 180180120180120 OFFOFFOFFXV. Normal Sequence of Operationcontinuously. 36 HEATING MODEThe normal operational sequence in heating mode is asfollows:•R and W thermostat contacts close, initiating a call forheat.•Integrated control module performs safety circuit•Induced draft blower is energized causing pressureenergized with induced draft blower.•Igniter warm up begins upon close of pressure switchcontacts.•Gas valve opens at end of igniter warm up period,•Integrated control module monitors flame presence.•Circulator blower is energized on heat speed following•Furnace runs, integrated control module monitors safety•R and W thermostat contacts open, completing the call•Gas valve closes, extinguishing flame.•Induced draft blower is de-energized following a fifteengized.•Circulator blower is de-energized following a select-able heat off delay period (60, 90, 120, or 180 seconds).•Furnace awaits next call from thermostat.COOLING MODEThe normal operational sequence in cooling mode is asfollows:•R and Y thermostat contacts close, initiating a call forcool.•Integrated control module performs safety circuitchecks.•Outdoor fan and compressor are energized.•Circulator blower is energized on cool speed following•Furnace circulator blower and outdoor cooling unit run,•R and Y thermostat contacts open, completing the call•Outdoor fan and compressor are de-energized.•Circulator blower is de-energized following a fixed fortyfive second cool off delay period. Electronic air cleanerterminals are de-energized.•Furnace awaits next call from thermostat.FAN ONLY MODEThe normal operational sequence in fan only mode is asfollows:•R and G thermostat contacts close, initiating a call forfan.•Integrated control module performs safety circuit•Circulator blower is energized on cool speed. Elec-•Circulator blower runs, integrated control module moni-•R and G thermostat contacts open, completing the

36 callfor fan.•Circulator blower is
callfor fan.•Circulator blower is de-energized. Electronic air cleanerterminals are de-energized.•Furnace awaits next call from thermostat.XVI. Operational ChecksBURNER FLAMEThe burner flames should be inspected with the burnercompartment door installed. A sight glass is provided forinspection purposes. Flames should be stable, quiet, soft,and blue (dust may cause orange tips but they must not be Check the burner flames for: 1. Good adjustment2. Stable, soft and blue 3. Not curling, floating, or lifting off. 1.Allow the furnace to operate with burners firing continu-2.Gradually block the return air to furnace. Remove 37 •The gas valve to close and extinguish flame,•The induced draft blower to deenergized after a•The circulator blower to remain energized continu-3.Remove the return air blockage to clear overheatingXVIII. Troubleshooting1.Disconnect all power to the furnace. Do not touch the2.Firmly touch a clean, unpainted, metal surface of the3.Service integrated control module or connecting wiring4.Discharge your body to ground before removing a new WARNING To avoid electrical shock, injury or death,disconnect electrical power beforeperforming any service or maintenance.Refer to the troubleshooting chart on the following pages forassistance in determining the source of unit operational Troubleshooting ChartNotes: 1) Integrated control module will automatically attempt to reset from lock out after one hour. 2) LED flash code will cease if power to the control module is interrupted through the disconnect or door switch. 3) Integrated control module will automatically attempt to reset from lock out after 20 minutes. Symptoms of AbnormalOperationAssociatedLED Code(See Note 2)Fault Description(s)Possible Causes - Furnace fails to operate. and - Inte g rated control module dia g nostic LED provides no si g None - No 115 V power to furnace, or no 24 V power to inte g rated control module. - Blown fuse, or circuit breaker. - No si g nal from thermostat. - Manual disconnect switch OFF, door switch open, or 24 V wires miswired, loose or misconnected wires

37 . - Blown fuse, or circuit breaker.-
. - Blown fuse, or circuit breaker.- Improper thermostat connection or settin g - Furnace fails to operate. and - Inte g rated control module dia g nostic LED is lit continuously.Continuous - Inte g rated control module has an internal fault. - Inte g rated control module has an internal fault. - Furnace is not operatin g - Furnace lockout due to an excessive - Failure to establish flame. Cause may be no g to burners, front cover pressure switch stuck open, bad i g niter or i g niter ali g nment, improper orifices, or coated/oxidized or misconnected and - Inte g rated control module dia g nostic LED is flashin g one flash.1 Flash number of i g nition "retries" (3 total attempts), or "recycles" (5 total recycles). See note 1. flame sensor. - Loss of flame after establishment. Cause may be interrupted g as supply, lazy burner flames ( improper g as pressure or restriction in flue and/or combustion air pipin g ), front cover pressure switch openin g , or improper induced draft blower performance. - Furnace fails to operate. and - Inte g rated control module dia g nostic LED is flashin g two flashes.2 Flashes - Pressure switch circuit is closed even thou g h induced draft blower is not operatin g - Induced draft blower pressure switch contacts stickin g - Shorts in pressure switch circuit. - Induced draft blower runs continuously with no further furnace operation. and - Inte g rated control module dia g nostic LED is flashin g three flashes.3 Flashes - Pressure switch circuit does not close in response to induced draft blower operation. - Pressure switch hose blocked, pinched, or misconnected. - Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower. - Incorrect pressure switch set point or malfunctionin g switch contacts. - Loose or misconnected wirin g - Circulator blower runs continuously with no further furnace operation. and - Inte g rated control module dia g nostic LED is flashin g four flashes.4 Flashes - Primary limit circuit is open. (P

38 rimary or auxiliary limit). - Insufficie
rimary or auxiliary limit). - Insufficient conditioned air over the heat exchan g er. Cause may be blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower. - Loose or misconnected wirin g - Circulator blower runs continuously with no further furnace operation. and - Inte g rated control module dia g nostic LED is flashin g five flashes.5 Flashes - Rollout limit circuit is open. - Rollout limit(s) is(are) open due to flame rollout. Cause may be misali g ned burners, blocked flue and/or air inlet pipe, or failed induced draft blower. - Loose or misconnected wirin g - Furnace fails to operate. and - Inte g rated control module dia g nostic LED is flashin g six flashes.6 Flashes - Polarity of 115 V or 24 VAC power is reversed. - Polarity of 115 VAC power to furnace or inte g rated control module is reversed. - Oran g e and g ray wires to transformer are reversed.- Poor unit g round. 1 1 3 4 5 6 ON 2 Corrective Action Cautions andNotes - Assure 115 V and 24 V power to furnace and inte g rated control module. - Check inte g rated control module fuse (3 A). Replace if necessary. - Check for possible shorts in 115 V and 24 V circuits. Repair as necessary. - Turn power OFF prior to repair. - Replace inte g rated control module fuse with 3 A automotive style fuse. - Replace bad inte g rated control module with known g ood control module. - Turn power OFF prior to repair. - Read precautions in "Electrostatic Dischar g section of manual. - Locate and correct g as interruption. - Check front cover pressure switch operation (hose, wirin g , contact operation). Correct if necessary. - Turn power OFF prior to repair. - Replace or reali g n i g niter. - Check flame sense si g nal. Sand sensor if coated/oxidized. - I g nitor is fra g ile, handle with care. - Sand flame sensor with emery cloth - See "Flue and Combustion Air Pipe" section for pipin g details. - Check flue pipin g for blocka g e, proper len g th, elbows, and termination. - Verify proper induced draft blower performance. - Replace indu

39 ced draft blower pressure switch if bad.
ced draft blower pressure switch if bad. - Check for and correct shorted wirin g - Turn power OFF prior to repair. - Replace pressure switch with proper replacement part. - Check and correct pressure switch hose. - Check flue and/or inlet air pipin g for blocka g e, proper len g th, elbows and termination. Check drain system. - Verify proper pressure switch set point and contact motion. - Check and correct wirin g - Turn power OFF prior to repair. - See "Flue and Combustion Air Pipe" section for pipin g details. - Replace pressure switch with proper replacement part. - Check filters and ductwork for blocka g e. Clean filters or remove obstruction. - Check for proper circulator blower speed and performance. Correct speed or replace blower if necessary. - Check and correct wirin g - Turn power OFF prior to repair. - See Specification Sheet for allowable rise ran g e and proper circulator blower speed. - Check burners for proper ali g nment. - Check flue and/or air inlet pipin g for blocka g e, proper len g th, elbows, and termination. - Check induced draft blower for proper performance. Replace if necessary. - Check and correct wirin g - Turn power OFF prior to repair. - See "Flue and Combustion Air Pipe" section for pipin g details. - Replace induced draft blower with proper replacement part. - Review wirin g dia g ram. - Verify proper g roundin g - Check and correct wirin g - Turn power OFF prior to repair. Troubleshooting ChartNotes: 1) Integrated control module will automatically attempt to reset from lock out after one hour. 2) LED flash code will cease if power to the control module is interrupted through the disconnect or door switch. 3) Integrated control module will automatically attempt to reset from lock out after 20 minutes. Symptoms of AbnormalOperationAssociatedLED Code(See Note 2)Fault Description(s)Possible Causes - Induced draft and circulator blower run continuously with no further furnace operation. and - Inte g rated control module dia g nostic LED is flashin g continuously.ContinuousFlashin g - Flame has been sensed with

40 no call for heat. - Short to g round
no call for heat. - Short to g round in flame sense circuit. - Limit circuit (primary or auxiliary) has opened five times durin g a sin g le call for heat. See note 1. - Insufficient conditioned air over the heat exchan g er. Cause may be blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower. - Loose or misconnected wirin g - Pressure switch circuit has opened five times durin g a sin g le call for heat. See note 3. - Pressure switch hose blocked, pinched, or misconnected. - Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower. - Incorrect pressure switch set point or malfunctionin g switch contacts. - Loose or misconnected wirin g - Circulator blower runnin g continuously with no further furnace operation and- Inte g rated control module dia g nostic LED is flashin g nine flashes.9 Flashes - Furnace is not operatin g and - Inte g rated control module dia g nostic LED is flashin g ei g ht flashes.8 Flashes7 Flashes - Normal furnace operation. but - Inte g rated control module dia g nostic LED is flashin g seven flashes. - Flame sense micro-amp si g nal is low. - Flame sensor is coated/oxidized. - Flame sensor incorrectly positioned in burner flame. - Lazy burner flame due to improper g as pressure, or combustion air. White-RodgersControl Only 7 HeatcraftControl Only 8 9 HeatcraftControl Only Corrective ActionCautions andNotes - Correct short at flame sensor or in flame sensor wirin g - Turn power OFF prior to repair. - Check filters and ductwork. For blocka g e . Clean filters or remove obstruction. - Check for proper circulation blower speed and performance. Correct speed or replace blower if necessary. - Check and correct wirin g - Turn power OFF prior to repair. - See Specification Sheet for allowable rise ran g e and proper circulator blower speed. - Check and correct pressure switch hose. - Check flue and/or inlet air pipin g for blocka g e, proper len g th, elbows and termination. Check drain system. - Verify proper pr

41 essure switch set point and contact moti
essure switch set point and contact motion. - Check and correct wirin g - Sand flame sensor if coated/oxidized. Inspect for proper sensor ali g nment. - Check inlet air pipin g for blocka g e, proper len g th, elbows, and termination. - Check for proper g as pressures. - Turn power OFF prior to repair. - Sand flame sensor with emery cloth. - See "Flue and Combustion Air Pipe" section for pipin g details. - See ratin g plate for proper g as pressures. - Turn power OFF prior to repair. - See "Flue and Combustion Air Pipe" section for pipin g details. - Replace pressure switch with proper replacement part. 40 •Wiring. Check electrical connections for tightness and/or corrosion. Check wires for damage.•Filters.FILTERS CAUTION 1.Turn OFF electrical power to furnace.2.Remove blower compartment door.3.Push back and up on the wire filter retainer to release4.Slide filter forward and out.5.Replace filter by reversing the procedure for removal.1.Turn OFF electrical power to furnace.2.Remove the blower compartment door.3.Grasp the lower portion of the filter and lift up.4.Angle the filter towards the blower until the filter is clear5.Lower the filter down and pull outward.5.Replace the filter by reversing the procedure for re-1.Automatic reset. The integrated control module will2.Manual power interruption. Interrupt 115 volt power to3.Manual thermostat cycle. Lower the thermostat so that0 - 20 seconds. WARNING To avoid electrical shock, injury or death,disconnect electrical power beforeIf you must handle the igniter, handle withcare. Touching the igniter element withpremature failure. Only a qualified servicershould ever handle the igniter.ANNUAL INSPECTIONThe furnace should be inspected by a qualified installer, orservice agency at least once per year. This check should be•Flue pipe system. Check for blockage and/or leakage.Check the outside termination and the connections at•Combustion air intake pipe system (where applicable).•Heat exchanger. Check for corrosion and/or buildup•Burners. Check for proper ignition, burner flame, and•Drainage sy

42 stem. Check for blockage and/or leakage
stem. Check for blockage and/or leakage. 41 Front of FurnaceBlowerGrab HereAnd Lift Filter Front of FurnaceBlower a. Lift filter above bottom b. Tilt filter to clear rail.rail Front of FurnaceBlower Front of FurnaceBlower c.Lower filter below top d. Pull filter out.1.Turn OFF electrical power to furnace.2.Remove access door in ductwork above furnace.3.Remove filters.4.Replace filters by reversing the procedure for removal.5.Turn ON electrical power to furnace.1.Turn OFF electrical power to furnace.2.Remove filter(s) from the central return register or3.Replace filter(s) by reversing the procedure for re-4.Turn ON electrical power to furnace.1.Turn OFF the electrical power and gas supply to the2.Disconnect the gas line and remove the burner/ mani-fold assembly by removing the screws securing the3.Disconnect the flue pipe system from the induced draft4.Remove the induced draft blower and, drain and pres-sure tap hoses from the recuperator coil front cover.5.Remove the recuperator coil front cover to expose the6.Remove the recuperator coil turbulators individually by7.Clean the recuperator coil tubes using a long handle8.Clean the primary heat exchanger tubes using a wirebrush attached to a length of high grade stainless steelcable, such as drain cleanout cable. Attach a variablespeed reversible drill to the other end of the cable.of the heat exchanger tubes. While reversing the drill,work the cable in and out several times to obtainsufficient cleaning. Repeat for each tube. 42 9.Clean residue from furnace using a vacuum cleaner.10.Replace the parts removed in the previous steps in11.Turn on electrical power and gas to furnace. Check for12.Severe heat exchanger fouling is an indication of anXX. Before Leaving an InstallationXXI. Repair and Replacement PartsGas ValveBlower MotorGas ManifoldBlower WheelNatural Gas OrificeBlower Mounting BracketPropane Gas OrificeBlower CutoffIgniterBlower HousingFlame SensorCapacitorRollout Limit SwitchHeat ExchangerPrimary Limit SwitchRecuperator CoilAuxiliary Limit SwitchCoil Front CoverPressure SwitchIntegrated Control ModuleInduced Draft Blowe