Amana Furnace VR8205 User Manual

Heating Air Conditioning

A higher standard of comfort

GUI* & GCI*

Gas Fired Warm Air

Furnace

Installation Instructions

Affix this manual, Specification Sheet and Users

Information Manual adjacent to the furnace.

Table of Contents

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

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

I. Safety and Unit Location..................................................... 3

II. General Information............................................................. 4

III. Air Requirements ................................................................. 4

IV. Category I Venting (Vertical Venting) ................................. 6

V. Masonry Chimneys .............................................................. 8

VI. Gas Piping .......................................................................... 12

VIl. Electrical Wiring ................................................................. 16

VIlI. Circulating Air and Filters ................................................ 18

IX. Sequence of Operation (Integrated Ignition Control) .... 21

X. Start-Up, Adjustments, and Checks ................................ 21

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

Amana Forced Air Central Furnace Design Complies With Requirements

Embodied in The American National Standard / National Standard of Canada

Shown Below.

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

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to

know the product better than the customer. This

includes all safety precautions and related items.

Remember,itisyourresponsibilitytoinstalltheproduct

safely and to know it well enough to be able to instruct

a customer in its safe use.

Prior to actual installation, thoroughly familiarize

yourself with this Instruction Manual. Pay special

attentiontoallsafetywarnings.Oftenduringinstallation

or repair it is possible to place yourself in a position

which is more hazardous than when the unit is in

operation.

Safety is a matter of common sense...a matter of

thinking before acting. Most dealers have a list of

specific good safety practices...follow them.

TheprecautionslistedinthisInstallationManualshould

not supersede existing practices but should be

considered as supplemental information.

Amana

Fayetteville, TN 37334

October 1997(1)

10759818

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and masonry acid washing materials. If the furnace is

installed near an area which will be frequently con-

taminated by these substances, the furnace should

be sealed from this area so that little contaminated air

can reach the furnace. The furnace must still have an

adequate supply of combustion air, either from a

nearby uncontaminated room or from outdoors. For

details, see “AIR REQUIREMENTS” Section III.

I. Safety and Unit Location

WARNING

To prevent personal injury or death due to

improper installation, adjustment,

alteration, service, or, maintenance refer

to this manual or for additional assistance

or information consult a qualified installer,

service agency or the gas supplier.

• Provisions must be made for venting combustion

products outdoors through a proper venting system.

The length of flue pipe could be a limiting factor in

locating the furnace.

• When installed horizontally, the furnace must be in-

stalled with the access doors vertical so that the

burners fire horizontally into the heat exchanger. The

unit cannot be installed with the access doors on top

or bottom. (See Specification Sheet)

WARNING

This product contains or produces a

chemical or chemicals which may cause

serious illness or death and which are

known to the State of California to cause

cancer, birth defects or other reproductive

harm.

• Allow clearances from the enclosure as shown on

Specification Sheet for fire protection, proper opera-

tion, and service access. These clearances must be

permanently maintained. The combustion and venti-

lating air openings in the front and top panels of the

furnace must never be obstructed.

WARNING

• This furnace shall not be connected to a chimney flue

serving a separate appliance designed to burn solid

fuel.

To prevent possible death, personal injury

or equipment damage due to fire, the

following points must be observed when

installing the unit.

• When the furnace is used in connection with a cooling

unit, the furnace must be upstream of, or in parallel

with, the cooling unit. For details see Section VIlI.

WARNING

• On Counterflow Installations, the air conditioning coil

must be downstream from the heat exchanger of the

furnace.

To prevent possible death, personal injury

orpropertydamageduetoelectricalshock,

the furnace must be located to protect the

electrical components from water.

• Counterflow Installation over a noncombustible floor.

Before setting the furnace over the plenum opening,

insure the surface around the opening is smooth and

level. A tight seal should be made between the furnace

base and floor by using a silicone rubber caulking

compound or cement grout.

NOTE: This unit must not be used as a “construction

heater” during the finishing phases of construction on a

new structure. This type of use may result in premature

failure of the unit due to extremely low return air tempera-

tures and exposure to corrosive or very dirty atmospheres.

• Counterflow Installation over a combustible floor. If

installation over a combustible floor becomes neces-

sary, use an accessory subbase as shown on the

Specification Sheet. Follow the instructions with the

subbase for proper installation. Do not install the

furnace directly on carpeting, tile, or other combustible

material other than wood flooring. (Note: The subbase

will not be required if an air conditioning coil is installed

between the supply air opening on the furnace and the

floor.)

WARNING

To prevent possible death, personal injury

or property damage, do not install this unit

in a mobile home, trailer or recreational

vehicle.

• The furnace must be level. If the furnace is to be set on

a floor that may become wet or damp at times, the

furnace should be supported above the floor on a

concrete base sized approximately 1-1/2" larger than

the base of the furnace.

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°F

and 100°F.

ADDITIONAL LOCATION CONSIDERATIONS

• The furnace should be as centralized as is practical

with respect to the air distribution system.

• Do not install the furnace where the combustion air is

exposed to the following substances: permanent wave

solutions, chlorinated waxes or cleaners, chlorine

based swimming pool chemicals, water softening

chemicals, deicing salts or chemicals, carbon tetra-

chloride, halogen type refrigerants, cleaning solutions

(such as perchloroethylene), printing inks, paint re-

movers, varnishes, hydrochloric acid, cements and

glues, antistatic fabric softeners for clothes dryers,

• 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 shown

on the Specification Sheet. The length of the rod will

depend on the application and clearance necessary.

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• When installed in a residential garage, the furnace

must be positioned so the burners and ignition source

are located not less than 18 inches (457 mm) above the

floor and protected from physical damage by vehicles.

III. Air Requirements

COMBUSTION AND VENTILATION AIR

WARNING

Possible death, personal injury or property

damage may occur if the furnace and other

fuel-burning appliances are not provided

withenoughfreshairforpropercombustion

and ventilation of flue gases. Most homes

require outside air to be supplied into the

furnace area.

II. General Information

WARNING

Possible death, personal injury or property

damageduetofire, explosion, smoke, soot,

condensation, electrical shock or carbon

monoxide may result from improper

installation, repair, operation, or

maintenance on this product.

Improved construction and additional insulation in build-

ings has reduced the heat loss, making these buildings

much tighter around doors and windows so air infiltration is

minimal. This creates a problem supplying combustion and

ventilation 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.) increases

this problem causing appliances to starve for air.

To ensure the furnace operates safely and efficiently, it

must be installed, operated and maintained in accordance

with these installation and operating instructions, all local

building codes and ordinances, or, in their absence, with

the latest edition of the National Fuel Gas Code, ANSI

Z223.1*, and/or CAN/CGA B149 Installation Codes.

The rated heating capacity of the furnace should be greater

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

The total heat loss should be calculated by an approved

method or in accordance with “ASHRAE. Guide” or “Manual

J-Load Calculations” published by the Air Conditioning

Contractors of America.

This furnace must use indoor air for combustion. It cannot

be installed as a direct vent (i.e., sealed combustion)

furnace. The burner box is present only to help reduce

sound transmission from the burners to the occupied space.

AIR REQUIREMENTS

*Obtain from: American National Standards Institute 1430

Broadway New York, NY 10018

Most homes will require outside air supplied to the furnace

area by means of ventilation grilles or ducts connecting

directly to the outdoors or spaces open to the outdoors such

as attics or crawl spaces. The following information on air

for combustion and ventilation is reproduced from the

National Fuel Gas Code NFPA54/ANSI Z223.1 Section

5.3.

TRANSPORTATION DAMAGE

Check the furnace for any shipping damage. If damage is

found, contact the company where the furnace was pur-

chased.

5.3.1 General:

While checking for transportation damage, remove all pack-

aging material and dispose or recycle according to local

codes.

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

installed in buildings and which require air for combustion,

ventilation and dilution of flue gases from within the build-

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

THERMOSTAT LOCATION

Locate the thermostat about 5 feet high on a vibration-free constructed and installed so that all air combustion is

inside wall, in an area having good air circulation

obtained from the outside atmosphere and all flue gases

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

furnaces which incorporate an integral total enclosure and

use only outside air for combustion and dilution of flue

gases.

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

• drafts or dead spots behind door, in corners or under

cabinets.

• hot or cold air from ducts.

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

facilities for ventilation permit satisfactory combustion of

gas, proper venting and the maintenance of ambient tem-

perature at safe limits under normal conditions of use.

Equipment shall be located so as not to interfere with proper

circulation of air. When normal infiltration does not provide

the necessary air, outside air shall be introduced.

• 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 for

mounting instructions.

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shall be provided as required for: cooling of equipment or

material, controlling dew point, heating, drying, oxidation or

dilution, safety exhaust, odor control, and air for compres-

sors.

(d) In addition to air needed for combustion, air shall be

supplied for ventilation, including all air required for comfort

and proper working conditions for personnel.

(e) While all forms of building construction cannot be

covered in detail, air for combustion, ventilation and dilution

of flue gases for gas utilization equipment vented by natural

draft normally may be obtained by application of one of the

methods covered in 5.3.3 and 5.3.4.

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

kitchen ventilation systems, clothes dryers, and fireplaces

shall be considered in determining the adequacy of a space

to provide combustion air requirements.

Figure 1

Equipment Located in Confined Spaces; All

Air from Inside Building. See 5.3.3-a

5.3.2 Equipment Located in Unconfined Spaces: In

unconfined spaces (see definition below) in buildings,

infiltration may be adequate to provide air for combustion

ventilation and dilution of flue gases. However, in buildings

of tight construction (for example, weather stripping, heavily

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

need to be provided using the methods described in 5.3.3-

b or 5.3.4.

(b) All Air from Outdoors: The confined space shall be

provided with two permanent openings, one commencing

within 12 inches of the top and one commencing within 12

inches of the bottom of the enclosure. The openings shall

communicate directly, or by ducts, with the outdoors or

spaces (crawl or attic) that freely communicate with the

outdoors.

Space, Unconfined. For purposes of this Code, a space

whose volume is not less than 50 cubic feet per 1,000 BTU

per hour of the aggregate input rating of all appliances

installed in that space. Rooms communicating directly with

the space in which the appliances are installed through

openings not furnished with doors, are considered a part of

the unconfined space.

1. When directly communicating with the outdoors, each

opening shall have a minimum free area of 1 square

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

equipment in the enclosure (Figure 2).

5.3.3 Equipment Located in Confined Spaces: (a) All Air

from Inside the Building: The confined space shall be

provided with two permanent openings communicating

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

that the combined volume of all spaces meets the criteria

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

equipment installed in the combined space shall be consid-

ered in making this determination. Each opening shall have

a minimum free area of 1 square inch per 1,000 BTU per

hour of the total input rating of all gas utilization equipment

in the confined space, but not less than 100 square inches.

One opening shall be within 12 inches of the top and one

within 12 inches of the bottom of the enclosure. (Figure 1 )

Figure 2

Equipment Located in Confined Spaces; All

Air from Outdoors—Inlet Air from Ventilated

Crawl Space and Outlet Air to Ventilated

Attic. See 5.3.3-b

2. When communicating with the outdoors through verti-

cal ducts, each opening shall have a minimum free area

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

rating of all equipment in the enclosure (See Figure 3).

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5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be

given to the blocking effect of louvers, grilles or screens

protecting openings. Screens used shall not be smaller

than 1/4 inch mesh. If the area through a design of louver

or grille is known, it should be used in calculating the size

of opening required to provide the free area specified. If the

design and free area is not known, it may be assumed that

wood louvers will have 20-25 percent free area and metal

louvers and grilles will have 60-75 percent free area.

Louvers and grilles shall be fixed in the open position or

interlocked with the equipment so that they are opened

automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Ex-

hausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes

dryers, or fireplaces may create conditions requiring spe-

cial attention to avoid unsatisfactory operation of installed

gas utilization equipment.

Figure 3

Equipment Located in Confined Spaces; All

Air from Outdoors Through Ventilated Attic.

See 5.3.3-b.

IV. Category I Venting (Vertical Venting)

WARNING

3. When communicating with the outdoors through hori-

zontal ducts, each opening shall have a minimum free

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

input rating of all equipment in the enclosure. (Figure 4)

Topreventpossibledeathorpersonalinjury

due to asphyxiation, Amana Non-

Condensing Gas Fired Warm Air Furnaces

must be Category I vented. Do not vent any

ofthesefurnacesusingCategoryIIIventing.

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

furnace vented as Category I is considered a fan-assisted

appliance and does not have to be “gas tight.” NOTE:

Single stage gas furnaces with induced draft blowers draw

products of combustion through a heat exchanger allowing

in some instances common venting with natural draft appli-

ances (i.e. water heaters).

All installations must be vented in accordance with National

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

Canada, the furnaces must be vented in accordance with

the National Standard of Canada, CAN/CGA B149.1 and .2

- latest editions and amendments.

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

directly with the outdoors, each opening shall have a free area of not less than one square inch

per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

NOTE: The vertical height of the Category I venting system

must be at least as great as the horizontal length of the

venting system.

Figure 4

Equipment Located in Confined Spaces; All

Air from Outdoors. See 5.3.3-b.

WARNING

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

sectional area as the free area of the openings to which

they connect. The minimum dimension of rectangular

air ducts shall not be less than 3 inches.

Topreventpossibledeathorpersonalinjury

due to asphyxiation, common venting with

other manufacturer’s induced draft

appliances is not allowed.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern

when special engineering, approved by the authority hav-

ing jurisdiction, provides an adequate supply of air for

combustion, ventilation, and dilution of flue gases.

Common venting with specific Amana Category I 80%

furnaces is allowed with the addition of a common vent kit

(CVK)foreachappliance. Contactthelocalinstallingdealer,

distributor or Amana directly for more information.

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The minimum vent diameter for the Category I venting 1/2” beyond the furnace cabinet. Vent the furnace in

system is as shown below:

accordance with the National Fuel Gas Code, NFPA54/

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

in accordance with the National Standard of Canada, CAN/

CGA B149 - latest editions and amendments.

MINIMUM VENT DIAMETER

MODEL

115

140

GUI*

3 Inch

4 Inch

5 Inch

GCI*

4 Inch

5 Inch

Under some conditions, larger vents than those shown

above may be required or allowed.

When an existing furnace is removed from a venting system

serving other appliances, the venting system may be too

large to properly vent the remaining attached appliances.

The following steps shall be followed with each appliance

remaining connected to the common venting system placed

in operation, while the other appliances remaining con-

nected to the common venting system are not in operation.

Figure 5

Upflow Rotated Induced Draft Blower

(a) Seal any unused openings in the common venting

system.

Counterflow units are shipped with the induced draft

blower discharging from the top of the furnace. (“Top” as

viewed for an counterflow installation.) The induced draft

blower can be rotated 90 degrees counterclockwise for

Category I venting, with the airflow horizontal right to left

(Figure 6). For horizontal installations, a 3-inch B-vent pipe

can 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/ANSI

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

accordance with the National Standard of Canada, CAN/

CGA B149 - latest editions and amendments.

(b) Visually inspect the venting system for proper size and

horizontal pitch as required in the National Fuel Gas

Code, ANSI Z223.1, or the CAN/CGA B149 Installation

Codes and these instructions. Determine there is no

blockage or restriction, leakage, corrosion or other

deficiencies which could cause an unsafe condition.

all doors between the space where the appliances

remain connected to the common venting system are

located and other spaces of the building. Turn on all gas

appliances not connected to the common venting sys-

tem and operate on high speed all exhaust fans (range

hoods and bathroom), except summer exhaust fans.

Close fireplace dampers.

Vent

(d) Following the lighting instructions, place the furnace

being inspected in operation. Adjust thermostat so

appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or

pipe.

Supply

Air

Return

Air

(f) After it has been determined that each appliance re-

maining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, fireplace dampers and

any other gas-burning appliance to their previous con-

ditions of use.

Figure 6

Counterflow Rotated Induced Draft Blower

To rotate the induced draft blower counterclockwise pro-

ceed as follows:

(g) If improper venting is observed during any of the above

tests, the common venting system must be corrected in

accordance with the latest edition of the National Fuel

Gas Code, ANSI Z223.1.

1. Disconnect electrical power from furnace.

WARNING

When resizing any portion of the common venting system,

use the appropriate table in Appendix G in the latest edition

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

To prevent death or personal injury due to

electrical shock, disconnect electrical

power.

Upflow or Horizontal units are shipped with the induced

draft blower discharging from the top of the furnace. (“Top”

is as viewed for an upflow installation.) The induced draft

blower can be rotated 90 degrees counterclockwise for

Category I venting, with the airflow horizontal left to right

(Figure 5). For horizontal installations, a 4-inch single wall

pipe can be used to extend the induced draft blower outlet

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

Note: The assembly, starting from the outside, is

induced draft blower, outer gasket, rotation plate, inner

gasket, partition panel (See Figure 7).

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V. Masonry Chimneys

WARNING

Possibility of property damage, personal

injury, or death - Damaging condensation

can occur inside masonry chimneys when

a single fan assisted Category I appliance

(80% AFUE furnace) is vented without

adequate dilution air. Do not connect an

80% furnace to a masonry chimney unless

the furnace is common vented with a draft

hood equipped appliance, or the chimney

is lined with a metal liner or Type B metal

vent. All installations using Masonry

chimneysmustbesizedinaccordancewith

the appropriate Venting Tables.

If an 80% furnace is common vented with a

drafthoodequippedappliance,thepotential

for condensation damage may still exist

with extremely cold conditions, long vent

connectors, exterior chimneys, or any

combination of these conditions. The risk

of condensation damage is best avoided by

using the masonry chimney as a pathway

for properly sized metal liner or Type B

metal vent.

Figure 7

Blower Assembly

3. Remove and save the four screws which hold the

rotation plate on the partition panel. Note that one of the

screws which hold the induced draft blower on the

rotation 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, using

the four screws removed in step 3. Tighten screws to

provide an airtight seal.

Crown

Wash

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.

Roof Line

Clay Tile Size Generally

Clay Tile Size: 8" x 8" x12"

12" x 12" (24" Length)

(Each x 24" Length)

Attic Floor

WARNING

1/2" to 1" Air Space

To prevent death or serious illness to

building occupants due to flue products

leakingintothebuilding,properinstallation

of gaskets and screws is essential for

providing a gas tight seal between the

partitionpanelandtheinduceddraftblower.

Second Floor

Throat

Damper

First Floor

Water Heater

Vent Connector

F.A.F. Vent

Connector

Breech

Natural Draft

Water Heater

Fan Assisted

Forced Air

Furnace

Clean Out

Basement Floor

Figure 8

Typical Multiple Flue Clay Tile Chimney

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CHECKLIST SUMMARY

CHECK 1 - PROPER CHIMNEY TERMINATION.

This checklist serves as a summary of the items to be A masonry chimney used as a vent for gas fired equipment

checked before venting an Air Command 80 furnace into a must extend at least three feet above the highest point

masonry chimney. In addition, we recommend that a quali- where it passes through the roof. It must extend at least two

fied serviceman use this checklist to perform a yearly feet higher than any portion of a building within a horizontal

inspection of the furnace venting system.

distance of 10 feet. In addition, the chimney must terminate

at least 3 feet above any forced air inlet located within 10

feet. The chimney must extend at least five feet above the

highest connected equipment draft hood outlet or flue

collar.

This checklist is only a summary. For detailed information

on each of the procedures mentioned, see the paragraph

referenced with each item.

This inspection is based upon a draft topical report, “Ma-

sonry Chimney Inspection and Relining”, issued by the Gas

Research Institute. While not yet finalized, we believe this

report represents the best information on this subject which

is currently available.

If the chimney does not meet these termination require-

ments, but all other requirements in the checklist can be

met, it may be possible for a mason to extend the chimney.

If this will not be practical, see Fix 1, page 12.

Proper Chimney

Termination?

(Check 1)

Line, terminate with

listed vent cap

(Fix 1)

10' or Less

Yes

2' Min.

3' Min.

Chimney channel

free of solid and

liquid fuel

appliances?

(Check 2)

Change venting

arrangements

(Fix 2)

Wall or

Parapet

Yes

Chimney

Rebuild crown

(Fix 3)

and /or Reline

(Fix 4)

Crown in good

condition?

(Check 3)

10' or Less

2' Min.

Yes

Ridge

3' Min.

Cleanout free of

debris?

Reline

(Fix 4)

(Check 4)

Chimney

Yes

Figure 9

Liner in good

condition?

(Check 5)

Termination 10 Feet Or Less From Ridge,

Wall or Parapet

Reline

(Fix 4)

Yes

Dilution air

available?

(Check 6)

Reline

(Fix 4)

Yes

Complete the

installation.

(Check 7)

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More than 10'

CHECK 4 - DEBRIS IN CLEANOUT

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

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

lower edge of the lowest chimney inlet opening.

3' Min.

Achimneywithoutacleanoutcouldbecomepartiallyblocked

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

refined (Fix 4).

: No Height

NOTE

above parapet

required when distance

from walls or parapet is

more than 10 feet.

Remove the cleanout cover, and examine the cleanout for

debris. If significant amounts of any of the following are

found:

Chimney

Wall or

Parapet

• Fuel oil residue

• Bricks

Height above any

roof surface within

10 feet horizontally.

• Mortar or sand

More than 10'

10"

• Pieces of the tile liner

• Rusted pieces of the metallic liner

reline the chimney (Fix 4).

Ridge

2' Min.

CHECK 5 - LINER CONDITION.

3' Min.

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

assumed that all existing metal liners are correctly installed

and in good condition.

Chimney

Remove the lowest existing vent connector, and examine

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

amount of soot may be considered acceptable, provided

the installer vacuums it away. If rusted pieces of the liner

have collected here, the metal liner must be removed and

replaced (Fix 4).

Figure 10

Termination More Than 10 Feet From Ridge,

Wall or Parapet

Next, gently tap the inside of the liner with a phillips

screwdriver. If the screwdriver perforates the liner, or if the

tapping does not sound like metal hitting metal, the liner

must be removed and replaced (Fix 4).

CHECK 2 - ANY SOLID OR LIQUID FUEL

APPLIANCES VENTED INTO THIS CHIMNEY

CHANNEL

Solid fuel appliances include fireplaces, wood stoves, coal

furnaces, and incinerators.

Remember that all appliances must be vented inside the

liner. Venting one appliance inside the liner and another

appliance outside the liner is not acceptable.

Liquid fuel appliances include oil furnaces, oil-fired boilers

and oil-fired water heaters.

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

B vent must be supported so as to not come into direct

contact with the chimney walls or tile liner. If it is not, it can

probably be rehung so as to be acceptable. A thimble or fire

stop may be helpful here.

Appliances which burn propane (sometimes referred to as

LP (liquefied petroleum)) gas are considered gas-fired

appliances.

CHECK 3 - CHIMNEY CROWN CONDITION.

Flexible liners should be hung straight or nearly straight. If

it is spiraled in the chimney and in good condition, it should

be rehung. To do this, break the top seal; pull up and cut off

the excess liner length, and refit the top seal. Use caution

when doing this, as the cut edges of flexible liners may be

sharp.

Damage from condensate usually shows up first in the

crown. If any of the following trouble signs are present, the

condition of the crown is not satisfactory:

a) Crown leaning

b) Bricks missing

c) Mortar missing

d) Tile liner cracked

e) No tile liner

The surfaces of the liner must be physically sound. If gaps

or holes are present, the metal liner must be removed and

replaced (Fix 4).

Finally, confirm that the metallic liner is the correct size for

the appliances to be installed. Use the GAMA tables and

rules.

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

becomes sandy and/or erodes.)

For problems a, b, or c, see Fix 3. If problems d, e, or f are

present, see Fix 4. IMPORTANT: It may be necessary to

follow both Fix 3 and Fix 4.

If a metal liner is not present, a clay tile liner must be

present, or the chimney must be lined (Fix 4).

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Use a flashlight and small mirror at the cleanout or vent

connector to inspect the clay tile liner. If any of the following

problems are present:

FIX 1 - LINER TERMINATION.

Any cap or roof assembly used with a liner must be

approved by the liner manufacturer for such use. The liner

and cap/roof assembly must then terminate above the roof

in accordance with the manufacturer’s instructions.

• Tile sections misaligned

• Tile sections missing

In some cases, a shorter extension above the roof may be

possible with a liner than would be required with a masonry

chimney.

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent

connectors

For further information on relining, see Fix 4.

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an

FIX 2 -CHANGE VENTING ARRANGEMENTS

approved fire clay tile

If the masonry chimney has more than one channel, it may

be possible to vent the gas appliances into one channel and

vent the solid or liquid fuel appliance(s) into another

channel(s). Do not vent an Air Command 80 inside of a

metal liner with other appliances vented outside the liner.

reline the chimney (Fix 4).

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

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

the minimum size established by the tables in National Fuel

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

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

latest editions and amendments. If the liner is too small or

too large, then the chimney must be relined (Fix 4).

Alternatively, the homeowner may agree to discontinue use

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

be cleaned to remove creosote buildup. The fireplace

opening must then be permanently sealed.

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

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

the fuel oil residue.

CHECK 6 - DILUTION AIR.

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

a source of dilution air is required.

If none of the above options is practical, the Air Command

80 may need to be vented vertically with a B Vent.

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through the

draft hood of a natural draft appliance only if the appliance’s

vent connector does not include a vent damper.

Under some conditions an Air Command 90 or 95 could be

installed rather than an Air Command 80. The Air Com-

mand 90 or 95 can be vented horizontally or vertically

through PVC pipe.

FIX 3 - REBUILD THE CROWN.

If dilution air will not be available, the chimney must be

relined (Fix 4).

If the chimney crown is damaged, a qualified mason must

repair it in accordance with nationally recognized building

codes or standards. One such standard which may be

referencedistheStandardforChimneys, Fireplaces, Vents,

and Solid Fuel Burning Appliances, ANSI/NFPA 211.

CHECK 7 - COMPLETE THE INSTALLATION.

If Checks 1 through 6 have been satisfactory, and the liner

is an acceptable size as determined by the tables in

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

edition and in the National Standard of Canada, CAN/CGA

B149.1 and CAN/CGA B149.2 - latest editions and amend-

ments, then the clay tile liner can probably be used as a vent

for the gas appliances. However, the installer must keep in

mind the following factors which may render the tile liner

unsuitable for use as a vent:

FIX 4 - RELINING.

Relining options include B vent and flexible liners.

If the chimney has diagonal offsets, B vent probably cannot

be used.

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

Supports (such as fire stops or thimbles) must be used to

prevent the B vent from coming into direct contact with the

tile liner or chimney walls. Direct contact would result in

higher heat loss, with an increased possibility of poor

venting system performance.

• Extremely cold weather

• Long vent connectors

• Masonry chimneys with no air gap between the liner

and the bricks. (In practice, this can be difficult to

detect.)

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

• Exterior chimneys (The tables in National Fuel Gas and other appliances outside. The excess space between

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 editions and amendments

assume interior chimneys.)

the B vent and the chimney walls must be covered at the top

of the chimney by a weatherproof, corrosion resistant

flashing.

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

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

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

effects.

If, in the judgment of the local gas utility, installer, and/or

local codes; one or more of the above factors is likely to

present a problem, the chimney must be relined (Fix 4).

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A B-vent installed as described in this section is considered Finally, cap the chimney and terminate the liner in accor-

to be an enclosed vent system, and the sizing tables in dance with the liner manufacturer’s instructions.

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 editions and amend-

The rating plate is stamped with the model number, type of

ments may be used.

VI. Gas Piping

gas and gas input rating. Make sure the furnace is equipped

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

materials:

to operate on the type of gas available.

Inlet GasPressure

• For most residential applications, an aluminum liner

Natural

Propane

Min. 5.0" W.C., Max. 10.0" W.C.

Min. 11.0" W.C., Max. 14.0" W.C.

should be acceptable.

• If the combustion air supplied to the furnace will be

contaminated with compounds containing chlorine or

fluorine, a liner of AL294C stainless steel should be

used. Common sources of chlorine and fluorine com-

pounds include indoor swimming pools and chlorine

bleaches, paint strippers, adhesives, paints, varnishes,

sealers, waxes (which are not yet dried) and solvents

used during construction and remodeling. Various

commercial and industrial processes may also be

sources of chlorine/fluorine compounds.

Inlet gas pressure must not exceed the maximum value

shown in table above.

NOTE: Adjusting the minimum supply pressure below the

limits in the above table could lead to unreliable ignition.

Gas input to the burners must not exceed the rated input

shown on the rating plate. Overfiring of the furnace could

result in premature heat exchanger failure. Gas pressures

in excess of 14 inches water column could result in perma-

nent damage to the gas valve.

• Heavier gauge 300 and 400 series stainless steel

liners were developed for use with oil or solid fuel

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

appliances. Flexible liners specifically intended and

IMPORTANT NOTE: The furnace will naturally derate itself

with altitude. Do not attempt to increase the firing rate by

tested for gas applications are listed in the UL “Gas and changing orifices or increasing the manifold pressure. This

Oil Equipment Directory”. (UL Standard 1777).

can cause poor combustion and equipment failure.

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

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

latest edition and in the National Standard of Canada,

CAN/CGA B149.1 and CAN/CGA B149.2 - latest editions

and amendments.

At all altitudes, the manifold pressure must be within 0.3

inches WC of that listed on the “Specification Sheet” for the

fuel used. At all altitudes and with either fuel, the air

temperature rise must be within the range listed on the

furnace nameplate.

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

instructions and your local codes. Excess liner length

should be pulled out of the chimney and cut off. Use caution

when doing this, as the cut edges of flexible liners may be

sharp. Do not spiral excess liner inside of the chimney.

Support the liner as recommended by the liner manufac-

turer.

GAS PIPING

IMPORTANT NOTE: To avoid possible unsatisfactory op-

eration or equipment damage due to underfiring of equip-

ment, do not undersize the natural/propane gas piping from

the meter/tank to the furnace. Include all appliances which

may be operated simultaneously when sizing a trunk line.

Some manufacturers of flexible liners offer an insulation

sleeve designed to be added to the liner before it is installed

in the chimney. (Poured insulation, either vermiculite or

other materials, is no longer recommended.) Insulation will

need to be added to the flexible liner if:

The gas pipe supplying the furnace must be properly sized

based on gas flow required, specific gravity of the gas and

length of the run. The gas line installation must comply with

local codes, or in the absence of local codes, with the latest

edition of the National Fuel Gas Code ANSI Z223.1.

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

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

• The previous liner was properly sized and installed,

Length of

Pipe in Feet

Nominal Black Pipe Size

and suffered from condensation damage.

1/2"

132

3/4"

1 1/4"

1 1/2"

1600

1100

980

100

278

190

152

130

115

105

520

350

285

245

215

195

180

170

160

150

1050

730

590

500

440

400

370

350

320

305

• It is required by your local building codes.

Even if none of those three conditions exist which require

additional liner insulation, the installer may wish to con-

sider it if:

760

670

610

560

530

490

460

• The local climate is very cold

• The chimney is very tall

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

number of elbows

(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on

0.60 Specific Gravity Gas)

• Local experience indicates that flexible liners installed

without insulation are likely to have condensation

problems.

BTUH Furnace Input

CFH =

Heating Value of Gas (BTU/Cubic Foot)

Insulation must be selected and installed in accordance

with the liner manufacturer’s instructions.

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NATURAL GAS CONNECTION

UPFLOW INSTALLATIONS

Refer to Figure 11 for the general layout at the furnace. The When the gas piping enters through the right side of the

following rules apply:

furnace, the installer must supply the following fittings

(starting from the gas valve):

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

piping.

• 90 degree elbow

• Close nipple

2. Use pipe joint compound on male threads only. Pipe

joint compound must be resistant to the action of the

fuel used.

• 90 degree elbow

• Straight pipe to reach the exterior of the furnace (Fig-

ures 12 & 13).

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it can

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

three inches long.

5. Use two pipe wrenches when making connection to the

gas valve to keep it from turning. The orientation of the

gas valve on the manifold must be the same as shipped

from the factory.

6. Within six feet of the unit, install a manual cutoff valve

between the meter and the unit. If a union is installed,

the union must be downstream of the manual shutoff

valve, between the shutoff valve and the furnace.

7. Tighten all joints securely.

8. The furnace must be connected to the building piping

by 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.

Figure 12

Gas Inlet Through Furnace Right Side

• 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.

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

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

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

2" to another pipe size.

• The connectors or semirigid tubing must be pro-

tected against physical and thermal damage when

installed.Aluminum-alloytubingandconnectorsmust

be coated to protect against external corrosion when

in contact with masonry, plaster or insulation or are

subject to repeated wettings by such liquids as water

(except rain water), detergents or sewage.

Figure 13

Gas Inlet Through Furnace Bottom Side

(Upflow)

Figure 11

General Furnace Layout

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When the gas piping enters through the left side of the

furnace, the installer must supply the following fittings

(starting from the gas valve):

COUNTERFLOW INSTALLATIONS

When the gas piping enters through the left side of the

furnace, the installer must supply a straight pipe to reach

the exterior of the furnace (Figure 17).

• Straight pipe to reach the exterior of the furnace (Fig-

ures 14 & 15).

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

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

the installer may also need to supply a transition piece

from 1/2 inch to another pipe size.

Figure 17

Gas Inlet Through Left Side

(Counterflow)

Figure 14

Gas Inlet Through Furnace Left Side

(Upflow)

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

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

installer may also need to supply a transition piece from

1/2" to another pipe size.

When the gas piping enters through the right side of the

furnace, the installer must supply the following fittings

(starting at the gas valve):

• 90 degree elbow.

• Close nipple.

• 90 degree elbow.

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

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

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

installer may also need to supply a transition piece from

1/2 inch to another pipe size.

Figure 15

Gas Inlet Through Furnace Top Side

(Upflow)

The gas piping connections shown in Figures 13 and 14 are

for a furnace equipped for a right hand discharge. Adapta-

tion for left hand discharge should be self explanatory.

Figure 18

Gas Inlet Through Right Side

(Counterflow)

Figure 16

Horizontal Furnace

(Right Hand Discharge)

“Left side” and “right side” above are as viewed for a

counterflow installation. Adaptation for horizontal airflow

should be self explanatory.

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For satisfactory operation, propane gas pressure must be

10 inch WC at the furnace manifold with all gas appliances

in operation. Maintaining proper gas pressure depends on

three main factors:

CHECKING GAS PIPING

CAUTION

To prevent personal injury or property

damage due to fire, the following

instructions must be performed regarding

gasconnections,pressuretesting,location

of shutoff valve and installation of gas

piping.

1. Vaporization rate, depending on temperature of the

liquid, and “wetted surface” area of the container or

containers.

2. Proper pressure regulation. (Two-stage regulation is

recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and be-

tween second stage regulator and the appliance. Pipe

size will depend on length of pipe run and total load of

all appliances.

Before placing in operation, leak test the unit and gas

connections. To avoid the possibility of explosion or fire,

never use a match or open flame to test for leaks. Never

exceed specified pressures for testing. Higher pressure

may damage the gas valve and cause overfiring, resulting

in heat exchanger failure.

Complete information regarding tank sizing for vaporiza-

tion, recommended regulator settings, and pipe sizing is

available from most regulator manufacturers and propane

gas suppliers.

This unit and shutoff valve must be disconnected from the

gas supply piping system before supply piping system

pressure testing with test pressures in excess of 1/2 psig

(3.48 kPa).

Since propane gas will quickly dissolve white lead or most

standard commercial compounds, special pipe dope must

be used. Shellac base compounds resistant to the actions

of liquefied petroleum gases such as Gasolac, Stalactic,

Clyde’s or John Crane are satisfactory.

This unit must be isolated from the gas supply system by

closing its manual shutoff valve before pressure testing of

gas supply piping system with test pressures equal to or

less than 1/2 psig (3.48 kPa).

Refer to Figure 19 for typical propane gas installations.

TANKS AND PIPING - PROPANE GAS UNITS

WARNING

Topreventdeath,personalinjuryorproperty

damage due to fire or explosion caused by

a propane gas leak, install a gas detecting

warning device. Since rust can reduce the

level of odorant in propane gas, a gas

detectingwarningdeviceistheonlyreliable

way to detect a propane gas leak. Contact a

local propane gas supplier about installing

a gas detecting warning device.

Figure 19

Propane Gas Installation (Typ.)

PROPANE GAS PIPING CHARTS

Sizing Between First and Second Stage Regulator

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.

Capacities in 1,000 BTU/hour.

WARNING

Pipe or

Tubing

Length,

Feet

Nominal Pipe Size

Schedule 40

All metal inserts, screens or turbulators

must be removed from the heat exchanger

tubes when using propane gas. Failure to

complycouldcauseseriouspersonalinjury

or death. Failure to comply with this

requirement will also void warranty

coverage.

Tubing Size, O.D. Type L

3/8"

1/2"

5/8"

3/4"

7/8"

1/2"

3/4"

730

500

400

370

330

300

260

220

200

190

170

160

1,700

1,100

920

850

770

700

610

540

490

430

400

380

3,200

2,200

2,000

1,700

1,500

1,300

1,200

1,000

900

5,300

3,700

2,900

2,700

2,400

2,200

1,900

1,700

1,400

1,300

1,200

1,100

8,300

5,800

4,700

4,100

3,700

3,300

2,900

2,600

2,300

2,100

1,900

1,800

3,200

2,200

1,800

1,600

1,500

1,300

1,200

1,000

900

7,500

4,200

4,000

3,700

3,400

3,100

2,600

2,300

2,100

1,900

1,700

1,500

100

125

150

175

200

830

780

730

830

770

720

All propane gas equipment must conform to the safety

standards of the National Board of Fire Underwriters (See

NBFU Manual 58).

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

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

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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.

Power supply to the furnace must be NEC Class 1, and

must comply with all applicable codes. The furnace must be

electrically grounded in accordance with the local codes or,

in their absence, with the latest edition of the National

Electrical Code, ANSI NFPA No. 70 and/or the CSA C22. 1

Electrical Code. A fused disconnect must be provided and

sized in accordance with the unit maximum overcurrent

protection.

Pipe or

Tubing

Nominal Pipe Size

Schedule 40

Tubing Size, O.D. Type L

Length, 3/8"

Feet

1/2"

5/8"

3/4"

7/8" 1-1/8" 1/2"

3/4"

1-1/4" 1-1/2"

199

131

107

329

216

181

145

131

121

104

501

346

277

233

198

187

155

138

122

109

100

935

630

500

427

376

340

289

255

224

202

187

172

275

189

152

129

114

103

567

393

315

267

237

217

185

162

146

132

112

100

1,071 2,205 3,307

732 1,496 2,299

590 1,212 1,858

504 1,039 1,559

448

409

346

307

275

252

209

185

913

834

724

630

567

511

439

390

1,417

1,275

1,066

976

866

787

100

125

150

200

250

665

590

*Data in accordance with NFPA pamphlet NO. 54

WARNING

To prevent death, serious personal injury

or property damage due to fire or explosion

caused by a propane gas leak, install a gas

detecting warning device.

Figure 20

Typical Field Wiring

(24 VAC Control Circuit)

A 40 VA transformer and an integrated electronic control

are built into the furnace to allow use with most cooling

equipment.

WARNING

If the propane gas furnace is installed in a

basement, an excavated area or a confined

space, a warning device is required due to:

• Propane gas is heavier than air and any

leaking gas can settle in any low areas

or confined spaces.

CAUTION

To avoid the risk of electrical shock, wiring

to the unit must be properly polarized and

grounded.

• Propane gas odorant may fade, making

the gas undetectable except with a

warning device.

If the presence of gas is suspected, follow

the instructions on Page 2 of this manual.

To provide more reliable sensing of flame, the ground wire

must 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 of

the furnace (as viewed for an upflow installation). If this is

suitable for your installation, no changes are necessary.

VIl. Electrical Wiring

WARNING

If the line voltage wiring is to enter through the right side of

the furnace (as viewed for an upflow installation), relocate

the junction box as shown in Figure 21.

To prevent death or personal injury due to

electric shock, disconnect electrical power

before changing any electrical wiring.

CAUTION

When servicing controls, label all wires

before disconnecting. Wiring errors can

cause improper and dangerous operation.

After servicing is completed, always verify

proper operation.

Junction

Box

The unit wiring harness is an integral part of the furnace.

Field alteration to comply with electrical codes should not

be required.

Figure 21

Junction Box (Left Side)

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WARNING

To prevent death or personal injury due to

electricshock,disconnectelectricalpower.

Low Voltage

Terminals

Heating Fan

Off Adjustments

1. Remove both doors from the furnace.

2. Remove and save the screws holding the junction box

to the left side of the furnace.

Style A

3. Disconnect the hose from the pressure switch. Leave

the other end attached to the induced draft blower.

Pins (4)

4. Remove five wires entering junction box from split

grommet in blower deck.

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

Style B

6. Rotate the junction box 180 degrees so the access

panel continues to face forward. The open snap bush-

ing should now be at the bottom.

Jumper

7. Insert five wires into the split grommet on the right side

of the blower deck.

Figure 22

Integrated Ignition Control

8. Insert the five wires through the open bushing in the

bottom of the junction box.

(Viewed in an Upflow Installation)

AIR CIRCULATION BLOWER FAN TIMING

9. Attach the junction box to the right side of the furnace,

using the screws removed in step 2.

All items in this section refer to the air circulation blower fan,

not to the induced draft blower. The timing sequence for the

induced draft blower is not adjustable.

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 the

burners or by the rotation of the fan. Also confirm that

wiring location will not interfere with filter removal or

other maintenance.

When a call for cooling occurs, the circulation fan will come

on. It will remain on for 45 seconds after the call for cooling

ends. This fan timing is not adjustable.

During normal heating operation, the circulation fan will

come on 37 seconds after the gas valve opens. This timing

is not adjustable.

After the junction box is in the desired location, use washers

to connect field-supplied conduit to the junction box in

accordance with NEC and local codes. Connect hot, neu-

tral, and ground wires as shown in the furnace wiring

diagram. The wires and ground screw are located in the

furnace junction box.

As shipped, the circulation fan will remain on for 90 seconds

after the gas valve closes. If desired, this timing may be

adjusted. The adjustment pins or switches are near the low

voltage terminal strip (Figure 23).

Low voltage wiring may enter through the right or left side

of the furnace (as viewed for an upflow installation - top or

bottomforahorizontalinstallation). SeeSpecificationSheet

for hole locations. Run the thermostat wires through either

grommet in the blower deck (Figure 21).

Style B

Style A

Second

Delay

Low voltage wires may be connected to the terminal strip as

shown in Figure 22.

Second

Delay

IMPORTANT NOTE: To avoid possible equipment mal-

function, route the low voltage wires to avoid interference

with filter removal or other maintenance.

120

Second

Delay

180

Second

Delay

Switches viewed in an upflow installation.

Figure 23

Heating Fan Off Adjustments

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HEAT ANTICIPATOR SETTING

VIlI. Circulating Air and Filters

Adjust the heat anticipator in the room to obtain the proper

number of heating cycles per hour. The heat anticipator is

a wire-wound adjustable heater that prevents the room

temperature from “overshooting” the room thermostat set-

ting. The heat anticipator must be set at 0.7 amps. The heat

anticipator is part of the thermostat. If the thermostat fails

for any reason, replace the thermostat.

DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed

for the CFM and external static pressure rating of the

furnace. Ductwork should be designed in accordance with

the recommended methods of “Air Conditioning 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 the

Installation of Air Conditioning, Warm Air Heating and

Ventilating Systems. Pamphlets No. 90A and 90B.

LINE VOLTAGE CONNECTION FOR OPTIONAL

HUMIDIFIER AND ELECTRONIC AIR CLEANER

The control module is equipped with line voltage accessory

terminals used for controlling the power to an optional field-

supplied humidifier and/or electronic air cleaner.

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

duct connected to the furnace. Supply and return con-

nections to the furnace may be made with flexible joints to

reduce noise transmission. To prevent the blower from

interfering with combustion air or draft when a central return

is used, a connecting duct must be installed between the

unit and the utility room wall. A room, closet, or alcove must

not be used as a return air chamber.

Accessory Load Specification

Air Cleaner: 1.0 Amp max. at 120 VAC

Humidifier: 1.0 Amp max. at 120 VAC

Accessory Installation:

Follow the electronic air cleaner and humidifier manufactur-

ers’ instructions for mounting and electrically grounding

these accessories. Check that the power supply to the

furnace has been disconnected. Wire the accessories to

the control module as shown below. All connections to the

control module are to be made through 1/4 inch female

terminals.

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

the furnace should be installed in parallel with or on the

upstream side of the cooling unit to avoid condensation in

the heating element. With a parallel flow arrangement, the

dampers or other means used to control the flow of air must

be adequate to prevent chilled air from entering the furnace

and, if manually operated, must be equipped with means to

prevent operation of either unit unless the damper is in the

full heat or cool position.

If it is necessary to supply additional line voltage wiring to

the interior of the furnace, the wiring must comply with all

local codes. This wiring must have a minimum temperature

rating of 105°C and must be routed away from the burner

compartment. All line voltage wire splices must be made

inside the furnace junction box.

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

recommended that a removable access panel be provided

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

the furnace is installed and shall be of such a size that the

heat exchanger can be viewed for visual light inspection or

such that a sampling probe can be inserted into the air-

stream. The access panel must be made to prevent air

leaks when the furnace is in operation.

Control Module

Neutral

Hot 120 VAC

120 VAC

When the furnace is heating, the temperature of the return

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

When a furnace is installed so that supply ducts carry air

circulated by furnace to areas outside the space containing

the furnace, the return air shall also be handled by a duct

sealed to the furnace casing and terminating outside the

space containing the furnace.

Air

Cleaner

Optional

Accessories

{

Filters - Read This Section Before Installing The Return

Air Ductwork

Humidifier

Figure 24

Filters must be used with this furnace. Discuss filter main-

tenance with the building owner. Filters do not ship with this

furnace, but must be provided by the installer. Filter(s) must

comply with UL900 or CAN/ULCS111 standards. If the

furnace is installed without filters, the warranty will be

voided.

Line Voltage Connection for Accessories

Accessory Operation: The furnace control module ener-

gizes the humidifier whenever the induced draft blower is

energized (when an air cleaner is installed on the system,

the humidifier is not energized until the air cleaner is

energized). The control module energizes the air cleaner

whenever the air circulation blower is energized.

The following chart shows recommended minimum filter

sizes for each furnace model. Larger sizes are also accept-

able.

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Guide dimples locate the side and bottom return cutout

locations. Use a straight edge to scribe lines connecting the

dimples. Cut out the opening on these lines. An undersized

opening will cause reduced airflow. For bottom return

connection, remove the bottom of the cabinet before setting

the furnace on the raised platform or return air duct.

Minimum Recommended Filter Sizes

Qty. - Nominal Size, Inches (Sq. In. Surface Area)

Size_Air Flow

Disposable

Permanent

045_30

070_30

070_40

090_30

090_50

115_40

115_50

140_50

1 - 20 X 25 (500)

2 - 14 X 25 (350)

1 - 24 X 24 (576)

2 - 18 X 25 (450)

2 - 14 X 25 (350)

2 - 18 X 25 (450)

1 - 15 X 20 (300)

1 - 16 X 25 (400)

1 - 20 X 25 (500)

1 - 18 X 25 (450)

1 - 20 X 25 (500)

HORIZONTAL INSTALLATIONS

Filter(s) must be installed external to the furnace casing.

Using a central return with filters installed in the duct behind

the return air grille allows filters to be replaced by just

removing the grille. This prevents having to go into the attic

or crawl space when a filter has to be changed.

Figure 25

Upflow/Horizontal Furnaces

Refer to the preceding chart on Recommended Minimum

Filter Sizes. (Figure 25)

COUNTERFLOW INSTALLATIONS

A filter rack is shipped with the furnace. To use this rack,

proceed as follows:

UPFLOW INSTALLATIONS

This furnace contains rails for installing 16 x 25 x 1 filters on

each side of the interior furnace cabinet. A retainer is also

included for bottom return. Refer to the chart below for filter

sizes when using bottom return.

Bottom Return Air Filters

Size

045, 070

Filter Size, Inches

14 X 25 X 1

Type

16 X 25 X 1

115, 140

20 X 25 X 1

Figure 28

Furnace Mounted Filter Rack

Figure 26

Bottom Return

Filter Sizes

1. Center the filter rack over the plenum flange and push

down firmly (Figure 28). Since the return air plenum will

need to be attached later, do not screw the filter rack

down.

The illustration below shows how the filter is retained over

the bottom return air opening.

2. Install the return air plenum on the furnace. For proper

filter performance, the sides of the plenum must be at

least as tall as dimension “A” shown in Figures 29 and

30.

Return Air

Optional

Access

Door

Figure 27

Filter Retainer

"A"

Min

One inch throwaway filters should be sized for a face

velocity of 300 feet per minute or less (14 x 25 x 1

throwaway = 730 CFM max.; 16 x 25 x 1 throwaway = 830

CFM max.; 18 x 25 x 1 throwaway = 940 CFM max.; 20 x

25 x 1 throwaway = 1040 CFM max.) All other filters should

be sized according to their manufacturer’s instructions.

Figure 29

Return Air Plenum Installation

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

or bottom return.

For air delivery of 1800 CFM or higher; use two side returns,

or one side return plus bottom return.

NOTE: For easier filter inspection and replacement, the

installer may wish to provide a removable panel in the front

of the return air plenum.

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Heating

Timing Chart for Integrated Ignition Control Normal Heating Operation

Off

Air Circulation Blower

Induced Draft Blower

Open

Closed

Gas Valve

Ignitor

Off

Closed

Open

Pressure Switch

Off

Combustion Blower

Off

Thermostat

Seconds*

17 21 24

60, 90, 120,

or 180

or 15

* Timings may vary ±2 seconds.

Integrated Ignition Control

Diagnostic Signal Chart

Refer to Abnormal

Operation Number

Internal Control Failure

System Lockout

Pressure Switch Stuck Closed

Pressure Switch Stuck Open

Open Limit Control

Light Signal

Continuous Light

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

Continuous Flashing

Open Rollout Control

Flame Sensed No Call For Heat

Timing Chart for Normal Cooling Operation

Off

Indoor Fan

Outdoor Fan

And

Compressor

Off

Thermostat

Seconds

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9. After a 15 second delay while flue products are purged

from the furnace heat exchanger, the induced draft

blower motor is de-energized.

CAUTION

To prevent personal injury, use only blunt

pointed screws to attach the plenum to the

furnace and filter rack. Screws should not

be placed where they could interfere with

filter replacement.

10. The air circulation blower has an adjustable delay-off

timing of 60, 90, 120 or 180 seconds (starting from the

time the gas valve closes). This allows more heat from

the furnace to be transferred to the conditioned space.

After this time has elapsed, the blower will be de-

energized.

Dimension "A",

Inches

Minimum Recommended

Filter Sizes, Inches

Size_Air

Flow

NORMAL COOLING SEQUENCE - INTEGRATED

IGNITION CONTROL

Fiberglass

Permanent

Throwaway

Throwaway Perm.

With the room thermostat in the FAN-AUTO position, the

indoor air circulation blower and outdoor condensing unit

will be energized when a call for cooling occurs. When the

call for cooling ends, the outdoor condensing unit will be de-

energized. The indoor air circulation blower will continue to

run for 45 seconds.

045_30

070_30

070_40

090_30

090_50

115_40

115_50

140_50

15-1/2

19-3/4

14-1/4

24-1/4

17-3/4

23-1/2

(2) 16x20x1

(2) 20x20x1

(2) 16x20x1

(2) 25x20x1

(2) 20x20x1

(2) 25x20x1

(2) 10x20x1

(2) 15x20x1

OTHER ITEMS

Constant Fan. During normal operation, the air circu-

lation blower will continually run at “Cooling” speed as

long as power is present at terminal G. If a call for heat

occurs, the blower will run at heating speed throughout

the heating cycle.

Figure 30

Counterflow Furnaces

If a trip on high/auxiliary/rollout limit occurs, the air

circulation blower will run at “Heating” speed. Even if

power is present at terminal G, the blower will run at

heating speed until the limit closes.

3. With the air flow direction arrow pointing toward the

furnace, insert the filters from the left side of the blower.

Starting with the right filter, push the filter into the

plenum so the bottom of the filter fits into the filter rack

and the upper edge rests against the side of the

plenum. Repeat with the left filter (Figure 29).

X. Start-Up, Adjustments, and Checks

GENERAL OPERATION

This furnace is equipped with an electronic ignition device

to light the burners and an induced draft blower to exhaust

combustion products.

OTHER FILTER OPTIONS

External filter grilles can be used instead of the filter rack.

An interlock switch prevents furnace operation if the blower

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

except for inspection and maintenance.

IX. Sequence of Operation (Integrated

Ignition Control)

This furnace is also equipped with a self-diagnosing elec-

tronic control module. In the event a furnace component is

not operating properly, the control module LED will flash

on and off in a factory-programmed sequence, depending

on the problem encountered. This light can be viewed

through the observation window in the blower access door.

Refer to the Diagnostic Signal Chart for further explanation

of the lighting codes and Section X, Abnormal Operation -

Integrated Ignition Control for an explanation of the pos-

sible problem.

Refer to Timing Charts for sequencing.

NORMAL HEATING SEQUENCE

1. Thermostat calls for heat.

2. The induced draft blower is energized.

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

seconds.

4. The gas valve is energized delivering gas to the burners

and starting combustion.

On new installations, or if a functional part such as the gas

valve, pressure switch, or limit control has been replaced,

verify that the furnace is operating properly after servicing.

5. The control checks for a signal from the flame sensor

within seven seconds after the gas valve is energized.

Gas will only continue to flow if a signal is present.

Check furnace operation as outlined in the following in-

structions. If any sparking, odors, or unusual noises are

encountered, shut off electrical power and recheck for

wiring errors, or obstructions in or near the blower motors.

Various shipping materials must be removed before the

blower motor is operated.

6. The control waits 30 seconds and turns on the air

circulation blower to the speed that was selected for

heating operation.

7. The thermostat is satisfied and opens.

8. The control de-energizes the gas valve.

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ROLLOUT PROTECTION DEVICE

If the flames from the burners are not properly drawn into

the heat exchanger, a protection device will open causing

the gas valve to close. In GUI(-) furnaces installed horizon-

tal right-to-left airflow, the device must be relocated.

Supply

Air

Return

Air

Figure 31

Right To Left Installation

Return

Air

Supply

Air

Figure 32

Left To Right Installation

Figure 33

Rollout Switch Relocation (Upflow)

If relocation is required, proceed as follows:

1. Disconnect electrical power.

WARNING

To prevent death or personal injury due to

electricshock,disconnectelectricalpower.

2. See Figures 33 and 34. Remove the cover from the

burner 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 near

the flame sensor end of the manifold assembly. Re-

move and save the mounting screws.

4. For most installations, it will not be necessary to remove

the wires from the rollout protection device.

5. For horizontal-left installations, a hole is provided near

the ignitor end of the manifold assembly. Insert the

rollout protection device into this hole and attach with

screws removed in step 3.

6. Secure rollout wires to manifold and insure no wires can

come in contact with burners or other hot surfaces.

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

closed position.

8. Replace the cover on the burner box, placing the

screws from step 2 in their original locations.

Figure 34

Rollout Switch Relocation

(Counterflow)

WARNING

Topreventdeath,personalinjuryorproperty

damage due to fire or explosion, a qualified

servicer must determine the reason the

rollout protection device opened before the

device is reset.

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the observation window in the blower access door and

make a note of the number of flashes in sequence between

pauses. Next, refer to the Diagnostic Signal Chart for an

interpretation of the signals and to this section for a descrip-

tion.

BURNER BOX

This furnace must use indoor air for combustion. It is not a

direct vent furnace, and it cannot be installed as a direct

vent furnace. The burner box (on some models) is present

only to reduce the burner sound transmission.

1. Internal Control Failure with Integrated Ignition

Control

AUXILIARY LIMIT CONTROL (FIGURE 35)

An internal control failure occurs when the integrated

ignition control senses an internal problem and stops

the unit.

A manual reset limit is located on the blower side of the

blower deck, near the center. To access this auxiliary limit,

disconnect the electrical power and remove the blower

door. If the limit control opens, the air circulation blower will

run continuously. The diagnostic light will flash four times.

These symptoms are identical to a trip of the primary limit

control. See Section X, Abnormal Operation - Integrated

Ignition Control for diagnosis.

To solve this problem, replace the ignition control.

2. System Lockout

A system lockout occurs when the integrated ignition

control determines that a measurable combustion can-

not be established or maintained after three consecu-

tive tries (four, if flame is established then lost) to turn

on the furnace.

The auxiliary limit control is designed to prevent furnace

operation in case of main blower failure on horizontal and

counterflow installations. It may also open if the power

supply is interrupted while the furnace is firing.

If a flame is not sensed during the first six seconds after

a gas valve has been energized, the ignition control will

internally turn off the gas. After 60 seconds, during

which time the induced draft blower purges the heat

exchanger, the ignitor will re-energize and preheat for

27 seconds. The gas valve is then re-energized. If a

flame is not sensed again in six seconds, the gas valve

will de-energize and another purge is performed. The

ignition control will cycle the gas valve three times

before it determines it cannot establish measurable

combustion and enter a lockout state. If a flame is

sensed but lost after 10 seconds, the control will cycle

four more times before locking out. A lockout stops

ignition attempts and causes the air blower to run

continuously. The diagnostic light will indicate either

condition with one short flash followed by a longer off.

The auxiliary limit control is suitable for both horizontal right

and horizontal left installations. Regardless of airflow direc-

tion, it does not need to be relocated.

WARNING

Topreventdeath,personalinjuryorproperty

damage due to fire, follow these directions

for the auxiliary limit control. If the auxiliary

limit control opens, it may be reset one time

only.

The control can be reset and brought out of lockout

mode by turning the thermostat off and then back on. It

can also reset by turning off the electrical disconnect

switch to the furnace for 30 seconds. The control will

reset after one hour.

(SERVICER’S NOTE: If it becomes necessary to slide the

blower assembly out of the furnace, the auxiliary limit

control should be removed first. After the blower assembly

is reinstalled, the auxiliary limit must be reinstalled.)

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 Closed

A sticking pressure switch can be caused by either a

faulty pressure switch, faulty wiring, a disconnected

hose, or a restricted intake or flue piping. In the case

of a pressure switch sticking closed, the probable

cause is a faulty pressure switch or wiring.

If the ignition control senses that the pressure switch

is closed and the induced draft blower is off, it will shut

down the unit until the fault is corrected. The light code

for this problem is two short flashes followed by a

longer pause.

4. Pressure Switch Stuck Open

A sticking open pressure switch can be caused by a

faulty pressure switch, a disconnected hose to the

pressure switch, a restricted air intake or flue piping, or

a faulty wiring.

Figure 35

Auxiliary Limit Control

If the ignition control senses that the induced draft

blower is energized but the pressure switch is not

closed, the control will keep the blower on and wait for

the switch to close. The diagnostic light code for this

problem is three short flashes followed by a pause.

ABNORMAL OPERATION - INTEGRATED IGNITION

CONTROL

The following presents the probable causes of question-

able furnace operation and how to fix them. Look through

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5. Open Limit Control (Primary or Auxiliary)

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

An open limit control can be caused by a low condi-

tioned air flow due to dirty filter or resistance in duct

work, a faulty blower, a blower speed set too low, or a

faulty limit.

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.

When the limit control opens, the induced draft and air

circulation blowers are turned on. The induced draft

blower will remain on for the first fifteen seconds of this

period. The air circulation blower will remain on until

the limit control is closed. The diagnostic light code for

this is four short flashes followed by a pause.

NOTE: There is an approximate 20 second delay between

thermostat energizing and burner firing.

Gas Valves

6. Open Rollout Control

An open rollout control is can be caused by insufficient

combustion 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 limit

is manually reset. The induced draft blower will remain

on for the first fifteen seconds of this period. The

diagnostic light code for this is five short flashes

followed 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 the

induced draft blower continuously. The diagnostic light

code for this is continuous light flashing. Probable

cause is miswiring.

Figure 36

Honeywell Model VR-8205

OPERATING INSTRUCTIONS

1. 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 to

automatically light the burners. Do not try to light burners

by hand.

Figure 37

White Rodgers Model 36E36

5. Honeywell Model VR8205, or White Rodgers Model

36E36, or Robertshaw Model 7222: Turn the gas

control knob clockwise

to the OFF position.

Note: The knob should turn easily. Do not use exces-

sive force.

Gas Control

Valve Lever

(In ON Position)

Outlet Pressure Tap

(Side of Valve)

White Rodgers Model 36E22: Push the switch to the

OFF position.

OUTLET

INLET

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

gas, including near the floor.

Pressure Regulator

Adjustment (Under

Cap Screw)

7. If gas can be smelled following the five minute waiting

period in Step 6, immediately follow the instructions on

Page 2 of this manual. If you do not smell gas after five

minutes:

Inlet Pressure Tap

Figure 38

Robertshaw Model 7222

Honeywell Model VR8205, or White Rodgers Model

36E36, or Robertshaw Model 7222: Turn the gas

control 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 the

ON position.

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Main

Solenoid

Redundant

Solenoid

INLET

OUTLET

ON/Off

Switch

Inlet Pressure Tap

(Side of Valve)

Outlet Pressure Tap

(Side of Valve)

Main Regulator

Adjust

Figure 39

White Rodgers Model 36E22

Figure 41

Measuring Inlet Gas Pressure

(Alternate Method)

CHECK GAS INPUT AND PRESSURES

Gas supply pressure and manifold pressure with the burn-

ers operating must be as specified on the rating plate.

CHECK MANIFOLD PRESSURE

A tapped opening is provided in the gas valve to facilitate

measurement of the manifold pressure. See the “Outlet

Pressure Tap” in Figures 36, 37, 38, & 39. A “U Tube”

manometer having a scale range from 0 to 12 inches of

water should be used for this measurement. The manifold

pressure must be measured with the burners operating .

CHECKING GAS PRESSURE

Gas inlet pressure should be checked and adjusted in

accordance to the type of fuel being consumed.

With Power and Gas Off:

1. Honeywell Model VR8205, or White Rodgers Models

36E36 or 36E22, or Robertshaw Model 7222: Connect

a water manometer or adequate gauge to the “inlet

pressure tap” of the gas valve.

To adjust the pressure regulator, remove the adjustment

screworcoveronthegasvalve.Turnout(counterclockwise)

to decrease pressure, turn in (clockwise) to increase pres-

sure. Only small variations in gas flow should be made by

means of the pressure regulator adjustment. For natural

gas, the manifold pressure must be between 3.2 and 3.8

inches water column (3.5 nominal). For propane gas, the

manifold pressure must be between 9.7 and 10.3 inches

water column (10.0 nominal). Any major changes in flow

should be made by changing the size of the burner orifice.

As an alternative method, inlet gas pressure can also

be measured by removing the cap from the drip leg and

installing a predrilled cap with a hose fitting (Figure 41).

With Power and Gas On:

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

consuming appliances.

Inlet GasPressure

Natural

Propane

Min. 5.0" W.C., Max. 10.0" W.C.

Min. 11.0" W.C., Max. 14.0" W.C.

CHECK GAS INPUT (NATURAL GAS ONLY)

To measure the gas input using the gas meter proceed as

follows:

Inlet Gas Pressure Must Not Exceed the Maximum Value Shown.

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

furnace.

Figure 40

If operating pressures differ from above, make necessary

pressure regulator adjustments, check piping size, etc.,

and/or consult with local utility.

2. With the furnace operating, time the smallest dial on the

meter for one complete revolution. If this is a 2 cubic

foot dial, divide the seconds by 2; if it is a 1 cubic foot

dial, use the seconds as is. This gives the seconds per

cubic foot of gas being delivered to the furnace.

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3. INPUT = GAS HTG VALUE x 3600 SEC. PER CUBIC

FOOT (3600 is a conversion factor- 3600 seconds = 1

hour.)

Connect the correct motor leads to the COOL, HEAT, and

PARK terminals. If heating speed will equal cooling speed,

use the jumper wire provided. All unused motor leads that

are not connected to “PARK” terminals on the control must

be taped to prevent shorts.

Example: Natural gas with a heating value of 1000 BTU

per 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 the

gas supplier.

This measured input must not be greater than the input

indicated in Specification Sheet.

4. Relight all other appliances turned off in Step 1. Be sure

all pilot burners are operating.

CHECK BURNER FLAMES

Flames should be stable, soft and blue, (dust may cause

orange tips but they must not be yellow), extending directly

outward from the burners without curling, floating or lifting

off.

Figure 42

High Limit Control

CHECK HIGH LIMIT CONTROL

CHECK TEMPERATURE RISE

WARNING

Check the temperature rise through the unit by placing

thermometers in supply and return air registers as close to

the furnace as possible. Be sure the thermometers do not

“see” the heat exchangers or false readings could be

obtained.

To prevent death, personal injury, property

damage or premature failure of heat

exchanger, do not adjust the limit control

(factory preset).

1. All registers must be open, all duct dampers must be in

their final (fully or partially open) position, and the unit

operated for 15 minutes before taking readings.

Check limit control operation after 15 minutes of operation

by blocking the return air grille(s).

2. The temperature rise must be within the range specified

on the rating plate or Specification Sheet.

1. After several minutes the burners must go OFF. Blower

will continue to run.

NOTE: Air temperature rise is the temperature difference

between supply and return air.

2. Remove air restrictions and burners will relight after a

cool down period of a few minutes.

With a properly designed system, the proper amount of

temperature rise will normally be obtained when the unit is

operated at rated input with the “as shipped” blower speed.

Adjust the thermostat setting below room temperature

1. Burners must go off.

2. Circulating air blower will continue to run for 60, 90, 120

or 180 seconds as set.

If the correct amount of temperature rise is not obtained, it

may be necessary to change the blower speed. A faster

blower speed will lower the temperature rise. A slower

blower speed will increase the temperature rise.

IMPORTANT NOTE: This unit must not be used as a

construction heater during the finishing phases of construc-

tion of a new structure. This type of use may result in

premature failure due to extremely low return air tempera-

tures and exposure to corrosive or very dirty atmospheres.

NOTE: Blower speed must be set to give the correct air

temperature rise through the furnace as marked on the

rating plate.

TO TURN OFF FURNACE

1. Set the thermostat to lowest setting.

CHANGING BLOWER SPEEDS

WARNING

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

To avoid death or personal injury due to

electricalshock,turnoffpowertothefurnace

before changing speed taps.

3. Honeywell Model VR-8205, or White Rodgers Model

36E36, or Robertshaw Model 7222: Turn the gas

control knob clockwise

to the OFF position.

The knob should turn easily. Do not use excessive

force.

All furnaces ship at high speed for cooling and the speed

listed in Specification Sheet for heating. These speeds

should be adjusted by the installer to match the job require-

ments. See Specification Sheet for details.

White Rodgers Model 36E22: Push switch to the OFF

position.

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

5. Replace the door on the unit.

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XI. Maintenance

WARNING

Front of Furnace

To prevent death or personal injury due to

electric shock, disconnect electrical power

before performing any maintenance.

Blower

IMPORTANT NOTE: Handle the ignitor with care. Touch-

ing the ignitor body with bare fingers, rough handling, or

vibration could result in early ignitor failure. Only a qualified

servicer should ever handle the ignitor.

Grab Here

And Lift

Have the furnace checked at least once a year, before the

heating season begins, to be sure there is adequate com-

bustion air and the vent system is working properly.

1. Lift filter above bottom

rail.

2. Tilt filter to clear rail.

Have vent pipe checked to be sure it is not blocked by debris

which could permit fumes to enter the house. Replace any

rusted or leaking sections of vent pipe.

Front of Furnace

AIR FILTER

WARNING

Blower

Topreventdeath,personalinjuryorproperty

damage due to fire, never operate furnace

without a filter installed. Dust and lint will

build up on internal parts resulting in loss

of efficiency, equipment damage and

possible fire.

3. Lower filter below top

rail.

4. Pull filter out.

A return air filter is not supplied with this furnace; however,

there must be a means of filtering all of the return air. The

installer will supply filter(s) at the time of installation.

Figure 43

Filter Removal

Filters should be inspected, cleaned or changed every two

months or as required. It is the owner’s personal responsi-

bility to keep air filters clean. Remember - dirty filters are the

most common cause of inadequate heating or cooling

performance.

Replace the filter with the same type and size filter when

needed.

Use a vacuum cleaner to clean out the blower area and the

adjacent area of the return air duct.

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

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

recommended on adhesive container. Spray adhesives for

use with permanent metal filters can be found at some

hardware stores. Reinstall filter by placing it into the furnace

along the side of the blower. Engage filter in top rail, move

toward side of furnace and drop it into the bottom rail. BE

SURE AIRFLOW DIRECTION ARROW POINTS TO-

WARDS THE BLOWER.

WARNING

Topreventdeath,personalinjuryorproperty

damageduetoelectricalshock, disconnect

electricalpowertofurnacebeforeremoving

filter or performing any other maintenance.

Become familiar with filter location and procedures for

removal, cleaning and replacing them. If help is needed,

contact the installer of the furnace or a qualified servicer.

When the filter is located in the bottom of the furnace on a

bottom return system the filter is held in place by a sheet

metal retainer strap. To change and clean the filter slide one

end of the retainer towards the front and remove filter.

AIR FILTER - UPFLOW FURNACES

If the filter is in the furnace retaining rails, remove it as

follows: Pull off the non-louvered door. The blower motor

will automatically stop through the interlock switch.

AIR FILTER - COUNTERFLOW FURNACES

A furnace mounted filter rack, shipped with the furnace, can

be used in counterflow installation.

Grasp the lower portion of the filter, lift up to disengage it

from the lower railing, move towards blower, drop filter

down. Pull filter outward (Figure 43).

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The furnace-mounted filter rack includes a rack mounted

on the top of the furnace. Two filters fit into the rack and rest

against the sides of the return air plenum, forming a “V”

above the furnace.

BLOWER MOTOR

The air circulating blower motor bearings are permanently

lubricated. No further lubrication is required.

The filters should be inspected frequently and cleaned or

replaced when necessary. In some installations, the filters

can be inspected after disconnecting the electrical power

and removing the optional access door in the return air

plenum. If this access panel is not present, proceed as

follows:

INDUCED DRAFT BLOWER MOTOR

The induced draft blower motor is permanently lubricated.

No further lubrication is required.

FLAME SENSOR (INTEGRATED IGNITION CONTROL)

(QUALIFIED SERVICER ONLY)

1. Disconnect the electrical power.

The fuel or combustion air supply can create a nearly

invisible coating on the flame sensor. This coating acts as

an insulator, causing a drop in the flame sensing signal. To

remove this coating, a qualified servicer should carefully

clean the flame sensor with emery cloth or steel wool. After

cleaning, the microamp signal should be in the range listed

in Specification Sheet.

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

3. Remove the left filter by reaching to the left side of the

blower, pushing the filter up slightly to remove it from

the filter rack, and pulling it down to the left of the blower

and out the blower door. Repeat with the right filter.

4a. Dirty throwaway filters must be replaced with the same

filter type and size.

IGNITOR (QUALIFIED SERVICER ONLY)

4b. Dirty, permanent metal filters must be cleaned as

follows:

If the ignitor and the surrounding air are at about 70°F and

the ignitor wires are not connected to any other electrical

components, the resistance of the ignitor should not ex-

ceed 200 ohms. If it does, the ignitor should be replaced.

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

should then be sprayed with a filter adhesive as is

recommended on the adhesive container. Many hard-

ware stores stock spray adhesives for use with perma-

nent filters.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

At the start of each heating season, inspect and if nec-

essary, clean the furnace flue passages.

If badly torn or uncleanable, these filters must be

replaced by equal size permanent, high velocity filters.

Throwaway filters must not be used as replacement for

permanent filters. Under normal use, permanent filters

should last for several years.

CLEANING FLUE PASSAGES (QUALIFIED SERVICER

ONLY)

5. To reinstall the filters, first MAKE CERTAIN THE

AIRFLOW DIRECTION ARROW POINTS TOWARDS

THE FURNACE. Then insert the filters from the left side

of the blower. Starting with the right filter, push the filter

into the plenum so that the bottom of the filter rests in

the filter rack and the upper edge rests against the side

of the plenum. Repeat with the left filter (Figure 44).

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

2. Remove burner assembly by disconnecting the gas line

and removing the manifold brackets from the partition

panel.

3. Remove the flue from the induced draft blower and the

collector box from the partition panel.

4. The primary heat exchanger tubes can be cleaned

using a round wire brush attached to a length of high

grade stainless steel cable, such as drain cleanout

cable. Attach a variable speed reversible drill to the

other end of the spring cable. Slowly rotate the cable

with the drill and insert it into one of the primary heat

exchanger tubes. While reversing the drill, work the

cable in and out several times to obtain sufficient

cleaning. Use a large cable for the large tube, and then

repeat the operation with a small cable for the smaller

tube. Repeat for each tube.

6. Replace the blower door, then reconnect the electrical

power.

5. When all heat exchanger tubes have been cleaned,

replace the parts in the reverse order in which they

were removed.

6. To reduce the chances of repeated fouling of the heat

exchanger, perform the steps listed in Section X, Start-

up, Adjustments, and Checks.

Figure 44

Furnace mounted Filter Rack

(Counterflow)

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BURNERS

GENERAL INFORMATION

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

to provide the furnace model, manufacturing, and se-

rial numbers with the order.

WARNING

To prevent personal injury or death, do not

remove any internal compartment covers

or attempt any adjustment. Electrical

components are contained in both

compartments. Contact a qualified service

agent at once if an abnormal flame

appearance should develop.

2. Although only functional parts are shown in the parts

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

description.

3. Parts are available from your Amana distributor

Gas Valve

Blower/Box Gasket

Flame Roll-out Switch

Auxiliary Limit

Heat Exchanger

Door Switch

Gas Orifice, Natural

Gas Orifice, Propane

Burner

Ignitor

Periodically during the heating season make a visual check

of the burner flames. Turn the furnace on at the thermostat.

Wait a few minutes, since any dislodged dust will alter the

normal flame appearance. Flames should be stable, quiet,

soft and blue with slightly orange tips. They should not be

yellow. They should extend directly outward from the burner

ports without curling downward, floating or lifting off the

ports.

Flame Sensor

Gas Manifold

Ignition Control

Limit Switch

Transformer

Blower Wheel

Blower Housing

Blower Cutoff

Pressure Switch

Pressure Switch Hose

Induced Draft Blower

Collector Box

Blower Motor

Motor Mount Bracket

Capacitor

CLEANING OF BURNERS (QUALIFIED SERVICER

ONLY)

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 of

burner.

6. Replace burners and burner retention bracket, inspect

the burner assembly for proper seating of burners in

retention slots.

7. Reinstall the burner box front cover.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Figure 45

Burner Flame

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