RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNELAs a professional installer you have an obligation toknow the product better than the customer. Thisincludes all safety precautions and related items.

Prior to actual installation, thoroughly familiarizeyourself with this Instruction Manual. Pay specialattention to all safety warnings. Often during installationor repair it is possible to place yourself in a positionwhich is more hazardous than when the unit is inoperation.

Remember, it is your responsibility to install the productsafely and to know it well enough to be able to instructa customer in its safe use.

Safety is a matter of common sense...a matter ofthinking before acting. Most dealers have a list ofspecific good safety practices...follow them.

The precautions listed in this Installation Manual shouldnot supersede existing practices but should beconsidered as supplemental information.

AmanaFayetteville, TN 37334

A higher standard of comfortHeating ¡ Air Conditioning

®

October 1997(1) 10759818

Amana Forced Air Central Furnace Design Complies With RequirementsEmbodied in The American National Standard / National Standard of CanadaShown Below.

ANSI Z21.47•CAN/CGA-2.3 Central Furnaces

GUI* & GCI*Gas Fired Warm Air

Furnace

Installation InstructionsAffix this manual, Specification Sheet and Users

Information Manual adjacent to the furnace.

Table of Contents

To The Owner .............................................................................. 2To The Installer ............................................................................ 2

I. Safety and Unit Location..................................................... 3II. General Information ............................................................. 4III. Air Requirements ................................................................. 4IV. Category I Venting (Vertical Venting) ................................. 6V. Masonry Chimneys .............................................................. 8

VI. Gas Piping .......................................................................... 12VIl. Electrical Wiring ................................................................. 16VIlI. Circulating Air and Filters ................................................ 18IX. Sequence of Operation (Integrated Ignition Control) .... 21X. Start-Up, Adjustments, and Checks ................................ 21

XI. Maintenance ....................................................................... 27

2

WARNINGIf the information in these instructions isnot followed exactly, a fire or explosionmay result causing property damage,personal injury or loss of life.– Do not store or use gasoline or other

flammable vapors and liquids in thevicinity of this or any other appliance.

– What to do if you smell gas:• Do not try to light any appliance.• Do not touch any electrical switch; do

not use any phone in your building.• Immediately call your gas supplier

from a neighbor’s phone. Follow thegas supplier’s instructions.

• If you cannot reach your gas supplier,call the fire department.

– Installation and service must beperformed by a qualified installer, serviceagency or the gas supplier.

WARNINGShould overheating occur or the gas supplyfail to shut off, turn off the manual gascontrol valve to the furnace before shuttingoff the electrical supply.

To The OwnerIt is important that you fill out the owner’s registration cardand mail it today. This will assist Amana in contacting youshould any service or warranty information change in thefuture. When filling in the registration card, be sure toinclude the Model, Manufacturing and Serial Numbers,plus the installation date.

Your warranty certificate is also supplied with the unit.Read the warranty carefully and note what is covered.Keep the warranty certificate in a safe place, so you canfind it, if necessary.

If additional operating instructions are required, call thedealer where the purchase was made.

To The InstallerBefore installing this unit, please read this manual tofamiliarize yourself on the specific items which must beadhered to, such as maximum external static pressure tounit, air temperature rise, minimum or maximum CFM,motor speed connections, and venting. These furnacesare designed for Category I venting only.

WARNINGTo prevent possible death or personal injurydue to asphyxiation, Amana Non-Condensing Gas Fired Warm Air Furnacesmust be Category I vented. Do not vent anyof these furnaces using Category III venting.

Keep this literature in a safe place for futurereference.

3

and masonry acid washing materials. If the furnace isinstalled near an area which will be frequently con-taminated by these substances, the furnace shouldbe sealed from this area so that little contaminated aircan reach the furnace. The furnace must still have anadequate supply of combustion air, either from anearby uncontaminated room or from outdoors. Fordetails, see “AIR REQUIREMENTS” Section III.

• Provisions must be made for venting combustionproducts outdoors through a proper venting system.The length of flue pipe could be a limiting factor inlocating the furnace.

• When installed horizontally, the furnace must be in-stalled with the access doors vertical so that theburners fire horizontally into the heat exchanger. Theunit cannot be installed with the access doors on topor bottom. (See Specification Sheet)

• Allow clearances from the enclosure as shown onSpecification Sheet for fire protection, proper opera-tion, and service access. These clearances must bepermanently maintained. The combustion and venti-lating air openings in the front and top panels of thefurnace must never be obstructed.

• This furnace shall not be connected to a chimney flueserving a separate appliance designed to burn solidfuel.

• When the furnace is used in connection with a coolingunit, the furnace must be upstream of, or in parallelwith, the cooling unit. For details see Section VIlI.

• On Counterflow Installations, the air conditioning coilmust be downstream from the heat exchanger of thefurnace.

• Counterflow Installation over a noncombustible floor.Before setting the furnace over the plenum opening,insure the surface around the opening is smooth andlevel. A tight seal should be made between the furnacebase and floor by using a silicone rubber caulkingcompound or cement grout.

• Counterflow Installation over a combustible floor. Ifinstallation over a combustible floor becomes neces-sary, use an accessory subbase as shown on theSpecification Sheet. Follow the instructions with thesubbase for proper installation. Do not install thefurnace directly on carpeting, tile, or other combustiblematerial other than wood flooring. (Note: The subbasewill not be required if an air conditioning coil is installedbetween the supply air opening on the furnace and thefloor.)

• The furnace must be level. If the furnace is to be set ona floor that may become wet or damp at times, thefurnace should be supported above the floor on aconcrete base sized approximately 1-1/2" larger thanthe base of the furnace.

ADDITIONAL LOCATION CONSIDERATIONS• The furnace should be as centralized as is practical

with respect to the air distribution system.• Do not install the furnace directly on carpeting, tile, or

combustible material other than wood flooring.• When suspending the furnace from rafters or joists,

use 3/8" threaded rod and 2” x 2” x 3/8” angle as shownon the Specification Sheet. The length of the rod willdepend on the application and clearance necessary.

I. Safety and Unit Location

WARNINGTo prevent personal injury or death due toimproper installation, adjustment,alteration, service, or, maintenance referto this manual or for additional assistanceor information consult a qualified installer,service agency or the gas supplier.

WARNINGThis product contains or produces achemical or chemicals which may causeserious illness or death and which areknown to the State of California to causecancer, birth defects or other reproductiveharm.

WARNINGTo prevent possible death, personal injuryor equipment damage due to fire, thefollowing points must be observed wheninstalling the unit.

WARNINGTo prevent possible death, personal injuryor property damage due to electrical shock,the furnace must be located to protect theelectrical components from water.

NOTE: This unit must not be used as a “constructionheater” during the finishing phases of construction on anew structure. This type of use may result in prematurefailure of the unit due to extremely low return air tempera-tures and exposure to corrosive or very dirty atmospheres.

WARNINGTo prevent possible death, personal injuryor property damage, do not install this unitin a mobile home, trailer or recreationalvehicle.

ADDITIONAL SAFETY CONSIDERATIONS• This furnace is approved for Category I Venting only.• When the furnace is heating, the temperature of the

return air entering the furnace must be between 55°Fand 100°F.

• Do not install the furnace where the combustion air isexposed to the following substances: permanent wavesolutions, chlorinated waxes or cleaners, chlorinebased swimming pool chemicals, water softeningchemicals, deicing salts or chemicals, carbon tetra-chloride, halogen type refrigerants, cleaning solutions(such as perchloroethylene), printing inks, paint re-movers, varnishes, hydrochloric acid, cements andglues, antistatic fabric softeners for clothes dryers,

4

• When installed in a residential garage, the furnacemust be positioned so the burners and ignition sourceare located not less than 18 inches (457 mm) above thefloor and protected from physical damage by vehicles.

II. General InformationWARNING

Possible death, personal injury or propertydamage due to fire, explosion, smoke, soot,condensation, electrical shock or carbonmonoxide may result from improperinstallation, repair, operation, ormaintenance on this product.

To ensure the furnace operates safely and efficiently, itmust be installed, operated and maintained in accordancewith these installation and operating instructions, all localbuilding codes and ordinances, or, in their absence, withthe latest edition of the National Fuel Gas Code, ANSIZ223.1*, and/or CAN/CGA B149 Installation Codes.

The rated heating capacity of the furnace should be greaterthan or equal to the total heat loss of the area to be heated.The total heat loss should be calculated by an approvedmethod or in accordance with “ASHRAE. Guide” or “ManualJ-Load Calculations” published by the Air ConditioningContractors of America.

*Obtain from: American National Standards Institute 1430Broadway New York, NY 10018

TRANSPORTATION DAMAGECheck the furnace for any shipping damage. If damage isfound, contact the company where the furnace was pur-chased.

While checking for transportation damage, remove all pack-aging material and dispose or recycle according to localcodes.

THERMOSTAT LOCATIONLocate the thermostat about 5 feet high on a vibration-freeinside wall, in an area having good air circulation

Do not install the thermostat where it may be affected by:

• drafts or dead spots behind door, in corners or undercabinets.

• hot or cold air from ducts.

• radiant heat from sun or appliances.

• concealed pipes and chimneys.

• unheated (uncooled) areas behind the thermostat,such as an outside wall.

Consult the instructions packaged with the thermostat formounting instructions.

III. Air Requirements

COMBUSTION AND VENTILATION AIR

WARNINGPossible death, personal injury or propertydamage may occur if the furnace and otherfuel-burning appliances are not providedwith enough fresh air for proper combustionand ventilation of flue gases. Most homesrequire outside air to be supplied into thefurnace area.

Improved construction and additional insulation in build-ings has reduced the heat loss, making these buildingsmuch tighter around doors and windows so air infiltration isminimal. This creates a problem supplying combustion andventilation air for gas fired and other fuel burning appli-ances. Use of appliances pulling air out of the house(clothes dryers, exhaust fans, fireplaces, etc.) increasesthis problem causing appliances to starve for air.

This furnace must use indoor air for combustion. It cannotbe installed as a direct vent (i.e., sealed combustion)furnace. The burner box is present only to help reducesound transmission from the burners to the occupied space.

AIR REQUIREMENTSMost homes will require outside air supplied to the furnacearea by means of ventilation grilles or ducts connectingdirectly to the outdoors or spaces open to the outdoors suchas attics or crawl spaces. The following information on airfor combustion and ventilation is reproduced from theNational Fuel Gas Code NFPA54/ANSI Z223.1 Section5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipmentinstalled in buildings and which require air for combustion,ventilation and dilution of flue gases from within the build-ing. They do not apply to (1) direct vent equipment which isconstructed and installed so that all air combustion isobtained from the outside atmosphere and all flue gasesare discharged to the outside atmosphere, or (2) enclosedfurnaces which incorporate an integral total enclosure anduse only outside air for combustion and dilution of fluegases.

(b) Equipment shall be installed in a location in which thefacilities for ventilation permit satisfactory combustion ofgas, proper venting and the maintenance of ambient tem-perature at safe limits under normal conditions of use.Equipment shall be located so as not to interfere with propercirculation of air. When normal infiltration does not providethe necessary air, outside air shall be introduced.

5

(c) In addition to air needed for combustion, process airshall be provided as required for: cooling of equipment ormaterial, controlling dew point, heating, drying, oxidation ordilution, safety exhaust, odor control, and air for compres-sors.

(d) In addition to air needed for combustion, air shall besupplied for ventilation, including all air required for comfortand proper working conditions for personnel.

(e) While all forms of building construction cannot becovered in detail, air for combustion, ventilation and dilutionof flue gases for gas utilization equipment vented by naturaldraft normally may be obtained by application of one of themethods covered in 5.3.3 and 5.3.4.

(f) Air requirements for the operation of exhaust fans,kitchen ventilation systems, clothes dryers, and fireplacesshall be considered in determining the adequacy of a spaceto provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces: Inunconfined spaces (see definition below) in buildings,infiltration may be adequate to provide air for combustionventilation and dilution of flue gases. However, in buildingsof tight construction (for example, weather stripping, heavilyinsulated, caulked, vapor barrier, etc.), additional air mayneed to be provided using the methods described in 5.3.3-b or 5.3.4.

Space, Unconfined. For purposes of this Code, a spacewhose volume is not less than 50 cubic feet per 1,000 BTUper hour of the aggregate input rating of all appliancesinstalled in that space. Rooms communicating directly withthe space in which the appliances are installed throughopenings not furnished with doors, are considered a part ofthe unconfined space.

5.3.3 Equipment Located in Confined Spaces: (a) All Airfrom Inside the Building: The confined space shall beprovided with two permanent openings communicatingdirectly with an additional room(s) of sufficient volume sothat the combined volume of all spaces meets the criteriafor an unconfined space. The total input of all gas utilizationequipment installed in the combined space shall be consid-ered in making this determination. Each opening shall havea minimum free area of 1 square inch per 1,000 BTU perhour of the total input rating of all gas utilization equipmentin the confined space, but not less than 100 square inches.One opening shall be within 12 inches of the top and onewithin 12 inches of the bottom of the enclosure. (Figure 1 )

Figure 1 Equipment Located in Confined Spaces; All

Air from Inside Building. See 5.3.3-a.

(b) All Air from Outdoors: The confined space shall beprovided with two permanent openings, one commencingwithin 12 inches of the top and one commencing within 12inches of the bottom of the enclosure. The openings shallcommunicate directly, or by ducts, with the outdoors orspaces (crawl or attic) that freely communicate with theoutdoors.

1. When directly communicating with the outdoors, eachopening shall have a minimum free area of 1 squareinch per 4,000 BTU per hour of total input rating of allequipment in the enclosure (Figure 2).

Figure 2Equipment Located in Confined Spaces; AllAir from Outdoors—Inlet Air from Ventilated

Crawl Space and Outlet Air to VentilatedAttic. See 5.3.3-b

2. When communicating with the outdoors through verti-cal ducts, each opening shall have a minimum free areaof 1 square inch per 4,000 BTU per hour of total inputrating of all equipment in the enclosure (See Figure 3).

6

Figure 3Equipment Located in Confined Spaces; AllAir from Outdoors Through Ventilated Attic.

See 5.3.3-b.

3. When communicating with the outdoors through hori-zontal ducts, each opening shall have a minimum freearea of 1 square inch per 2,000 BTU per hour of totalinput rating of all equipment in the enclosure. (Figure 4)

*If the appliance room is located against an outside wall and the air openings communicatedirectly with the outdoors, each opening shall have a free area of not less than one square inchper 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

Figure 4Equipment Located in Confined Spaces; All

Air from Outdoors. See 5.3.3-b.

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to whichthey connect. The minimum dimension of rectangularair ducts shall not be less than 3 inches.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily governwhen special engineering, approved by the authority hav-ing jurisdiction, provides an adequate supply of air forcombustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall begiven to the blocking effect of louvers, grilles or screensprotecting openings. Screens used shall not be smallerthan 1/4 inch mesh. If the area through a design of louveror grille is known, it should be used in calculating the sizeof opening required to provide the free area specified. If thedesign and free area is not known, it may be assumed thatwood louvers will have 20-25 percent free area and metallouvers and grilles will have 60-75 percent free area.Louvers and grilles shall be fixed in the open position orinterlocked with the equipment so that they are openedautomatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Ex-hausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothesdryers, or fireplaces may create conditions requiring spe-cial attention to avoid unsatisfactory operation of installedgas utilization equipment.

IV. Category I Venting (Vertical Venting)

WARNINGTo prevent possible death or personal injurydue to asphyxiation, Amana Non-Condensing Gas Fired Warm Air Furnacesmust be Category I vented. Do not vent anyof these furnaces using Category III venting.

Category I Venting is venting at a non-positive pressure. Afurnace vented as Category I is considered a fan-assistedappliance and does not have to be “gas tight.” NOTE:Single stage gas furnaces with induced draft blowers drawproducts of combustion through a heat exchanger allowingin some instances common venting with natural draft appli-ances (i.e. water heaters).

All installations must be vented in accordance with NationalFuel Gas Code, NFPA 54/ANSI Z223.1 - latest edition. InCanada, the furnaces must be vented in accordance withthe National Standard of Canada, CAN/CGA B149.1 and .2- latest editions and amendments.

NOTE: The vertical height of the Category I venting systemmust be at least as great as the horizontal length of theventing system.

WARNINGTo prevent possible death or personal injurydue to asphyxiation, common venting withother manufacturer’s induced draftappliances is not allowed.

Common venting with specific Amana Category I 80%furnaces is allowed with the addition of a common vent kit(CVK) for each appliance. Contact the local installing dealer,distributor or Amana directly for more information.

7

The minimum vent diameter for the Category I ventingsystem is as shown below:

MINIMUM VENT DIAMETERMODEL GUI* GCI*

45 3 Inch 4 Inch70 4 Inch 4 Inch90 4 Inch 4 Inch

115 5 Inch 5 Inch140 5 Inch 5 Inch

Under some conditions, larger vents than those shownabove may be required or allowed.

When an existing furnace is removed from a venting systemserving other appliances, the venting system may be toolarge to properly vent the remaining attached appliances.

The following steps shall be followed with each applianceremaining connected to the common venting system placedin operation, while the other appliances remaining con-nected to the common venting system are not in operation.

(a) Seal any unused openings in the common ventingsystem.

(b) Visually inspect the venting system for proper size andhorizontal pitch as required in the National Fuel GasCode, ANSI Z223.1, or the CAN/CGA B149 InstallationCodes and these instructions. Determine there is noblockage or restriction, leakage, corrosion or otherdeficiencies which could cause an unsafe condition.

(c) Where practical, close all building doors, windows, andall doors between the space where the appliancesremain connected to the common venting system arelocated and other spaces of the building. Turn on all gasappliances not connected to the common venting sys-tem and operate on high speed all exhaust fans (rangehoods and bathroom), except summer exhaust fans.Close fireplace dampers.

(d) Following the lighting instructions, place the furnacebeing inspected in operation. Adjust thermostat soappliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5minutes of main burner operation. Use the flame of amatch or candle, or smoke from a cigarette, cigar, orpipe.

(f) After it has been determined that each appliance re-maining connected to the common venting systemproperly vents when tested as outlined above, returndoors, windows, exhaust fans, fireplace dampers andany other gas-burning appliance to their previous con-ditions of use.

(g) If improper venting is observed during any of the abovetests, the common venting system must be corrected inaccordance with the latest edition of the National FuelGas Code, ANSI Z223.1.

When resizing any portion of the common venting system,use the appropriate table in Appendix G in the latest editionof the National Fuel Gas Code, ANSI Z223.1.

Upflow or Horizontal units are shipped with the induceddraft blower discharging from the top of the furnace. (“Top”is as viewed for an upflow installation.) The induced draftblower can be rotated 90 degrees counterclockwise forCategory I venting, with the airflow horizontal left to right(Figure 5). For horizontal installations, a 4-inch single wallpipe can be used to extend the induced draft blower outlet

1/2” beyond the furnace cabinet. Vent the furnace inaccordance with the National Fuel Gas Code, NFPA54/ANSI Z223.1 - latest edition. In Canada, vent the furnacein accordance with the National Standard of Canada, CAN/CGA B149 - latest editions and amendments.

Figure 5Upflow Rotated Induced Draft Blower

Counterflow units are shipped with the induced draftblower discharging from the top of the furnace. (“Top” asviewed for an counterflow installation.) The induced draftblower can be rotated 90 degrees counterclockwise forCategory I venting, with the airflow horizontal right to left(Figure 6). For horizontal installations, a 3-inch B-vent pipecan be used to extend the induced draft blower outlet 1/2”beyond the furnace cabinet. Vent the furnace in accor-dance with the National Fuel Gas Code, NFPA54/ANSIZ223.1 - latest edition. In Canada, vent the furnace inaccordance with the National Standard of Canada, CAN/CGA B149 - latest editions and amendments.

SupplyAir

ReturnAir

Vent

Figure 6Counterflow Rotated Induced Draft Blower

To rotate the induced draft blower counterclockwise pro-ceed as follows:

1. Disconnect electrical power from furnace.

WARNINGTo prevent death or personal injury due toelectrical shock, disconnect electricalpower.

2. Remove the round cutout from the side of the furnace.

Note: The assembly, starting from the outside, isinduced draft blower, outer gasket, rotation plate, innergasket, partition panel (See Figure 7).

8

Figure 7Blower Assembly

3. Remove and save the four screws which hold therotation plate on the partition panel. Note that one of thescrews which hold the induced draft blower on therotation plate needs to be removed.

4. Turn the rotation plate 90 degrees counterclockwise.The inner gasket must turn with the rotation plate.

5. Reinstall the rotation plate on the partition panel, usingthe four screws removed in step 3. Tighten screws toprovide an airtight seal.

6. Make sure all wires are at least one inch from flue pipe.Relocate junction box to right side of cabinet if nec-essary. Refer to Section Vl for instructions.

WARNINGTo prevent death or serious illness tobuilding occupants due to flue productsleaking into the building, proper installationof gaskets and screws is essential forproviding a gas tight seal between thepartition panel and the induced draft blower.

V. Masonry Chimneys

WARNINGPossibility of property damage, personalinjury, or death - Damaging condensationcan occur inside masonry chimneys whena single fan assisted Category I appliance(80% AFUE furnace) is vented withoutadequate dilution air. Do not connect an80% furnace to a masonry chimney unlessthe furnace is common vented with a drafthood equipped appliance, or the chimneyis lined with a metal liner or Type B metalvent. All installations using Masonrychimneys must be sized in accordance withthe appropriate Venting Tables.If an 80% furnace is common vented with adraft hood equipped appliance, the potentialfor condensation damage may still existwith extremely cold conditions, long ventconnectors, exterior chimneys, or anycombination of these conditions. The riskof condensation damage is best avoided byusing the masonry chimney as a pathwayfor properly sized metal liner or Type Bmetal vent.

WashCrown

Clay Tile Size: 8" x 8" x12"(Each x 24" Length)

Clay Tile Size Generally12" x 12" (24" Length)

1/2" to 1" Air Space

Second Floor

First Floor

Attic Floor

Roof Line

ThroatDamper

Breech

Clean OutFan AssistedForced AirFurnace

Natural DraftWater Heater

Water HeaterVent Connector

Basement Floor

F.A.F. VentConnector

Figure 8Typical Multiple Flue Clay Tile Chimney

9

CHECKLIST SUMMARYThis checklist serves as a summary of the items to bechecked before venting an Air Command 80 furnace into amasonry chimney. In addition, we recommend that a quali-fied serviceman use this checklist to perform a yearlyinspection of the furnace venting system.

This checklist is only a summary. For detailed informationon each of the procedures mentioned, see the paragraphreferenced with each item.

This inspection is based upon a draft topical report, “Ma-sonry Chimney Inspection and Relining”, issued by the GasResearch Institute. While not yet finalized, we believe thisreport represents the best information on this subject whichis currently available.

Yes

Proper Chimney Termination?

(Check 1)

Line, terminate with listed vent cap

(Fix 1)

Chimney channel free of solid and

liquid fuel appliances?

(Check 2)

Change venting arrangements

(Fix 2)

Crown in good condition? (Check 3)

Rebuild crown (Fix 3)

and /or Reline (Fix 4)

Cleanout free of debris?

(Check 4)

Reline(Fix 4)

Liner in good condition?(Check 5)

Dilution air available?(Check 6)

Complete the installation.(Check 7)

Reline(Fix 4)

Reline(Fix 4)

No

Yes

Yes

Yes

Yes

No

No

No

No

No

Yes

CHECK 1 - PROPER CHIMNEY TERMINATION.A masonry chimney used as a vent for gas fired equipmentmust extend at least three feet above the highest pointwhere it passes through the roof. It must extend at least twofeet higher than any portion of a building within a horizontaldistance of 10 feet. In addition, the chimney must terminateat least 3 feet above any forced air inlet located within 10feet. The chimney must extend at least five feet above thehighest connected equipment draft hood outlet or fluecollar.

If the chimney does not meet these termination require-ments, but all other requirements in the checklist can bemet, it may be possible for a mason to extend the chimney.If this will not be practical, see Fix 1, page 12.

2' Min. 2' Min.3' Min.

10' or Less

Wall orParapet

Chimney

Ridge2' Min.

10' or Less

3' Min.

Chimney

Figure 9Termination 10 Feet Or Less From Ridge,

Wall or Parapet

10

Wall orParapet

Chimney

NOTE: No Height above parapet required when distancefrom walls or parapet ismore than 10 feet.

More than 10'

3' Min.

Ridge

3' Min.

Chimney

2' Min.

More than 10'

10"

Height above anyroof surface within10 feet horizontally.

Figure 10Termination More Than 10 Feet From Ridge,

Wall or Parapet

CHECK 2 - ANY SOLID OR LIQUID FUELAPPLIANCES VENTED INTO THIS CHIMNEYCHANNELSolid fuel appliances include fireplaces, wood stoves, coalfurnaces, and incinerators.

Liquid fuel appliances include oil furnaces, oil-fired boilersand oil-fired water heaters.

Appliances which burn propane (sometimes referred to asLP (liquefied petroleum)) gas are considered gas-firedappliances.

CHECK 3 - CHIMNEY CROWN CONDITION.Damage from condensate usually shows up first in thecrown. If any of the following trouble signs are present, thecondition of the crown is not satisfactory:

a) Crown leaning

b) Bricks missing

c) Mortar missing

d) Tile liner cracked

e) No tile liner

f) Salt staining at mortar pints. (White stains, and mortarbecomes sandy and/or erodes.)

For problems a, b, or c, see Fix 3. If problems d, e, or f arepresent, see Fix 4. IMPORTANT: It may be necessary tofollow both Fix 3 and Fix 4.

CHECK 4 - DEBRIS IN CLEANOUTA cleanout (dropleg) must be present such that the upperedge of the cleanout cover is at least 12 inches below thelower edge of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blockedby debris. If no cleanout is present, the chimney must berefined (Fix 4).

Remove the cleanout cover, and examine the cleanout fordebris. If significant amounts of any of the following arefound:

• Fuel oil residue

• Bricks

• Mortar or sand

• Pieces of the tile liner

• Rusted pieces of the metallic liner

reline the chimney (Fix 4).

CHECK 5 - LINER CONDITION.If a metal liner is present, it must be checked. It cannot beassumed that all existing metal liners are correctly installedand in good condition.

Remove the lowest existing vent connector, and examinethe inside of the elbow or tee at the base of the liner. A smallamount of soot may be considered acceptable, providedthe installer vacuums it away. If rusted pieces of the linerhave collected here, the metal liner must be removed andreplaced (Fix 4).

Next, gently tap the inside of the liner with a phillipsscrewdriver. If the screwdriver perforates the liner, or if thetapping does not sound like metal hitting metal, the linermust be removed and replaced (Fix 4).

Remember that all appliances must be vented inside theliner. Venting one appliance inside the liner and anotherappliance outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner.B vent must be supported so as to not come into directcontact with the chimney walls or tile liner. If it is not, it canprobably be rehung so as to be acceptable. A thimble or firestop may be helpful here.

Flexible liners should be hung straight or nearly straight. Ifit is spiraled in the chimney and in good condition, it shouldbe rehung. To do this, break the top seal; pull up and cut offthe excess liner length, and refit the top seal. Use cautionwhen doing this, as the cut edges of flexible liners may besharp.

The surfaces of the liner must be physically sound. If gapsor holes are present, the metal liner must be removed andreplaced (Fix 4).

Finally, confirm that the metallic liner is the correct size forthe appliances to be installed. Use the GAMA tables andrules.

If a metal liner is not present, a clay tile liner must bepresent, or the chimney must be lined (Fix 4).

11

Use a flashlight and small mirror at the cleanout or ventconnector to inspect the clay tile liner. If any of the followingproblems are present:

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or ventconnectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than anapproved fire clay tile

reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to dothis from the cleanout. The liner must be at least as large asthe minimum size established by the tables in National FuelGas Code, NFPA 54/ANSI Z223.1 - latest edition and in theNational Standard of Canada, CAN/CGA B149.1 and .2 -latest editions and amendments. If the liner is too small ortoo large, then the chimney must be relined (Fix 4).

CHECK 6 - DILUTION AIR.If gas-fired appliances are to be vented into a clay tile liner,a source of dilution air is required.

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through thedraft hood of a natural draft appliance only if the appliance’svent connector does not include a vent damper.

If dilution air will not be available, the chimney must berelined (Fix 4).

CHECK 7 - COMPLETE THE INSTALLATION.If Checks 1 through 6 have been satisfactory, and the lineris an acceptable size as determined by the tables inNational Fuel Gas Code, NFPA 54/ANSI Z223.1 - latestedition and in the National Standard of Canada, CAN/CGAB149.1 and CAN/CGA B149.2 - latest editions and amend-ments, then the clay tile liner can probably be used as a ventfor the gas appliances. However, the installer must keep inmind the following factors which may render the tile linerunsuitable for use as a vent:

• Extremely cold weather

• Long vent connectors

• Masonry chimneys with no air gap between the linerand the bricks. (In practice, this can be difficult todetect.)

• Exterior chimneys (The tables in National Fuel GasCode, NFPA 54/ANSI Z223.1 - latest edition and in theNational Standard of Canada, CAN/CGA B149.1 andCAN/CGA B149.2 - latest editions and amendmentsassume interior chimneys.)

If, in the judgment of the local gas utility, installer, and/orlocal codes; one or more of the above factors is likely topresent a problem, the chimney must be relined (Fix 4).

FIX 1 - LINER TERMINATION.Any cap or roof assembly used with a liner must beapproved by the liner manufacturer for such use. The linerand cap/roof assembly must then terminate above the roofin accordance with the manufacturer’s instructions.

In some cases, a shorter extension above the roof may bepossible with a liner than would be required with a masonrychimney.

For further information on relining, see Fix 4.

FIX 2 -CHANGE VENTING ARRANGEMENTSIf the masonry chimney has more than one channel, it maybe possible to vent the gas appliances into one channel andvent the solid or liquid fuel appliance(s) into anotherchannel(s). Do not vent an Air Command 80 inside of ametal liner with other appliances vented outside the liner.

Alternatively, the homeowner may agree to discontinue useof the fireplace (solid fuel appliance). If so, the tile liner mustbe cleaned to remove creosote buildup. The fireplaceopening must then be permanently sealed.

If oil-fired appliance(s) are being replaced by gas-firedappliance(s), the tile liner must first be cleaned to removethe fuel oil residue.

If none of the above options is practical, the Air Command80 may need to be vented vertically with a B Vent.

Under some conditions an Air Command 90 or 95 could beinstalled rather than an Air Command 80. The Air Com-mand 90 or 95 can be vented horizontally or verticallythrough PVC pipe.

FIX 3 - REBUILD THE CROWN.If the chimney crown is damaged, a qualified mason mustrepair it in accordance with nationally recognized buildingcodes or standards. One such standard which may bereferenced is the Standard for Chimneys, Fireplaces, Vents,and Solid Fuel Burning Appliances, ANSI/NFPA 211.

FIX 4 - RELINING.Relining options include B vent and flexible liners.

If the chimney has diagonal offsets, B vent probably cannotbe used.

If B vent is to be used, it must be supported adequately.Supports (such as fire stops or thimbles) must be used toprevent the B vent from coming into direct contact with thetile liner or chimney walls. Direct contact would result inhigher heat loss, with an increased possibility of poorventing system performance.

It is not acceptable to vent one appliance inside the B ventand other appliances outside. The excess space betweenthe B vent and the chimney walls must be covered at the topof the chimney by a weatherproof, corrosion resistantflashing.

The B vent should then be topped with a listed vent cap. Thelisted vent cap will, when installed per the manufacturer’sinstructions, prevent problems due to rain, birds, or windeffects.

12

A B-vent installed as described in this section is consideredto be an enclosed vent system, and the sizing tables inNational Fuel Gas Code, NFPA 54/ANSI Z223.1 - latestedition and in the National Standard of Canada, CAN/CGAB149.1 and CAN/CGA B149.2 - latest editions and amend-ments may be used.

If a flexible liner is to be used, it must be made of the propermaterials:

• For most residential applications, an aluminum linershould be acceptable.

• If the combustion air supplied to the furnace will becontaminated with compounds containing chlorine orfluorine, a liner of AL294C stainless steel should beused. Common sources of chlorine and fluorine com-pounds include indoor swimming pools and chlorinebleaches, paint strippers, adhesives, paints, varnishes,sealers, waxes (which are not yet dried) and solventsused during construction and remodeling. Variouscommercial and industrial processes may also besources of chlorine/fluorine compounds.

• Heavier gauge 300 and 400 series stainless steelliners were developed for use with oil or solid fuelappliances. They are not suitable for use with gas-firedappliances. Flexible liners specifically intended andtested for gas applications are listed in the UL “Gas andOil Equipment Directory”. (UL Standard 1777).

For sizing of flexible liners, see Note 22 and the tables inthe National Fuel Gas Code, NFPA 54/ANSI Z223.1 -latest edition and in the National Standard of Canada,CAN/CGA B149.1 and CAN/CGA B149.2 - latest editionsand amendments.

To install the liner, read and follow the liner manufacturer’sinstructions and your local codes. Excess liner lengthshould be pulled out of the chimney and cut off. Use cautionwhen doing this, as the cut edges of flexible liners may besharp. Do not spiral excess liner inside of the chimney.Support the liner as recommended by the liner manufac-turer.

Some manufacturers of flexible liners offer an insulationsleeve designed to be added to the liner before it is installedin the chimney. (Poured insulation, either vermiculite orother materials, is no longer recommended.) Insulation willneed to be added to the flexible liner if:

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

• The previous liner was properly sized and installed,and suffered from condensation damage.

• It is required by your local building codes.

Even if none of those three conditions exist which requireadditional liner insulation, the installer may wish to con-sider it if:

• The local climate is very cold

• The chimney is very tall

• The vent connectors used are very long or have a largenumber of elbows

• Local experience indicates that flexible liners installedwithout insulation are likely to have condensationproblems.

Insulation must be selected and installed in accordancewith the liner manufacturer’s instructions.

Finally, cap the chimney and terminate the liner in accor-dance with the liner manufacturer’s instructions.

VI. Gas PipingThe rating plate is stamped with the model number, type ofgas and gas input rating. Make sure the furnace is equippedto operate on the type of gas available.

Inlet Gas PressureNatural Min. 5.0" W.C., Max. 10.0" W.C.Propane Min. 11.0" W.C., Max. 14.0" W.C.

Inlet gas pressure must not exceed the maximum valueshown in table above.

NOTE: Adjusting the minimum supply pressure below thelimits in the above table could lead to unreliable ignition.

Gas input to the burners must not exceed the rated inputshown on the rating plate. Overfiring of the furnace couldresult in premature heat exchanger failure. Gas pressuresin excess of 14 inches water column could result in perma-nent damage to the gas valve.

IMPORTANT NOTE: The furnace will naturally derate itselfwith altitude. Do not attempt to increase the firing rate bychanging orifices or increasing the manifold pressure. Thiscan cause poor combustion and equipment failure.

At all altitudes, the manifold pressure must be within 0.3inches WC of that listed on the “Specification Sheet” for thefuel used. At all altitudes and with either fuel, the airtemperature rise must be within the range listed on thefurnace nameplate.

GAS PIPINGIMPORTANT NOTE: To avoid possible unsatisfactory op-eration or equipment damage due to underfiring of equip-ment, do not undersize the natural/propane gas piping fromthe meter/tank to the furnace. Include all appliances whichmay be operated simultaneously when sizing a trunk line.

The gas pipe supplying the furnace must be properly sizedbased on gas flow required, specific gravity of the gas andlength of the run. The gas line installation must comply withlocal codes, or in the absence of local codes, with the latestedition of the National Fuel Gas Code ANSI Z223.1.

Natural Gas Capacity of PipeIn Cubic Feet of Gas Per Hour (CFH)

Length of Nominal Black Pipe SizePipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 160020 92 190 350 730 110030 73 152 285 590 98040 63 130 245 500 76050 56 115 215 440 67060 50 105 195 400 61070 46 96 180 370 56080 43 90 170 350 53090 40 84 160 320 490

100 38 79 150 305 460(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on0.60 Specif ic Gravity Gas)

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

13

NATURAL GAS CONNECTIONRefer to Figure 11 for the general layout at the furnace. Thefollowing rules apply:

1. Use black iron or steel pipe and fittings for the buildingpiping.

2. Use pipe joint compound on male threads only. Pipejoint compound must be resistant to the action of thefuel used.

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it canenter the gas valve. The drip leg must be a minimum ofthree inches long.

5. Use two pipe wrenches when making connection to thegas valve to keep it from turning. The orientation of thegas valve on the manifold must be the same as shippedfrom the factory.

6. Within six feet of the unit, install a manual cutoff valvebetween the meter and the unit. If a union is installed,the union must be downstream of the manual shutoffvalve, between the shutoff valve and the furnace.

7. Tighten all joints securely.

8. The furnace must be connected to the building pipingby one of the following:

• Rigid metallic pipe and fittings.

• Semirigid metallic tubing and metallic fittings. Alumi-num alloy tubing must not be used in exterior loca-tions.

• Listed gas appliance connectors, used in accor-dance with the terms of their listing, must be com-pletely in the same room as the furnace.

• The connectors or semirigid tubing must be pro-tected against physical and thermal damage wheninstalled. Aluminum-alloy tubing and connectors mustbe coated to protect against external corrosion whenin contact with masonry, plaster or insulation or aresubject to repeated wettings by such liquids as water(except rain water), detergents or sewage.

Figure 11General Furnace Layout

UPFLOW INSTALLATIONSWhen the gas piping enters through the right side of thefurnace, the installer must supply the following fittings(starting from the gas valve):

• 90 degree elbow

• Close nipple

• 90 degree elbow

• Straight pipe to reach the exterior of the furnace (Fig-ures 12 & 13).

Figure 12Gas Inlet Through Furnace Right Side

A ground joint union, drip leg, and manual shutoff valvemust also be supplied by the installer. In some cases, theinstaller may also need to supply a transition piece from 1/2" to another pipe size.

Figure 13 Gas Inlet Through Furnace Bottom Side

(Upflow)

14

When the gas piping enters through the left side of thefurnace, the installer must supply the following fittings(starting from the gas valve):

• Straight pipe to reach the exterior of the furnace (Fig-ures 14 & 15).

• A ground joint union, drip leg, and manual shutoff valvemust also be supplied by the installer. In some cases,the installer may also need to supply a transition piecefrom 1/2 inch to another pipe size.

Figure 14 Gas Inlet Through Furnace Left Side

(Upflow)

Figure 15Gas Inlet Through Furnace Top Side

(Upflow)

The gas piping connections shown in Figures 13 and 14 arefor a furnace equipped for a right hand discharge. Adapta-tion for left hand discharge should be self explanatory.

Figure 16Horizontal Furnace

(Right Hand Discharge)

COUNTERFLOW INSTALLATIONSWhen the gas piping enters through the left side of thefurnace, the installer must supply a straight pipe to reachthe exterior of the furnace (Figure 17).

Figure 17Gas Inlet Through Left Side

(Counterflow)A ground joint union, drip leg, and manual shutoff valvemust also be supplied by the installer. In some cases, theinstaller may also need to supply a transition piece from1/2" to another pipe size.

When the gas piping enters through the right side of thefurnace, the installer must supply the following fittings(starting at the gas valve):

• 90 degree elbow.

• Close nipple.

• 90 degree elbow.

• Straight pipe to reach exterior of furnace (Figure 18).

A ground joint union, drip leg, and manual shutoff valvemust also be supplied by the installer. In some cases, theinstaller may also need to supply a transition piece from1/2 inch to another pipe size.

Figure 18Gas Inlet Through Right Side

(Counterflow)

“Left side” and “right side” above are as viewed for acounterflow installation. Adaptation for horizontal airflowshould be self explanatory.

15

CHECKING GAS PIPING

CAUTIONTo prevent personal injury or propertydamage due to fire, the followinginstructions must be performed regardinggas connections, pressure testing, locationof shutoff valve and installation of gaspiping.

Before placing in operation, leak test the unit and gasconnections. To avoid the possibility of explosion or fire,never use a match or open flame to test for leaks. Neverexceed specified pressures for testing. Higher pressuremay damage the gas valve and cause overfiring, resultingin heat exchanger failure.

This unit and shutoff valve must be disconnected from thegas supply piping system before supply piping systempressure testing with test pressures in excess of 1/2 psig(3.48 kPa).

This unit must be isolated from the gas supply system byclosing its manual shutoff valve before pressure testing ofgas supply piping system with test pressures equal to orless than 1/2 psig (3.48 kPa).

TANKS AND PIPING - PROPANE GAS UNITS

WARNINGTo prevent death, personal injury or propertydamage due to fire or explosion caused bya propane gas leak, install a gas detectingwarning device. Since rust can reduce thelevel of odorant in propane gas, a gasdetecting warning device is the only reliableway to detect a propane gas leak. Contact alocal propane gas supplier about installinga gas detecting warning device.

WARNINGAll metal inserts, screens or turbulatorsmust be removed from the heat exchangertubes when using propane gas. Failure tocomply could cause serious personal injuryor death. Failure to comply with thisrequirement will also void warrantycoverage.

All propane gas equipment must conform to the safetystandards of the National Board of Fire Underwriters (SeeNBFU Manual 58).

For satisfactory operation, propane gas pressure must be10 inch WC at the furnace manifold with all gas appliancesin operation. Maintaining proper gas pressure depends onthree main factors:

1. Vaporization rate, depending on temperature of theliquid, and “wetted surface” area of the container orcontainers.

2. Proper pressure regulation. (Two-stage regulation isrecommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and be-tween second stage regulator and the appliance. Pipesize will depend on length of pipe run and total load ofall appliances.

Complete information regarding tank sizing for vaporiza-tion, recommended regulator settings, and pipe sizing isavailable from most regulator manufacturers and propanegas suppliers.

Since propane gas will quickly dissolve white lead or moststandard commercial compounds, special pipe dope mustbe used. Shellac base compounds resistant to the actionsof liquefied petroleum gases such as Gasolac, Stalactic,Clyde’s or John Crane are satisfactory.

Refer to Figure 19 for typical propane gas installations.

Figure 19Propane Gas Installation (Typ.)

PROPANE GAS PIPING CHARTSSizing Between First and Second Stage RegulatorMaximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.Pipe or Nominal Pipe SizeTubing Tubing Size, O.D. Type L Schedule 40Length, 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"

Feet10 730 1,700 3,200 5,300 8,300 3,200 7,50020 500 1,100 2,200 3,700 5,800 2,200 4,20030 400 920 2,000 2,900 4,700 1,800 4,00040 370 850 1,700 2,700 4,100 1,600 3,70050 330 770 1,500 2,400 3,700 1,500 3,40060 300 700 1,300 2,200 3,300 1,300 3,10080 260 610 1,200 1,900 2,900 1,200 2,600

100 220 540 1,000 1,700 2,600 1,000 2,300125 200 490 900 1,400 2,300 900 2,100150 190 430 830 1,300 2,100 830 1,900175 170 400 780 1,200 1,900 770 1,700200 160 380 730 1,100 1,800 720 1,500

To convert to capacities at 15 psig settings - multiply by 1.130To convert to capacities at 5 psig settings - multiply by 0.879

16

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 or Nominal Pipe SizeTubing Tubing Size, O.D. Type L Schedule 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"

Feet10 39 92 199 329 501 935 275 567 1,071 2,205 3,30720 26 62 131 216 346 630 189 393 732 1,496 2,29930 21 50 107 181 277 500 152 315 590 1,212 1,85840 19 41 90 145 233 427 129 267 504 1,039 1,55950 18 37 79 131 198 376 114 237 448 913 1,41760 16 35 72 121 187 340 103 217 409 834 1,27580 13 29 62 104 155 289 89 185 346 724 1,066

100 11 26 55 90 138 255 78 162 307 630 976125 10 24 48 81 122 224 69 146 275 567 866150 9 21 43 72 109 202 63 132 252 511 787200 8 19 39 66 100 187 54 112 209 439 665250 8 17 36 60 93 172 48 100 185 390 590

*Data in accordance with NFPA pamphlet NO. 54

WARNINGTo prevent death, serious personal injuryor property damage due to fire or explosioncaused by a propane gas leak, install a gasdetecting warning device.

WARNINGIf the propane gas furnace is installed in abasement, an excavated area or a confinedspace, a warning device is required due to:

• Propane gas is heavier than air and anyleaking gas can settle in any low areasor confined spaces.

• Propane gas odorant may fade, makingthe gas undetectable except with awarning device.

If the presence of gas is suspected, followthe instructions on Page 2 of this manual.

VIl. Electrical Wiring

WARNINGTo prevent death or personal injury due toelectric shock, disconnect electrical powerbefore changing any electrical wiring.

CAUTIONWhen servicing controls, label all wiresbefore disconnecting. Wiring errors cancause improper and dangerous operation.After servicing is completed, always verifyproper operation.

The unit wiring harness is an integral part of the furnace.Field alteration to comply with electrical codes should notbe required.

Power supply to the furnace must be NEC Class 1, andmust comply with all applicable codes. The furnace must beelectrically grounded in accordance with the local codes or,in their absence, with the latest edition of the NationalElectrical Code, ANSI NFPA No. 70 and/or the CSA C22. 1Electrical Code. A fused disconnect must be provided andsized in accordance with the unit maximum overcurrentprotection.

Figure 20Typical Field Wiring

(24 VAC Control Circuit)

A 40 VA transformer and an integrated electronic controlare built into the furnace to allow use with most coolingequipment.

CAUTIONTo avoid the risk of electrical shock, wiringto the unit must be properly polarized andgrounded.

To provide more reliable sensing of flame, the ground wiremust run to the electrical panel.

Line voltage wiring must enter into the junction box pro-vided with the furnace.

As shipped, the junction box is attached to the left side ofthe furnace (as viewed for an upflow installation). If this issuitable for your installation, no changes are necessary.

If the line voltage wiring is to enter through the right side ofthe furnace (as viewed for an upflow installation), relocatethe junction box as shown in Figure 21.

Figure 21Junction Box (Left Side)

JunctionBox

17

WARNINGTo prevent death or personal injury due toelectric shock, disconnect electrical power.

1. Remove both doors from the furnace.

2. Remove and save the screws holding the junction boxto the left side of the furnace.

3. Disconnect the hose from the pressure switch. Leavethe other end attached to the induced draft blower.

4. Remove five wires entering junction box from splitgrommet in blower deck.

5. Swap locations of the two bushings in the junction box.

6. Rotate the junction box 180 degrees so the accesspanel continues to face forward. The open snap bush-ing should now be at the bottom.

7. Insert five wires into the split grommet on the right sideof the blower deck.

8. Insert the five wires through the open bushing in thebottom of the junction box.

9. Attach the junction box to the right side of the furnace,using the screws removed in step 2.

10. Reconnect the hose to the pressure switch.

11. Check the location of the pressure hose and all wiring.Confirm that it will not be damaged by heat from theburners or by the rotation of the fan. Also confirm thatwiring location will not interfere with filter removal orother maintenance.

After the junction box is in the desired location, use washersto connect field-supplied conduit to the junction box inaccordance with NEC and local codes. Connect hot, neu-tral, and ground wires as shown in the furnace wiringdiagram. The wires and ground screw are located in thefurnace junction box.

Low voltage wiring may enter through the right or left sideof the furnace (as viewed for an upflow installation - top orbottom for a horizontal installation). See Specification Sheetfor hole locations. Run the thermostat wires through eithergrommet in the blower deck (Figure 21).

Low voltage wires may be connected to the terminal strip asshown in Figure 22.

IMPORTANT NOTE: To avoid possible equipment mal-function, route the low voltage wires to avoid interferencewith filter removal or other maintenance.

Heating Fan Off Adjustments

Low VoltageTerminals

OR

ON

OFF

12

B1

B2

B3

B4

Pins (4)

Jumper

Style A

Style B

Figure 22Integrated Ignition Control

(Viewed in an Upflow Installation)

AIR CIRCULATION BLOWER FAN TIMINGAll items in this section refer to the air circulation blower fan,not to the induced draft blower. The timing sequence for theinduced draft blower is not adjustable.

When a call for cooling occurs, the circulation fan will comeon. It will remain on for 45 seconds after the call for coolingends. This fan timing is not adjustable.

During normal heating operation, the circulation fan willcome on 37 seconds after the gas valve opens. This timingis not adjustable.

As shipped, the circulation fan will remain on for 90 secondsafter the gas valve closes. If desired, this timing may beadjusted. The adjustment pins or switches are near the lowvoltage terminal strip (Figure 23).

60SecondDelay

12

ON

OF

F B1

B2

B3

B4

90SecondDelay

12

ON

OF

F B1

B2

B3

B4

120SecondDelay

12

ON

OF

F B1

B2

B3

B4

180SecondDelay

12

ON

OF

F B1

B2

B3

B4

Style A Style B

Switches viewed in an upflow installation.

Figure 23Heating Fan Off Adjustments

18

HEAT ANTICIPATOR SETTINGAdjust the heat anticipator in the room to obtain the propernumber of heating cycles per hour. The heat anticipator isa wire-wound adjustable heater that prevents the roomtemperature from “overshooting” the room thermostat set-ting. The heat anticipator must be set at 0.7 amps. The heatanticipator is part of the thermostat. If the thermostat failsfor any reason, replace the thermostat.

LINE VOLTAGE CONNECTION FOR OPTIONALHUMIDIFIER AND ELECTRONIC AIR CLEANERThe control module is equipped with line voltage accessoryterminals used for controlling the power to an optional field-supplied humidifier and/or electronic air cleaner.

Accessory Load Specification

Air Cleaner: 1.0 Amp max. at 120 VACHumidifier: 1.0 Amp max. at 120 VAC

Accessory Installation:

Follow the electronic air cleaner and humidifier manufactur-ers’ instructions for mounting and electrically groundingthese accessories. Check that the power supply to thefurnace has been disconnected. Wire the accessories tothe control module as shown below. All connections to thecontrol module are to be made through 1/4 inch femaleterminals.

If it is necessary to supply additional line voltage wiring tothe interior of the furnace, the wiring must comply with alllocal codes. This wiring must have a minimum temperaturerating of 105°C and must be routed away from the burnercompartment. All line voltage wire splices must be madeinside the furnace junction box.

Control Module

Coo

lH

eat

Par

kP

ark

Line

Tra

nsfo

rmer

EA

CH

um

Cir

Line

Tra

nsfo

rmer

EA

CH

um

Hot 120 VACNeutral

120 VAC

Air Cleaner

Humidifier

Optional Accessories{

Figure 24Line Voltage Connection for Accessories

Accessory Operation: The furnace control module ener-gizes the humidifier whenever the induced draft blower isenergized (when an air cleaner is installed on the system,the humidifier is not energized until the air cleaner isenergized). The control module energizes the air cleanerwhenever the air circulation blower is energized.

VIlI. Circulating Air and Filters

DUCTWORK - AIR FLOWDuct systems and register sizes must be properly designedfor the CFM and external static pressure rating of thefurnace. Ductwork should be designed in accordance withthe recommended methods of “Air Conditioning Contrac-tors of America” Manual D.

A duct system must be installed in accordance with Stan-dards of the National Board of Fire Underwriters for theInstallation of Air Conditioning, Warm Air Heating andVentilating Systems. Pamphlets No. 90A and 90B.

A closed return duct system must be used, with the returnduct connected to the furnace. Supply and return con-nections to the furnace may be made with flexible joints toreduce noise transmission. To prevent the blower frominterfering with combustion air or draft when a central returnis used, a connecting duct must be installed between theunit and the utility room wall. A room, closet, or alcove mustnot be used as a return air chamber.

When the furnace is used in connection with a cooling unit,the furnace should be installed in parallel with or on theupstream side of the cooling unit to avoid condensation inthe heating element. With a parallel flow arrangement, thedampers or other means used to control the flow of air mustbe adequate to prevent chilled air from entering the furnaceand, if manually operated, must be equipped with means toprevent operation of either unit unless the damper is in thefull heat or cool position.

When the furnace is installed without a cooling coil, it isrecommended that a removable access panel be providedin the outlet air duct. This opening shall be accessible whenthe furnace is installed and shall be of such a size that theheat exchanger can be viewed for visual light inspection orsuch that a sampling probe can be inserted into the air-stream. The access panel must be made to prevent airleaks when the furnace is in operation.

When the furnace is heating, the temperature of the returnair entering the furnace must be between 55°F and 100°F.

When a furnace is installed so that supply ducts carry aircirculated by furnace to areas outside the space containingthe furnace, the return air shall also be handled by a ductsealed to the furnace casing and terminating outside thespace containing the furnace.

Filters - Read This Section Before Installing The ReturnAir Ductwork

Filters must be used with this furnace. Discuss filter main-tenance with the building owner. Filters do not ship with thisfurnace, but must be provided by the installer. Filter(s) mustcomply with UL900 or CAN/ULCS111 standards. If thefurnace is installed without filters, the warranty will bevoided.

The following chart shows recommended minimum filtersizes for each furnace model. Larger sizes are also accept-able.

19

Minimum Recommended Filter SizesQty. - Nominal Size, Inches (Sq. In. Surface Area)

Size_Air Flow Disposable Permanent

045_30 1 - 20 X 25 (500) 1 - 15 X 20 (300)

070_30 1 - 20 X 25 (500) 1 - 15 X 20 (300)

070_40 2 - 14 X 25 (350) 1 - 16 X 25 (400)

090_30 1 - 24 X 24 (576) 1 - 16 X 25 (400)

090_50 2 - 18 X 25 (450) 1 - 20 X 25 (500)

115_40 2 - 14 X 25 (350) 1 - 18 X 25 (450)

115_50 2 - 18 X 25 (450) 1 - 20 X 25 (500)

140_50 2 - 18 X 25 (450) 1 - 20 X 25 (500)

Figure 25Upflow/Horizontal Furnaces

UPFLOW INSTALLATIONSThis furnace contains rails for installing 16 x 25 x 1 filters oneach side of the interior furnace cabinet. A retainer is alsoincluded for bottom return. Refer to the chart below for filtersizes when using bottom return.

Bottom Return Air Filters

Size Filter Size, Inches Type

045, 070 14 X 25 X 1 P

90 16 X 25 X 1 P

115, 140 20 X 25 X 1 P

Figure 26Bottom Return

Filter Sizes

The illustration below shows how the filter is retained overthe bottom return air opening.

Figure 27Filter Retainer

One inch throwaway filters should be sized for a facevelocity of 300 feet per minute or less (14 x 25 x 1throwaway = 730 CFM max.; 16 x 25 x 1 throwaway = 830CFM max.; 18 x 25 x 1 throwaway = 940 CFM max.; 20 x25 x 1 throwaway = 1040 CFM max.) All other filters shouldbe sized according to their manufacturer’s instructions.

For air delivery of less than 1800 CFM; use one side returnor bottom return.

For air delivery of 1800 CFM or higher; use two side returns,or one side return plus bottom return.

Guide dimples locate the side and bottom return cutoutlocations. Use a straight edge to scribe lines connecting thedimples. Cut out the opening on these lines. An undersizedopening will cause reduced airflow. For bottom returnconnection, remove the bottom of the cabinet before settingthe furnace on the raised platform or return air duct.

HORIZONTAL INSTALLATIONSFilter(s) must be installed external to the furnace casing.Using a central return with filters installed in the duct behindthe return air grille allows filters to be replaced by justremoving the grille. This prevents having to go into the atticor crawl space when a filter has to be changed.

Refer to the preceding chart on Recommended MinimumFilter Sizes. (Figure 25)

COUNTERFLOW INSTALLATIONSA filter rack is shipped with the furnace. To use this rack,proceed as follows:

Figure 28Furnace Mounted Filter Rack

1. Center the filter rack over the plenum flange and pushdown firmly (Figure 28). Since the return air plenum willneed to be attached later, do not screw the filter rackdown.

2. Install the return air plenum on the furnace. For properfilter performance, the sides of the plenum must be atleast as tall as dimension “A” shown in Figures 29 and30.

"A"Min

Return Air

OptionalAccess

Door

Figure 29Return Air Plenum Installation

NOTE: For easier filter inspection and replacement, theinstaller may wish to provide a removable panel in the frontof the return air plenum.

20

Seconds 0 45

OnOff

OnOff

OnOff

Indoor Fan

Outdoor FanAnd

Compressor

Thermostat

Timing Chart for Normal Cooling Operation

Integrated Ignition Control

Diagnostic Signal Chart

HeatingTiming Chart for Integrated Ignition Control Normal Heating Operation

Light SignalRefer to AbnormalOperation Number

Continuous Light 1 Internal Control Failure1 Flash 2 System Lockout2 Flashes 3 Pressure Switch Stuck Closed3 Flashes 4 Pressure Switch Stuck Open4 Flashes 5 Open Limit Control5 Flashes 6 Open Rollout Control

Continuous Flashing 7 Flame Sensed No Call For Heat

OnOff

OpenClosed

OnOff

ClosedOpen

OnOff

OnOff

Seconds* 0 17 21 24 54 0 5 60, 90, 120, or 15 or 180

Air Circulation Blower

Gas Valve

Ignitor

Pressure Switch

Combustion Blower

Thermostat

* Timings may vary ±2 seconds.

Induced Draft Blower

21

9. After a 15 second delay while flue products are purgedfrom the furnace heat exchanger, the induced draftblower motor is de-energized.

10. The air circulation blower has an adjustable delay-offtiming of 60, 90, 120 or 180 seconds (starting from thetime the gas valve closes). This allows more heat fromthe furnace to be transferred to the conditioned space.After this time has elapsed, the blower will be de-energized.

NORMAL COOLING SEQUENCE - INTEGRATEDIGNITION CONTROLWith the room thermostat in the FAN-AUTO position, theindoor air circulation blower and outdoor condensing unitwill be energized when a call for cooling occurs. When thecall for cooling ends, the outdoor condensing unit will be de-energized. The indoor air circulation blower will continue torun for 45 seconds.

OTHER ITEMSConstant Fan. During normal operation, the air circu-lation blower will continually run at “Cooling” speed aslong as power is present at terminal G. If a call for heatoccurs, the blower will run at heating speed throughoutthe heating cycle.

If a trip on high/auxiliary/rollout limit occurs, the aircirculation blower will run at “Heating” speed. Even ifpower is present at terminal G, the blower will run atheating speed until the limit closes.

X. Start-Up, Adjustments, and Checks

GENERAL OPERATIONThis furnace is equipped with an electronic ignition deviceto light the burners and an induced draft blower to exhaustcombustion products.

An interlock switch prevents furnace operation if the blowerdoor is not in place. Keep the blower access doors in placeexcept for inspection and maintenance.

This furnace is also equipped with a self-diagnosing elec-tronic control module. In the event a furnace component isnot operating properly, the control module LED will flashon and off in a factory-programmed sequence, dependingon the problem encountered. This light can be viewedthrough the observation window in the blower access door.Refer to the Diagnostic Signal Chart for further explanationof the lighting codes and Section X, Abnormal Operation -Integrated Ignition Control for an explanation of the pos-sible problem.

On new installations, or if a functional part such as the gasvalve, pressure switch, or limit control has been replaced,verify that the furnace is operating properly after servicing.

Check furnace operation as outlined in the following in-structions. If any sparking, odors, or unusual noises areencountered, shut off electrical power and recheck forwiring errors, or obstructions in or near the blower motors.Various shipping materials must be removed before theblower motor is operated.

CAUTIONTo prevent personal injury, use only bluntpointed screws to attach the plenum to thefurnace and filter rack. Screws should notbe placed where they could interfere withfilter replacement.

Siz e_Air

Dimension "A",

Inches

M inimum R ecommended

F ilter Siz es, Inches

F lowT hrow aw ay Perm.

F iberglass

T hrow aw ayPermanent

045_30 15-1/2 8 (2) 16x 20x 1 (2) 10x 20x 1

070_30 15-1/2 8 (2) 16x 20x 1 (2) 10x 20x 1

070_40 19-3/4 8 (2) 20x 20x 1 (2) 10x 20x 1

090_30 14-1/4 13 (2) 16x 20x 1 (2) 15x 20x 1

090_50 24-1/4 13 (2) 25x 20x 1 (2) 15x 20x 1

115_40 17-3/4 11 (2) 20x 20x 1 (2) 15x 20x 1

115_50 23-1/2 11 (2) 25x 20x 1 (2) 15x 20x 1

140_50 23-1/2 11 (2) 25x 20x 1 (2) 15x 20x 1

Figure 30Counterflow Furnaces

3. With the air flow direction arrow pointing toward thefurnace, insert the filters from the left side of the blower.Starting with the right filter, push the filter into theplenum so the bottom of the filter fits into the filter rackand the upper edge rests against the side of theplenum. Repeat with the left filter (Figure 29).

OTHER FILTER OPTIONSExternal filter grilles can be used instead of the filter rack.

IX. Sequence of Operation (IntegratedIgnition Control)

Refer to Timing Charts for sequencing.

NORMAL HEATING SEQUENCE1. Thermostat calls for heat.

2. The induced draft blower is energized.

3. The ignitor is energized and is allowed to preheat for 17seconds.

4. The gas valve is energized delivering gas to the burnersand starting combustion.

5. The control checks for a signal from the flame sensorwithin seven seconds after the gas valve is energized.Gas will only continue to flow if a signal is present.

6. The control waits 30 seconds and turns on the aircirculation blower to the speed that was selected forheating operation.

7. The thermostat is satisfied and opens.

8. The control de-energizes the gas valve.

22

Figure 33Rollout Switch Relocation (Upflow)

Figure 34Rollout Switch Relocation

(Counterflow)

ROLLOUT PROTECTION DEVICEIf the flames from the burners are not properly drawn intothe heat exchanger, a protection device will open causingthe gas valve to close. In GUI(-) furnaces installed horizon-tal right-to-left airflow, the device must be relocated.

Supply Air

Return Air

Figure 31Right To Left Installation

Supply Air

Return Air

Figure 32Left To Right Installation

If relocation is required, proceed as follows:

1. Disconnect electrical power.

WARNINGTo prevent death or personal injury due toelectric shock, disconnect electrical power.

2. See Figures 33 and 34. Remove the cover from theburner box. Save the screws that held it in place. (Note:There are several screw holes, but only four screws.This is intentional, and not a manufacturing defect.)

3. As shipped, the rollout protection device is located nearthe flame sensor end of the manifold assembly. Re-move and save the mounting screws.

4. For most installations, it will not be necessary to removethe wires from the rollout protection device.

5. For horizontal-left installations, a hole is provided nearthe ignitor end of the manifold assembly. Insert therollout protection device into this hole and attach withscrews removed in step 3.

6. Secure rollout wires to manifold and insure no wires cancome in contact with burners or other hot surfaces.

7. Push the button to confirm the rollout control is in theclosed position.

8. Replace the cover on the burner box, placing thescrews from step 2 in their original locations.

WARNINGTo prevent death, personal injury or propertydamage due to fire or explosion, a qualifiedservicer must determine the reason therollout protection device opened before thedevice is reset.

23

BURNER BOXThis furnace must use indoor air for combustion. It is not adirect vent furnace, and it cannot be installed as a directvent furnace. The burner box (on some models) is presentonly to reduce the burner sound transmission.

AUXILIARY LIMIT CONTROL (FIGURE 35)A manual reset limit is located on the blower side of theblower deck, near the center. To access this auxiliary limit,disconnect the electrical power and remove the blowerdoor. If the limit control opens, the air circulation blower willrun continuously. The diagnostic light will flash four times.These symptoms are identical to a trip of the primary limitcontrol. See Section X, Abnormal Operation - IntegratedIgnition Control for diagnosis.

The auxiliary limit control is designed to prevent furnaceoperation in case of main blower failure on horizontal andcounterflow installations. It may also open if the powersupply is interrupted while the furnace is firing.

The auxiliary limit control is suitable for both horizontal rightand horizontal left installations. Regardless of airflow direc-tion, it does not need to be relocated.

WARNINGTo prevent death, personal injury or propertydamage due to fire, follow these directionsfor the auxiliary limit control. If the auxiliarylimit control opens, it may be reset one timeonly.

(SERVICER’S NOTE: If it becomes necessary to slide theblower assembly out of the furnace, the auxiliary limitcontrol should be removed first. After the blower assemblyis reinstalled, the auxiliary limit must be reinstalled.)

Figure 35Auxiliary Limit Control

ABNORMAL OPERATION - INTEGRATED IGNITIONCONTROLThe following presents the probable causes of question-able furnace operation and how to fix them. Look through

the observation window in the blower access door andmake a note of the number of flashes in sequence betweenpauses. Next, refer to the Diagnostic Signal Chart for aninterpretation of the signals and to this section for a descrip-tion.

1. Internal Control Failure with Integrated IgnitionControl

An internal control failure occurs when the integratedignition control senses an internal problem and stopsthe unit.

To solve this problem, replace the ignition control.

2. System Lockout

A system lockout occurs when the integrated ignitioncontrol determines that a measurable combustion can-not be established or maintained after three consecu-tive tries (four, if flame is established then lost) to turnon the furnace.

If a flame is not sensed during the first six seconds aftera gas valve has been energized, the ignition control willinternally turn off the gas. After 60 seconds, duringwhich time the induced draft blower purges the heatexchanger, the ignitor will re-energize and preheat for27 seconds. The gas valve is then re-energized. If aflame is not sensed again in six seconds, the gas valvewill de-energize and another purge is performed. Theignition control will cycle the gas valve three timesbefore it determines it cannot establish measurablecombustion and enter a lockout state. If a flame issensed but lost after 10 seconds, the control will cyclefour more times before locking out. A lockout stopsignition attempts and causes the air blower to runcontinuously. The diagnostic light will indicate eithercondition with one short flash followed by a longer off.

The control can be reset and brought out of lockoutmode by turning the thermostat off and then back on. Itcan also reset by turning off the electrical disconnectswitch to the furnace for 30 seconds. The control willreset after one hour.

IMPORTANT: If you have to frequently reset your furnace,it means that a problem exists that should be corrected.Contact a qualified servicer for further information.

3. Pressure Switch Stuck ClosedA sticking pressure switch can be caused by either afaulty pressure switch, faulty wiring, a disconnectedhose, or a restricted intake or flue piping. In the caseof a pressure switch sticking closed, the probablecause is a faulty pressure switch or wiring.

If the ignition control senses that the pressure switchis closed and the induced draft blower is off, it will shutdown the unit until the fault is corrected. The light codefor this problem is two short flashes followed by alonger pause.

4. Pressure Switch Stuck OpenA sticking open pressure switch can be caused by afaulty pressure switch, a disconnected hose to thepressure switch, a restricted air intake or flue piping, ora faulty wiring.

If the ignition control senses that the induced draftblower is energized but the pressure switch is notclosed, the control will keep the blower on and wait forthe switch to close. The diagnostic light code for thisproblem is three short flashes followed by a pause.

24

5. Open Limit Control (Primary or Auxiliary)

An open limit control can be caused by a low condi-tioned air flow due to dirty filter or resistance in ductwork, a faulty blower, a blower speed set too low, or afaulty limit.

When the limit control opens, the induced draft and aircirculation blowers are turned on. The induced draftblower will remain on for the first fifteen seconds of thisperiod. The air circulation blower will remain on untilthe limit control is closed. The diagnostic light code forthis is four short flashes followed by a pause.

6. Open Rollout Control

An open rollout control is can be caused by insufficientcombustion air, a restricted flue passage, or a re-stricted heat exchanger.

The opening of the rollout control signals the air circu-lation blower and the induced draft blower to turn on.The air circulation blower will remain on until the limitis manually reset. The induced draft blower will remainon for the first fifteen seconds of this period. Thediagnostic light code for this is five short flashesfollowed by a pause.

7. 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 theinduced draft blower continuously. The diagnostic lightcode for this is continuous light flashing. Probablecause is miswiring.

OPERATING INSTRUCTIONS1. Close the manual gas valve external to the furnace.

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

3. Set room thermostat to lowest possible setting.

4. Remove the door on the front of the furnace.

Note: This furnace is equipped with an ignition device toautomatically light the burners. Do not try to light burnersby hand.

5. Honeywell Model VR8205, or White Rodgers Model36E36, or Robertshaw Model 7222: Turn the gascontrol knob clockwise to the OFF position.Note: The knob should turn easily. Do not use exces-sive force.

White Rodgers Model 36E22: Push the switch to theOFF position.

6. Wait five minutes to clear out any gas. Then smell forgas, including near the floor.

7. If gas can be smelled following the five minute waitingperiod in Step 6, immediately follow the instructions onPage 2 of this manual. If you do not smell gas after fiveminutes:

Honeywell Model VR8205, or White Rodgers Model36E36, or Robertshaw Model 7222: Turn the gascontrol knob counterclockwise to the ON posi-tion. The knob should turn easily. Do not use exces-sive force.

White Rodgers Model 36E22: Push the switch to theON position.

8. Replace the door on the front of the furnace.

9. Open the manual gas valve external to the furnace.

10. Turn on the electrical power supply to the furnace.

11. Set the room thermostat to the desired temperature.

NOTE: There is an approximate 20 second delay betweenthermostat energizing and burner firing.

Gas Valves

Figure 36Honeywell Model VR-8205

Figure 37White Rodgers Model 36E36

Gas Control Valve Lever

(In ON Position)

INLET OUTLET

Pressure RegulatorAdjustment (UnderCap Screw)

Outlet Pressure Tap(Side of Valve)

Inlet Pressure Tap

Figure 38Robertshaw Model 7222

25

OFF

ON

M

P

C

1

3

2

WR

INLET OUTLET

Main RegulatorAdjust

Inlet Pressure Tap (Side of Valve)

Outlet Pressure Tap (Side of Valve)

MainSolenoid

RedundantSolenoid

ON/OffSwitch

Figure 39White Rodgers Model 36E22

CHECK GAS INPUT AND PRESSURESGas supply pressure and manifold pressure with the burn-ers operating must be as specified on the rating plate.

CHECKING GAS PRESSUREGas inlet pressure should be checked and adjusted inaccordance to the type of fuel being consumed.

With Power and Gas Off:

1. Honeywell Model VR8205, or White Rodgers Models36E36 or 36E22, or Robertshaw Model 7222: Connecta water manometer or adequate gauge to the “inletpressure tap” of the gas valve.

As an alternative method, inlet gas pressure can alsobe measured by removing the cap from the drip leg andinstalling a predrilled cap with a hose fitting (Figure 41).

With Power and Gas On:

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

Inlet Gas PressureNatural Min. 5.0" W.C., Max. 10.0" W.C.Propane Min. 11.0" W.C., Max. 14.0" W.C.

Inlet Gas Pressure Must Not Exceed the Maximum Value Shown.

Figure 40

If operating pressures differ from above, make necessarypressure regulator adjustments, check piping size, etc.,and/or consult with local utility.

Figure 41 Measuring Inlet Gas Pressure

(Alternate Method)

CHECK MANIFOLD PRESSUREA tapped opening is provided in the gas valve to facilitatemeasurement of the manifold pressure. See the “OutletPressure Tap” in Figures 36, 37, 38, & 39. A “U Tube”manometer having a scale range from 0 to 12 inches ofwater should be used for this measurement. The manifoldpressure must be measured with the burners operating .

To adjust the pressure regulator, remove the adjustmentscrew or cover on the gas valve. Turn out (counterclockwise)to decrease pressure, turn in (clockwise) to increase pres-sure. Only small variations in gas flow should be made bymeans of the pressure regulator adjustment. For naturalgas, the manifold pressure must be between 3.2 and 3.8inches water column (3.5 nominal). For propane gas, themanifold pressure must be between 9.7 and 10.3 incheswater column (10.0 nominal). Any major changes in flowshould be made by changing the size of the burner orifice.

CHECK GAS INPUT (NATURAL GAS ONLY)To measure the gas input using the gas meter proceed asfollows:

1. Turn off gas supply to all other appliances except thefurnace.

2. With the furnace operating, time the smallest dial on themeter for one complete revolution. If this is a 2 cubicfoot dial, divide the seconds by 2; if it is a 1 cubic footdial, use the seconds as is. This gives the seconds percubic foot of gas being delivered to the furnace.

26

3. INPUT = GAS HTG VALUE x 3600 SEC. PER CUBICFOOT (3600 is a conversion factor- 3600 seconds = 1hour.)

Example: Natural gas with a heating value of 1000 BTUper cubic foot and 34 seconds per cubic foot as deter-mined by Step 2, then:

Input = 1000 x 3600 x 34

= 106,000 BTU per Hour

NOTE: BTU content of the gas can be obtained from thegas supplier.

This measured input must not be greater than the inputindicated in Specification Sheet.

4. Relight all other appliances turned off in Step 1. Be sureall pilot burners are operating.

CHECK BURNER FLAMESFlames should be stable, soft and blue, (dust may causeorange tips but they must not be yellow), extending directlyoutward from the burners without curling, floating or liftingoff.

CHECK TEMPERATURE RISECheck the temperature rise through the unit by placingthermometers in supply and return air registers as close tothe furnace as possible. Be sure the thermometers do not“see” the heat exchangers or false readings could beobtained.

1. All registers must be open, all duct dampers must be intheir final (fully or partially open) position, and the unitoperated for 15 minutes before taking readings.

2. The temperature rise must be within the range specifiedon the rating plate or Specification Sheet.

NOTE: Air temperature rise is the temperature differencebetween supply and return air.

With a properly designed system, the proper amount oftemperature rise will normally be obtained when the unit isoperated at rated input with the “as shipped” blower speed.

If the correct amount of temperature rise is not obtained, itmay be necessary to change the blower speed. A fasterblower speed will lower the temperature rise. A slowerblower speed will increase the temperature rise.

NOTE: Blower speed must be set to give the correct airtemperature rise through the furnace as marked on therating plate.

CHANGING BLOWER SPEEDS

WARNINGTo avoid death or personal injury due toelectrical shock, turn off power to the furnacebefore changing speed taps.

All furnaces ship at high speed for cooling and the speedlisted in Specification Sheet for heating. These speedsshould be adjusted by the installer to match the job require-ments. See Specification Sheet for details.

Connect the correct motor leads to the COOL, HEAT, andPARK terminals. If heating speed will equal cooling speed,use the jumper wire provided. All unused motor leads thatare not connected to “PARK” terminals on the control mustbe taped to prevent shorts.

Figure 42High Limit Control

CHECK HIGH LIMIT CONTROL

WARNINGTo prevent death, personal injury, propertydamage or premature failure of heatexchanger, do not adjust the limit control(factory preset).

Check limit control operation after 15 minutes of operationby blocking the return air grille(s).

1. After several minutes the burners must go OFF. Blowerwill continue to run.

2. Remove air restrictions and burners will relight after acool down period of a few minutes.

Adjust the thermostat setting below room temperature

1. Burners must go off.

2. Circulating air blower will continue to run for 60, 90, 120or 180 seconds as set.

IMPORTANT NOTE: This unit must not be used as aconstruction heater during the finishing phases of construc-tion of a new structure. This type of use may result inpremature failure due to extremely low return air tempera-tures and exposure to corrosive or very dirty atmospheres.

TO TURN OFF FURNACE1. Set the thermostat to lowest setting.

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

3. Honeywell Model VR-8205, or White Rodgers Model36E36, or Robertshaw Model 7222: Turn the gascontrol knob clockwise to the OFF position.The knob should turn easily. Do not use excessiveforce.

White Rodgers Model 36E22: Push switch to the OFFposition.

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

5. Replace the door on the unit.

27

XI. Maintenance

WARNINGTo prevent death or personal injury due toelectric shock, disconnect electrical powerbefore performing any maintenance.

IMPORTANT NOTE: Handle the ignitor with care. Touch-ing the ignitor body with bare fingers, rough handling, orvibration could result in early ignitor failure. Only a qualifiedservicer should ever handle the ignitor.

Have the furnace checked at least once a year, before theheating season begins, to be sure there is adequate com-bustion air and the vent system is working properly.

Have vent pipe checked to be sure it is not blocked by debriswhich could permit fumes to enter the house. Replace anyrusted or leaking sections of vent pipe.

AIR FILTER

WARNINGTo prevent death, personal injury or propertydamage due to fire, never operate furnacewithout a filter installed. Dust and lint willbuild up on internal parts resulting in lossof efficiency, equipment damage andpossible fire.

A return air filter is not supplied with this furnace; however,there must be a means of filtering all of the return air. Theinstaller will supply filter(s) at the time of installation.

Filters should be inspected, cleaned or changed every twomonths or as required. It is the owner’s personal responsi-bility to keep air filters clean. Remember - dirty filters are themost common cause of inadequate heating or coolingperformance.

WARNINGTo prevent death, personal injury or propertydamage due to electrical shock, disconnectelectrical power to furnace before removingfilter or performing any other maintenance.

Become familiar with filter location and procedures forremoval, cleaning and replacing them. If help is needed,contact the installer of the furnace or a qualified servicer.

AIR FILTER - UPFLOW FURNACESIf the filter is in the furnace retaining rails, remove it asfollows: Pull off the non-louvered door. The blower motorwill automatically stop through the interlock switch.

Grasp the lower portion of the filter, lift up to disengage itfrom the lower railing, move towards blower, drop filterdown. Pull filter outward (Figure 43).

Front of Furnace

Blower

Grab HereAnd Lift

Filt

er

Front of Furnace

Blower

1. Lift filter above bottom 2. Tilt filter to clear rail.rail.

Front of Furnace

Blower

Front of Furnace

Blower

3. Lower filter below top 4. Pull filter out.rail.

Figure 43 Filter Removal

Replace the filter with the same type and size filter whenneeded.

Use a vacuum cleaner to clean out the blower area and theadjacent area of the return air duct.

Clean, wash and dry a permanent filter. When using a metalfilter, both sides should be sprayed with a dust adhesive asrecommended on adhesive container. Spray adhesives foruse with permanent metal filters can be found at somehardware stores. Reinstall filter by placing it into the furnacealong the side of the blower. Engage filter in top rail, movetoward side of furnace and drop it into the bottom rail. BESURE AIRFLOW DIRECTION ARROW POINTS TO-WARDS THE BLOWER.

When the filter is located in the bottom of the furnace on abottom return system the filter is held in place by a sheetmetal retainer strap. To change and clean the filter slide oneend of the retainer towards the front and remove filter.

AIR FILTER - COUNTERFLOW FURNACESA furnace mounted filter rack, shipped with the furnace, canbe used in counterflow installation.

28

The furnace-mounted filter rack includes a rack mountedon the top of the furnace. Two filters fit into the rack and restagainst the sides of the return air plenum, forming a “V”above the furnace.

The filters should be inspected frequently and cleaned orreplaced when necessary. In some installations, the filterscan be inspected after disconnecting the electrical powerand removing the optional access door in the return airplenum. If this access panel is not present, proceed asfollows:

1. Disconnect the electrical power.

2. Remove the non-louvered door from the furnace.

3. Remove the left filter by reaching to the left side of theblower, pushing the filter up slightly to remove it fromthe filter rack, and pulling it down to the left of the blowerand out the blower door. Repeat with the right filter.

4a. Dirty throwaway filters must be replaced with the samefilter type and size.

4b. Dirty, permanent metal filters must be cleaned asfollows:

Wash, rinse, and dry the permanent filters. Both sidesshould then be sprayed with a filter adhesive as isrecommended on the adhesive container. Many hard-ware stores stock spray adhesives for use with perma-nent filters.

If badly torn or uncleanable, these filters must bereplaced by equal size permanent, high velocity filters.Throwaway filters must not be used as replacement forpermanent filters. Under normal use, permanent filtersshould last for several years.

5. To reinstall the filters, first MAKE CERTAIN THEAIRFLOW DIRECTION ARROW POINTS TOWARDSTHE FURNACE. Then insert the filters from the left sideof the blower. Starting with the right filter, push the filterinto the plenum so that the bottom of the filter rests inthe filter rack and the upper edge rests against the sideof the plenum. Repeat with the left filter (Figure 44).

6. Replace the blower door, then reconnect the electricalpower.

Figure 44Furnace mounted Filter Rack

(Counterflow)

BLOWER MOTORThe air circulating blower motor bearings are permanentlylubricated. No further lubrication is required.

INDUCED DRAFT BLOWER MOTORThe induced draft blower motor is permanently lubricated.No further lubrication is required.

FLAME SENSOR (INTEGRATED IGNITION CONTROL)(QUALIFIED SERVICER ONLY)The fuel or combustion air supply can create a nearlyinvisible coating on the flame sensor. This coating acts asan insulator, causing a drop in the flame sensing signal. Toremove this coating, a qualified servicer should carefullyclean the flame sensor with emery cloth or steel wool. Aftercleaning, the microamp signal should be in the range listedin Specification Sheet.

IGNITOR (QUALIFIED SERVICER ONLY)If the ignitor and the surrounding air are at about 70°F andthe ignitor wires are not connected to any other electricalcomponents, the resistance of the ignitor should not ex-ceed 200 ohms. If it does, the ignitor should be replaced.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)At the start of each heating season, inspect and if nec-essary, clean the furnace flue passages.

CLEANING FLUE PASSAGES (QUALIFIED SERVICERONLY)

1. Shut off electric power and gas supply to the furnace.

2. Remove burner assembly by disconnecting the gas lineand removing the manifold brackets from the partitionpanel.

3. Remove the flue from the induced draft blower and thecollector box from the partition panel.

4. The primary heat exchanger tubes can be cleanedusing a round wire brush attached to a length of highgrade stainless steel cable, such as drain cleanoutcable. Attach a variable speed reversible drill to theother end of the spring cable. Slowly rotate the cablewith the drill and insert it into one of the primary heatexchanger tubes. While reversing the drill, work thecable in and out several times to obtain sufficientcleaning. Use a large cable for the large tube, and thenrepeat the operation with a small cable for the smallertube. Repeat for each tube.

5. When all heat exchanger tubes have been cleaned,replace the parts in the reverse order in which theywere removed.

6. To reduce the chances of repeated fouling of the heatexchanger, perform the steps listed in Section X, Start-up, Adjustments, and Checks.

29

BURNERS

WARNINGTo prevent personal injury or death, do notremove any internal compartment coversor attempt any adjustment. Electricalcomponents are contained in bothcompartments. Contact a qualified serviceagent at once if an abnormal flameappearance should develop.

Periodically during the heating season make a visual checkof the burner flames. Turn the furnace on at the thermostat.Wait a few minutes, since any dislodged dust will alter thenormal flame appearance. Flames should be stable, quiet,soft and blue with slightly orange tips. They should not beyellow. They should extend directly outward from the burnerports without curling downward, floating or lifting off theports.

CLEANING OF BURNERS (QUALIFIED SERVICERONLY)

1. Shut off electric power and gas supply to the furnace.

2. Remove the burner box front cover.

3. Remove the burner retention bracket.

4. Remove the burners.

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

6. Replace burners and burner retention bracket, inspectthe burner assembly for proper seating of burners inretention slots.

7. Reinstall the burner box front cover.

Check the burner flames for: 1. Good adjustment2. Stable, soft and blue 3. Not curling, floating, or lifting off.

Figure 45Burner Flame

GENERAL INFORMATION1. When ordering any of the listed functional parts, be sure

to provide the furnace model, manufacturing, and se-rial numbers with the order.

2. Although only functional parts are shown in the partslist, all sheet metal parts, doors, etc. may be ordered bydescription.

3. Parts are available from your Amana distributor

Gas Valve Blower/Box GasketGas Orifice, Natural Flame Roll-out SwitchGas Orifice, Propane Auxiliary LimitBurner Heat ExchangerIgnitor Door SwitchFlame Sensor TransformerGas Manifold Blower WheelIgnition Control Blower HousingLimit Switch Blower CutoffPressure Switch Blower MotorPressure Switch Hose Motor Mount BracketInduced Draft Blower CapacitorCollector Box