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Home My WebLink About44908-Z Qhs k�o Town of Southold 7/17/2020 A�; P.O.Box 1179 V0 co -0 4?x 53095 Main Rd j®1 ��yf Southold,New York 11971 4 CERTIFICATE OF OCCUPANCY No: 41259 Date: 7/17/2020 THIS CERTIFIES that the building HVAC Location of Property: 1265 Brigantine Dr., Southold SCTM#: 473889 Sec/Block/Lot: 79.4-54 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 6/12/2020 pursuant to which Building Permit No. 44908 dated 6/23/2020 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built"HVAC as applied for. The certificate is issued to Thiede,Jeffrey&Kristen of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 44908 7/2/2020 PLUMBERS CERTIFICATION DATED Authorize Signatur TOWN OF SOUTHOLD BUILDING DEPARTMENT y a TOWN CLERKS OFFICE o • SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 44908 Date: 6/23/2020 Permission is hereby granted to: Thiede, Jeffrey 80 Warren St#10 New York, NY 10007 To: legalize "as built" electric to propane conversion and "as built' AC unit as applied for. At premises located at: 1265 Brigantine Dr., Southold SCTM # 473889 Sec/Block/Lot# 79.4-54 Pursuant to application dated 6/12/2020 and approved by the Building Inspector. To expire on 12/23/2021. Fees: AS BUILT- SINGLE FAMILY ADDITION/ALTERATION $400.00 CO -ALTERATION TO DWELLING $50.00 Total: $450.00 ing&Ddf -Ms—p—ector Form No.6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the Building Department with the following: A. For new building or new use: 1. Final survey of property with accurate location of all buildings,property lines, streets, and unusual natural or topographic features. 2. Final Approval from Health Dept. of water supply and sewerage-disposal (S-9 form). 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of 1% lead. 5. Commercial building, industrial building,multiple residences and similar buildings and installations, a certificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. B. For existing buildings (prior to April 9, 1957) non-conforming uses,or buildings and "pre-existing"land uses: 1. Accurate survey of property showing all property lines, streets,building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant. If a Certificate of Occupancy is denied,the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees 1. Certificate of Occupancy-New dwelling$50.00,Additions to dwelling$50.00,Alterations to dwelling$50.00, Swimming pool $50.00,Accessory building$50.00,Additions to accessory building$50.00,Businesses $50.00. 2. Certificate of Occupancy on Pre-existing Building- $100.00 3. Copy of Certificate of Occupancy- $.25 4. Updated Certificate of Occupancy- $50.00 5. Temporary Certificate of Occupancy-Residential$15.00, Commercial$15.00 Date. New Construction: Old or Pre-existing Building: 1/ (check one) Location of Property: t o"� r - i s�e �ir t,- 6 House No. Street J Hamlet Owner or Owners of Property: � r � 1, o e�� c, l�P( s� 77, i e_4 Suffolk County Tax Map No 1000, Section D'J"t, ©1) Block 041-lo Lot 0,5-7• od u Subdivision f,.<-L,r '1-( S ©n I IN-Va-_ Filed Map. �] Lot: 7 Permit No. Date of Permit. Applicant: �� rV ej r_ Health Dept. Approval: Underwriters Approval: Planning Board Approval: Request for: Temporary Certificate Final Certificate: (check one Fee Submitted: $ pli ant Signature '\\j Building Department Application AUTIIORIZATION (Where the Applicant is not the Owner) e-Ci& residing at (Print property owner's name) (Mailing Address) do hereby authorize (Agent) to apply on my behalf to the Southold Building Department. (O e s S aturc) atc) ' (Print per's Name) CONSENT TO INSPECTION • �"'' �� ''� the undersigned, do(es) hereby state: Owner(s) a e(s) That the undersigned(is) (are) thewner(s) of the premises in the Town of Southold, located at 1(&6S-21r(ei LYT�I��-k pe- S oLX�o t�t which is shown and designated onl& Suffolk County Tax Map as District 1000, Section Gam, BlockpClLot b�� Db �l That the undersigned (has) (have) filed, or cause to be filed, an application in the Southold Town Build' Inspector's Office for the following: , -121 -, wi �c-�-�-�� —L-� —J \ On cDi That the undersigned do(es) hereby give consent to the Building Inspectors of the Town of Southold to enter upon the above described property, including any and all buildings located thereon, to conduct such inspections as they may deem necessary with respect to the aforesaid application, including inspections to determine that said premises comply with all of the laws, ordinances, rules and regulations of the Town of Southold. The undersigned, in consenting to such inspections, do(es) so with the knowledge and understanding that any information obtained in the conduct of such inspections may be used in subsequent prosecutions for violations of the laws, ordinances, rules or regulations of the Town of Southold. c Date c ®�-C� IC30 �— ' \gnature) N rmt Name) (Signature) (Print Name) ®��OF SOU��®l Town Hall Annex ® Telephone(631)765-1802 54375 Main Road Fax(631)765-9502 P.O.Box 1179 Q sean.devlin(a-)town.Southold.ny.us Southold,NY 11971-0959 ® �� ®lyC®UNTI,�� BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICAL COMPLIANCE SITE LOCATION Issued To: Jeffrey Thiede Address: 1265 Brigantine Dr city,Southold st: NY zip: 11971 Building Permit#: 44908 Section: 79 Block. 4 Lot 54 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor: DBA: Flanders Heating and AC License No: 52079H SITE DETAILS Office Use Only Residential X Indoor Basement Service Commerical Outdoor 1st Floor Pool New Renovation 2nd Floor Hot Tub Addition Survey Attic Garage INVENTORY Service 1 ph Heat Duplec Recpt Ceiling Fixtures Bath Exhaust Fan Service 3 ph Hot Water GFCI Recpt Wall Fixtures Smoke Detectors Main Panel A/C Condenser 1 Single Recpt Recessed Fixtures CO2 Detectors Sub Panel A/C Blower 1 Range Recpt Ceiling Fan Combo Smoke/CO Transformer UC Lights Dryer Recpt Emergency Fixtures Time Clocks Disconnect Switches 4'LED Exit Fixtures Pump Other Equipment: Notes: " AS BUILT " " NO VISUAL DEFECTS " AC C Z Inspector Signature: Date: July 2, 2020 S Devlin-Cert Electrical Compliance Form.xis SOUIyO� # # TOWN OF SOUTHOLD BUILDING DEPT. 765-1802 INSPECTION [ ] FOUNDATION 1ST [ ] ROUGH PL13G. [ ] FOUNDATION-2ND [ ] INSULATIOWCAULKING [ ] FRAMING/STRAPPING [ ] FINAL [' ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH)' [ ELECTRICAL (FINAL) [ ] CODE VIOLATION [` _] PRE C/O A<� REMARKS.. yw&t, fAex-1'12.Ir__A L, 1 N 5?Ezrz&jNj - DATE 7 Z INSPECTOR t,.�c D� �pF SOUTy " hod ��o f TOWN-OF SOUTHOLD BUILDING DEPT. 765.1802 INSPECTION [ '] FOUNDATION 1ST [ ] ROUGH PL13G. [ ] FOUNDATION 2ND [ ] IN ULATION/CAULKING [ ] FRAMING /STRAPPING [ FINAL [ ] -FIREPLACE & CHIMNEY [ ] -FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] 'FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) [ ] ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] PRE C/O REMARKS: DATE INSPECTOR vs ------ --- - # # TOWN OF SOUTHOLD BUILDING DEPT: couto, 765-1802 s. INSPECTION [ ] FOUNDATION IST [ ] ROUGH PLBG. [ ] FOUNDATION 2ND [�] I LATIOWCAULKING - [ ] FRAMING /STRAPPING [ FINAL [ ] FIREPLACE & CHIMNEY [ ]` FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) [ ] ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] PRE C/O REMARKS: a� • D DATE 07//�' z-o INSPECTOR FIELD INSPECTION REPORT DATE COMMENTS *d FOUNDATION (IST) y --------------------------------- FOUNDATION (2ND) �z �o ROUGH FRAMING& y PLUMBING 6 INStiLATION PER N.Y. uJ STATE ENERGY CODE 4-o67P. D G'. - FINAL DITIONAL CO MEN, S .a-an z rn � b o z x r� H C� d tai y TOWN OF SOUTHOLD BUILDING PERMIT APPLICATION CHECKLIST BUILDING DEPARTMENT Do you have or need the following,before applying? TOWN HALL Board of Health SOUTHOLD,NY 11971 4 sets of Building Plans _. TEL:(631)765-1802 Planning Board approval FAX:(631)765-9502 Survey Southoldtownny.gov PERMIT NO. Check Septic Form N.Y:S D.E C Trustees C O'Application Flood Permit Examined 20l Single&Separate Truss Identification Form Storm-Water Assessment Form Contact: Approved ,20A Mail to- Disapproved a/c Phone• - Expiration 200 p — t , J U N la 2020 ilding nspector APPLICATION FOR BUILDING PERMIT \ �] ' y Date 204[ INSTRUCTIONS a This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets of plans,accurate plot plan to scale.Fee according to schedule. b Plot plan showing location of lot and of buildings on premises,relationship to adjoining premises or public streets or areas,and waterways c.The work covered by this application may not be commenced before issuance of Building Permit d Upon approval of this application,the Building Inspector will issue a Building Permit to the applicant Such a permit shall be kept on the premises available for inspection throughout the work e.No building shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has not been completed within 18 months from such date.If no zoning amendments or other regulations affecting the property have been enacted in the interim,the Building Inspector may authorize,in writing,the extension of the permit for an addition six months.Thereafter,a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of Southold,Suffolk County,New York,and other applicable Laws,Ordinances or Regulations,for the construction of buildings,additions,or alterations or for removal or demolition as herein described The applicant agrees to comply with all applicable laws,ordinances,building code,housin code,and regula ions,and to admit authorized inspectors on premises and in building for necessary inspections S XSi ature of applicant or name,if a corporation) -� 1,91a DI L 0✓ 111 -7 (Mailing address of applicant) St to whether applicant is owner,lessee agent,architect,engineer,general contractor,electric n,plumber or builder Name of owner of premises �, mA C_ rid t it :a 1 (As on the tax roll or latest deed) If applicant is a corporation,signature of duly authorized officer (Name and title of corporate officer) Builders License No. Plumbers License No. Electricians License No fl� Other Trade's License No. Cor1/0r► NSC, �CC�h5�—►`®, ✓�`��7 y 1. Location of land on which proposed work will be done: C J q House Number reet Hamlet County Tax Map No. 1000 Section U 7 C/. bO Block 0�lG b d Lot U Jrq. 6 6 o g Subdivision Cat ` Filed Map No._-T/4 Lot 7 �k r E� 2 State existing use and occupancy of premises a d intended use and occupancy of proposed construction: a a. Existing use and occupancy � - war\ eS �, e '(�6 VIA, CSS t,&C v��W(*kA, ��t, b. Intended use and occupancy r�¢^p pL�v�� C'�-�c ��.1> Cy�4 It 61-1 V-- A�./d� f p,v(�t'l c-7 3. Nature of work(check which applicable):New Building Addition Alteration Repair Removal Demolition Other Work (Description) 4. Estimated Cost Oto,0 . OC1 Fee (To be paid on filing this application) 5. If dwelling,number of dwelling unitsL__Number of dwelling units on each floor If garage, number of cars 6. If business,commercial or mixed occupancy,specify nature and extent of each type of use. V3 (o3 3 1 7. Dimensions of existing structures,if any:Front -)-4 Rear Depth f 9 Height Number of Stories (5he_5Z o T Dimensions of same structure with alterations or additions: Front 54-� c,,.5 CsJzi°Q - Depth Height Number of Stories 8. Dimensions of entire new construction:Front:�-&-,t,_e, ci,-z Depth Height Number of Stories 9. Size of lot:Front ►1_0 0 I Rear I D& Depth `� 10.Date of Purchase' 1 6 0 f� Name of Former OwnerA�Y1 �' �.�¢;Ca'tC� I )Jc��t 0 11.Zoite or use district in which premises are situated 12.Does proposed construction violate any zoning law,ordinance or regulation?YES NO V00"" 13.Will lot be re-graded?YES NO Will ex ess fill be removed from premises?YES NO 3e c-'" 15' f(,,t e.dV_' i"v1��4 r�,n :�#I b 14.Names of Owner of premises Wf14kevi-V6+e 6k-ddress N t�� 10 W-7 Phone No.9i%--_V54- Name of Architect Address Phone No Name of Contractor f I& rS Z;:k ,n Address cP l r7 LC-4-A-}' Phone No C-3/- 741- a�k,0 6 At R Co P_ha 1'r i o 10 r.,,6 v�trct Jt tl"�Yr �,rn� h�cs c rS 1 I�;j/� 15 a.Is this property within 100 feet of a tidal wetland or a freshwater wetland?*YES NO *IF YES,SOUTHOLD TOWN TRUSTEES&D.E C.PERMITS MAY BE RF JIRED. b.Is this property within 300 feet of a tidal wetland?*YES NO ►/ *IF YES,D.E.C.PERMITS MAY BE REQUIRED. 16.Provide survey,to scale,with accurate foundation plan and distances to property lines. 17.If elevation at any point on property is at 10 feet or below,must provide topographical data on survey. 18.Are there any covenants and restrictions with respect to this property?*YES NO *IF YES,PROVIDE A COPY. STATE OF NEW YORK) nn SS: COUNTY,OF rt�t7I 1`�2a o-I ��°— ` y` being duly sworn,deposes and says that(s)he is the applicant (Name of individual signing c ct)above named, (S)He is the Nw4i (Contractor,Agent,Corporate Officer,etc.) of said owner or owners,and is duly authorized to perform or have performed the said work and to make and file this application, that all statements contained in this application are true to the best of his knowledge and belief;and that the work will be performed in the manner set forth in the application filed therewith. Sworn to before me this of BETSY A PERKINS otaq Public,State of New York Notary Pui},,i� ° 'pi�tiified in Suffolk County 202-1 �f#�ignature of Applic t ,Commission Exp:res July IS G Z 5 _ y ♦4 y!. BUILDING DEPARTMENT- Electrical Inspector €: TOWN OF SOUTHOLD Town Hall Annex - 54375 Main Road - PO Box 1179 Southold, New York 11971-0959 Telephone (631) 765-1802 - FAX (631) 765-9502 rogerr southoldtownn ov sea nd southoldtownn .qov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INFORMATION (Ail information Required) Date: Company Name: (�,� Name: License No.: email: Address: Phone No.: (off I _ a —,9116-b JOB SITE INFORMATION (All Information Required) Name: �'�'�Q � 4. r1s�-6 vu--ok ,e-4 -� Address: 1 c ��r�� a� �\� t l i Cross Street: P0��h Phone No.: -�. ", - 1 � � ISI�,n -� 7 6 v`�- �, Ott 5`r Bldg.Permit#: Tax Map District: 1000 Section:_15 %60 Block: ® LID ® Lot: BRIEF DESCRIPTION OF WORK (Please Print Clearly) �c A>ACA bV— CQ COA Circle All That Apply: Is job ready for inspection?: YES / NO Rough In Final Do you need a Temp Certificate?: YES / NO Issued On Temp Information: (All information required) Service Size 1 Ph 3 Ph Size: A # Meters Old Meter# New Service - Fire Reconnect - Flood Reconnect- Service Reconnected - Underground - Overhead # Underground Laterals 1 2 H Frame Pole Work done on Service? Y N Additional Information: PAYMENT DUE WITH APPLICATION Request for inspection Form.As ` �, J.KEVIN MCLAUGHLIN Attorney At Law Telephone(631)765-6085 Winds Way Professional Center Facsitmle(631)765-1856 44210 Rt.48,P O.Box 1210 Email 1kmclaw2c optonline.net Southold,New York 11971 June 9, 2020 Southold Town Building Department Attn. Michael Verity P.O. Box 1179 Southold, NY 11971 Re: 1265 Brigantine Drive, Southold, NY Dear Mike: I have enclosed the duly signed Authorization of owner, Application for Building Permit, Application for Certificate of Occupancy, Application for Electrical Inspection, Consent to Inspect, along with copies of the Service Instructions for the propane furnace and the central air- conditioning system. This is an "as-built" application, as the propane furnace (which replaced electric heat) and the central air-conditioning system were installed by Flanders Heating &Air Conditioning in 2012. Please advise as to the fees required to be paid and I will forward my check(s) to you. Thanks. Very ruly yours, e ' cLaughlin Encs. !.KEVIN MCLAUGHLIN Attorney At Law Telephone(631)765-6085 Winds Way Professional Center Facsumle(631)765-1856 44210 Rt.48,P.O.Box 1210 Email lkmclaw a,optonline.net Southold,New York 11971 June 25, 2020 Southold Town Building Department Attn. Sue P.O. Box 1179 Southold, NY 11971 Re: 1265 Brigantine Avenue, Southold, NY Permit No. 44908 Dear Sue: I have enclosed my check in the sum of$630.00, representing the filing fee for the building permit and the electrical inspection. Please contact Sheri Winter Parker at 631-848-7730 to arrange for access to the subject premises. Very truly/yours, J. evi a Enc. I ��:-• '-J 15'1 JUN 2 9 2020 ; SURVEY. OF PROP.PRTY _ ; V -AT BA YVIE iY - . - TLS WN . Ok -S O UTH. 6L.D - g" SUFFOLK COUNTY, NE ,YORK F w�1�({{flyy''00 NTT-79gf-44—h5�4 dA11UARY- 25,, 1999 ' a ." ;JULY 27, 2011 (mflrom`enls shown) Aug. 2 20t! tcer#)Rcatla �- ' ^ ns sadded?. 1s4.StY fr hSe. 'VD osphv)t -devewayY' _° 7p8, a x _ c ca& a hUe 72 y 3 � i'— PIPE0) _491 �s $ LOT NUMBERS REFER TO MAP � OF "HARBOR LIC$TS ESTATES", SECTION 3 F100 IN TBE SUFFOLK M Q COUNTY CLERK'S OFFICE ON AUGUST CERTIFIED TOt 7, t988 AS FILE NO. 5147. JEFFREY DOUGLAS TMIEDE KRISTEN TMIEDE FIDELITY,NATIONAL. TITLE I INSURANCE COUP �3 WELLS FARGO BANK, N.A. AREA" 20;663 sq. ft. Atq ,s too_ aura ,,_.x � OF ALTU'A;;+u'01 �; h't" yEiY 3'CRn S7'.T£. rJ:rCr;:t7V '-;ti' m' SL" nc F377�'=� ia>uS7c (�YtiJ) FXC r G;Y 72 ;G'?10N 7>^ >a"t6�., iU1 2. ALt C "- clloX 909 , HEREON AS PER r A44 A,40 COPIES TFd,=.'R[CF .JtY`r if''_ c SE,., C ,.v;tRv-`i%.''� ,�� 7!z'rrifr{PFs aR ET �t E Yh= c;Cg G -wE tst;,n-S5..4 Sn1M+ MAP',,' Ex„ n� i+TFtJL {t,v 11 f Vi'Nt}SE''57 ;�'fA LFFF ,�Prinf•:: tiLC'' <; •„;�. aa•..:.,z>x�,._....,...:., :."•.a:::w,c:%".'..'.'C:..,E....,..... rr`aM:'a.,.?'.,.:..._.._,..',Mka;waa�.«.::..G.-,_ ':>„Y...�'`� R'= .':'-i e':�'...:....�m..>_..__. __ ->'_�._.. _ »...,...>-.`...:,�e........':_:,..,. .a; ;.'„M°>.w`?�..ws"`.::.;..M,. 6ad APPROVED AS NOTED DATE: ��92 B.P.# QUQ FEE: v d By —&�� NOTIFY BUILDING DEPARTMENT AT 765-1802 8 AM TO 4 PM FOR THE FOLLOWING INSPECTIONS: l.-FOUNDATION - TWO REQUIRED ELECTRICAL FOR POURED CONCRETE INSPECTION REQUIRED 2. ROUGH - FRAMING & PLUMBING 3: INSULATION 4. FINAL - CONSTRUCTION MUST BE COMPLETE F0I1 C.O. ALL CONSTRUCTION SHALL MEET THE REQUIREMENTS OF THE CODES OF NEW YORK STATE. NOT RESPONSIBLE FOR DESIGN OR CONSTRUCTION ERRORS. COMPLY WITH ALL CODES OF NEW YORK STATE & TOWN CODES AS REQUIRED AND CONDITIONS OF c A �QI 17H0 TOWN PI ANNIN(;ROARD SeUTk',CJ DJOW UTEES kls nG OCCUPANCY OR USE IS UNLAWFUL WITHOUT CERTIFICATE OF OCCUPANCY D t� SSX14 �Uli R-41 OA Air Conditioner E 07 UP TO 14 SEER .......... N; .FV 0olingPeifinwnx You Can Count On'. X kmlmv To receive the Lifetime Compressor Limited Warranty and 10-Year Parts Limited Warranty,online registration most be completed within 60 days of installation Online registration is not required in California or Ouebec.Full warranty details available at wwwamana-hac com Amana is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company,LY,Houston,7X All rights reserved � . 4 ' O n ~ / ` . ^� SS�� N=� D U/O [� ,�� _^�yl^J^f^��yl��— ��^� U�X�� . Conditioner .~.^ � UP7Tl14 ��D = .° . . ~��.` VVebuild quality into every component ofour Amonallbrand Premium Comfort heating and air conditioning products.That's why ourAmonuw We back the quality of nurAmono Distinctions brand . � Distinctions'brand SSX14High-Efficiency Air Conditioner 8SX14Hi Air Conditioner with the following: has oSeasonal Energy Efficiency Bating(SEER)ofupto14-- .ALifetime Compressor Limited Warranty* o significant improvement in efficiency over many ofthe lower for as UunQ as you mmnn your home SEER units installed inhomes today.With onAmanu ^A10-YeerParts Limited Warranty* onall Distinctions brand SGX14Air Conditioner,your savings, functional parts versus lower SEER units,can odd up very quickly especially mhot weather,when energy use can increase dramatically. Additional Information The savings start with our efficient condensing coil design. Before purchasing this appliance,read important Al VVouse onlyh/gh«uo|hxnf|eduopportubmgand oonugotedri" information about its estimated annual energy consumption, aluminum fins,which withstand the corrosive effects of yearly operating cost,orenergy efficiency rating that iu moisture and extreme temperature ».Our coil design provides available from your retailer. more cooling surface,which further increases efficiency and ^Toreceive the Lifetime Compressor Limited Warranty and,0-Year Parts Limited decreases your energy bill.Additionally,every coil that goes Warrao�,online registration must becompleted within 60 days o/installation. into anAmanoDistinctions brand 8SX14Air Conditioner Online registration mnot required inCalifornia or0uebec Full warranty details om��mwwva�o�mmm mthnmugh�1o��d� ^ Quality You've Come to Expect from Ammana Brand ProductsJeatiny |naddition tooutstanding energy efficiency,the Amono Distinctions brand SSX14High-Efficiency Air Conditioner =� S j "=° =�� =�°� LASTS AND LASTS AND LASTS' provides you with the following benefits: ° Chlorine-free R410Arefrigerant * Acompressor sound cover and a louvered sound-control top * Atactopy-insta||od filter dryer that keeps moisture and debris out nfyour system * A|ouveved cabinet made o(heavy-gauge galvanized steel that protects the coil while its app||anoe-qua|ity,post-paint finish resists the effects ofweather and time * Anattractive design,finished manArchitectural Gray color that complements any home environment ` °aNED Y STAR ratings are dependent upon conditions beyond equipment installation.To make certain your HVAC equipment qualiflas fo STAR designation,get complete information at www.energystargov. 0zo09Goodman Company,LP.mnanaoaregistered trademark mMaytag Corporation ----- mits related companies and is used under license mGoodman Company,LP,xouston,m V��N AJI rights reserved CB-DSsxw ri Service Instructions SSX & ASX Condensing Units and SSZ & ASZ Split System Heat Pumps with R-41 OA Refrigerant Blowers, Coils, & Accessories 0 o D 0 0 D 0 0 0 0 of9 - 0 0 0 0 D 0 0 • . 0 0 This manual is to be used by qualified, professionally trained HVAC technicians only Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person. RS6200006 November2006 Copyright©2006 Goodman Manufacturing Company, L P � l IMPORTANT INFORMATION IMPORTANT INFORMATION ..................................... 2-3 TROUBLESHOOTINGCHART .......................................24 PRODUCT IDENTIFICATION...................................... 4-8 SERVICETABLE OF CONTENTS.......................... ......25 ACCESSORIES.......................................... .............9-16 SERVICING ............................................................26-61 PRODUCT DESIGN ................................................17-18 ACCESSORIES WIRING DIAGRAMS ....................62-66 SYSTEM OPERATION ...........................................19-23 Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required In the repair and who is equipped with the proper tools,parts,testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS. IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS,WORDS AND LABELS A WARNING THIS UNIT SHOULD NOT BE CONNECTED TO.OR USED IN CONJUNCTION WITH,ANY DEVICES THAT ARE NOT DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE NOT BEEN TESTED AND APPROVED BY GOODMAN SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY,REDUCED UNIT PERFORMANCE ANDIOR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN A WARNING A WARNING INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED TO PREVENT THE RISK OF PROPERTY DAMAGE,PERSONAL INJURY,OR DEATH, ONLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN ENTRY DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER LEVEL TECHNICIAN AS SPECIFIED BY THE AIR CONDITIONING AND FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE. REFRIGERATION INSTITUTE(ARI). ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE,PERSONAL INJURY,OR DEATH. AWARNING GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT,YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT.MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT. A WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.MULTIPLE POWER SOURCES MAY BE PRESENT.FAILURE TO DO SO'MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product For further assistance, please contact. CONSUMER INFORMATION LINE GOODMAN® BRAND PRODUCTS AMANAO BRAND PRODUCTS TOLL FREE TOLL FREE 1-877-254-4729 (U.S. only) 1-877-254-4729 (U.S. only) email us at, customerservice@goodmanmfg.com email us at: hac.consumer.affairs@amanahvac.com fax us at: (731) 856-1821 fax us at. (931) 438-4362 (Not a technical assistance line for dealers) (Not a technical assistance line for dealers) Outside the U.S., call 1-713-861-2500. Outside the U.S.,call 1-931-433-6101. (Not a technical assistance line for dealers.) (Not a technical assistance line for dealers.) Your telephone company will bill you for the call. Your telephone company will bill you for the call. ,y t - r IMPORTANT INFORMATION SAFE REFRIGERANT HANDLING While these items will not cover every conceivable situation,they should serve as a useful guide. A WARNING A'WARNING REFRIGERANTS ARE HEAVIER THAN AIR.THEY CAN"PUSH OUT"THE TO AVOID POSSIBLE EXPLOSION: OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE TO AVOID •NEVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER.IF YOU POSSIBLE DIFFICULTY IN BREATHING OR DEATH: MUST HEAT A CYLINDER FOR FASTER CHARGING,PARTIALLY IMMERSE -NEVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE.BY IT IN WARM WATER. LAW,ALL REFRIGERANTS MUST BE RECLAIMED. •NEVER FILL A CYLINDER MORE THAN 80%FULL OF LIQUID REFRIGERANT. -IF AN INDOOR LEAK IS SUSPECTED,THOROUGHLY VENTILATE THE AREA •NEVER ADD ANYTHING OTHER THAN R-22 TO AN R-22 CYLINDER OR BEFORE BEGINNING WORK. R-410A TO AN R-410A CYLINDER.THE SERVICE EQUIPMENT USED MUST -LIQUID REFRIGERANT CAN BE VERY COLD.TO AVOID POSSIBLE FROST- BE LISTED OR CERTIFIED FOR THE TYPE OF REFRIGERANT USED. BITE OR BLINDNESS,AVOID CONTACT WITH REFRIGERANT AND WEAR •STORE CYLINDERS IN A COOL,DRY PLACE.NEVER USE A CYLINDER GLOVES AND GOGGLES.IF LIQUID REFRIGERANT DOES CONTACT YOUR AS A PLATFORM OR A ROLLER. SKIN OR EYES,SEEK MEDICAL HELP IMMEDIATELY. -ALWAYS FOLLOW EPA REGULATIONS.NEVER BURN REFRIGERANT, AS POISONOUS GAS WILL BE PRODUCED. A WARNING TO AVOID POSSIBLE EXPLOSION,USE ONLY RETURNABLE(NOT DISPOSABLE) SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM. AWARNING •ENSURE THE CYLINDER IS FREE OF DAMAGE WHICH COULD LEAD TO A LEAK OR EXPLOSION. •ENSURE THE HYDROSTATIC TEST DATE DOES NOT EXCEED 5 YEARS. THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY("EPA") •ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS. HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL OF REFRIGERANTS INTRODUCED INTO THIS UNIT.FAILURE TO WHEN IN DOUBT,DO NOT USE CYLINDER. FOLLOW THESE REGULATIONS MAY HARM THE ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES.THESE REGULATIONS MAY VARY BY JURISDICTION.A CERTIFIED TECHNICIAN MUST PERFORM THE INSTALLATION AND SERVICE OF THIS PRODUCT.SHOULD QUESTIONS A WARNING ARISE,CONTACT YOUR LOCAL EPA OFFICE.VIOLATIONS OF EPA REGULATIONS MAY RESULT IN FINES OR PENALTIES. TO AVOID POSSIBLE INJURY,EXPLOSION OR DEATH,PRACTICE SAFE HANDLING OF REFRIGERANTS. A WARNING In either of these instances,an electrical short between the terminal and the compressor housing may result in the loss SYSTEM CONTAMINANTS,IMPROPER SERVICE PROCEDURE AND/OR PHYSICAL of integrity between the terminal and its dielectric embed- ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL TERMINALS MAY ment. This loss may cause the terminals to be expelled, CAUSE DANGEROUS SYSTEM VENTING. thereby venting the vaporous and liquid contents Of the compressor housing and system. Thesuccessful developmentof hermetically sealed refrigera- Aventing compressor terminal normally presents no danger tion compressors has completely sealed the compressor's to anyone,providing the terminal protective cover is properly moving parts and electric motor inside a common housing, in place. minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings. If, however, the terminal protective cover is not properly in Fundamental to the design of hermetic compressors is a place,a venting terminal may discharge a combination of method whereby electrical current is transmitted to the (a) hot lubricating oil and refrigerant compressor motorthrough terminal conductors which pass (b) flammable mixture(if system is contaminated through the compressor housing wall. These terminals are with air) sealed in a dielectric material which insulates them from the in a stream ofspraywhich may be dangerous to anyone in the housing and maintains,the pressure tight integrity of the vicinity. Death or serious bodily injury could occur.- hermetic compressor. The terminals and their dielectric Under no circumstances is a hermetic compressor to be embedment are strongly constructed,but are vulnerable to electrically energized and/or operated without having the careless compressor installation or maintenance proce- terminal protective cover properly in place. dures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants. See Service Section S-17 for proper servicing. r PRODUCT IDENTIFICATION SFS-1 14 036 1 A A Brand Name Minor Revision A: Initial Release S:Goodman (High Feature Set Modes) A:Amana Deluxe Major Revision A:Initial Release Product Family S: Split System Electrical Product Type 1:208/230V/60Hz/1 ph 3:208/230V/60Hz/3ph X:Condenser R-41 OA 4:460V/60Hz/3ph Z:Heat Pump R-41 OA Nominal Capacity 018: 1.5 tons 024: 2 tons SEER 036: 3 tons 042: 3.5 tons SEER Rating 048: 4 tons 060: 5 tons 090: 7 5 tons 120: 10 tons 4 PRODUCT IDENTIFICATION MB EE 8 00 A A 1 Design Series MB: Modular Blower Voltage/Hz/Phase 1: 208-230/60/1 Motor Types Design Series E:,Variable-speed R: Constant-speed A: First Series Air Flow Delivered Circuit Breaker 08: 800 CFM 2: 208/230-60-1 12: 1,200 CFM 16: 1,600 CFM Factory-installed 20: 2,000 CFM Electric Heat 00: No Heat MODEL MFG.# MODEL MFG. # MBRO800 MBR0800 MBE1200 MBE1200 MBR1200 MBR1200 MBE1600 MBE1600 MBR1600 MBR1600 MBE2000 MBE2000 MBR2000 MBR2000 CA U F 18 A 4 A Product Type Revision CA:A Coil, Upflow/Downflow A• First Revision CH: Horizontal A Cod,Cased B:Second Revision System Type Refrigerant C:Third Revision U. Uncased Coil 4: R-41 OA P• Painted Case Cod Expansion Device Cabinet Description Cabinet Description F. Flowrator Coil CA Models CH Models A: 14" Cabinet Height) Nominal Capacity B: 17 1/2" A. 14" 18: 18,000 BTUH C.21 B: 17 1/2" 24. 24,000 BTUH D:24 1/2" C. 21" D•24 1/2" 25 25,000 BTUH 30.30,000 BTUH 32:32,000 BTUH MODEL MFG.# 36. 36,000 BTUH MODEL MFG.# CA*F03OB4* CA*F03OB4* 37: 37,000 BTUH CHPF030A4* CHPF030A4* CA*F036B4* CA*F036B4* 48:48,000 BTUH CHPF036134* CHPF036134* CA*F042C4* CA*F042C4* 49:49,000 BTUH CHPF042A4* CHPF042A4* CA*F048C4* CA*F048C4* 60.60,000 BTUH CHPF048D4* CHPF048D4* CA*F057D4* CA*F057D4* 61:61,000 BTUH CHPF060D4* CHPF060D4* CA*F06OD4* CA*F06OD4* 62. 62,000 BTUH CH36FCB CH36FCB CH48FCB CH48FCB CH60FCB CH60FCB 5 z � PRODUCT IDENTIFICATION C A P F 1824 A 6 A ProductT e C:Indoor Coil Revision A: Revision Applicaton A: Upflow/DownflowCoil Refrigerant H: Horizontal A Coil S: Horizontal Slab Coil 6: R-22 4: R-41 OA Cabinet Finish U:Unpainted Nominal Width for Gas Furnace P: Painted A: Fits 14"Furnace Cabinet C:Unpainted Case I B: Fits 171/2"Furnace Cabinet Expansion Device C: Fits 21"Furnace Cabinet F:Flowrator D: Fits 241/2"Furnace Cabinet N: Does Not Apply(Horizontal Slab Coils) Nominal Capacity Range @ 13 SEER 1824: 1 1/2 -2 Tons 3030: 21/2 Tons 3642: 3-3 1/2 Tons 6 s PRODUCT IDENTIFICATION THIS NOMENCLATURE IS TO BE USED AFTER JULY 2006 A R U F 3642 1 6 A Product Type Minor Revision A: Single Piece AirHandler Application C: Ceiling Mount PSC Motor D: Downflow PSC Motor Refrigerant E: Multi-Position Variable Speed Motor R: Multi-Position PSC Motor W:Wall Mount PSC Motor Cabinet Finish Electrical Supply U: Unpainted 1:208-230V/60Hz/1 ph P: Painted N: Uncased Expansion Device F:Flowrator Multi-Position&Downflow Applications Nominal Capacity Range @ 13 SEER 3642: 3-3 1/2 Tons 1830: 1 1/2-3 1/2 Tons Nominal Capacity Range @ 10 SEER 1729: 1 1/2-21/2 Tons(For Export Systems) Ceiling Mount&Wall Mount Applications Nominal Cooling Capacity/Electric Heat kw 1805: 1 1/2 Tons Cooling/5kw Electric Heat 2405: 2 Tons Cooling/5kw Electric Heat 3608: 3 Tons Cooling/8kw Electric Heat 7 PRODUCT IDENTIFICATION Model No. Description SSX14*"*'1* {S}Goodman-High feature set model {S}Split System {X}Condenser R-410A{"'}SEER{'***)Nominal Capacity{1}Voltage{'}Revision ASX14**1* {A}Amana®Brand Deluxe[ {S}Split System {X}Condenser R-41 OA{'*}SEER{****}Nominal Capacity{1}Voltage{*)Revision SSZ14*'*'1* {S)Goodman-High feature set model {S}Split System {X}Heat Pump R-41 OA{"}SEER{****}Nominal Capacity{1}Voltage{'}Revision ASZ14*'**1* {A}Amana®Brand Deluxel {S)Split System {X}Heat Pump R-410A{**}SEER{****}Nominal Capacity{1}Voltage{*}Revision MBE'***AAI {MB}Modular Blower{E}Vanalble Spd {"}Airflow{"}Heat{A}Circuit Breaker{A}Series{1)Voltage MBR***'AA1 {MB}Modular Blower{R}Constant Spd.{"}Airflow{**}Heat{A}Circuit Breaker{A}Series{1}Voltage CAUF*'**4' {CA}A Coil{U}Uncased{F}Flowrator{**'}BTU{*)Cabinet Size{4}Ultron{*}Revision CAUX**"4* {CA}A Coil{U}Uncased{X}TXV{***)BTU{"}Cabinet Size{4}Ultron{*)Revision CAPF****4* {CA}A Coil{P}Painted{F}Fiowrator{***}BTU{*}Cabinet Size{4}Ultron{*}Revision CAPX**"*4* {CA}A Coil{P}Painted{X}TXV{*"}BTU{'}Cabinet Size{4}Ultron(')Revision CHPF****4* (CH)Horizontal{P}Painted{F}Flowrator{**'}BTU{*}Cabinet Size(4)Ultron{*}Revision CHPX****4* {CH}Horizontal{P}Painted{X}TXV{***}BTU{*}Cabinet Size{4}Ultron{"}Revision CH**FCB {CH}Horizontal{**}Capacity{F}Flowrator(C)Cased Coil{B}Series CAUF****6* {CA}A Cod{U)Uncased{F}Flowrator{***}BTU{')Cabinet Size{6}Ultron or R-22{')Revision CAPF'*'*6* {CA}A Coil{P}Painted{F}Flowrator{***}BTU{'}Cabinet Size{6}Ultron or R-22{*}Revision CHPF***'6' {CH}Horizontal{P}Painted{F}Flowrator{"'}BTU{'}Cabinet Size{6}Ultron or R-22{'}Revision CSPF****6* {CH}Horizontal{P}Painted{F}Flowrator{"'}BTU{'}Cabinet Size{6}Ultron or R-22{*}Revision a ACCESSORIES SSX14 Model Description - SSX14- $SX14 SSX14 SSX14, SSX14 SSX14- SSX14 018', '624,, 030.•.; 036 042 048 060 ASC01 Anti-Short Cycle Kit X X X X X X X CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK0W Freeze Protection Kit X X X X X X X TX2N43 TXV Kit X TX3N4Z JTXV Kit X X X TX5N4Z TXV Kit X X X Installed on indoor coil Z Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed,non-bleed,expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. ASX14 Madel Description ASX14 ;ASX14, ASX141' ASX14,- ASX14 ASX14• ASX14 018 '024 030 036, 042 048 0601 ASC01 Anti-Short Cycle Kit X X X X X X X CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X x FSK01A Freeze Protection Kit X X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X X TX5N43 1TXV Kit I I IX X X Installed on indoor coil Z Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed, non-bleed,expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. 9 C ACCESSORIES SSx1 6 Madel Description ;° SSX16 SSX16 SSX1.6 SSX16 SSX16 SSX16 024 630 06 042- 048 A°.060 ASC01 Anti-Short Cycle Kit X X X X X X CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK01A Freeze Protection Kit X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X TX5N43 TXV Kit X X X Installed on indoor coil z Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed, non-bleed,expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. ASM 6 Model, Description ASX16 ASX16 ASX16 , .'- ASX16 ASX16 ASX16' '024 -'030 036 042 048 060 ASC01 Anti-Short Cycle Kit X X X X X X CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK01A1 Freeze Protection Kit X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X TX5N43 TXV Kit X X X 1 Installed on indoor coil 2 Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed,non-bleed, expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. 10 ACCESSORIES SSZ14 Madel, .: Description SSZ14`� SSZ14 SSZ14, SSZ14- SSZ14 SSZ14 'SSZ14 018 .024 '030' 036 . 042 048 060 AFE18-60A All-Fuel Kit X X X X X X X ASC01 Anti-Short Cycle Kit X X X X X X X CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X - X X CSR-U-3 Hard-start Kit X X FSK01A' Freeze Protection Kit X X X X X X X OT/EHR18-60 Emergency Heat Relay kit X X X X X X X OT18-60A2 Outdoor Thermostat w/Lockout Stat X X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X X TX5N43 TXV Kit X X X 'Installed on indoor coil 2 Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Condensing units and heatp pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed expansion valve refrigerant metering device. ASZ14 Madel" .°' Description ASZ14'- ASZ14 ASZ14 ASZ14, •ASZ14 ASZ14' ASZ14 018'' 024 '' 030 036 042 '048 _ 060 AFE18-60A All-Fuel Kit X X X X X X X ASC01 Anti-Short Cycle Kit X X X X X X X CSR-U-1 Hard-start Kit X X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK01A' Freeze Protection Kit X X X X X X X OT18-60A2 Outdoor Thermostat X X X X X X X OY-EHR18-60 Emergency Heat Relat Kit X X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X X TX5N43 TXV Kit X X X 'Installed on indoor coil 2 Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Condensing units and heatp pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed expansion valve refrigerant metering device. 11 19 ACCESSORIES SSZ16 Model Description g SSZ116 SSZ16 SSZ16 SSZ16 . SSZ16• SSZ16 024 030 036 042 048 060 AFE18-60A All-Fuel Kit X X X X X X ASC01 Anti-Short Cycle Kit X X X X X X CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK01A' Freeze Protection Kit X X X X X X OT/EHR18-60 Emergency Heat Relay Kit X X X X X X OY/EH R18-60 Emergency Heat Relay Kit X X X X X X OT18-60A2 Outdoor Thermostat w/ Lockout Stat X X X X X X TX2N43 TXV Kit X TX3N43 TXV Kit X X TX5N43 1TXV Kit I X I X X Installed on indoor coil z Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed,non-bleed,expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. ASZ16 Model Description ASZ16 ASZ16 .ASZ16`+ ASZ16 ASZ16 - ASZ16 024 ,030 036 042, 048- 060 AFE18-60A All-Fuel Kit X X X X X X ASC01 Anti-Short Cycle Kit X X X X X X CSR-U-1 Hard-start Kit X X X CSR-U-2 Hard-start Kit X X X X CSR-U-3 Hard-start Kit X X FSK01A' Freeze Protection Kit X X X X X X OT/EHR18-60 Emergency Heat Relay Kit X X X X X X OY/EH R18-60 Emergency Heat Relay Kit X X X X X X OT18-60A2 Outdoor Thermostat w/ Lockout Stat X X X X X X TX2N43 TXV Kit X TX3N43 lTXV Kit I X X TX5N43 TXV Kit I I X X I X 3 Installed on indoor coil Z Required for heat pump applications where ambient temperatures fall below 0°F with 50%or higher relative humidy. 3 Field-installed,non-bleed,expansion valve kit—Condensing units and heat pumps with reciprocating compressors require the use of start-assist components when used in conjunction with an indoor coil using a non-bleed thermal expansion valve refrigerant metering device. 12 ACCESSORIES EXPANSION VALVE KITS Ib FLARE CONNECTION ForApplications requiring BULB TO BE LOCATED a fieldinstalledaccess fitting AT 10 OR 20 CLOCK � SUCTION UNE BULB OOO EVAPORATORCOIL — L�0 \ SEAL SUPPLIED W/KIT PISTON TAILPIECE SEAL SUPPLIED W/KIT SEAL EXPANSION VALVE DISTRIBUTOR ` BODY \\ m REMOVE BEFORE INSTALLING EXPANSION VALVE 3/8"- SWEAT It 7/8"NUT 114'FLARE ForApplications not requiring CONNECTION afield installed access fitting BULB TO BE LOCATED AT 10 OR 2 O'CLOCK O BULB SUCTION LINE 0 PISTON TAILPIECE EVAPORATOR COIL EXPANSION VALVE DISTRIBUTOR SEAL BODY m \ 3/8"- SWEAT RE ?E BEFORE SEAL SUPPLIED WI KIT o SEAL SUPPLIED W/KIT INSTALLING 7/8"NUT EXPANSION VALVE OT/EH R18-60 OUTDOOR THERMOSTAT& EMERGENCY HEAT RELAY OT18-60 3 COLD. MD WARM m.�....... •�:� 4 L�u®o•R 13 ACCESSORIES 1001, jjY, FSK01A _ FREEZE THERMOSTAT KIT Wire Nut Y ' av Y s � Wire Nut Install Line Install Line Thermostat Thermostat Here O° ®� U Here Wire Nut Y Bjd�k Y OO ire Nut m a a m O O ASC01 A ANTI-SHORT-CYCLE CONTROL KIT ,-,---SHORT CYCLE Y1 R1 PROTECTOR Y2 R2 p '", YELLOW 1-y CONTACTOR nri nn T2 T1 BLACK 1�' ----------- THERMOSTAT L2 L1 WIRE 0 ® C -------------- U U - ------UNIT �.;; •e�.. y ," ". .: BLACK 1 TERMINAL M, BOARD 14 ACCESSORIES COIL ACCESSORIES COIL MODEL T=4 TXV KIT TX3N4 TXV KIT TX5N4 TXV KIT FSK01A FREEZE PROTECTION KIT CXF030B4* X X CA'F036134' X X CA!F042C4' X X CA'F048C4' X X CA'F057D4' X X CXF060D4* X X CHPF030A4* X X CHPF036B4' X X CHPF042A'P X X CHPF048D4' X X CHPF060D4* X X CH36FCB X X CH48FCB X X CH60FCB X X CA*F18246' X X X CA*F30306* X X CA'F36426' X X X CHPF18246' X X CHPF30306' X X CHPF36426* X X CSCF1824N6' X' X CSCF303N6* X X CSCF3642N6' X X X ^ Y �� HKR SERIES ELECTRIC HEAT KITS �r ELECTRIC HEAT KITAPPLICATIONS - MBR&MBE ELECTRIC HEAT KIT BLOWER HKR-03A HKR-05(C)A HKR-06A, HKR-08(C)A HKR-10(C)A HKR-15(C)A HKR-20(C)A HKR-21(C)A HKR3-15A HKR3-20A MBR0800AA-1 X X X X X MBR1200AA-1 X X X X X X X X X X MBR1600AA-1 X X X X X X X X X X MBR2000AA-1 X X X X X X X X X X MBE1200AA-1 X X X MBE1600AA-1 - X X MBE2000AA-1 - X X X X=Allowable combinations -=Indicate restricted combinations ELECTRIC HEAT KITAPPLICATIONS -ARPF ARPF1824 ARPF1931, ARPF3030 ARPF364Z ARPF3743 ' •ARPF4860 1116 1/16; 1/16 1/16 1/16 1/16 HKR-03* X X X X X X HKR-05* HKR-05C* X X X X X X HKR-06* X X X X X X HKR-08* HKR-08C* X' X' X X X X HKR-10* HKR-10C* X' X' X' X X X HKR-15C* Xz X2 X2 X3 X3 X HKR-20C* X2 X3 X3 X HKR-21 C* Xz X3 X3 X A HKR3-15* Xz X3 X3 X ^ HKR3-20* Xz X3 X3 X * Revision level that may or may not be designated ' Air handler must either be on medium or high speed C Circuit breaker option Air handler must be on high speed A Heat kit requires three-phase power supply 3 For static pressure of 0.6 or higher, air handler must be on mariiiim nr hich cnaari 15 r• r ACCESSORIES ELECTRIC HEAT KITAPPLICATIONS -ARUF ARUF1729 ARUF1824 ARUF1431. ARUF3030, ARUF3642 ARUF3743 ARUF4860 1/96 1116„ 1116 1116 1116 1/16 1/16 HKR-03* X X X X X X X HKR-05*, HKR-05C* X X X X X X X HKR-06* X X X X X X X HKR-08*, HKR-08C* X' X' X' X X X X HKR-10*, HKR-10C* X' X' X' X' X X X HKR-15C* X2 X2 X2 X2 X3 X3 X HKR-20C* X2 X3 X3 X HKR-21 C* X2 X3 X3 X ^ HKR3-15* X2 X3 X3 X ^ HKR3-20* X2 X3 X3 X * Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply ' Air handler must either be on medium or high speed 2 Air handler must be on high speed ' For static pressure of 0.6 or higher, air handler must be on medium or high speed ARUF024- ARUF032- ARUF042- A_RUF049- ARUF061 00A1A 00A1B . 00A1B 00A1B 00A1B HKR-03* X X X X X HKR-05*, HKR-05C* X X X X X HKR-06* X X X X X HKR-08*, HKR-08C* X X' X X X HKR-10*, HKR-10C* X' X' X' X X HKR-15C* X2 X2 X3 X HKR-20C* X2 X3 X HKR-21 C* X2 X3 X ^ HKR3-15* X2 X3 X ^ HKR3-20* X2 X3 X * Revision level that may or may not be designated C Circuit breaker option ^ Heat kit requires three-phase power supply Air handler must either be on medium or high speed 2 Air handler must be on high speed 3 For static pressure of 0.6 or higher, air handler must be on medium or high speed 16 . , PRODUCT DESIGN This section gives a basic description of cooling unit opera- COILS AND BLOWER COILS tion, its various components and their basic operation. MBR/MBE blower cabinets are designedto be used as atwo- Ensure your system is properly sized for heat gain and loss piece blower and coil combination. MBR/MBE blower sec- according to methods of the Air Conditioning Contractors tions can be attached to cased evaporator coil. This two- Association(ACCA)or equivalent. Ipiece arrangement allows for a variety of mix-matching possibilities providing greater flexibility. The MBE blower CONDENSING UNIT cabinet uses a variable speed motor that maintains a con- The condenser air is pulled through the condenser coil by a stant airflow with a higher duct static. direct drive propeller fan. This condenser air is then dis- It is approved for applications with cooling coils of up to'0.8 charged out of the top of the cabinet. These units are inches W.C.external static pressure and includes a feature designed forfree air discharge,so no additional resistance, thatallows airflowto be changed by+15%.The MBR blower like ductwork, shall be attached. i cabinetuses a PSC motor.Itis approved for applications with The suction and liquid line connections on present models cooling coils of up to 0.5 inches W.C. external static pres- are of the sweat type for field piping with rrefrigerant type sure. copper. Front seating valves are factory installed to accept The MBR/MBE blower cabinets with propercoil matches can thefield run copper.Thetotal refrigerant charge for a normal be positioned for upflow, counterflow, horizontal right or installation is factory installed in the condensing unit. horizontal left operation.All units are constructed with R-4.2 ASX,SSX,ASZ and SSZ models are available'in 11/2 through insulation. In areas of extreme humidity(greater than 80% 5 ton sizes and use R-410A refrigerant.Theyare designed for consistently),insulate the exterior of the blower with insula- 208/230 volt single phase applications. tion having a vapor barrier equivalent to ductwork insulation, ASX and ASZ R-41 OA model units use the Copeland Scroll Providing local codes permit. "Ultratech" Series compressors which are specifically de- The CAPX/CHPX coils are equipped with a thermostatic signed for R-410Arefrigerant.These units also have Copeland® expansion valve that has a built-in internal check valve for ComfortAlertdiagnostics. refrigerant metering. The CACF/CAPF/CHPF coils are equipped with a fixed restrictor orifice. SSX and SSZ R-41 OA model units use the Copeland Scroll "Ultratech" Series compressors which are specifically de- The coils are designed for upflow,counterflow or horizontal signed for R-410Arefrigerant. application, using two-speed direct drive motors on the i CACF/CAPF/CHPX models and BPM(Brushless Permanent There are a number of design characteristics which are Magnet)or ECM motors on the MBE models. different from the traditional reciprocating and/orscroll com- pressors. I - "Ultractech" Series scroll compressors will 'not have a dis- charge thermostat.Some of the early model scroll compres- sors required discharge thermostat. "Ultratech" Series scroll compressors use "POE" or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS. "POE" oil must be used if additional oil is required. i i I I I I 17 I I PRODUCT DESIGN The ASX [16 & 18] and ASZ [16 & 18] series split system units use a two-stage scroll compressor. The two-step modulator has an internal unloading mechanism that opens a bypass port in the first compression pocket, effectively reducing the displacement of the scroll. The opening and closing of the bypass port is controlled by an internal electrically operated solenoid. -",,I Modulation Ring � �^ -'&Bypass Seals ®, As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form,the gas,which is now ?o `" at a high pressure, is discharged out of a port located at the ° - center. During compression,several pockets are being compressed Solenoid Coll, `4, Assembly ". �" simultaneously,resulting in a very smooth process Both the A suction process outer portion of the scroll members and the p ( p ) discharge process(inner portion)are continuous The ZPS/ZRS two-step modulated scroll uses a single step Some design characteristics of the Compliant Scroll com- of unloading to go from full capacity to approximately 67% pressorare: capacity.A single speed,high efficiency motor continues to Compliant Scroll compressors are more tolerantofliquld run while the scroll modulates between the two capacity refrigerant. steps. NOTE: Even though the compressor section of a Scroll .ry compressor is more tolerant of liquid refrigerant,contin- ued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing w failure. Compliant Scroll compressors use white oil which is Bypass Ports Bypass Ports compatible with 3GS. 3GS oil may be used if additional Closed Open oil is required 100% Capacity 67% Capacity. Compliant scroll compressors perform"quiet"shutdowns that allow the compressorto restart immediately without the need for a time delay. This compressor will restart A scroll is an involute spiral which, when matched with a even if the system has not equalized. mating scroll form as shown,generates a series of crescent NOTE: Operating pressures and amp draws may differ shaped gas pockets between the two members from standard reciprocating compressors.This informa- During compression, one scroll remains stationary (fixed tion can be found in the unit's Technical Information scroll)while the otherform(orbiting scroll)is allowed to orbit Manual. (but not rotate)around the first form. 18 SYSTEM OPERATION COOLING HEATING The refrigerant used in the system is R-41 OA. It is a clear, The heating portion of the refrigeration cycle is similarto the colorless, non-toxic and non-irritating liquid. R-410A is a cooling cycle.By energizing the reversing valve solenoid coil, 50:50 blend of R-32 and R-125. The boiling point at atmo- the flow of the refrigerant is reversed. The indoor coil now spheric pressure is-62:9°F. becomes the condenser coil,and the outdoor coil becomes A few of the important principles that make-the refrigeration the evaporator coil. cycle possible are: heat always flows from a warmer to a The check valve at the indoor coil will open by the flow of cooler body.Under lower pressure,a refrigerantwill absorb refrigerant letting the now condensed liquid refrigerant by- heat and vaporize at a low temperature. The vapors maybe pass the indoor expansion device. The check valve at the drawn off and condensed ata higher pressure and tempera- outdoor coil will be forced closed by the refrigerant flow, ture to be used again. thereby utilizing the outdoor expansion device. The indoor evaporator coil functions to cool and dehumidify The restrictor orifice used with the CA*F,CHPF and CH**FCB the air conditioned spaces through the evaporative process coils will be forced onto a seat when running in the cooling taking place within the coil tubes. cycle, only allowing liquid refrigerant to pass through the NOTE: The pressures and temperatures shown in the orifice opening. In the heating cycle, it will be forced off the refrigerant cycle illustrations on the following pages are for seatallowing liquid to flow around the restrictor.Acheckvalve demonstration purposes only.Actual temperatures and pres- is not required in this circuit. sures are to be obtained from the"Expanded Performance COOLINGCYCLE Chart". When the contacts of the room thermostat close making Liquid refrigerant at condensing pressure and temperatures, terminals Rto Y&G,the lowvoltage circuit of the transformer (270 psig and 1220F), leaves the outdoor condensing coil is completed.Current nowflows through the magnetic hold- through the drier and is metered into the indoor coil through ing coils of the compressor contactor (CC) and-fan relay the metering device. As the cool, low pressure, saturated (RFC). refrigerant enters the tubes of the indoor coil,a portion of the liquid immediately vaporizes.It continuesto soak up heat and This draws in the normally open contact CC, starting the vaporizes as it proceeds through the coil,cooling the indoor compressor and condenser fan motors.At the same time, coil down to about 48°F contacts RFC close,starting the indoor fan motor. Heat is continually being transferred to the cool fins and tubes When the thermostat is satisfied, it opens its contacts, of the indoor evaporator coil by the warm system air. This breaking the low voltage circuit, causing the compressor warming process causes the refrigerant to boil. The heat contactor and indoor fan relay to open, shutting down the removed from the air is carried off by the vapor. ' system. As the vapor passes through the last tubes of the coil, it If the room thermostat fan selector switch should be set on becomes superheated.That is,it absorbs more heat than is the"on"position,then the indoor blowerwould run continuous necessary to vaporize it.This is assurance that only dry gas rather than cycling with the compressor. will reach the compressor. Liquid reaching the compressor ASZ and SSZ models energize the reversing valve thorough can weaken or break compressor valves. the"O"circuit in the room thermostat.Therefore,the revers- The compressor increases the pressure of the gas, thus ing valve remains energized as long as the thermostat adding more heat,and discharges hot,high pressure super- subbase is in the cooling position.The only exception to this heated gas into the outdoor condenser coil. is during defrost. In the condenser coil,the hot refrigerant gas,being warmer than the outdoor air, first loses its superheat by heat trans- ferred from the gas through the tubes and fins ofthe coil.The refrigerant now becomes saturated,partliquid,partvaporand then continues to give up heat until it condenses to a liquid alone.Once the vapor is fully liquefied,it continues to give up heat which subcools the liquid,and it is ready to repeat the cycle. 19 SYSTEM OPERATION DEFROST CYCLE HEATING CYCLE The defrosting of the outdoor coil is jointly controlled by the The ASZ and SSZ model heat pumps use a different control defrost control board and the defrost thermostat. circuit than preceding heat pump models.These models do Solid State Defrost Control not use a reversing relay to energize the reversing valve.Also, many previous models energized the reversing valve off the During operation the power to the circuit board is controlled "B" terminal on the thermostat, and all previous models by a temperature sensor,which is clamped to a feeder tube energized the reversing valve in the heating cycle. entering the outdoor coil.Defrost timing periods of 30,60,or The reversing valve on the SSZ andASZ models is energized 90 minutes may be selected by connecting the circuit board jumperto 30,60,or 90 respectively Accumulation of time for in the cooling cycle through the "0" terminal on the room the timing period selected starts when the sensor closes thermostat. (approximately 31'F),and when the room thermostat calls These models have a 24 volt reversing valve coil.When the for heat. At the end of the timing period, the unit's defrost thermostat selector switch is set in the cooling position,the cycle will be initiated provided the sensor remains closed. "0"terminal on the thermostat is energized all the time. When the sensor opens (approximately 75° F),the defrost Care must be taken when selecting a room thermostat.Refer cycle is terminated and the timing period is reset. If the to the installation instructions shipped with the product for defrost cycle is not terminated due to the sensor tempera- approved thermostats. ture,a ten minute override interrupts the unit's defrost period DF2 TEST JUMPER WIRE 90 A o6D 0 0 DF1 p 30 C Y ❑ ❑ W2 R R DFT 20 SYSTEM OPERATION COOLING CYCLE Reversing Valve (Energized) Indoor � Outdoor Coil � Coil Accumulator Thermostatic Expansion Valve F � Bi-Flow Filter Dryer Check Valve HEATING CYCLE Reversing Valve (De-Energized) Indoor � Outdoor Coil � Coil Accumulator Thermostatic ,WE:a Expansion Valve LenrFilteir FP Check Valve 21 V 1 1 SYSTEM OPERATION EXPANSION VALVE/CHECK VALVE ASSEMBLY EXPANSION VALVE/C HECK VALVE ASSEMBLY IN COOLING OPERATION IN HEATING OPERATION 71 1 Most expansion valves used in current Amana®Brand Heat Pump products use an internally checked expansion valve. This type of expansion valve does not require an external check valve as shown above. However,the principle of operation is the same. RESTRICTOR ORIFICE ASSEMBLY RESTRICTOR ORIFICE ASSEMBLY IN COOLING OPERATION IN HEATING OPERATION In the cooling mode,the orifice is pushed into its In the heating mode,the orifice moves back off its seat,forcing refrigerant to flow through the metered seat,allowing refrigerantto flow unmetered around hole in the center of the orifice. the outside of the orifice. 22 x SYSTEM OPERATION AFE18-60A CONTROL BOARD controls,if the outdoor thermostat fails closed in this position DESCRIPTION during the heating season, it will turn on the furnace during the cooling season on a "Y" cooling demand. In this The AFE1 8 control is designed for use in heat pumpapplica- situation, the furnace produces heat and increases the tions where the indoor coil is located above/downstreamofa indoor temperature thereby never satisfying the cooling gas or fossil fuel furnace. It will operate with single and two - demand. The furnace will continue to operate and can only stage heat pumps and single and two stage furnaces. The be stopped by switching the thermostat to the off position or AFE18 control will turn the heat pump unit off when the removing power to the unit and then replacing the outdoor furnace is turned on. An anti-short cycle feature is also thermostat. When the AFE18 receives a "Y" and "O" incorporated which initiates a 3 minute timed off delaywhen input from the indoor thermostat, it recognizes this as a the compressor goes off. On initial power up or loss and cooling demand in the cooling mode. If the outdoor thermo- restoration of power, this 3 minute timed off delay will be stat is stuck in the closed position switching the"Y"demand initiated.The compressorwon'tbeallowed torestart until the to the "W1" furnace input during the cooling mode as 3 minute off delay has expired. Also included is a 5 second described above, the AFE18 won't allow the furnace to de-bounce feature on the"Y,E,W1 and O"thermostat inputs. operate. The outdoor thermostat will have to be replaced to These thermostat inputs must be present for 5 seconds restore the unit to normal operation. before the AFE18 control will respond to it. An optional outdoor thermostat,OT18-60A,can be used with WARN IN G the AFE18 to switch from heat pump operation to furnace operation below a specific ambient temperature setting,i.e. HIGH VOLTAGE! break even temperature during heating. When used in this Disconnect ALL power before servicing or Installing.Multiple power sources p manner,the"Y"heat demand is switched to the"W1"input may be present.Failure to do so may to the furnace by the outdoor thermostat and the furnace is cause property damage,"personal injury used to satisfy the first stage "Y" heat demand. On some or death. Von- �," � ° :�� ,�. gip':;' ,�°� `:... - .:' •` x. s T �� ° `e- °W° .a•a, �;'g,, x�^ "#. n�'�e�[yy$"S�„ _� 5 30;r�:.ap.,� s ' s �s �_ ped.,s ,s. •,7< " r®• .�.� �, b "° •,:max (,mow �✓6,� °� 19 I � S 23 ` I I TROUBLESHOOTING CHART COOLING/HP ANALYSIS CHART Unsatisfactory System Complaint No Cooling Cooling/Heating Operating Pressures m L y: V m p E ° oo o y POSSIBLE CAUSE N 'o v au o M FO o `m r E v L Te St Method p DOTS IN ANALYSIS a r — N m o j 3 m o a Remedy R GUIDE INDICATE o - °o 3 0 U m d "POSSIBLE CAUSE" to g c u n 0 o a 5 0 0 `o m` .°n °w 2 m aci 22 E E o ° c m E n m 3 3 m L N L _m U) U U W U U U U F- z U U in 7 7 J _i 2 2 Pow er Failure • Test Voltage S-1 Blown Fuse • 1 • 1 • Inspect Fuse Size&Type S-1 Unbalanced Power,3PH • e s Test Voltage S-1 Loose Connection • • • Inspect Connection-Tighten S-2,S-3 Shorted or Broken Wires • • • • • • Test Circuits With Ohmmeter S-2,S-3 Open Fan Overload • • Test Continuity of Overload S-17A Faulty Thermostat • • • • Test Continuity of Thermostat&Wiring S-3 Faulty Transformer o • Check Control Circuit w ith Voltmeter S-4 Shorted or Open Capacitor o • o • • Test Capacitor S-15 Internal Compressor Overload Open • ♦ Test Continuity of Overload S-17A Shorted or Grounded Compressor a • Test Motor Windings S-17B Compressor Stuck • • • ♦ Use Test Cord S-17D Faulty Compressor Contactor • • • Test Continuity of Coil&Contacts S-7,S-8 Faulty Fan Relay • Test Continuity of Coil And Contacts S-7 Open Control Circuit • Test Control Circuit w ith Voltmeter S-4 Low Voltage • • • Test Voltage S-1 Faulty Evap Fan Motor • • ♦ Repair or Replace S-16 Shorted or Grounded Fan Motor • 1 • Test Motor Windings S-16 Improper Cooling Anticipator e • Check Resistance of Anticipator S-36 Shortage of Refrigerant • • ♦ • • Test For Leaks,Add Refrigerant S-101,103 Restricted Liquid Line • • • • • Remove Restriction,Replace Restricted Part S-112 Open Element or Limit on Elec Heater lTest Heater Element and Controls S-26,S-27 Dirty Air Filter • • • • ♦ Inspect Filter-Clean or Replace Dirty Indoor Coil o • • • ♦ Inspect Coil-Clean Not enough air across Indoor Coil • • • • ♦ Check Blow er Speed,Duct Static Press,Filter S-200 Too much air across Indoor Coil ♦ • Reduce Blow er Speed S-200 Overcharge of Refrigerant • e • ♦ e • Recover Part of Charge S-113 Dirty Outdoor Coil • • e ♦ • Inspect Coil-Clean Noncondensibles • • ♦ • Recover Charge,Evacuate,Recharge S-114 Recirculation of Condensing Air • • • Remove Obstruction to Air Flow Infiltration of Outdoor Air • o • Check Window s,Doors,Vent Fans,Etc Improperly Located Thermostat • • Relocate Thermostat Air Flow Unbalanced • • Readjust Air Volume Dampers System Undersized • • Refigure Cooling Load Broken Internal Parts • ♦ Replace Compressor S-115 Broken Valves • • • • Test Compressor Efficiency S-104 Inefficient Compressor • ♦ • • Test Compressor Efficiency S-104 Wrong Type Expansion Valve • • • • • • ♦ Replace Valve S-110 Expansion Device Restricted • • • • • • • Remove Restriction or Replace Expansion Device S-110 Oversized Expansion Valve • • Replace Valve Undersized Expansion Valve • • • • o Replace Valve Expansion Valve Bulb Loose • • Tighten Bulb Bracket S-105 Inoperative Expansion Valve • e • Check Valve Operation S-110 Loose Hold-down Bolts • Tighten Bolts Faulty Reversing Valve • ♦ ♦ ♦ ♦ ♦ ♦ Replace Valve or Solenoid S-21,122 Faulty Defrost Control • ♦ ♦ ♦ ♦ ♦ ♦ Test Control S-24 Faulty Defrost Thermostat ♦ ♦ ♦ ♦ ♦ ♦ ♦ Test Defrost Thermostat S-25 Flow rator Not Seating ProperFy • • 1 ICheck Flow rator&Seat or Replace Flow rator S-111 • Cooling or Heating Cycle(Heat Pump) ♦ Heating Cycle Only(Heat Pump) 24 SERVICING Table of Contents S-1 Checking Voltage..........................................26 S-'25 Testing-Defrost Thermostat...........................40 S-2 Checking Wiring............................................26 S-26 Checking Heater Limit Control(s)...................41' S-3 Checking Thermostat,Wiring&Anticipator ..26 S-27 Checking Heater Elements ............................41 S-3A Thermostat&Wiring .....................................26 S-40 MBR/ARUF Electronic Blower Time Delay....41 S-313 Cooling Anticipator........................................27 S-41 MBE/AEPF With SSX and ASX units ...........43 S-3C Heating Anticipator........................................27 S-60 Electric Heater(optional item).......................47 S-3D Checking Encoded Thermostats ...................27 S-61A Checking Heater Limit Control(S)..................48 S-4 Checking Transformer&Control Circuit .......28 S-61 B Checking Heater Fuse Line...........................49 S-5 Checking Cycle Protector ........... ...... .........28 S-62 Checking Heater Elements ...........................49 S-6 Checking Time Delay Relay..........................28 S-100 Refrigeration Repair Practice.........................49 S-7, Checking Contactor and/or Relays................ 29 S-101 LeakTesting ........ .... ... ...................... ... .. 50 S-8 Checking Contactor Contacts .......................29 S-102 Evacuation .................................................... 50 S-9 Checking Fan Relay Contact ........................29 S-103 Charging........................................................ 50 S-12 Checking High Pressure Control ................... 30 S-104 Checking Compressor Efficiency ..................51 S-13 Checking Low Pressure Control .................... 30 S-1 05A Piston Chart for SSX14 and ASX14 Units......:51 S-15 Checking Capacitor.......................................30 S-105B Thermostatic Expansion Valve...................... 51 S-1 5A Resistance Check......................................... 31 S-106 Overfeeding ...................................................52 S-1 5B Capacitance Check............... .......................32 S-107 Underfeeding.................. .............................. 52 S-1 6A Checking Fan&Blower Motor S-108 Superheat ..................................................... 52 . Windings(PSC Motors) ............................... 32 S-109 Checking Subcooling .......... ........ ................ 55 S-1 6B Checking Fan&Blower Motor(ECM Motors) 32 S-109A Two Speed Application..... ............................ 55 S-16C Checking ECM Motor Windings........... ........ 32 S-1098 Heat Pump Heating Mode .............................56 S-16D ECM CFM Adjustments........................i........W S-110 ' Checking Expansion Valve Operation ...........56 S-16E Blower Performance Data..............................36 S-111 Fixed Orifice Restriction Devices . ................ 56 S-17 Checking Compressor Windings....... ........... 38 S-112 Checking Restricted Liquid Line.................... 57 S-1 7A Resistance Test............................ ...............38 S-113 Refrigerant Overcharge... .... ......................... 57 S-17B Ground Test.. ................... ........................... 38 S-114 Non-condensables ..................................... . 57 S-17C UnloaderTest.. ............................ . .. ........ 39 S-115 Compressor Burnout ......... ........ .................. 57 S-17D Operation Test ..............................................39 S-120 Refrigerant Piping.......................................... 58 S-18 Testing Crankcase Heater(optional item) .....40 S-202 Duct Static Pressure S-21 Checking Reversing Valve and Solenoid........40 &Static Pressure Drop Across Coils. .........60 S-24 Testing Defrost Control..................................40 S-203 Air Handler External Static ...........................60 S-204 Coil Static Pressure Drop ........ ................... 61 WA WARNING F H VOLTAGE! connectALL power before servicing or installing.Multiple power sources may be present.Failure to so may cause property damage,personal injury or death. 25 r SERVICING S-1 CHECKING VOLTAGE S-2 CHECKING WIRING 1. Remove outer case, control panel cover,etc.,from unit being tested. &WARNING With power ON: HIGH VOLTAGEI Disconnect ALL power before servicing A WARNING or installing.Multiple power sources maybe present.Failure to do so may Line Voltage now present. cause property damage,personal injury or death. 2. Using a voltmeter,measure the voltage across terminals L1 and L2 of the contactorforthe condensing unit oratthe 1. Check wiring visually for signs of overheating,damaged field connections for the air handler or heaters. insulation and loose connections. 3. No reading-indicates openwiring,openfuse(s)no power 2. Use an ohmmeter to check continuity of any suspected or etc.,from unit to fused disconnect service. Repair as openwires. needed. 3. If any wires must be replaced,replace with comparable 4. With ample voltage at line voltage connectors,energize gauge and insulation thickness. the unit. 5 Measure the voltage with the unit starting and operating, S-3 CHECKING THERMOSTAT, WIRING, AND and determine the unit Locked Rotor Voltaae. NOTE: If ANTICIPATOR checking heaters, be sure all heating elements are THERMOSTAT WIRE SIZING CHART energized. Locked Rotor Voltage is the actual voltage available at LENGTH OF RUN MIN.COPPER WIRE the compressor during starting,locked rotor,or a stalled GAUGE(AWG) condition. Measured voltage should be above minimum 25 feet 18 listed in chart below. 50 feet 16 75 feet 14 To measure Locked Rotor Voltage attach a voltmeter to 100 feet 14 the run"R"and common"C"terminals of the compressor, 125feet 12 or to the T,and TZ terminals of the contactor.Startthe unit 150 feet 12 and allow the compressor to run for several seconds,then shut down the unit. Immediately attempt to restart the S-3A'THERMOSTAT AND WIRING unit while measuring the Locked Rotor Voltage. 6. Lock rotor voltage should read within the voltage tabula- A WARNING tion as shown. If the voltage falls below the minimum voltage,check the line wire size. Long runs of undersizedLine Voltage now present. wire can cause low voltage. If wire size is adequate,notify the local power company in regard to either low or high With power ON,thermostat calling for cooling voltage. 1. Use a voltmeter to check,for 24 volts at thermostat wires UNIT SUPPLY VOLTAGE C and Y in the condensing unit control panel. 2. No voltage indicates trouble in the thermostat,wiring or VOLTAGE MIN. MAX. external transformer source. 460 437 506 3. Check the continuity of the thermostat and wiring. Repair 208/230 -198 253 or replace as necessary. Indoor Blower Motor NOTE: When operating electric heaters on voltages other than 240 volts, refer to the System Operation section on With power ON: electric heaters to calculate temperature rise and air flow. Low voltage may cause insufficient heating. A WARNING Line Voltage now present. 1. Set fan selector switch at thermostat to"ON" position. 2. With voltmeter, check for 24 volts at wires C and G 3. No voltage indicates the trouble is in the thermostat or wiring. 26 S SERVICING- 4. Check the continuity of the thermostat and wiring!.Repair element helping the thermostat call forthe next cooling cycle. or replace as necessary. This prevents the room temperature from rising too high Resistance Heaters before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degree 1. Set room thermostat to a higher setting than room range. temperature so both stages call for heat. The anticipator is supplied in the thermostat and is not to be 2. With voltmeter, check for 24 volts at each heater relay. replaced. If the anticipator should fail for any reason, the Note:BBA/BBC heater relays are DC voltage. thermostat must be changed. 3. No voltage indicates the trouble is in the thermostat or wiring. S-3C HEATING ANTICIPATOR 4 Check the continuity of the thermostat and wiring. Repair The heating anticipator is a wire wound adjustable heater or replace as necessary, which is energized during the "ON" cycle to help prevent NOTE: Consideration must be given to how the heaters are overheating of the conditioned space. wired(O.D.T.and etc.). Also safety devices must be checked The anticipator is a part of the thermostat and if it should fail for continuity. for any reason, the thermostat must be replaced. See the following tables for recommended heater anticipator setting S-313 COOLING ANTICIPATOR in accordance to the number of electric heaters installed. The cooling anticipator is a small heater (resistor) in the thermostat. During the "off' cycle, it heats the bimetal S-3D TROUBLESHOOTING ENCODED TWO STAGE COOLING THERMOSTATS OPTIONS Troubleshooting Encoded Two Stage Cooling Thermostats Options SOT TEST FUNCTION SIGNAL OUT SIGNAL FAN INDICATION Si+ LOW SPEED COOL YCON+ Y1 Si-. 'LO SPEED COOL' •YCON-' 'Y/Y2 HI• •ERROR CONDITION (DIODE ON THERMOSTAT BACKWARDS) S1+- HI SPEED COOL YCON+- Y/Y2 S2+ LO SPEED HEAT W1 HEATER Wiwi SEE NOTE 3 INPUT S2- O ED- O FROM (FUTURE USE) , THERMOSTAT S2+- LO SPEED HEAT W1 HEATER Wiwi SEE NOTE 3 HI SPEED HEAT W2 HEATER EM/W2 S3+ G NONE G 'S3-' N/A N/A N/A •ERROR CONDITION(S3 CAN ONLY READ+) •S3+-• WA WA N/A -ERROR CONDITION(S3 CAN ONLY READ+) POWER R+- 24 VAC RTO TSTAT R TO THERMOSTAT COM GND COM TO TSTAT NOTES 1)THE TEST SPADE CAN BE CONNECTED TO ANY OTHER TEST SPADE ON EITHER BOARD 2)THE+LED WILL BE RED AND WILL LIGHT TO INDICATE+HALF CYCLES THE-LED WILL BE GREEN AND WILL LIGHT TO INDICATE-HALF CYCLES BOTH RED AND GREEN ILLUMINATED WILL INDICATE FULL CYCLES DENOTED BY+- 3)SIGNAL OUT CONDITION FOR W1,W2 HEATER WILL BE AFFECTED BY OT1 PJ4 AND OT2 PJ2 JUMPERS AND OUTDOOR THERMOSTATS ATTACHED THE TABLE ABOVE ASSUMES OT1 PJ4 IS REMOVED AND OT2 PJ2 IS MADE WITH NO OUTDOOR THERMOSTATS ATTACHED The chart above provides troubleshooting for either version of the encoded thermostat option. This provides diagnostic information forthe GMC CHET18-60 ora conventional two cool/two stage heat thermostat with I N4005 diodes added as called out in the above section. A test lead orjumperwire can be added from the testterminal to anyterminal on the 1313682-74 or 1313682-71 variable speed terminal board and provide information through the use of the LED lights on the 1313682-71 VSTB control. Using this chart, a technician can determine if the proper input signal is being received by the encoded VSTB control and diagnose any problems that.may be relayed to the output response of the 1313682-74 VSTM control. 27 r f SERVICING S-4 CHECKING TRANSFORMER With power ON: AND CONTROL CIRCUIT - A WARNING ®WARNING Line Voltage now present. IGH VOLTAGE! 1. Apply 24 VAC to terminals R,and R2. Disconnect ALL power before servicing or installing.Multiple power sources HIGH Should read 24 VAC at terminals Y,and Y2. may be present.Failure to do so may3. Remove 24 VAC at terminals R,and R2. met cause property damage,personal injury 4. Should read 0 VAC at Y,and Y2. or death. W I 5. Reapply 24 VAC to R1 and R2 -within approximately three(3)to four(4)minutes should read 24 VAC at Y,and A step-down transformer(208/240 volt primary to 24 volt sec- Y2, ondary)is provided with each indoor unit. This allows ample If not as above-replace relay. capacity for use with resistance heaters. The outdoor sec- tions do not contain a transformer. S-6 CHECKING TIME DELAY RELAY AWARNING Time delay relays are used in some of the blowercabinets to Disconnect ALL power before servicing. improve efficiency by delaying the blower off time. Time delays are also used in electric heaters to sequence in 1. 'Remove control panel cover, or etc., to gain access to multiple electric heaters. transformer. A WARNING With power ON: Disconnect ALL power before servicing. F A EWARNING 1. Tag and disconnect all wires from male spade connec- Line Voltage now present. 1 tions of relay. 2. Using an ohmmeter, measure the resistance across 2. Using a voltmeter,check voltage across secondary volt- terminals H1 and H2. Should read approximately 150 age side of transformer(R to C). ohms. 3. No voltage indicates faulty transformer,bad wiring,orbad 3. Using an ohmmeter, check for continuity across termi- splices. nals 3 and 1, and 4 and 5. 4 Check transformer primary voltage atincoming linevolt- 4. Apply 24 volts to terminals H1 and H2. Check for age connections and/or splices. continuity across other terminals-should test continu- 5 If line voltage available at primary voltage side of trans- ous. If not as above-replace. former and wiring and splices good,transformer is inop- NOTE: The time delay for the contacts to make will be erative. Replace. approximately 20 to 50 seconds and to open after the coil is de-energized is approximately 40 to 90 seconds. S-5 CHECKING CYCLE PROTECTOR Some modelsfeature a solid state,delay-on make afterbreak time delay relay installed in the low voltage circuit. This control is used to prevent short cycling of the compressor under certain operating conditions. The component is normally closed (R, to Y,). -A power OHMMETER interruption will break circuit(R,to Y)for approximately three minutes before resetting. TESTING COIL CIRCUIT 1. Remove wire from Y,terminal. 2. Wait for approximately four(4) minutes if machine was running. 28 s _ SERVICING S-7 CHECKING CONTACTOR AND/OR RELAYS • Fo &WARNING T2 T1 HIGH VOLTAGE! Disconnect ALL power before servicing ; cc r installing.Multiple power sources VOLT/OHM may be present.Failure to do so may METER cause property damage,personal injury • : L2 L1 or death. ' -- Ohmmeter for testing holding coil The compressor contactor and other relay holding coils are —Voltmeter for testing contacts wired into the low or line voltage circuits. When the control TESTING COMPRESSOR CONTACTOR circuit is energized, the coil pulls in the normally open contacts or opens the normally closed contacts. When the (Single Phase) coil is de-energized, springs return the contacts to their THREE PHASE normal position. Using a voltmeter,test across terminals: NOTE:Most single phase contactors break only one side of A. 1-1-1-2, 1-1-1-3, and 1_2-1_3 - If voltage is present, the line (L 1), leaving 115 volts to ground present at most proceed to B.If voltage is not present,check breaker internal components. or fuses on main power supply.. 1. Remove the leads from the holding coil. B. T1-T2,T1-T3,and T2-T3-If voltage readings are not 2. Using an ohmmeter, test across the coil terminals. the same as in"A", replace contactor. If the coil does not test continuous, replace the relay or contactor. T3 T2 T1 S-8 CHECKING CONTACTOR CONTACTS _ ®WARNING VOLT/OHM Disconnect ALL power before servicing. METER f L3 2 1 SINGLE PHASE: --- 1 Disconnect the wire leads from the terminal(T)side of the ---- ohmmeter for testing holding coil Contactor. — Voltmeter for testing contacts , 2. With power ON,energize the contactor. TESTING COMPRESSOR CONTACTOR (Three-phase) AWARNING S-9 CHECKING FAN RELAY CONTACTS ELl e Voltage now present. 3. Using a voltmeter,test across terminals. AWARNING A. L2-T1 -No voltage indicates CC1 contacts open. HIGH VOLTAGE! If a no voltage reading is obtained-replace the contactor. Disconnect ALL power before servicing or installing.Multiple power sources may be present.Failure to do so may .0—N cause property damage,personal injury or death. 1. Disconnect wires leads from terminals 2 and 4 of Fan Relay Cooling and 2 and 4,5 and 6 of Fan Relay Heating. 2. Using an ohmmeter,test between 2 and 4-should read open.Test between 5 and 6-should read continuous. 3. With power ON,energize the relays. 29 i SERVICING A WARNING Line Voltage now present. 4 3 OHMMETER 2 1 TESTING FAN RELAY LIQUID LINE 4. Using an ohmmeter,test between 2 and 4-should read continuous. Test between 5 and 6-should read open. AUTOMATIC RESET 5. If not as above,replace the relay. If it cuts-out at 610 PSIG t 10 PSIG,it is operating normally (See causes for high head pressure in Service Problem S-12 CHECKING HIGH PRESSURE CONTROL Analysis Guide). If it cuts out below this pressure range, replace the control. Fo &WARNING S-13 CHECKING LOW PRESSURE CONTROL HIGH VOLTAGE! The low pressure control senses the pressure in the suction Disconnect ALL power before servicing line and will open its contacts on a drop in pressure. The low r installing.Multiple power sources pressure control will automatically reset itself with a rise in may be present.Failure to do so may pressure. cause property damage,personal injury The low pressure control is designed to cut-out (open) at or death. approximately 50 PSIG. It will automatically cut-in(close)at approximately 85 PSIG. The high pressure control capillary senses the pressure in the Test for continuity using a VOM and if not as above,replace compressor discharge line. If abnormally high condensing the control. pressures develop,the contacts of the control open,breaking the control circuit before the compressor motor overloads. S-15 CHECKING CAPACITOR This control is automatically reset. CAPACITOR,RUN A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor. 1. Using an ohmmeter, check across terminals of high The capacitors primary function is to reduce the line current pressure control,with wire removed. If not continuous, while greatly improving the torque characteristics of a motor. the contacts are open. This is accomplished by using the 900 phase relationship 3. Attach a gauge to the dill valve port on the base valve. between the capacitor current and voltage in conjunction with With power ON: the motor windings, so that the motor will give two phase operation when connected to a single phase circuit. The Acapacitor also reduces the line current to the motor by WARNING improving the powerfactor. Line Voltage now present. The line side of this capacitor is marked with"COM"and is wired to the line side of the circuit. 4. Start the system and place apiece of cardboard in front CAPACITOR,START of the condenser,coil, raising the condensing pressure. 5. Check pressure at which the high pressure control cuts- out. 30 T SERVICING ' SCROLL COMPRESSOR MODELS S-16A RESISTANCE,CHECK In most cases hard start components are not required on Scroll compressor equipped units due to a non-replaceable A WARNING check valve located in the discharge line of the compressor. However, in installations that encounter low lock rotor volt- HIGH VOLTAGE! age,a hard start kit can improve starting characteristics and Disconnect ALL power before servicing or installing. reduce light dimming within the home. Only hard start kits Multiple power sources may be present.Failure to do approved by Amana®brand or Copeland should be used. so may cause property damage,personal injury "Kick Start"and/or"Super Boost'kits are,not approved start or death. assist devices. Thedischarge check valve closes off high side pressuretothe 1. Discharge capacitor and remove wire leads. compressor after shut down allowing equalization through the scroll flanks. Equalization requires only about"/z second. &WARNING To prevent the compressorfrom short cycling,a Time Delay Discharge capacitor through a 20 to 30 OHM Relay(Cycle Protector)has been added to the low voltage resistor before handling. circuit. RELAY, START A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed. This type of relay is position sensitive. The normally closed contacts are wired in series with the start capacitor and the OHMMETER relay holding coil is wired parallel with the start winding. As the motor starts and comes up to speed, the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor. Two quick ways to test a capacitor are a resistance and a CAPACITOR capacitance check. TESTING CAPACITOR RESISTANCE STA CA ACT OR 2. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor- A. Good Condition-indicator swings to zero and slowly returns to infinity. (Start capacitor with bleed resistor will not return to infinity. It will still read the resistance of the RED 70 resistor). VIOLET 20 YELLOW 12 B. Shorted-indicator swings to zero and stops there- #ORANGE', RT replace. AY C. Open-no reading-replace. (Start capacitor would read resistor resistance.) o2Q T2 T1 0 0 L)=LL RUN B B CAPACITOR CONTACTOR HARD START KIT WIRING 31 r t , SERVICING S-15B CAPACITANCE CHECK 1. Remove the motor leads from its respective connection Using a hookup as shown below, take the amperage and points and capacitor(if applicable). voltage readings and use them in the formula: 2. Check the continuity between each of the motor leads 3.1 Touch one probe of the ohmmeter to the motor frame (ground)and the other probe in turn to each lead. Ifthewindings do not test continuous ora reading is obtained from lead to ground,replace the motor. VOLTMETER S-16B CHECKING FAN AND BLOWER MOTOR (ECM MOTORS) An ECM is an ElectronicallyCommutated Motorwhich offers 15 AMP many significant advantages over PSC motors.The ECM has FUSE near zero rotor loss,synchronous machine operation,vari- able speed,low noise,and programmable airflow.Because of the sophisticated electronics within the ECM motor,some technicians are intimated by the ECM motor,however,these AMMETER fears are unfounded.GE offers two ECM motor testers,and with a VOM meter, one can easily perform basic trouble- shooting on ECM motors.An ECM motor requires power(line voltage)and a signal (24 volts)to operate.The ECM motor CAPACITOR stator contains permanent magnet. As a result, the shaft feels"rough"when turned by hand.This is a characteristic of the motor,not an indication of defective bearings. TESTING CAPACITANCE ®WARNING - ®WARNING Line Voltage now present. Discharge capacitor through a 20 to 30 OHM resistor before handling. 1. Disconnect the 5-pin connector from the motor. 2. Using a volt meter,check for line voltage atterminals#4 &#5 at the power connector. If no voltage is present: Capacitance(MFD)=2650XAmperage 3. Check the unit for incoming power See section S-1. Voltage 4. Check the control board, See section S-40. S-16A CHECKING FAN AND BLOWER MOTOR 5 If line voltage is present,reinsert the 5-pin connector and WINDINGS (PSC MOTORS) remove the 16-pin connector. The auto reset fan motor overload is designed to protect the 6 Check for signal(24 volts)at the transformer motor against high temperature and high amperage condi- 7 Check for signal(24 volts)from the thermostat to the"G" tions by breaking the common circuitwithin the motor,similar terminal at the 16-pin connector. to the compressor internal overload However,heat gener- 8. Using an ohmmeter,check for continuity from the#1 &#3 ated within the motor is faster to dissipate than the compres- (common pins)to the transformer neutral or"C"thermo- sor,allow at least 45 minutes for the overload to reset,then statterminal.If you do not have continuity,the motor may retest. function erratically. Trace the common circuits, locate and repair the open neutral. ®WARNING 9. Setthe thermostatto"Fan-On".Using a voltmeter,check for 24 volts between pin#15(G)and common. HIGH VOLTAGE! 10. Disconnect powerto compressor.Setthermostatto call Disconnect ALL power before servicing for cooling. Using a voltmeter,check for 24 volts at pin# or installing.Multiple power sources may be present.Failure to do so mayA6 and/or#14. cause property damage,personal injury 11. Set the thermostat to a call for heating.Using a voltmeter, or death. check for 24 volts at pin#2 and/or#11. 32 SERVICING Lines 1 and 2 will be connected O for 120VAC Power Connector applications only Gnd (4)--AC Line Connection 5 AC Line Connection OUT- © 18 OUT+ ADJUST+/- [fl 15 G(FAN) Y1 © 1a Y/Y2 COOL Q 13 EM HttW2 DELAY 24 Vac(R) COMMON2 0 11 HEAT W/W1 BK/PWM(SPEED) COMMOM O(REV VALVE) 16-PIN ECM HARNESS CONNECTOR If you do not read voltage and continuity as described, the problem is in the control or interface board,but not the motor. If you registervoltage as described,the ECM power head is defective and must be replaced. 33 . . Symptom Fault Description(s) Possible Causes Corrective Action Cautions and Notes M -Motor rocks _This is normal start-up for _ _ _ C slightly variable speed motor. ♦I when starting. -Manual disconnect switch off or -Check 230 Vac power at motor door switch open. -Check low voltage(24 Vac R to C)at motor. _Turn power OFF prior to repair ^z -Blown fuse or circuit breaker -Check low voltage connections Wait 5 minutes after u -24 Vac wires miswired (G,Y,W,R,C)at motor. -No movement. -Unseated pins in wiring -Check for unseated pins in connectors disconnecting power before harness connectors. on motor harness. opening motor. -Motor won't -Bad motor/control module -Test with a temporary jumper between R-G. -Handle electronic motor/control with care. start. -Moisture present in motor or control module. -Check m -Check for loose motor mount -Turn power OFF prior to repair. -Loose motor mount. Wait 5 minutes after but won't start. -Motor rocks, _Blower wheel not tight on motor shaft. -Make sure blower wheelmr motor/control replacement tight en shaft.nt check, disconnecting power before _Bad motor/control module. -ECMPerfacemeopening motor. ECM motors only. -Handle electronic motor/control with care -Motor- oscillates up& -It is normal for motor to down while oscillate with — — — being tested no load on shaft. off of blower. -Variation in 230 Vac to motor. -Check line voltage for variation or"sag" -Unseated pins in wiring harness -Check low voltage connections -Varies up and down connectors (G,Y,W,R,C)at or intermittent. -Erratic CFM command from motor,unseated pins in motor -Tum power OFF prior to repair. "BK"terminal. harness connectors. -Motor starts, -Improper thermostat connection or setting. -Check-out system controls-Thermostat but runs -Moisture present in motor/control module. -Perform Moisture Check erratically. -Does removing panel or filter -"Hunts"or"puffs"at -Incorrect or dirty filter(s) reduce"puffing"? high CFM(speed). -Incorrect supply or return ductwork. -Check/replace filter -Tum power OFF prior to repair. -Incorrect blower speed setting. -Check/correct duct restrictions. -Adjust to correct blower speed setting. 'Moisture Check -Connectors are oriented"down"(or as recommended by equipment manufacturer). -Arrange harnesses with"drip loop"under motor. -is conaensate arain ptuggea,, -C;necK for tow aimow(too much latent capacity). -Unecn ioi unueic.ndigea wnauion. L.nec.n aria plug iadns in[Loon UUUS,Ldoulet Note:You must use the correct replacement control/motor module since they are factory programmed for specific operating modes.Even though they look alike,different modules may have completely different functionality The ECM variable speed motors are c Important Note:Using the wrong motor/control module voids all product warranties and may produce unexpected results. CHART CONTINUED ON NEXT PAGE CHART CONTINUED FROM PREVIOUS PAGE. Cn M Troubleshooting . . Symptom Fault Description(s) Possible Causes Corrective Action Cautions and Notesn -Check low voltage(Thermostat) -Turn power OFF prior to repair. - -Stays at low CFM despite -24 Vac wires misty fired or loose Hires and connections. Wart 5 minutes after Z system call for cool -"R"missing/not connected at motor. -Verify fan is not in delay mode- disconnecting power before ^ or heat CFM. -Fan in delay mode wait until delay complete. opening motor 61 -Perform motor/control replacement -Handle electronic motor/control check,ECM motors only. with care. -Motor starts, -Turn power OFF prior to repair. but runs Wait 5 minutes after erratically. " -Is fan in delay mode?-wait until delay time complete. y -Stays at high CFM Fan missing/not connected at motor -Perform motor/control replacement check,ECM disconnecting power before - n in delay mode. motors only. opening motor. -Handle electronic motor/control with care -Blower won't shut off. -Current leakage from controls -Check for Tnac switched t'stat -Turn power OFF prior to repair into G,Y,or W. - or solid state relay. -High static creating high blower speed -Incorrect supply or return ductwork. -Check/replace filter -Air Horse. -Incorrect or dirty filter(s). -Check/correct duct restrictions -Turn power OFF prior to repair -Incorrect blower speed setting -Adjust to correct blower speed setting. -Loose blower housing,panels,etc -Check for loose blower housing, -High static creating high blower panels,etc. -Excessive -Noisy blower or cabinet. speed. -Check for air whistling thru seams in -Turn power OFF prior to repair noise. -Air leaks in ductwork,cabinets, ducts,cabinets or panels or panels. -Check for cabinet/duct deformation -High static creating high blower speed. -Does removing panel or filter -"Hunts"or"puffs"at -Incorrect or dirty filter(s). reduce"puffing"? high CFM(speed) -Incorrect supply or return ductwork -Check/replace filter. -Tum power OFF prior to repair. -Incorrect blower speed setting -Check/correct duct restrictions. -Adjust to correct blower speed setting -Tum power OFF prior to repair -Motor failure or Wart 5 minutes after -Evidence of malfunction has Moisture in motor/control module -Replace motor and perform disconnecting power before Moisture occurred and moisture Moisture Checkopening motor is present -Handle electronic motor/control with care. 'Moisture Check -Connectors are oriented"down"(or as recommended by equipment manufacturer). -Arrange harnesses wrath"drip loop"under motor -Is conaensate grain plugged? -t;necK Tor low airnow(too mucn latent capacity). -UneLK rot uriaerrarargeo conuuwn -l.neC.K dnu prug redKs rn rewnr uuub,cauinei Note:You must use the correct replacement control/motor module since they are factory programmed for specific operating modes.Even though they look alike,different modules may have completely different W functionality.The ECM variable speed motors are c Ul Important Note:Using the wrong motor/control module voids all product warranties and may produce unexpected results / SERVICING S-16C CHECKING ECM MOTOR WINDINGS MOTOR SPEED ADJUSTMENT Each ECMTm blower motor has been preprogrammed for operation at 4 distinct airflow levels when operating in Cool- AWARNING ing/Heat Pump mode or Electric Heat mode.These 4 distinct HIGH VOLTAGE! levels mayalso be adjusted slightly lower or higher if desired. Disconnect ALL power before servicing The adjustment between levels and the trim adjustments are or installing.Multiple power sources made by changing the dipswitch(s)eithertoan OFF or ON may be present.Failure to do so may position. cause property damage,personal injury DIPSWITCH FUNCTIONS or death. The MBE / AEPF air handler motors have an electronic control that contains an eight (8) position dip switch. The 1. Disconnectthe 5-pin and the 16-pin connectors from the function of these dipswitches are shown in Table 1. ECM power head. 2. Remove the 2 screws securing the ECM power head and Dipswitch Number Function separate it from the motor. 2 Electric Heat 3. Disconnect the 3-pin motor connector from the power 3 N/A head and lay it aside. 5 Indoor Thermostat 6 Cooling & Heat Pump CFM 4. Using an ohmmeter,check the motor windings for con- 6 tinuity to ground (pins to motor shell). If the ohmmeter 8 CFM Trim Adjust indicates continuity to ground,the motor is defective and must be replaced. Table 1 5. Using an ohmmeter, check the windings for continuity CFM DELIVERY (pin to pin).If no continuity is indicated,the thermal limit Tables 2, 3, 6 and 6 show the CFM output for dipswitch (over load)device may be open.Allow motorto cool and combinations 1-2,and 5-6. retest. Electric Heat Operation 3-pin motor Model Switch 1 Switch 2 CFM connector + . "�', OFF OFF 1,200 ` MBE1200 ON OFF 1,000 OFF ON 800 ' ON ON 600 connector t° OFF OFF 1,600 ON OFF 11400 MBE1600 OFF ON 1,200 5-pinpr, ON ON 1,000 connector OFF OFF 2,000 MBE2000 ON OFF 1,800 S-16D ECM CFM ADJUSTMENTS MBE / AEPF OFF ON 1,600 ON ON 1,200 MBE MOTOR This section references the operation characteristics of the Table 2 MBE/AEPF models motor only. The ECM control board is Cooling/Heat Pump Operation factory set with the dipswitch#4 in the"ON"position and all Model Switch 5 Switch 6 CFM other dipswitches arefactoryset in the"OFF"position.When OFF OFF 1,200 MBE/AEPF are used with 2-stage cooling units, dipswitch ON OFF 1,000 #4 should be in the"OFF"position. MBE12oo OFF ON 800 For most applications, the settings are to be changed ON ON 600 according to the electric heat size and the outdoor unit OFF OFF 1,600 selection. MBE1600 ON OFF 1,400 The MBE/AEPF products use a General Electric EC MTM OFF ON 1,200 motor. This motor-provides many features not available on ON ON 1,000 the traditional PSC motor These features include: OFF OFF 2,000 • Improved Efficiency MBE2000 ON OFF 1,800- Constant CFM OFF ON 1,600 • Soft Start and Stop ON ON 1,200 • Improved Humidity Control Table 3 36 SERVICING THERMOSTAT"FAN ONLY"MODE AEPF DIPSWITCH FUNCTIONS During Fari Only Operations,the CFM output is 30%of the cooling setting. Model Switch 1 Switch 2 EMERGENCY HEAT PUMP CFM BACKUP CFM WITH BACKUP CFM TRIM ADJUST- OFF OFF! 1100 1210 Minor adjustments_ can be made through the dip switch AEPF1830" ON OFF 850 938 combination of 7-8. Table 4shows theswitchposition.forthis -OFF ON 700 770 feature. OFF - OFF 2050 2150 ON OFF 1750 1835 NOTE: The airflow will not make the decreasing adjustment AEPP303614260 OFF ON 1600 1680 in Electric Heat mode. ON ON 1200 1260 ON ON 1020 1020 CFM Switch 7 Switch 8 Tables +10% O N OFF Model Switch 5 Switch 6 EMERGENCY HEAT PUMP CFM BACKUP CFM WITH BACKUP -15% O F F O N OFF OFF 1100 1100 AEPF1830 ON OFF 850 850 Table 4 OFF ON 700 600 OFF OFF, 1800 ' 1600 HUMIDITYCONTROL ON OFF I1580 1580 When using a Humldstat(normally closed),cut jumper PJ6 AEPF3036/4260 OFF ON 1 1480 1480 on the control board.The Humidstat will only affect cooling ON ON 1 1200 1200 airflow by adjusting the Airflow to 85%. ON ON 1 1020 1020 Table 6 TWO STAGE HEATING 1 7-8 shall be OFF-ON for 2.5 ton applications When using staged electric heat, cut jumper PJ4 on the control board. S-16E BLOWER PERFORMANCE DATA M BR800'"-* M BR1200**' M BRI 600**-* M BR2000** SP® STATIC SCFM SCFM SUM SCFM 01 1,240 1,500 1,800 2,160 0.2 1,170 1,460 1,740 2,080 HIGH 0 3 1,120 1,360 1,680 1,990 0.4 1,060 1,280 1,610 1,890 0.5 980 1,200 1,520 1,790 0.6 900 1,110 1,430 1,690 0.1 900 1,380 1,540 1,730 02 850 1,320 1,490 1,670 MEDIUM 0.3 790 1,270 1,450 1,590 04 '740 1,200 1,400 1,520 0 5 680 1,140 13,560 1,420 0.6 605 1,040 1,280 1,320 0.1 650 1,170 1,130 1,520 02 590 1,130 1,100 1,450 LOW 0.3 540 1,080 1,070 1,360 0.4 500 1,020 1,030 1,290 0.5 430 950 990 1,200 0.6 330 830 930 1 1,090 NOTE:External static is for blower @ 230 Volts. It does not include Coil,Air Filter or Electric Heaters. 37 SERVICING S-17 CHECKING COMPRESSOR &WARNING HIGH VOLTAGEI ®WARNING Disconnect ALL power before servicing Hermetic compressor electrical terminal venting can or installing.Multiple power sources be dangerous.When insulating material which may be present.Failure to do so may meet supports a hermetic compressor or electrical terminal cause property damage,personal injury suddenly disintegrates due to physical abuse or as a or death. result of an electrical short between the terminal and the compressor housing,the terminal may be 1. Remove the leads from the compressor terminals. expelled,venting the vapor and liquid contents of the compressor housing and system. ®WARNING If the compressor terminal PROTECTIVE COVERandgasket [terminal e warnings S-17 before removing compressor (if required)are not properly in place and secured,there is a cover. remote possibility if a terminal vents,that the vaporous and liquid discharge can be ignited,spouting flames several feet, 2• Using an ohmmeter,test continuity between terminals causing potentially severe orfatal injuryto anyone in its path. S-R,C-R,and C-S,on single phase units orterminals T2, This discharge can be ignited external to the compressor if T2 and T3,on 3 phase units. the terminal cover is not properly in place and ifthe discharge impinges on a sufficient heat source. Ignition of the discharge can also occur at the venting terminal or insidethe compressor,if there is sufficient contaminant air c present in the system and an electrical arc occurs as the terminalvents. OHMMETER s R Ignition cannot occur at the venting terminal without the comp presence of contaminant air, and cannot occur externally from the venting terminal without the presence of an external TESTING COMPRESSOR WINDINGS ignition source. If either winding does not test continuous, replace the Therefore, proper evacuation of a hermetic system isessen- compressor. tial at the time of manufacture and during servicing. NOTE: If an open compressor is indicated,allow ample time To reduce the possibility of external ignition,all open flame, for the internal overload to reset before replacing compres- electrical power, and other heat sources should be extin- sor. guished or turned off prior to servicing a system If the following test indicates shorted, grounded or open S-17B GROUND TEST windings,see procedures S-19for the next steps to betaken. If fuse,circuit breaker,ground fault protective device,etc., has tripped, this is a strong indication that an electrical S-17A RESISTANCE TEST problem exists and must be found and corrected.The circuit Each compressor is equipped with an internal overload. protective device rating must be checked,and its maximum rating should coincide with that marked on the equipment The line break internal overload senses both motoramperage nameplate and winding temperature. High motortemperatureoramper- age heats the disc causing itto open,breaking the common With the terminal protective cover in place,it is acceptable circuit within the compressor on single phase units. to replace the fuse or reset the circuit breaker ONE TIME Heat generated within the compressor shell,usually due to ONLY to see if it was just a nuisance-opening If it opensagain, DO NOT continue to reset. recycling of the motor,high amperage or insufficient gas to cool the motor, is slow to dissipate. Allow at least three to Disconnect all power to unit, making sure that all power four hours for it to cool and reset,then retest. legs are open. Fuse,circuit breaker,ground fault protective device,etc.has 1. DO NOT remove protective,terminal cover.Disconnect . not tripped- the three leads going to the compressor terminals at the nearest-point to the compressor. 38 1 SERVICING 2. Identify the leads and using a Megger, Hi-,Potential Unloader Test Procedure Ground Tester, or other suitable instrument which puts If it is suspected that the unloader is-not working, the out a voltage between 300 and 1500 volts, check fora following methods may be used to verify operation. . + ground separately between each of the three leads and ground(such as an unpainted tube on the compressor). 1. Operate the system and measure compressor current. Do not use a lowvoltage output instrument such as a volt- Cycle the unloader ON and OFF at 10 second intervals. ohmmeter., The compressor amperage should go up ordown at least 25 percent. 2. If step one does not give the expected results,shut unit off.Apply 18 to 28 volt.ac to the unloader molded plug leads and listen for a click as the solenoid pulls in. Remove power and listen for another click as the unloader HI-POT returns to its original position., 3. If clicks can't be heard, shut off power and remove the control circuit molded plug from the compressor and measure the unloader coil resistance. The resistance COMPRESSORGROUNDTEST ' should be 32 to 60 ohms, depending on compressor temperature. 3. If a ground is indicated,then carefully remove the com- pressor terminal protective cover and inspect for loose 4. Next check the molded plug. leads or insulation breaks in the lead wires. A. Voltage check:Apply control voltage to the plug 4. If novisual problems indicated,carefully removethe leads wires(18 to 28 volt ac).The measured do voltage at the compressor terminals. at the female connectors in the plug should be around 15 to 27 vdc. A WARNING B. Resistance check'Measure the resistance from the end of one molded plug lead to eitherof thetwo Damage can occur to the glass embedded terminals if female connectors in the plug.One'of the connec- the leads are not properly removed.This can result in tors should read close to zero ohms while the terminal and hot oil discharging. othershould read infinity.Repeatwith otherwire. The same female connector as before should read Carefully retest for ground, directly between compressor zerowhiletheother connector again reads infinity. terminals and ground. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity 5. If ground is indicated,replace the compressor. previously should now read close,to zero ohms. S-17C UNLOADER TEST PROCEDURE C. Replace plug if either of these test methods doesn't show the desired results. A nominal 24-volt direct current coil activates the internal unloader solenoid.The input control circuit voltage must be S-17D OPERATION TEST 18 to 28 volt ac.The coil power requirement is 20 VA.The external electrical connection is made with a molded plug If thevoltage,capacitor,overload and motorwinding testfail assembly.This plug contains a full wave rectifier to supply to show the cause for failure: direct current to the unloader coil. ®WARNING �li l HIGH VOLTAGEI Disconnect ALL power before servicing or installing.Multiple power sources may be present.Failure to do so may cause property damage,personal injury, or death. 1. Remove unit wiring from disconnect switch and wire a test cord to the disconnect switch. NOTE:The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type. UNLOADER SOLENOID (Molded Plug) 39 SERVICING 2. With the protective terminal cover in place,use the three When stuck in the mid-position, part of the discharge gas leads to the compressor terminals that were discon- from the compressor is directed back to the suction side, nected at the nearest point to the compressor and resulting in excessively high suction pressure. An increase connectthe common,start and run clipstothe respective in the suction line temperature through the reversing valve can leads. also be measured. Check operation of the valve by starting 3. Connect good capacitors of the right MFD and voltage the system and switching the operation from COOLING to rating into the circuit as shown. HEATING cycle. 4. With power ON, close the switch. If the valve fails to change its position,test the voltage(24V) at the valve coil terminals, while the system is on the A WARNING COOLING cycle. If no voltage is registered at the coil terminals, check the Line Voltage now present. operation of the thermostat and the continuity of the connect- ing wiring from the"O"terminal of the thermostat to the unit. A.If the compressor starts and continues to run,the cause If voltage is registered at the coil, tap the valve body lightly for failure is somewhere else in the system. while switching the system from HEATING to COOLING,etc. B.If the compressor fails to start-replace. If this fails to cause the valve to switch positions,remove the coil connector cap and test the continuity of the reversing COPELAND COMPRESSOR valve solenoid coil. If the coil does not test continuous - replace it. 03 A 12345 L If the coil test continuous and 24 volts is present at the coil I I I I terminals,the valve is inoperative-replace it S-24 TESTING DEFROST CONTROL YEAR MONTH SERIAL PLANT To check the defrost control for proper sequencing,proceed NUMBER as follows: With power ON; unit not running. S-18 TESTING CRANKCASE HEATER 1. Jumper defrost thermostat by placing a jumper wire across the terminals "DFT" and "R" at defrost control (OPTIONAL ITEM) board. The crankcase heatermustbe energized a minimum of four 2. Connectjum per across test pins on defrost control board. (4)hours before the condensing unit is operated. 3. Set thermostat to call for heating.System should go into Crankcase heaters are used to prevent migration or,accumu- defrost within 21 seconds. lation of refrigerant in the compressor crankcase during the 4. Immediately remove jumper from test pins. off cycles and prevents liquid slugging oroil pumping on start up 5. Using VOM check for voltage across terminals"C&O". A crankcase heaterwill not prevent compressordamage due Meter should read 24 volts. to a floodback or overcharge condition. 6. Using VOM check for voltage across fan terminals DF1 and DF2 on the board.You should read line voltage(208- WARNING 230 VAC)indicating the relay is open in the defrost mode. Disconnect ALL power before servicing. 7. Using VOM check for voltage across"W2&C"terminals on the board.You should read 24 volts. 1. Disconnect the heater lead in wires. 8. If not as above,replace control board. 2. Using an ohmmeter,check heater continuity-should test 9. Set thermostat to off position and disconnect power continuous. If not,replace. before removing anyjumpers or wires. NOTE:The positive temperature coefficient crankcase heater NOTE: Remove jumper across defrost thermostat before is a 40 watt 265 voltage heater. The cool resistance of the returning system to service. heater will be approximately 1800 ohms. The resistance will .become greater as the temperature of the compressor shell S-25 TESTING DEFROST THERMOSTAT increases. 1. Install a thermocouple type temperature test lead on the tube adjacent to the defrost control. Insulate the lead S-21 CHECKING REVERSING.VALVE AND point of contact. SOLENOID 2. Check the temperature at which the control closes its Occasionally the reversing valve may stick in the heating or contacts by lowering the temperature of the control.Part cooling position or in the mid-position. # 0130M00009P which is used on 2 and 2.5 ton units should close at 34°F t 5°F.Part#0130M00001 P which is used on 3 thru 5 ton units should close at 31 OF t 3°F. 40 SERVICING 3. Check the temperature at which the control opens its During a cooling or heat pump heating demand, 24Vac is contacts by raising the temperature of the control.Part# supplied to terminal"G"of the EBTDR to turn on the-blower 0130M00009P which is,used on 2 and 2.5 ton units motor. The EBTDR initiates,a 7 second delay on and then should open at 60°F t 5°F.Part#0130M00001 P which energizes it's onboard relay The relay on the EBTDR board is used on 3.thru 5 ton units should open at 75°F,t 6°F closes it's normally open contacts and supplies powertothe 4. If not as above,replace control blower motor. When the"G"input is removed,the EBTDR initiates a 65 second delay off. When the 65 seconds delay 'S-26 CHECKING HEATER LIMIT CONTROL(S) expires the onboard relay is de-energized and it's contacts (OPTIONAL ELECTR/CHEATERS) open and remove powerfrom the blower motor. Each individual heater element is protected with an auto- During an electric heat only demand,"W1"is energized but matic rest limit control connected in serieswith each element "G" is not. IThe blower motor is connected to the normally to prevent overheating of components in case of low airflow. closed contacts of the relay on the EBTDR board. The other This limit control will open its circuit at approximately 150°F. side of this set of,contacts is connected to the heat se- to 160°F and close at approximately 110°F. quencer on the heater assembly that provides power to the first heater element.When"W1"is energized,the sequencer will close it's contacts within 10 to 20 seconds to supply QWARNING power to the first heater element and to the blower motor through the normally closed contacts on the relay on the DISCONNECT ELECTRICAL POWER SUPPLY. EBTDR. When the"W1"demand is removed,the sequencer opens it contacts within 30 to 70 seconds and removes power 1. Remove the wiring from the control terminals. from the heater element and the blower motor. 2. Using an ohmmeter test for continuity across the nor- The EBTDR'also contains a speedup terminal to reduce the mally closed contacts. No reading indicates the control delays during troubleshooting of the unit. When this terminal is open-replace if necessary. Make sure the limits are is shortedto the common terminal,"C",on the EBTDR board, cool before testing. the delay ON time is reduced to 3 seconds and the delay OFF IF FOUND OPEN-REPLACE-DO NOT WIRE AROUND. time is reduced to 5 second. S-27 CHECKING HEATER ELEMENTS Two additional terminals, M1 and M2, are on the EBTDR Optional electric heaters may be added, in the quantities board.These terminals are used to connectthe unused leads shown in the spec sheet for each model unit, to provide from the blower motor and have no affect on the board's electric resistance heating. Under no condition shall more operation. heaters than the quantity shown be installed. SEQUENCE OF OPERATION A WARNING This document covers the basic sequence of operation fora typical application with a mercury bulb thermostat. When a HIGH VOLTAGE! digital/electronic thermostat is used,the on/off staging of the Disconnect ALL power before servicing auxiliary heat will vary. Refer to the installation instruc- or installing.Multiple power sources tions and wiring diagrams provided with the MBR/AR*F may be present.Failure to do so may for specific wiring connections and system configura- -i cause property damage,personal injury F tion. or death. 91 MBR/AR*F WITH SINGLE STAGE CONDENSERS 1.0 Cooling Operation 1. Disassemble and remove the heating element(s). 1.1 On a demand forcooling,the room thermostat energizes 2. Visually inspect the heater assembly for any breaks in °G"and"Y"and 24Vac is supplied to"Y"at the condens- the wire or broken insulators. !ng unit and the"G"terminal on the EBTDR board. 3. Using an ohmmeter,test the element for continuity-no 1.2 The compressor and condenser fan are turned on and reading indicates the element is open. Replace as after a 7 second on delay,the relay on the EBTDR board necessary. is energized and the blower motor starts. S-40 MBR/AR*F ELECTRONIC BLOWER 1.3 When the cooling demand "Y" is satisfied, the room thermostat removes the 24Vac from"G"and"Y". TIME DELAY RELAY 1.4 The compressor and condenser fan are turned off and The MBR/AR*F contains an Electronic Blower Time Delay aftera65 second delayoff,the relayonthe EBTDR board Relay board, B1370735. This board provides on/off time is de-energized and the blower is turned off. delays forthe blower motor in cooling and heat pump heating demands when"G"is energized. 41 SERVICING 2.0 Heating Operation On heat pump units,when the room thermostat set to the 2.1 On a demand for heat,the room thermostat energizes heating mode,the reversing valve is not energized.As long "W1"and 24Vac is supplied to heat sequencer,'HR1,on as the thermostat is set for heating,the reversing valve will the heater assembly. be in the de-energized position for heating except during a 2.2 The contacts M1 and M2 will close within 10 to 20 defrost cycle. Some installations may use one or more seconds and turn on heater element#1. The normally outdoor thermostats to restrict the amount of electric heat closed contacts on the EBTDR are also connected to that is available above a preset ambient temperature. Use terminal M1. When M 1 and M2 close,the blower motor of optional controls such as these can change the operation will be energized thru the normally closed contacts on of the electric heaters during the heating mode. This the EBTDR board. At the same time, if the heater sequence of operation does not cover those applications assembly contains a second heater element, HR1 will 4.1 On a demand for first stage heat with heat pump units, contain a second set of contacts,M3 and M4,which will the room thermostat energizes"G"and"Y"and 24Vac close to turn on heater element#2. is supplied to "Y" at the heat pump unit and the "G" Note: If more than two heater elements are on the heater terminal on the EBTDR board. The heat pump is turned assembly, it will contain a second heat sequencer, HR2, on in the heating mode and the blower motor starts after which will control the 3rd and 4thheater elements ifavailable. a 7 second on delay. Ifthefirststage heatdemand,"W1"cannotbe satisfied bythe 4.2 If thefirst stage heat demand cannot be satisfied bythe heat pump, the temperature indoors will continue to drop. heat pump, the temperature indoors will continue to The room thermostatwill then energize"W2"and 24Vacwill drop. The room thermostat will then energize terminal be supplied to HR2 on the heaterassembly. When the"W2" "W2'for second stage heat and 24Vac will be supplied demand is satisfied, the room thermostat will remove the to heat sequencer HR1 on the heater assembly. 24Vacfrom HR2.The contacts on HR2 will open between 30 4.3 HR1 contacts M1 and M2 will close will close within 10 to 70 seconds and heater elements#3 and#4 will be turned to 20 seconds and turn on heater element#1: At the off. On most digital/electronic thermostats, "W2"will same time, if the heater assembly contains a second remain energized until the first stage demand "W1" is heater element, HR1 will contain a second set of satisfied and then the"W1"and"W2"demands will be contacts, M3 and M4, which will close and turn on removed. heater element#2. The blower motor is already on as 2.3 When the "W1" heat demand is satisfied, the room a result of terminal "G" on the EBTDR board being thermostat will remove the 24Vac from HR1. Both setof energized for the first stage heat demand. contacts on the relay opens within 30 to 70 seconds and Note: If more than two heater elements are on the heater turn off the heater element(s)and the blower motor. assembly, it will contain a second heat sequencer, HR2, which will control the 3rd and 41h heaterelements if available. MBR/AR*F WITH SINGLE STAGE HEAT PUMPS If the second stage heat demand,"W2"cannot be satisfied 3.0 CoolinggOperation by the heat pump,the temperature indoors will continue to drop The room thermostat will then energize "WY and On heat pump units, when the room thermostat set to the 24Vac will be supplied to HR2 on the heater assembly. cooling mode,24Vac is supplied to"O"which energizes the When the"WY demand is satisfied,the room thermostatwill reversingvalve As long as the thermostat is set for cooling, remove the 24Vac from HR2.The contacts on HR2 will open the reversing valve will be in the energized position for between 30 to 70 seconds and heater elements#3 and#4 cooling. will be turned off. On most dig ital/electronic thermostats, 3.1 On a demand forcooling,the room thermostat energizes "W3" will remain energized until the first stage heat "G"and"Y"and 24Vac is supplied to"Y"at the heat pump demand "Y" is satisfied and then the "G", "Y", "W2" and the"G"terminal on the EBTDR board. and "W3" demands will be removed. 3.2 The heat pump turned on in the cooling mode and after 4AAsthe temperature indoors increase,itwill reach a point a 7 second on delay,the relay on the EBTDR board is where the second stage heat demand, "W2", is satis- energized and the blower motor starts.. fied. 'When this happens, the room thermostat will 3.3 When the cooling demand is satisfied,the room thermo- remove the 24Vacfrom the coil of HR1.The contacts on stat removes the 24Vac from"G"and"Y". HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump remains on 3.4 The heat pump is turned off and after a 65 second delay along with the blower motor because the"Y"demand for off,the relay on the EBTDR board is de-energized and first stage heat will still be present. the blower motor is turned off. 4.5 When the first stage heat demand"Y"is satisfied,the 4.0 Heating Operation room thermostatwill removethe 24Vacfrom"G"and"Y". The"heat pump is turned off and the blower motor turns off after a 65 second off delay. 42 SERVICING 5.0 Defrost Operation MBE/AEPF WITH SINGLE STAGE ASX AND SSX On heat pump units,when the room thermostat is set to the CONDENSERS When used with a single stage SSX and ASX-condensers, heating mode,the reversing valve isnot energized. As long asthethermostat issetforheating,thereversing valvewillbe dip switch#4 must be set to the on position on the VSTB in the de-energized position for heating except during a inside the MBE/AEPF. The "Y""output from the indoor defrost cycle. thermostat must be.connected to the yellowwire labeled"Y/ Y2" inside the wire bundle marked "Thermostat" and the 5.1 The heat pump will be on and operating in the heating yellow wire labeled "Y/Y2" inside the wire bundle marked mode as described the Heating Operation in section 4. .Outdoor Unit"must be connected to"Y"at the condenser. 5.2 The defrost control in the heat pump unit checks to see The orange jumper wire from terminal"Y1"to terminal if a defrost is needed every 30,60 or 90 minutes of heat "O" on the VSTB inside the MBE/AEPF must.remain pump operation depending on the selectable setting by connected. monitoring the state of the defrost thermostat attached 1.0 Cooling Operation to the outdoor coil. 1.1 On a demand for cooling,the room thermostat energizes 5.3 If the temperature of the outdoor coil is low enough to "G"and"Y"and 24Vac is supplied to"G"and"Y/Y2"of cause the defrost thermostat to be closed when the the MBE/AEPF unit. The VSTB inside the MBE/AEPF defrost board checks it,the board will initiate a defrost will turn on the blower motor and the motorwill ramp up cycle. to the speed programmed in the motor based on,the 5.4 When a defrost cycle is initiated, the contacts of the settings for dip switch 5 and 6. The VSTB will supply HVDR relay on the defrost board open and turns off the 24Vac to"Y"at the condenser and the compressor and outdoor fan. The contacts of the LVDR relay on the condenser are turned on. defrost board closes and supplies 24Vac to "O" and 1.2 When the cooling demand is satisfied,the room thermo- "W2".The reversing valve is energized and the contacts stat removes the 24Vac from "G" and "Y". The MBE/ on HR1 close and turns on the electric heater(s). The AEPF removes the 24Vac from"Y'at the condenser and unit will continue to run in this mode until the defrost the compressor and condenser fan are turned off. The cycle is completed. blower motorwill ramp down to a complete stop based on 5.5 When the temperature of the outdoor coil rises high the time and rate programmed in the motor. enough to causes the,defrost thermostat to open, the 2.0 Heating Operation defrost cycle will be terminated. If at the end of the programmed 10 minute override time the defrost thermo- 2.1 On a demand for heat,the room thermostat energizes stat is still closed, the defrost board will automatically "W1" and 24Vac is supplied to terminal "E/W1" of the terminate the defrost cycle. VSTB inside the MBE/AEPF unit. The VSTB will turn on 5.6 When the defrost cycle is terminated,the contacts of the the blower motor and the motorwill ramp up to the speed programmed in the motor based on the settings for dip HVDR relay will close to start the outdoor fan and the switch 1 and 2. The VSTB will supply 24Vac to heat contacts of the LVDR relay will open and turn off the sequencer HR1 on the electric heater assembly. reversing valve and electric heater(s). The unitwill now be back in a normal heating mode with a heat pump 2.2 HR1 contacts M1 and M2 will close within 10 to 20 demand for heating as described in the Heating Opera- seconds and turn on heater element#1. At the same tion in section 4. time, if the heater assembly contains a second heater element,HR1 will contain a second set of contacts,M3 S-41 MBE/AEPF WITH SSX AND ASX and M4,which will close and turn on heater element#2. MBE ELECTRONIC BLOWER TIME DELAY RELAY Note: If more than two heater elements are on the heater assembly, it will contain a second heat sequencer, HR2, AEPF AIR HANDLER which will control the 3rd and 4th heater elements if available. SEQUENCE OF OPERATION For the 3.d and 4th heater elements to operate on a second stage heat demand, the PJ4 jumper on the This document covers the basic sequence of operation for a VSTB inside the MBE/AEPF must be cut. With the PJ4 typical application with a mercury bulb thermostat. When a jumper cut,the VSTB will run the blower motoron low speed digital/electronic thermostat is used,the on/off staging of the ona"W1"onlydemand. If the first stage heat demand,"W1" auxiliary heat will vary. Refer to the installation instruc- cannot be satisfied by the heat pump, the temperature tions and wiring diagrams provided with the MBE/AEPF indoors will continue to drop. The room thermostat will then forspecific wiring connections,dip switch setti ngs and energize "W2" and 24Vac will be supplied to HR2 on the system configuration. heater assembly and the blower motor will change to high speed. When the "W2" demand is satisfied, the room 43 y s SERVICING thermostat will remove the Mac from"W2"and the VSTB these can change the operation of the electric heaters will remove the 24Vac from HR2. The contacts on HR2 will during the heating mode. This sequence of operation open between 30 to 70 seconds and heater elements#3 and does not cover those applications. #4 will be turned off and the blower motor will change to low 4.1 On a demand for first stage heat with heat pump units, speed. On most digital/electronic thermostats, "W2" the room thermostat energizes"Y"and"G"and Mac will remain energized until the first stage demand is supplied to"G"and"Y/Y2"of the MBE/AEPF. The "W1"is satisfied and then the"W1"and 11W2"demands VSTB will turn on the blower motor and-the motor will will be removed. ramp up to the speed programmed in the motor based 2.3 When the "W1" heat demand is satisfied, the room on the settings of dip switch 1 and 2. The VSTB will thermostat will remove the 24Vac from"E/W1"and the supply 24Vac to"Y"at the heat pump and the heat pump VSTB removes the 24Vac from HR1. The contacts on is turned on in the heating mode. , HR1 will open between 30 to 70 seconds and turn off the 4.2 Ifthe first stage heat demand cannot be satisfied by the heater element(s)and the blower motor ramps down to heat pump, the temperature indoors will continue to a complete stop. drop. The room thermostat will then energize terminal MBE/AEPF WITH SINGLE STAGE SSZ & ASZ HEAT "W2"for second stage heat and Mac will be supplied to "E/W1" of the MBE/AEPF. The VSTB will supply PUMPS Mac to heat sequencer, HR1, on the electric heater When used with a single stage SSZ orASZ heat pumps,dip assembly. switch#4 must be set to the ON position on the VSTB inside 4.3 HR1 contacts M 1 and M2 will close within 10 to 20 the MBE. The"Y"output from the indoor thermostat must be and turn on heater element#1. At the connected to the yellow wire labeled"Y/Y2"inside the wire time,ecolfdthe heater assembly contains a second hea eer bundle marked"Thermostat"and the yellowwire labeled"Y/ element,HR1 will contain a second set of contacts,M3 Y2"inside the wire bundle marked"Outdoor Unit"must be and M4,which will close to turn on heater element#2. connected to "Y" at the heat pump. The orange jumper wire from terminal "Y1" to terminal "O" on the VSTB Note: If more than two heater elements are on the heater inside the MBE/AEPF must be removed. assembly, it will contain a second heat sequencer, HR2, which will control the 3'd and 4ch heater elements if available. 3.0 COOLING OPERATION For the 3rd and 4th heater elements to operate on a third On heat pump units,when the room thermostat is set to the stage heat demand,the PJ4 jumperon the VSTB inside cooling mode,Mac is supplied to terminal"0"of the VSTB the MBE/AEPF must be cut. If the second stage heat inside the MBE/AEPF unit. The VSTB will supply 24Vac to demand, "W2",,cannot be satisfied by the heat pump,the _"O"at the heat pump to energize the reversing valve.As long temperature indoors will continue to drop.The room thermo- asthethermostatissetforcooling,the reversing valve will be stat will then energize"W3"and 24Vac will be supplied to in the energized position for cooling. "W/W2"of the MBE/AEPF. The VSTB will supply 24Vac to 3.1 On a demand for cooling,the room thermostat energizes HR2 on the electric heater assembly. When the "W3" "G"and"Y"and Mac is supplied to terminals"G"and demand is satisfied, the room thermostat will remove the "Y/Y2"of the MBE/AEPF unit. The VSTB will turn on the Mac from "W/W2" of the MBE/AEPF. The contacts on blower motor and the motor will ramp up to the speed HR2 will open between 30 to 70 seconds and heater programmed in the motor based on the settings of dip elements#3 and#4 will be turned off. On most digital/ switch5and6. The VSTB will supply Mac to"Y"at the electronic thermostats, "W3" will remain energized heat pump. until the first stage demand "Y" is satisfied and then 3.2 The heat pump is turned on in the cooling mode. the "G", "Y", 66W2" and "W3" demands will be re- moved. 3.3 When the cooling demand is satisfied,the room thermo- stat 4.4Asthe temperature indoors increase,itwill reach a point removes the Mac from"G"and Y/Y2"oftheMBE/ p AEPF and the VSTB removes the Mac from"Y"at the where the second stage heat demand, "W2", is satis- heat pump. The heat pump is turned off and the blower fied. When this happens, the room thermostat will motor.will ramp down to a complete stop based on the remove the Mac from"E/W1"of the MBE/AEPF. The time and rate programmed in the motor. contacts on HR1 will open between 30 to 70 seconds and turn off both heater element(s). The heat pump 4.0 HEATING OPERATION remains on along with the blower motor because the"Y" On heat pump units,when the room thermostat is set to demand,for first stage heat will still be present. the heating mode,the reversing valve is not energized. 4.5 When the first stage heat demand"Y"is satisfied,the As long as the thermostat is setforheating,the reversing room thermostatwill remove the 24Vac from"G"and"Y/ valve will be in the de-energized position for`heating Y2"of the MBE/AEPF. The VSTB removes the Mac except during a defrost cycle. Some installations may from"Y"at the heat pump and the heat pump is turned use one or more outdoor thermostats to restrict the off.The blower motorwill ramp down to a complete stop amount of electric heat that is available above a preset based on the time and rate programmed in the motor ambient temperature. Use of optional controls such as control. 44 SERVICING 5.0 DEFROST OPERATION . MBE/AEPF WITH TWO STAGE ASX CONDENSERS On heat pump units,when the room thermostat is set to the 1.0 COOLING OPERATION heating mode,the`reversing valve is not energized. As long When used with the ASX two stage condensers,dip as the thermostat is set for heating,the reversing valve will be switch #4 must be set to the OFF position on the in the de-energized position for heating except during a VSTB inside the MBE/AEPF. The"Y1"output from defrost cycle. the indoorthermostat must be connected to the purple 5.1 The heat pump will be on and operating in the heating wire,labeled"Ylow/Y1" inside the wire bundle marked mode as described the Heating Operation in section 4. "Thermostat" and the purple wire labeled "Ylow/Y1" 5 2 The defrost control in the heat pump unit checks to see inside the wire bundle marked"Outdoor Unit"must be if a defrost is needed every 30,60 or 90 minutes of heat connected to "Ylow/Y1" at the condenser. The "Y2" pump operation depending on the selectable setting by outputfrom the indoorthermostat must be connected to, monitoring the state of the defrost thermostat attached to the yellow wire labeled "Y/Y2" inside the wire bundle the outdoor coil. marked"Thermostat"and the yellowwire labeled"Y/Y2" inside the wire bundle marked"Outdoor Unit"must be 5.3 If the temperature of the outdoor coil is low enough to connected to "Y/Y2" at the condenser. The orange cause the defrost thermostat to be closed when the jumper wire from terminal"Y1"to terminal "O"on defrost board checks it, the board will initiate a defrost the VSTB inside the MBE/AEPF must remain con- cycle. nected. 5.4 When a,defrost cycle is initiated, the contacts of the 1.1 On a demand for cooling,the room thermostat energizes HVDR relay on the defrost board open and turns off the "G"and"Y1"and 24Vac is supplied to"G"and"Ylow/Y1" outdoor fan. The contacts of the LVDR relay on the of the MBE/AEPF unit. The VSTB inside the MBE/ defrost board closes and supplies 24Vac to "O" and AEPF will turn on the blower motor and the motor will "W2".The reversing valve is energized and the contacts ramp up to 60%of the speed programmed in the motor on HR1 close and turns on the electric heater(s).The unit based on the settings for dip switch 5 and 6. The VSTB will continue to run in this mode until the defrost cycle is will supply24Vacto"Ylow/Y1"at the condenser and the completed. compressor and condenser fan starts in low speed 5.5 When the temperature of the outdoor coil rises high operation. enough to causes the defrost thermostat to open, the 1.2 If first stage cooling cannot satisfythe demand,the room ;t defrost cycle will be terminated. If at the end of the thermostat will energize"Y2"and supply 24Vac to the programmed 10 minute override time the defrost thermo- MBE/AEPF unit. The blower motor will change to the stat is still closed, the defrost board will automatically cfm for high speed operation and the VSTB will supply terminate the defrost cycle. 24Vac to"Y/Y2"at the condenser and the compressor 5.6 When the defrost cycle is terminated,the contacts of the and condenserfan will change to high speed operation. HVDR relay on the defrost board will close to start the When the"Y2"demand is satisfied,the thermostat will H' outdoorfan and the contacts of the LVDR relaywill open remove the"Y2"demand and the VSTB will remove the 1 and turn off the reversing valve and electricheater(s).The 24Vac from "Y/Y2"at the condenser. The blower will unitwill now be back in a normal heating mode with a heat drop to 60%of the programmed cfm and the compressor pump demand for heating as described in the Heating and condenser fan will change to low speed. On most Operation in section 4. digital/electronic thermostats, "Y2" will remain energized until the firststage cooling demand"Y1" SEQUENCE OF OPERATION is satisfied and then the "G", "Y1" and "Y2" de- This document covers the basic sequence of operation fora mands will be removed. typical application with a mercury bulb thermostat. When a 1.3 When the first stage cooling demand,"Y1",is satisfied, digital/electronic thermostat is used,the on/off staging ofthe the room thermostat removes the 24Vac from"G"and outdoor unit and auxiliary heat will vary. Refer to the "Y1". The MBE/AEPF removes the 24Vac from"Ylow/ installation instructions andwiring diagrams provided with the Y1'atthe condenserand the compressorand condenser MBE for specificwiring connections,dip switch settings and fan are turned off. The blower motorwill ramp down to a system configuration. complete stop based on the time and rate programmed in the motor. 2.0 Heating Operation 2.1 On a demand for heat,the room thermostat energizes "W1" and 24Vac is supplied to terminal "E/W1" of the VSTB inside the MBE/AEPF unit. The VSTB will turn on the blower motor and the motorwill ramp up to the speed programmed in the motor based on the settings for dip switch 1 and 2. The VSTB will supply 24Vac to heat sequencer HR1 on the electric heater assembly. 45 r . SERVICING 2.2 HR1 contacts M1 and M2 will close within 10 to 20 3.1 On a demand for cooling,the room thermostat energizes seconds and turn on heater element#1 At the same "G"and"Y1"and 24Vac is supplied to"G"and"Ylow/Y1" time, if the heater assembly contains a second heater of the MBE unit. The VSTB inside the MBE will turn on element, HR1 will contain a second set of contacts,M3 the blowermotorand the motorwill ramp upto 60%of the and M4,which will close and turn on heater element#2. speed programmed in the motor based on the settings for Note: If more than two heater elements are on the heater dip switch 5 and 6. The VSTB will supply 24Vac to"Y" assembly, it will contain a second heat sequencer, HR2, at the heat pump and the compressor and outdoor fan which will control the 3rd and 4'h heater elements if available. starts in low speed operation. For the 3'd and 41h heater elements to operate on a 3.2 If first stage cooling cannot satisfy the demand,the room second stage heatdemand,the PJ4 jumperon the VSTB thermostat will energize"Y2" and supply 24Vac to"Y/ inside the MBE/AEPF must be cut. With the PJ4 jumper Y2"of the MBE unit. The blower motor will change to the cut, the VSTB will run the blower motor on low speed on a cfm for high speed operation and the VSTB will supply "W1" only demand. If the first stage heat demand, "W1" 24Vac to"Y2"at the heat pump. The compressor and cannot be satisfied by the heat pump, the temperature outdoor fan will change to high speed operation. When indoors will continue to drop. The room thermostat will then the"Y2"demand is satisfied,the thermostat will remove energize "W2" and 24Vac will be supplied to HR2 on the the"Y2"demand and the VSTB will remove the 24Vac heater assembly and the blower motor will change to high from"Y2"at the heat pump. The blower will drop to 60% speed. When the "W2" demand is satisfied, the room of the programmed cfm and the compressor and outdoor thermostat will remove the 24Vac from"W2"and the VSTB . fan will change to low speed operation. On mostdigital/ will remove the 24Vac from HR2. The contacts on HR2 will electronic thermostats,"Y2"wull remain energized open between 30 to 70 seconds and heater elements#3 and untilthe first stage cooling demand"Y1"is satisfied #4 will be turned off and the blower motor will change to low and then the "G", "Y1" and "Y2" demands will beremoved. speed. On most digital/electronic thermostats, "W2" will remain energized until the first stage demand"W1" 3.3 When the first stage cooling demand,"Y1",is satisfied, is satisfied and then the "W1" and "W2" demands will the room thermostat removes the 24Vac from"G"'and be removed. "Y1". The VSTB removes the 24Vac from"Y'at the heat pump and the compressor and outdoor fan are turned off. 2.3 When the "W1" heat demand is satisfied, the room The blower motor will ramp down to a complete stop thermostat will remove the 24Vac from"E/W1"and the based on the time and rate programmed in the motor. VSTB removes the 24Vac from HR1. The contacts on HR1 will open between 30 to 70 seconds and turn off the 4.0 Heating Operation heaterelement(s)and the blower motor ramps down to a On heat pump units,when the room thermostat is set to complete stop. the heating mode,the reversing valve is not energized. As long as the thermostat is set for heating,the reversing MBE/AEPF WITH TWO STAGE ASZ HEAT PUMP UNITS valve will be in the de-energized position for heating 3.0 Cooling Operation except during a defrost cycle. Some installations may use one or more outdoor thermostats to restrict the When used with the ASZ two stage heat pump, dip amount of electric heat that is available above a preset switch #4 must be set to the OFF position on the ambient temperature Use of optional controls such as VSTB inside the MBE/AEPF. The"Y1"output from the these can change the operation of the electric heaters indoor thermostat must be connected to the purple wire during the heating mode. This sequence of operation labeled"Ylow/Y1"inside the wire bundle marked"Ther- does not cover those applications. mostat"and the purple wire labeled"Ylow/Y1"inside the wire bundle marked"Outdoor Unit"must be connected to 4.1 On a demand forfirst stage heatwith heat pump units,the "Y"at the heat pump. The"Y2"output from the indoor room thermostat energizes"G"and"Y1"and 24Vac is thermostat must be connected to the yellowwire labeled supplied to "G" and "Ylo/Y1" of the MBE/AEPF. The "Y/Y2"inside the wire bundle marked"Thermostat"and VSTB will turn on the blower motor and the motor will the yellow wire labeled "Y/Y2" inside the wire bundle ramp up to 60%of the speed programmed in the motor marked"Outdoor Unit"must be connected to"Y/Y2"at based on the settings of dip switch 1 and 2. The VSTB the heat pump. The orange jumper wire from termi- will supply 24Vac to "Y" at the heat pump. The nal "Y1" to terminal "O" 'on the VSTB inside the compressorwill start on h ig h speed and outdoorfan MBE/AEPF must be removed. will start on low speed on a "Y1" heating demand but the blower motor will deliver only 60% of the On heat pump units,when the room thermostat is set to the programmed cfm for high speed heating operation. cooling mode, Mac is supplied to terminal"0"of the VSTB inside the MBE unit. The VSTB will supply 24Vac to"0"at the heat pump to energize the reversing valve.As long as the thermostat is set for cooling, the reversing valve will be in the energized position for cooling. 46 1 SERVICING 4.2 If a thermostat that provides a"Y2"demand in heating is ': 4.6.When the first stage heat demand"Y1"is satisfied,the used and first stage heating cannot satisfy the demand, room thermostat will remove the 24Vac from "G" and the room thermostatwill energize"Y2"and supply 24Vac "Ylo/Y1" of the MBE/AEPF. The VSTB removes the to"Y/Y2"of the MBE unit. The blower motor will change 24Vacfrom"Ylo/Y1"atthe heat pump and the compres- to the cfm for high speed heating operation and the VSTB sor and outdoor fan are turned off. The blower motorwill will supply 24Vacto"Y/Y2"atthe heat pump.The outdoor ramp down to a complete stop based,on the time and fan will change to high speed operation., If the "Y2" rate programmed in the motor control. demand is present and becomes satisfied,the thermo- 5.0 Defrost Operation stat will remove the "Y2" demand and the VSTB will remove the 24Vacfrom "Y/Y2 at the heat pump. The On heat pump units,when the room thermostat is set to blower will drop to 60%of the programmed cfm and the the heating mode,the reversing valve is not energized. outdoor fan will change to low speed. On most digital/ As long asthethermostat is setforheating,the reversing electronic thermostats,"Y2"will remain energized until valve will be in the de-energized position for heating the first stage heating demand"Y1"is satisfied and then except during a defrost cycle. the"G","Y1"and"Y2"demands will be removed. 5.1 The heat pump will be'on and operating in the heating 4.3 Ifthe heat pump operation cannot satisfy the demand,the mode as described the Heating Operation in section 4. room thermostat energizes"W2/W3"and 24Vac is sup- 5.2 The defrost control in the heat pump unit checks to see plied to terminal "E/W1" of the VSTB inside the MBE/ if defrost is needed every 30,60 or 90 minutes of heat AEPF unit The VSTB will supply 24Vac to heat se- pump operation depending on the selectable setting by quencer HR1 on the electric heater assembly. monitoring the state of the defrost thermostat attached 4.4 HR1 contacts M1 and M2 will close within 10 to 20 to the outdoor coil. seconds and turn on heater element#1. At the same 5.3 If the temperature of the outdoor-coil is low enough to time, if the heater assembly contains a second heater cause the defrost thermostat to be,closed when the element, HR1 will contain a second set of contacts, M3 defrost board checks it,the board will initiate a defrost and M4,which will close and turn on heater element#2. cycle. Note: If more than two heater elements are on the heater 5.4 When a defrost cycle is initiated, the contacts of the assembly, it will contain a second heat sequencer, HR2, HVDR relay on the defrost board open and turns off the which will control the V and 4'h heater elements if available. outdoor fan. The contacts of the LVDR relay on the For the 3fd and 4 1 heater elements to operate on a defrost board closes and supplies 24Vac to "O" and second stage auxiliary heat demand,the PJ4 jumper on "W2".The reversing valve is energized and the contacts the VSTB inside the MBE/AEPF must be cut. If the"W2/ on HR1 close and turns on the electric heater(s). The W3" demand cannot be satisfied by the heat pump, the unit will continue to run in this mode until the defrost temperature indoors will continue to drop.The room thermo- cycle is completed. statwill'then energize"W3/W4"and 24Vacwill be supplied to 5.5 When the temperature of the,outdoor coil rises high "W/W2"ofthe MBE. The VSTB will supply 24Vac to HR2 on enough to causes the defrost thermostat to open, the the electric heater assembly. When the"W3/W4"demand is defrost cycle will be terminated. If at the end of the satisfied,the room thermostatwill remove the 24Vac from"W/ programmed 10 minute override time the defrost thermo- W2" of the MBE/AEPF The contacts on HR2 will open stat is still closed, the defrost board will automatically between 30to70seconds and heater elements#3and#4will terminate the defrost cycle. be turned off. On most digital/electronic thermostats, 5.6 When the defrost cycle is terminated,thecontacfsofthe "W3M4" will remain energized until the first.stage HVDR relay on the defrost board will close to start the demand "Y1" is satisfied and then the "G", 11Y1", 41Y2" outdoorfan and the contacts of the LVDRrelaywillopen "W2/W3" and "W3/W4" demands will be removed. and turn off the reversing valve and electric heater(s).The 4.5 As the temperature indoors increase,it will reach a point unit will now be back in a normal heating mode with a where the "W2/W3" demand is satisfied. When this heat pump demand for heating as described in the happens,the room thermostatwill remove the 24Vac from Heating Operation in section 4. "E/W1"ofthe MBE/AEPF. ThecontactsonHR1 5will open between 30 to 70 seconds and turn off the 1 and 2nd S-60 ELECTRIC HEATER (OPTIONAL ITEM) heater elements. If the "Y2" demand is present and Optional electric heaters may be added, in the quantities becomes satisfied the room thermostat will remove the shown in the specifications section, to provide electric 24Vac from"Y/Y2"of the MBE and the blower motor will resistance heating. Under no condition shall more heaters change to 60%of the programmed cfm. The VSTB will than the quantity shown be installed. remove the 24Vac from"Y/Y2"at the heat pump and the The low voltage circuit in the air handler is factory wired and outdoor fan will change to low speed operation. The heat terminates atthe location provided forthe electric heater(s). pump remains on along with the blower motor because A 'minimum of field wiring is' required to complete the the"Y1"demand for first stage heat will still be present. installation. 47 i SERVICING Other components such as a Heating/Cooling Thermostat and Outdoor Thermostats are available to complete the `ELECTRIC HEATER CAPACITY BTUH Installation. HTR ' 3.0 4.7 6.0 7.0 95 14.2 19.5 J716O0 The system CFM can be determined by measuring the static KW KW KW KW KW KW KW KW pressure external to the unit. The installation manual BTUH 10200 16200 20400 23800 32400 '48600166500 supplied with the blower coil,orthe blower performance table in the service manual, shows the CFM for the static mea- FORMULAS: sured. Heating Output= KW x 3413 x Corr. Factor Alternately,the system CFM can be determined by operating the electric heaters and indoor blower WITHOUT'having the Actual CFM=CFM(from table)x Corr. Factor compressor in operation. Measure the temperature rise as close to the blower inlet and outlet as possible. BTUH= KW x 3413 If otherthan a 240V power supply is used,refer to the BTUH CAPACITY CORRECTION FACTORchartbelow. BTUH=CFM x 1.08 x Temperature Rise(T) BTUH CAPACITY CORRECTION FACTOR CFM = KW x 3413 SUPPLY VOLTAGE 250 230 220 208 1.08 x T MULTIPLICATION FACTOR 1.08 .92 84 75 T= BTUH EXAMPLE: Five(5) heaters provide 24.0 KW at the rated CFM x 1.08 240V. Our actual measured voltage is 220V, and our S-61A CHECKING HEATER LIMIT CONTROL(S) measured temperature rise is 42°F. Find the actual CFM: Each individual heaterelementis protectedwith a limitcontrol Answer: 24.OKW,42°F Rise,240 V= 1800 CFM from the device connected in series with each element to prevent TEMPERATURE RISE chart on the right. overheating of components in case of low airflow. This limit Heating output at 220 V = 24 OKW x 3 413 x .84 = 68.8 control will open its circuit at approximately 1507. MBH. Actual CFM= 1800 x.84 Corr. Factor= 1400 CFM. &WARNING NOTE: The temperature rise table is for sea level installa- HIGH VOLTAGE! tions. The temperature rise at a particular KW and CFM will DisconnectALL power before servicing be greaterat high altitudes,whilethe external staticpressure or installing.Multiple power sources at a particular CFM will be less. may be present.Failure to do so may TEMPERATURE RISE(F°)@ 240V cause property damage,personal injury CFM 48 72 96 14.4 192 240 288 or death. KW KW KW KW KW KW KW 600 25 38 51 - _ _ _ 1. Remove the wiring from the control terminals. 700 22 33 43 - - - - 2. Using an ohmmeter, test for continuity across the nor- 800 19 1 29 38 1 57 - - _ mally closed contacts. No reading indicates the control 900 17 26 34 51 - _ _ is open-replace if necessary. 1000 15 23 30 46 - - _ IF FOUND OPEN-REPLACE-DO NOT WIRE AROUND. 1100 14 21 27 41 55 - - 1200 13 19 25 38 50 - _ S-61 B CHECKING HEATER FUSE LINK 1300 12 1 18 23 35 46 - (OPTIONAL ELECTRIC HEATERS) 1400 11 16 22 32 43 54 65 1500 10 15 20 30 40 50 60 Each individual heater element is protected with a one time 1600 9 14 19 28 38 47 57 fuse link which is connected in series with the element. The 1700 9' 14 18 27 36 44 53 fuse link will open at approximately 3330: 1800 8 13 17 25 34 42 50 &WARNING 1900 8 12 16 24 32 40 48 2000 8 12 15 23 30 38 45 Disconnect ALL power before servicing. 2100 7 11 14 22 29 36 43 2200 7 11 14' 21 27 34, 1 41 1. Remove heater element assembly so as to expose fuse 2300 7 10 13 20 26 33 39 link. 48 L SERVICING 2. Using an ohmmeter,test across the fuse link for continu- BRAZING MATERIALS ity- no reading indicates the-link is open. Replace as Copper to Copper Joints-Sil-Fos used without flux(alloy necessary. of 15%silver,80%copper,and 5%phosphorous). Recom- NOTE: The link is designed to open at approximately 333°F. mended heat 1400°F. DO NOT WIREAROUND-determine reason forfailure. Copper to Steel Joints-Silver Solder used without a flux S-62 CHECKING HEATER ELEMENTS (alloy of 30%silver,38%copper,32%zinc). Recommended heat -1200°F. FAWARNING S-101 LEAK TESTING connect ALL power before servicing. (NITROGEN OR NITROGEN-TRACED) 1. Disassemble and remove the Beating element. &WARNING 2. Visually inspectthe heater assemblyfor any breaks in the wire or broken insulators. To avoid the risk of fire or explosion,never use oxygen,high pressure air or flammable gases for leak 3. Using an ohmmeter,test the element for continuity-no testing of a refrigeration system. reading indicates the element is open. Replace as necessary. S-100 REFRIGERATION REPAIR PRACTICE &WARNING ® DANGER To avoid possible explosion,the line from the nitrogen cylinder must include a pressure regulator Lma removethe refrigerant charge in a proper and a pressure relief valve.The pressure relief valve before applying heat to the system. must be set to open at no more than 150 psig. When repairing the refrigeration system: Pressure testthe system using dry nitrogen and soapywater to locate leaks If you wish to use a leak detector,charge the system to 10 psi using the appropriate refrigerant then use ®WARNING nitrogen to finish charging the system to working pressure, HIGH VOLTAGE! then apply the detector to suspect areas. If leaks are found, Disconnect ALL power before servicing repairthem.After repair,repeatthe pressure test.If no leaks or installing.Multiple power sources exist, proceed to system evacuation. may be present.Failure to do so may it cause property damage,personal injuryS-102 EVACUATION or death. &WARNING 1. Never open a system that is under vacuum. Air and moisture will be drawn in. [REFRIGERANT UNDER PRESSURE! 2. Plu or ca all o enin s. lure to follow proper procedures may cause g p p g perty damage,personal injury or death. 3. Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper. Brazing materials do not This isthe most important part of the entire service procedure flow well on oxidized or oily surfaces The life and efficiency of the equipment is dependent upon the 4 Clean the inside of all new tubing to remove oils and pipe thoroughness exercised bythe serviceman when evacuating chips. air(non-con den sables)and moisture from the system. 5. When brazing, sweep the tubing with dry nitrogen to Air in a system causes high condensing temperature and prevent the formation of oxides on the inside surfaces. pressure, resulting in increased power input and reduced 6. Complete any repair by replacing the liquid line drierin the performance. system,evacuate and charge. Moisture chemically reacts with the refrigerant oil to form corrosive acids. These acids attack motor windings and parts,causing breakdown. 49 SERVICING The equipment required to thoroughly evacuate the system 4. Evacuate thesystem to at least 29 inches gauge before is a high vacuum pump, capable of producing a vacuum opening valve to thermocouple vacuum gauge. equivalent to 25 microns absolute and a thermocouple 5. Continue to evacuate to a maximum of 250 microns. vacuum gauge to give a true reading of the vacuum in the Close valve to vacuum pump and watch rate of rise. If system vacuum does not rise above 1500 microns in three to five NOTE: Never use the system compressor as a vacuum minutes,system can be considered properly evacuated. pump or run when undera high vacuum. Motor damage could 6. If thermocouple vacuum gauge continues to rise and occur. levels off at about 5000 microns, moisture and non- condensables are still present. If gauge continues to rise WARNING a leak is present. Repair and re-evacuate. Do not front seat the service valve(s)with the 7. Close valve to thermocouple vacuum gauge and vacuum compressor open,with the suction line of the pump. Shut off pump and prepare to charge. comprssor closed or severely restricted. S-103 CHARGING 1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses,thermocouple vacuum gauge &WARNING and charging cylinder as shown. 2. Startthe vacuum pump and open the shut off valve to the REFRIGERANT UNDER PRESSURE! high vacuum gauge manifold only. Afterthe compound *Do not overcharge system with refrigerant. gauge(lowside)has dropped to approximately29 inches *Do not operate unit in a vacuum or at negative of vacuum,open the valve to the vacuum thermocouple pressure. gauge. See that the vacuum pump will blank-off to a Failure to follow proper procedures may cause maximum of 25 microns. A high vacuum pump can only property damage, personal injury or death. produce a good vacuum if its oil is non-contaminated. R-22 A CAUTION MANIFOLD Use refrigerant certified to ARI standards.Used refrigerant may cause compressor damage and will LOW SIDE HIGH SIDE void the warranty.Most portable machines cannot GAUGE GAUGE .� clean used refrigerant to meet ARI standards. AND VALVE AND VALVE 0 0 800 PSI A CAUTION RATED " HOSES Operating the compressor with the suction valve CHARGING closed will void the warranty and cause serious CYLINDER compressor damage. AND SCALE Charge the system with the exact amount of refrigerant. VACUUM PUMP Refer to the specification section or check the unit name- TO ADAPTER plates for the correct refrigerant charge. UNIT SERVICE, VALVE PORTS An inaccurately charged system will cause future prob- 0 lems. VACUUM PUMP 1.- When using an ambient compensated calibrated charg- ing cylinder,allow liquid refrigerant only to enterthe high side- 2. After the system will take all it will take, close the valve on the high side of the charging manifold. 3. Startthe system and charge the balance of the refrigerant EVACUATION through the low side. 3. If the vacuum pump is working properly,close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set. With the valve on the charging cylinder closed,open the manifold valve to the cylinder. 50 SERVICING NOTE:R41 OA should be drawn out of the storage container If the test shows: or drum in liquid form due to its fractionation properties,but a. Below normal high side pressure. should be "Flashed" to its gas state before entering the system.There are commercially available restriction devices b. Above normal low side pressure. that fit into the system charging hose set to accomplish this. c. Low temperature difference across coil. DO NOT charge liquid R41 OA into the compressor, d. Low amp draw at compressor. 4. With the system still running, close the valve on the And the charge is correct. The compressor is faulty-replace charging cylinder. At this time,you may still have some the compressor. liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose. Reseatthe liquid S-106A PISTON CHART FOR SSX14 & ASX14 line core: Slowly open the high side manifold valve and transferthe liquid refrigerantfrom the liquid line hose and UNITS charging cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enterthe compressor. Final Charge Adjustment Remote Orifice Size The outdoor temperature must be 60°F or higher. Set the Condenser room thermostat to COOL,fan switch to AUTO,and set the SSX140181 0.049 temperature control well below room temperature. After system has stabilized per startup instructions, com- SSX140241 0.057 pare the operating pressures and outdoor unit amp draw to SSX140301 0.063 the numbers listed on the performance label on the outdoor unit. If pressures and amp draw are too low,add charge. If SSX140361 0.067 4 pressures and amp draw are too high,remove charge.Check SSX140421 0.074 subcooling and superheat as detailed in the following sec- tion. SSX140481 0.079 5. With the system still running,remove hose and reinstall SSX140601 0.088 both valve caps. 6. Check system for leaks. ASX140181A 0.049 Do notchargea remote condensing unitwith a non-matching ASX140241A 0.057 evaporator coil, or a system where the charge quantity is unknown Do not install orchargeR410Acondensers matched ASX140301A 0.063 with coils having capillary tubes or flow control restrictors. ASX140361A 0.067 ARI rated Coil combinations with thermostatic expansion valves (TEV's) should be charged by subcooling. See ASX140421A 0.074 "Checking Subcooling and Superheat"sections in this manual. ASX140481 A 0.079 Subcooling values for "Ultron" system are found in the Technical Information manuals for"Ultron"outdoor units ASX140601A 0.088 Due to their design,Scroll compressors are inherently more tolerant of liquid refrigerant. NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued S-106B THERMOSTATIC EXPANSION VALVE floodback or flooded start conditions may wash oil from the The expansion valve is designed to control the rate of liquid bearing surfaces causing premature bearing failure. refrigerantflow into an evaporatorcoil in exact proportion to the S-104 CHECKING COMPRESSOR EFFICIENCY rate of evaporation of the refrigerant in the coil. The amount of refrigerant entering the coil is regulated since the valve The reason for compressor inefficiency is broken or damaged responds to temperature of the refrigerant gas leaving the coil scroll flanks on Scroll compressors, reducing the ability of (feeler bulb contact)and the pressure of the refrigerant in the the compressorto pump refrigerant vapor. coil. This regulation of the flow prevents the return of liquid The condition of the scroll flanks is checked in the following refrigerant to the compressor. manner. The illustration below shows typical heatpump TXV/check 1. Attach gauges to the high and low side of the system. valve operation in the heating and cooling modes. 2. Start the system and run a"Cooling Performance Test. 51 SERVICING S-107 UNDERFEEDING 1—f a Underfeeding by the expansion valve results in low system capacity and low suction pressures If these symptoms are observed: COOLING HEATING 1. Check for a restricted liquid line or drier.A restriction will TXV VALVES be indicated by a temperature drop across the drier Some TXV valves contain an internal check valve thus eliminating the need for an external check valve and bypass 2. Checkthe operation of the power element of the valve as loop.The three forces which govern the operation of the valve described in S-110 Checking Expansion Valve Opera- are: (1)the pressure created in the power assembly by the tion. feeler bulb, (2)evaporator pressure,and(3)the equivalent pressure of the superheat spring in the valve. S-108 SUPERHEAT 0% bleed type expansion valves are used on indoor and The expansion valves are factory adjusted to maintain 8 to outdoor coils. The 0%bleed valve will not allow the system 12 degrees superheat of the suction gas. Before checking pressures(High and Low side)to equalize during the shut the superheat or replacing the valve,perform all the proce- down period. The valve will shut off completely at approxi- dures outlined under Air Flow, Refrigerant Charge,Expan- mately 100 PSIG. sionValve-Overfeeding,Underfeeding.These are the most 30%bleed valves used on some other models will continue common causes for evaporator malfunction. to allow some equalization even though the valve has shut-off CHECKING SUPERHEAT completely because of the bleed holes within the valve. This Refrigerant gas is considered superheated when its tem- type of valve should not be,used as a replacement for a 0% perature is higher than the saturation temperature corre- bleed valve,due to the resulting drop in performance. sponding to its pressure.The degree of superheat equals the The bulb must be securely fastened with two straps to a clean degrees of temperature increase above the saturation tem- straight section of the suction line. Application of the bulb to perature at existing pressure. See Temperature-Pressure a horizontal run of line is preferred. If a vertical installation Chart on following pages. cannot be avoided, the bulb must be mounted so that the capillary tubing comes out at the top. THE VALVES PROVIDED BY GOODMAN ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION. DO NOT USE SUB- STITUTES. S-106 OVERFEEDING Overfeeding by the expansion valve results in high suction pressure,cold suction line,and possible liquid slugging of the compressor. If these symptoms are observed: 1. Check for an overcharged unit by referring to the cooling performance charts in the servicing section. 2. Check the operation of the power element in the valve as explained in S-110 Checking Expansion Valve Operation. 3. Check for restricted or plugged equalizer tube. 52 t V� SERVICING Pressure vs. Temperature Chart R-41 OA PSIG OF PSIG OF PSIG OF PSIG --°F PSIG OF PSIG- T 12 -37.7 114.0- 37.8 216.0 74.3 318.0 100.2 420.0 120.7 522.0 137.6 14 -34.7 116.0 38.7 218.0 74.9 320.0 100.7 - 422.0 121.0 524.0 ' 137 9 16 -32.0 118.0 39.5 220.0 75.5 322.0 101.1 424:0 121.4 526.0 138.3 ` 18 -29.4 120.0 40.5 222.0 76.1 324.0 101.6 426.0 121.7 528.0 138.6 20 -36.9 122.0 41.3 224.0 76.7 326.0 102.0 428.0 122.1 530:0 138.9 22 -24.5 124.0 42.2 226.0 77.2 328.0 102.4 430.0 122.5 532.0 139.2 24 -22.2 126.0 43.0 228.0 .77.8 330.0 . 102.9 432.0 122.8 534.0 139.5 26 -20.0 128.0 - 43.8 230.0 78.4 332.0 103.3 434.0 123.2 536.0 139.8 28 -17.9 130.0 44.7 232.0 78.9 334.0 103.7 436.0 123.5 538.0 140.1 30 -15.8 132.0 45.5 234.0 79.5 336.0 104.2 438.0 123.9 540.0 140.4 32 -13.8 1340 46.3 236.0 80.0 338.0 104.6 440.0 124.2 544.0 141.0 34 -11.9 136.0 47.1 238.0 80.6 340.0 105.1 442.0 124.6 548.0 141.6 36 -10.1 138.0 47.9 240.0 81.1 342.0 105.4 444.0 124.9 552.0 142.1 38 -8.3 140.0 48.7 242.0 81.6 344.0 105.8 446.0 125.3 556.0 142.7 40 -6.5 142.0 49.5 244.0 82.2 346.0 106.3 448.0 125.6 560.0 143.3 42 -4.5 144.0 50.3 246.0 82.7 348.0 106.6 450.0 126.0 564.0 143.9 44 -3.2 146.0 51.1 248.0 83.3 350.0 107.1 452.0 126.3 568.0 1445 46 -1.6 148.0 51.8 250.0 83.8 352.0 107.5 454.0 126.6 572.0 145.0 48 0.0 150.0 52.5 252.0 84.3 354.0 107.9 456.0 127.0 576.0 145.6 50 1.5 152.0 53.3 254.0 84.8 356.0 108.3 458.0 127.3 580.0 146.2 52 3.0 154.0 54.0 256.0 85.4 358.0 108.8 460.0 127.7 584.0 146.7 54 4.5 156.0 54.8 258.0 85.9 360.0 109.2 462.0 128.0 588.0 147.3 56 5.9 158.0 55.5 260.0 86.4 362.0 109.6 464.0 128.3 592.0 147.9 58 7.3 160.0 56.2 262.0 86.9 364.0 110.0 466.0 128.7 596.0 148.4 60 8.6 162.0 57.0 264.0 87.4 366.0 110.4 468.0 129.0 600.0 149.0 62 10.0 164.0 57.7 266.0 87.9 368.0 110.8 470.0 129.3 604.0 1495 64 11.3 166.0 58.4 268.0 88.4 370.0 111.2 472.0 129.7 608.0 150.1 66 12.6 168.0 59.0 270.0 88.9 372.0 111.6 474.0 130.0 612.0 150.6 68 13.8 170.0 59.8 272.0 89.4 374.0 112.0 476.0 130.3 616.0 151.2 70 15.1 172.0 60.5 274.0 89.9 376.0 112.4 478.0 130.7 620.0 151.7 72 16.3 1740 61.1 276.0 90.4 378.0 112.6 480.0 131.0 624.0 152.3 74 17.5 1760 61.8 278.0 90.9 380.0 113.1 482.0 131.3 628.0 152.8 76 18.7 178.0 62.5 280.0 91.4 382.0 113.5 484.0 131.6 632.0 153.4 78 19.8 180.0 63.1 282.0 91.9 384.0 113.9 486.0 132.0 636.0 153.9 80 21.0 182.0 63.8 284.0 92.4 386.0 114.3 488.0 132.3 640.0 154.5 82 22.1 184.0 64.5 286.0 92.8 388.0 114.7 490.0 132.6 644.0 155.0 84 23.2 186.0 65.1 288.0 93.3 390.0 115.0 492.0 132.9 648.0 155.5 86 24.3 188.0 65.8 290.0 93.8 392.0 115.5 494.0 133.3 652.0 156.1 88 25.4 1900 66.4 292.0 - 94.3 394.0 115.8 496.0 133.6 656.0 156.6 90 26.4 192.0 67.0 294.0 94.8 396.0 116.2 498.0 133.9 660.0 157.1 92 27.4 1940 67.7 296.0 95.2 398.0 116.6 500.0 134.0 664.0 157.7 94 28.5 196.0 68.3 298.0 95.7 400.0 117.0 502.0 134.5 668.0 158.2 96 29.5 198.0 68.9 300.0 96.2 402.0 -117.3 504.0 134.8 672.0 158.7 98 30.5 200.0 69.5 302.0 96.6 404.0 117.7 506.0 135.2 676.0 159.2 100 31.2 202.0 70.1 304.0 97.1 406.0 118'.1 508.0 135.5 680.0 159.8 102 32.2 204.0 70.7 306.0 97.5 408.0 118.5 510.0 135.8 684.0 160.3 104 33.2 206.0 71.4 308.0 98.0 410.0 118.8 512.0 136.1 688.0 160.8 106 34.1 208.0 72.0 310.0 98.4 412.0 119.2 514.0 136.4 692.0 161.3 108 35.1 210.0 72.6 312.0 98.9 414.0 119.6 516.0 136.7 696.0 161.8 110 35.5 212.0 73.2 314.0 99.3 416.0 119.9 518.0 137.0 112 36.9 214.0 73.81 1 316.0 99.7 1 418.0 120.3 1 520.0 137.3 "'Based on ALLIED SIGNAL Data 53 ra SERVICING REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE °F AT SERVICE VALVE (PSIG) 8 10 12 14 16 18 189 58 56 54 52 50 48 195 60 58 56 54 52 50 202 62 60 58 56 54 52 208 64 62 60 58 1 56 54 215 66 64 62 60 58 56 222 68 66 64 62 60 58 229 70 68 66 64 62 60 236 72 70 68 66 64 62 243 74 72 70 68 66 64 251 76 74 72 70 68 66 259 78 76 74 72 70 68 266 80 78 76 74 72 70 274 82 80 78 76 74 72 283 84 82 80 78 76 74 291 86 84 82 80 78 76 299 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 '96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474- 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 - 122 120 118 ®CAUTION 2.'Temporarily install thermometer on suction(large)line To prevent personal injury,carefully connect and nearsuction line service valve with adequate contact and disconnect manifold gauge hoses.Escaping liquid insulate for best possible reading. refrigerant can cause burns.Do not vent refrigerant to atmosphere. Recover during system repair 3.,Referto the superheat table provided for proper system or final unit disposal. superheat. Add charge to lower superheat or recover charge to raise superheat. 1. Run system at least 10 minutes to allow pressure to stabilize. 54 SERVICING Superheat Formula = Suct. Line Temp. -Sat. Suct. Temp. 4. Review the technical information manual orspecification EXAMPLE: sheet for the model being serviced to obtain_the design subcooling. a. Suction Pressure= 143 5. Comparethe hi-pressure readingtothe"Required Liquid b. Corresponding Temp. OF.=50 Line Temperature"chart(page 43).Find the hi-pressure c. Thermometer on Suction Line=61'F. value on the left column. Follow that line right to the To obtain the degrees temperature of superheat, subtract column under the design subcooling value. Where the 50.0 from 61.0°F: two intersect is;the required liquid line temperature The difference is 11'Superheat.The 11°'Superheatwould fall Alternately you,can-convertthe liquid line pressure gauge in the i range of allowable superheat. reading to temperature by finding the gauge reading in SUPERHEATANDSUBCOOLINGADJUSTMENTONTXV Temperature-Pressure Chartandreadingtotheleft,find • APPLICATIONS the temperature in the F.Column. - 6. The difference between the thermometer reading and 1. Run system at least 10 minutes to allow pressure to pressure to temperature conversion is the amount of stabilize. subcooling. 2. Temporarily install thermometer on liquid (small) line Add charge to raise subcooling. Recover charge to lower near liquid line service valve with adequate contact and subcooling. insulate for best possible reading. Subcooling Formula=Sat. Liquid Temp. -Liquid Line 3. Check subcooling and superheat. Systems with TXV Temp. ' application should have a subcooling and superheat of EXAMPLE: 7 t 2°F. a. Liquid Line Pressure=417 a. If subcooling and superheat are low,adjust TXV b. Corresponding Temp.OF.=120° to 7-9 F then check subcooling. c. Thermometer on Liquid line= 109°F. b. If subcooling is low and superheat is high, add To obtain the amount of subcooling subtract 109°F from charge to raise subcooling to 7 t 2°F then check 120°F. superheat. c. superIf heat, and superheat are high,adjustTXV The difference is 11°subcooling.See the specification sheet valve to subcooling 9°F then check subcooling. or technical information manual for the design subcooling range for your unit. d. If subcooling is high and superheat is low,adjust TXV valve to 7 to 9°F superheat and remove S-1 09A TWO SPEED APPLICATION charge to lower the subcooling to 7 t 2°F. Run the remote on low stage cooling for 10 minutes until The TXV should NOT be adjusted at light load conditions refrigerant pressures stabilize. Follow the guidelines and 550 to 60°F, under such conditions only the subcooling methods below to check unit operation and ensure that the can be evaluated.This is because suction pressure is refrigerant charge is within limits. Charge the unit on low dependent on the indoor coil match,indoor airflow,and stage. wet bulb temperature. NOTE: Do NOT adjust charge based on suction pressure unless there is ,a gross 1 Purge gauge lines Connect service gauge manifold to undercharge. base-valve service ports. Run system at least 10 min- utes to allow pressure to stabilize. 4. Disconnect manifold set. Installation is complete. 2. Temporarily install thermometer on liquid (small) line S-109 CHECKING SUBCOOLING near liquid line service valve with adequate contact and Refrigerant liquid is considered subcooled when its tempera- insulate for best possible reading. ture is lower than the saturation temperature corresponding 3. Check subcooling and superheat. Systems with TXV to its pressure.The degree of subcooling equals the degrees application should have a subcooling of 5 to 7 OF and of temperature decrease belowthe saturation temperature at superheat of 7 to 9 OF. the existing pressure. a. If subcooling and superheat are low,adjustTXVto 1. Attach an accurate thermometer or preferably athermo- 7 to 9 OF superheat,then check subcooling. couple type temperature tester to the liquid line as it NOTE:To adjust superheat,turn the valve stem leaves the condensing unit. clockwise to increase and counter clockwise to 2. Install a high side pressure gauge on the high side(liquid) decrease. service valve at the front of the unit. 3. Record the gauge pressure and the temperature of the line. 55 r SERVICING b. If subcooling is low and superheat is high, add 4. If a temperature or pressure change is noticed, the charge to raise subcooling to 5 to 7 IF then check expansion valve is operating. If no change is noticed,the superheat. valve is restricted, the power element is faulty, or the c. If subcooling and superheat are high,adjustTXV equalizer tube is plugged. valve to 7 to 9 OF superheat,then check subcooling. 5. Capture the charge,replace the valve and drier,evacuate d. If subcooling is high and superheat is low,adjust and recharge. TXV valve to 7 to 9 OF superheat and remove S-111 FIXED ORIFICE RESTRICTOR DEVICES charge to lower the subcooling to 5 to 7 F. NOTE: Do NOT adjust the charge based on suction Thefixed orifice restrictor device(flowrator)used in conjunc- pressure unless there is a gross undercharge. tion with the indoor coil is a predetermined bore(I.D.). 4. Disconnect manifold set, installation is complete. It is designed to control the rate of liquid refrigerant flow into , Subcooling Formula = Sat. Liquid Temp. -,Liquid Line Temp. an evaporator coil. The amount of refrigerant that flows through the fixed orifice S-109B HEAT PUMP HEATING MODE restrictor device is regulated by the pressure difference Hot Gas Method between the high and low sides of the system. In the cooling cycle when the outdoor air temperature rises, System charge can be checked in the heating mode by the high side condensing pressure rises. At the same time, measuring the hot discharge gas at the compressor. the cooling load onthe indoorcoil increases,causing the low 1. Allow the system to operate at least 20 minutes. side pressure to rise, but at a slower rate. 2. Attach and insulate an electronic thermometer probe to Since the high side pressure rises fasterwhen the tempera- the vapor service valve(large line)at the base valve. ture increases, more refrigerant flows to the evaporator, 3. Operate the system for 10 minutes. increasing the cooling capacity of the system. 4. Using an accurate electronic thermometer,measurethe When the outdoor tem peratu re fal Is,the reverse takes place. temperature of the discharge gas at the probe and the The condensing pressure falls,and the cooling loads on the outdoor ambient temperature. indoor coil decreases,causing less refrigerant flow. 5. The temperaturemeasuredonthe vapor service valve line A strainer is placed on the entering side of thetubeto prevent should be equal to the outdoor ambient temperature plus any foreign material from becoming lodged inside the fixed 110°F(t 4°). For example, if the outdoor ambient tem- orifice restriction device. perature is 45°F,then the temperature measured by the If a restriction should become evident,proceed as follows: thermometer probe atthe vapor service valve line should 1. Recover refrigerant charge. be 155°F for a system that is properly charged. If the temperature measured by the thermometer probe is 2. Remove the orifice or tube strainer assembly and re- higher than the outdoor ambient plus 110°F,the system place charge should be adjusted by adding refrigerant to lower 3. Replace liquid line drier,evacuate and recharge. the temperature. If the temperature measured is lower CHECKING EQUALIZATION TIME than the outdoorambient plus 110°F,the system charge should be adjusted by recovering charge to raise the During the"OFF"cycle,the high side pressure bleeds to the temperature low side through the fixed orifice restriction device. Check NOTE:When adjusting the charge in this manner,allow equalization time as follows: the system to operate for at least 10 minutes before 1. Attach a gauge manifold to the suction and liquid line dill taking the next temperature reading. valves. S-110 CHECKING EXPANSION VALVE 2. -Start the system and allow the pressures to stabilize. OPERATION 3. Stop the system and check the time it takes for the high 1 Remove the remote bulb of the expansion valve from the and low pressure gauge readings to equalize. suction line. If it takes more than seven (7) minutes to equalize, the 2. Start the system and cool the bulb in a container of ice restrictor device is inoperative. Replace,install a liquid line water,closing the valve.As you cool the bulb,the suction drier,evacuate and recharge. pressure should fall and the suction temperature will rise. . 3. Next warm the bulb in your hand. As you warm the bulb, the suction pressure should rise and the suction tempera- ture will fall. 56 SERVICING S-112 CHECKING RESTRICTED LIQUID LINE -S-116,COMPRESSOR BURNOUT When the system is operating,the liquid line is warm to the When a compressor burns out, high temperature develops touch. If the liquid line is restricted, a definite temperature causing the refrigerant, oil and motor insulation to decom- drop will be noticed at the point of restriction. In severe pose forming acids and sludge. cases,frost will form at the restriction and extend down the If a compressor is suspected of being burned-out,attach a line in-the direction of the flow. refrigerant hose to the liquid line dill valve and properly remove Discharge and suction pressures will be low, giving the and dispose of the refrigerant. appearance of an undercharged unit. However,the unit will have normal to high subcooling. NOTICE Locate the restriction, replace the restricted part, replaceFor, lation of EPA regulations may result in fines drier,evacuate and recharge. other penalties. S-113 OVERCHARGE OF REFRIGERANT Now determine if a burn out has actually occurred. Confirm An overcharge of refrigerant is normally indicated by an by analyzing an oil sample using a Sporlan Acid Test Kit,AK- excessively high head pressure. 3 or its equivalent. An evaporator cod, using an expansion valve metering Remove the compressor and obtain an oil sample from the device,will basically modulate and control a flooded evapo- suction stub. If the oil is not acidic,either a burnout has,not rator and prevent liquid return to the compressor. occurred or the burnout is so mild that a complete clean-up An evaporator coil, using a capillary tube metering device, is not necessary. could allow refrigerant to return to the compressor under If acid level is unacceptable,the system must be cleaned by extreme overcharge conditions. Also with a capillary tube using the clean-up drier method. metering device,extreme cases of insufficient indooraircan cause icing of the indoor coil and liquid return to theA CAUTION compressor,but the head pressure would be lower. There are othercauses for high head pressure which may be Do not allow the sludge or oil to contact the skin. found in the"Service Problem Analysis Guide." Severe burns may result. If other causes checkout normal,an overcharge ora system NOTE: The Flushing Method using R-11 refrigerant is no containing non-condensables would be indicated.11 longerapproved byAmana®Heating-Cooling. If this system is observed: Suction Line Drier Clean-Up Method 1. Start the system. The POE oils used with R41 OA refrigerant is an excellent 2. Remove and capture small quantities of gas from the solvent.In the case of burnout,the POE oils will remove any suction line dill valve until the head pressure is reduced burnout residue left in the system. If not captured by the to normal. refrigerant filter,they will collect in the compressor or other 3. Observethe system while running a cooling performance system components, causing a failure of the replacement test. If a shortage of refrigerant is indicated, then the compressor and/or spread contaminants throughout the system contains non-condensables. system,damaging additional components. UseAMANA®brand part numberRF000127 suction linefilter S-114 NON-CONDENSABLES drier kit. This drier should be installed as close to the If non-condensables are suspected,shut down the system compressor suction fitting as possible. The filter must be and allow the pressures to equalize. Wait at least 15 accessible and be rechecked for a pressure drop after the minutes. Compare the pressure to the temperature of the system has operated for a time. It may be necessary to use coldest coil since this iswhere most ofthe refrigerantwill be. new tubing and form as required. If the pressure indicates a higher temperature than that of the NOTE: At least twelve (12) inches of the suction line coil temperature,non-condensables are present. immediately out of the compressor stub must be discarded Non-condensables are removed from the system by first due to burned residue and contaminates. removing the refrigerant charge,replacing and/or installing 1. Remove compressor discharge line strainer. liquid line drier,evacuating and recharging. 2. Remove the liquid line drier and expansion valve. 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean. 4. Install new components including liquid line drier. 57 SERVICING 5. Braze all joints, leak test, evacuate, and recharge 2. TXV Requirement:All line set applications over 50 ftwill system. require a TXV. 6 Startup the unit and record the pressure drop across the 3. Hard Start Assist- increased charge level in long line drier. applications can require extra work from the compressor 7. Continue to run the system fora minimum of twelve(12) at start-up.A hard start assist device may be required to hours and recheck the pressure drop across the drier. overcomethis. Pressure drop should not exceed 6 PSIG. 4. Liquid Line Solenoid-A long line set application can 8. Continue to run the system for several days,repeatedly critically increase the charge level needed for a system. checking pressure drop across the suction line drier. If As a result, the system is very prone to refrigerant the pressure drop never exceeds the 6 PSIG,the drier migration during its off-cycle and a liquid line solenoid will has trapped the contaminants.Remove the suction line help minimizethis.A liquid line solenoid is recommended drier from the system. for any long line application on straight cooling units. 9. If the pressure drop becomes greater, then it must be Tube Sizing: replaced and steps 5through 9 repeated until it does not 1. In long line applications,the"equivalent line length"is the exceed 6 PSIG. sum of the straight length portions of the suction line plus NOTICE:Regardless,the cause for burnout must be deter- losses (in equivalent length) from 45 and 90 degree mined and corrected before the new compressor is started. bends.Selectthe proper suction tube size based on equivalent length of the suction line(see Tables 4 S-120 REFRIGERANT PIPING &5) and recalculated system capacity. The piping of a refrigeration system is very important in relation to system capacity,proper oil return to compressor, Equivalent length= pumping rate of compressor and cooling performance of the Length horizontal evaporator. POE oils maintain a consistent viscosity over a large +Length vertical temperature range which aids in the oil return to the com- +Losses from bends(see Tables 4&5) pressor; however, there will be some installations which require oil return traps.These installations should be avoided whenever possible,as adding oil traps to the refrigerant lines 2. For any residential splitsystem installed with along also increases the opportunity for debris and moisture to be line set,the liquid line size must never exceed 3/8". introduced into the system. Avoid long running traps in Limiting the liquid line size to 3/8" is critical since an horizontal suction line. increased refrigerant charge level from having a larger LONG LINE SETAPPLICATION R-41 OA liquid line could possibly shorten a compressor's lifespan. This long line set application guideline applies to all ARI 3. Single Stage Condensing Unit:The maximum lengthof tubing must not exceed 150 feet. listed R-41 OA air conditioner and heat pump split system matches of nominal capacity 18,000 to 60,000 Btuh. This -50 feet is the maximum recommended vertical differ- guidelinewill cover installation requirements and additional ence between the condenser and evaporator when the accessories needed for split system installations where the evaporator is above the condenser.Equivalent length is line set exceeds 50 feet in actual length. not to exceed 150 feet. Additional Accessories: •The vertical difference between the condenserand evapo- rator when the evaporator is below the condenser can 1. Crankcase Heater- a long line set application can approach 150 feet,as long as the equivalent length does critically increase the charge level needed for a system. not exceed 150 feet. As a result, the-system is very prone to refrigerant .The distance between the condenser and evaporator in a migration during its off-cycle and a crankcase heaterwill completely horizontal installation in which the indoorand help minimize this risk. A crankcase heater is recom- outdoor unit do not differ more than 10 feet in vertical mende d for any long line application(50 watt minimum). distancefrom each othercan approach 150 feet,as long as the equivalent length does not exceed 150 feet. 58 SERVICING 4. Two-Stage Condensing-Unit: The maximum,length of TABLE 5. LOSSES FROM SUCTION LINE ELBOWS tubing must not exceed 75 feet where indoor coil is (EQUIVALENT LENGTH,FT.) located above the outdoor unit. NOTE: When the outdoor unit is located above the I.D. In. Type of elbow fitting 3/4 7/8 1-1/8 indoor coil,the maximum vertical rise must not exceed- 25 feet. If the maximum vertical rise exceeds 26 feet, 90°short radius 17 2 remature com ressor failure will occur.due to inad- 90°Ion radius 1.5 1.7 1 6 1 s p p 45° 0.7 0.8 1 equate oil return.- 5. Vibration and Noise:In long line applications,refriger- Installation Requirements anttubing is highly proneto transmit noise and vibration 1. In a completely horizontal installation with a long line to the structure it is fastened to.-Use adequate vibration- set where the evaporator is at the same altitude as isolating hardware when mounting line set to•adjacent (or slightly below)the condenser,the line set should structure. be sloped towards the evaporator.This helps reduce Most refrigerant tubing kits are supplied with 3/8"-thick refrigerant migration to the condenserduring a insulation onthevapor line.Forlong line installations over50 system's off-cycle. feet,especially if the line set passes through a high ambient 2. For a system installation where the evaporator is temperature,'/i'-thick suction line insulation is recommended above the condenser,an inverted vapor line trap to reduce loss of capacity.The liquid line should be insulated should be installed on the suction line just before the if passing through an area of 120°F or greater.Do not attach inlet to the evaporator(see Fig 6).The top of the the liquid lineto any non-insulated portion of the suction line. inverted loop must be slightly above the top of the Table 4 lists multiplier values to recalculate system-cooling evaporator coil and can be created simply by brazing capacity as a function of system's equivalent line length(as two 90°long radius elbows together,if a bending tool calculated from the suction line) and the selected suction is unavailable.Properly support and secure the tube size. Table 5 lists the equivalent length gained from inverted loop to the nearest point on the indoor unit or adding bends to the suction line.Properly size the suction adjacent structure. line to minimize capacity loss. TABLE 4.CAPACITY MULTIPLIERS ASA FUNCTION OF SUCTION LINE SIZE&EQUIVALENT LENGTH Nominal Vapor line EQUIVALENT LINE LENGTH(FT) ` capacity diameter Btuh (in) 50 75 100 125 150 i 18,000 3/4 99 97 96 95 24,000 314 1 99 99 98 97 x• 30,000 3/4 98 97 96 95 94 36,000 3/4 93 90 86 83 79 718 98 1 96 94 92 1 90 314 93 1 90 87 83 .80 Fig 6 Evaporator unit with Inverted vapor loop 42,000 718 97 .96 .94 93 92 1-118 1 1 99 99 98 314 .90 86 .82 78 N/R 3. An oil trap is required at the evaporator only if the 48,000 718 96 .94 93 .91 89 condenser is above the evaporator. Preformed oil 1-118 1 1 99 99 98 tra s are available at most HVAC supply houses,or oil 60,000 718 93 91 89 86 84 p pp y 1-1/8 1 99 96 1 98 97 s7 traps may be created by brazing tubing elbows together (see diagram below).Remember to add the equivalent NOTE:For a condenser with a liquid valve tube connection length from oil traps to the equivalent length calculation of the suction line. For example, if you construct an oil less than 3/8"diameter, use 3/8"liquid line tubing for a line trap using two 45°elbows,one short and one long 90° set greater than 25 feet. elbow in a '/" diameter suction line, the additional equivalent length would be 0.7+ 0.7+1.7+1.5, which equals 4.6 feet(refer to table 2). 59 SERVICING Oil Trap construction S-202 DUCT STATIC PRESSURES AND/OR STATIC PRESSURE DROP ACROSS COILS Long Radius Street Ell This minimum and maximum allowable duct static pressure —46^ forthe indoor sections are found in the specifications section. EII Tables are also provided for each coil, listing quantity of air 45^ (CFM)versus static pressure drop across the coil Street Ell Too great an external static pressurewill result in insufficient T air that can cause icing of the coil. Too much air can cause Short Radius Street Ell poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can also cause motor overloading and in many cases this constitutes a poorly designed system. S-203 AIR HANDLER EXTERNAL STATIC Fig 7 Oil Trap To determine proper air movement,proceed as follows: 1. Using a draft gauge(inclined manometer),measure the 4. Low voltage wiring.Verify low voltage wiring size static pressure of the return duct at the inlet of the unit, is adequate for the length used since it will be (Negative Pressure). increased in a long line application. 2• Measure the static pressure of the supply duct, (Positive Pressure). System Charging 3. Add the two readings together. R-41 OA condensers are factory charged for 15 feet of line set. To'calculate the,amount of extra refrigerant (in ounces) needed for a line set over 15 feet, multiply the additional �I length of line set by 0.6 ounces. Note for the following formula,the linearfeet of line set is the actual length of liquid line(orsuction line,since both should be equal)used,notthe equivalent length calculated for the suction line. ! it Extra refrigerant needed= (Linear feet of line set–15 ft.)x X oz./ft. TOTAL EXTERNAL STATIC Where X=0.6 for 3/8"liquid tubing Remember,for condensers with a liquid valve connection NOTE:Both readings may be taken simultaneously and read less than 3/8"diameter, 3/8"liquid tubing is required for a directly on the manometer if so desired. line set longer than 25 feet. 4. Consult proper table for quantity of air. Follow the charging procedures in the outdoor unit 1/0 If external static pressure is being measured on a furnace to manual to ensure proper superheat and sub-cooling levels, determine airflow,supply static must be taken between the especially on a system with a TXV installed in the indoor unit. A coil and the furnace. Heat pumps should be checked in both heating and cooling mode for proper charge level. This guideline is meant to provide installation instructions based on most common long line set applications. Installation variables may affect sys- tem operation. NO ADDITIONAL COMPRESSOR OIL IS NEEDED FOR LONG LINESETAPPLICATIONS ONRES/DENTIAL SPLIT SYSTEMS. 60 ' r SERVICING Air Flow 0 STATIC PRESSURE DROP If the total external static pressure and/or static pressure drop TOTAL EXTERNAL STATIC exceeds the maximum or minimum allowable statics,check forclosed dampers,dirtyfilters,undersized or poorly laid out S-204 COIL STATIC PRESSURE DROP duct work. 1. Using a draft gauge(inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil. 2. A direct reading can be taken of the static pressure drop across the coil. 3. Consult proper table for quantity of air. 61 ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGEI A WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. ALL FUEL SYSTEM AFE18-60A CONTROL BOARD 24VAC F1 3A POWER SUPPLY -s C>-VDC INPUT ROWER +svoc FURNACE DEMAND �-7 SUPPLY fW1-FURN OUTPUT F W1 'E�_ W2-HP BLOWER FAN DEMAND -12 +-a +. ? OUTPUT G _ �—o zavnc POWER SUPPLY I NPUTC -s c G-STAT (COMMON) N K1 SECOND STAGE FURNACE\ ?-s DEMANDOUTPUT \ A W2 t G-FURN COMPRESSOR OUTPUT J-2 _ 7 Y SECOND STAGE -3 Kz i COMPRESSOR OUTPUT Y2 Y2-HP REVERSING VALVE +\/DC OUTPUT 0 Y2-STAT 24VAC Y2-FURN POWER SUPPLY OUT 2-2 Ka TOTHERMOSTAT -r R 01 -ti Y-STAT CALLFOR 2-1 Y-FURN REVERSING VALVE H O CALLFOR Y-HP COMPRESSOR Y - CALLFOR z-a K3 EMERGENCYHEAT M E CALLFOR z-s BLOWER FAN Q G +svoc Q2 CALLFOR 9 FURNACE HEAT W1 POWER SUPPLY COMMON 2-3 c EIW1 OUT TO THERMOSTAT A C CALL FOR 2ND STAGE z-a FURNACE HEAT T W2 1 OK CALL FOR 2ND STAGE 2-6 COMPRESSOR Y2 zavgc MICROPROCESSOR I O POWER SUPPLY OUT < 3-s J TO HP CONTROL R VJ �C.BK HPCALL FOR FURNACE 3-a (DURING DEFROST) H W2 REVERSING � VALVE OUTPUT O Y COMPRESSOR A 0 3.2 CONTACTOR OUTPUTT Y s eK POWER SUPPLY COMMON 3s c OUT TO HP CONTROL C �- 33 ODT(OUTDOOR OT-N THERMOSTAT) M OT-N 3-1 3a 2ND STAGE COMPRESSOR OT-C � DEMAND OUTPUT 3s Y2 , BREAK FOR ODT ALL FUEL CONTROL BOARD-AFE1 8-60A This wiring diagram is for reference only. Not all wiring Is as shown above. Refer to the appropriate wiring diagram for the unit being serviced. (For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces) 62 l i ACCESSORIES WIRING,DIAGRAMS HIGH VOLTAGEI A WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO,SO MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. 10kw and Below, One Stage Electric Heat From Air Handler C G W2 R C BLUE WHITE G Q�e BROWN W2 N N BACK 0 RED E GI t EMERGENCY THERMOSTAT E HEAT O O RELAY 'O C R — OT/EHR18-60 0 Y C R W2 0 Y AF�COh' F From Outdoor Unit 15kw and Above, Two Stage Electric Heat From Air Handler a SEE NOTE �OsQ� C G W2 W3 R C BLUE WHITE G v BROWN W2 M O BLACK F RED C N L EMERGENCY THERMOSTAT E O HEAT O RELAY 'O R � OT/EHR18-60 0 Y C R W2 O Y Note: When using a Thermostat with only one stage for electric heat(W2),tie white and From Outdoor Unit brown wires from air handler together. Typical Wiring Schematics for OT/EHR18-60 (Outdoor Thermostat & Emergency Heat Relay) This wiring diagram Is for reference only. Not all wiring Is as shown above. Refer to the appropriate wiring diagram for the unit being serviced. 63 ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGEI ALL POWER BEFOREOR INTALLING THIS A-WARNING UNIT.ONNECT MULTIPLE POWER SOURCES MAY EING PR SE TS FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. 15kw and Above with Two OT/EH R1 8-60's, Two Stage Electric Heat and Two Stage Thermostat From Air Handler OT/EH R18-60#1 �,& / �e / P° C G W2 W3 R C BLUE va RE G aao m . 0 VV3 m r h EMERGENCY niEBMOsrAT E O HEAT O RELAY 'O R OT/EHR18-60#2 0 Y BWE VIVRE o BRW V B1 At1J EMERGENCY THMMOB AT HEAT RELAY C R VV2 O Y From Outdoor Unit Typical Wiring Schematics for OVEHRI8-60 (Outdoor Thermostat& Emergency Heat Relay). This wiring diagram Is for reference only Not all wiring Is as shown above Refer to the appropriate wiring diagram for the unit being serviced. 64 r ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGEI ®WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. R R TR R 1 4 HTR2 208/240 ,24V 2 BK 3 5 Y gL BL FL HTR3 TL PU BK PC —BL rFL HTR4 TL BK-01 BL EBTDR z R R G R BL 3 PU BL R K1 NO R XFMR-R Y M5 7 BL a BL XFMR-C K :OM M6 M8 `+ BRIO R 6 BR NC i� w w =SPEEDUP M1 s O Y O BL s BK RTTTT O — W BR G PK BL L1 L2 L1 L2 SR EQUIPMENT GROUND USE COPPER OR ALUMINUM WRE Typical Wiring Schematic MBR/AR*F Air Handler with Electric Heat. This wiring diagram is for reference only Not all wiring is as shown above Refer to the appropriate wiring diagram for the unit being serviced. 65 ACCESSORIES WIRING DIAGRAMS HIGH VOLTAGE! ,,AWA= DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. J _ L7 L2 0 m K J T m I L� O O O O O N N R BK BK O m R W m W q 2 BR w R e 6 3 R m BK BL m m O m PU R N BK BK R � a HTR2 TL O O Y HTR1 TL F }0- 0 a C7 N Y y Fw U ro �mm K m HKR Heat Kit 3 m 0 � m O W Z O m Y y m a F U U y m O m m m y vn Tc onEorx�1c q r, a "N�sr�T I dT d7 bT m 00gdO O rwry com o vrz�eop H �v, � E OT, PA m I VSTB Blower Section Typical Wiring Schematic MBE/AEPF with Electric Heat This wiring diagram is for reference only. Not all wiring is as shown above Refer to the appropriate wiring diagram for the unit being serviced 66 rA I GMH95 Gas Furnace r a Two-Stage Gas Valve Aia 6y" UP TO 95%AFUE Z, 7 U, I�tO R—Or-70i 4,d 1 11 liIft W 11 PREMIUM HEAL ING PE RF 0 R NI AN CE Heating X r. You Can Count On! Via; a kAT6;dMGES 1 A UNITREPLACEMEN UILULL 'To receive the Lifetime Heat Exchanger Limited Warranty,10-Year Unit Replacement Limited Warranty and 10-Year Parts Limited Warranty,online registration must be completed within 60 days of installation.Online registration is not required in California or Quebec Full warranty details available atwwwamana-haccom Amana is a registered trademark of Maytag Corporation or its related companies and Is used under license to Goodman Company,L P,Houston,IX All rights reserved p ri GMH95 Gas Furnace Two-Stage Gas Valve 777, UP TO 95%AFUE Headng Peior�nanx You Can Count On! We build quality into every component of our Amana®brand products. Additional Information And our Amana®Distinctions'brand GMH95 Two-Stage Gas Valve Gas Before purchasing this appliance,read important information Furnace is no exception.The GMH95 furnace can save you money on your about its estimated annual energy consumption,yearly operating heating bills versus lower AFUE units,and will provide you with dependable J cost,or energy efficiency rating that is available from your retailer. heating performance for years to come.Plus,at up to 95%AFUE,this Amana Distinctions brand unit meets the higher standard of the Environmental Protection Agency's Energy Star Program!" Two Stages of Comfort This unit features our TwinComforf two-stage gas valve technology, AHeating&Air Conditioning which delivers just the right amount of heat to provide steady,even warmth. ana" This technology helps eliminate the temperature swings resulting from abrupt, high-stage stops and starts of the furnace.Plus it helps ensure quiet operation LASTS AND LASTS AND LASTS'" and increased air filtration for better indoor air quality. Quality that is Built to Last The Amana Distinctions brand GMH95 Two-Stage Gas Valve Gas Furnace is built with a long-lasting,heavy-duty aluminized-steel tubular primary heat exchanger and a stainless-steel recuperative coil.The unit features a durable Silicon Nitride Igniter to help lengthen igniter life. Quality You've Come to Expect Your Amana Distinctions brand GMH95 Gas Furnace provides you with the following features: @ Quiet,energy-saving PSC multi-speed,direct-drive blower motor *Quiet,corrosion-resistant,induced-draft blower assembly e Heavy-gauge,reinforced,fully insulated steel cabinet with durable, baked-enamel,Architectural Gray paint finish Additionally,this furnace is designed to reduce NOx emissions,contributing to better air quality. Premium Comfort Your Amana Distinctions brand GMH95 Two-Stage Gas Valve Gas Furnace is protected by what we believe to be one of the best standard warranties*in the industry: -A Lifetime Limited Warranty*on the heat exchanger for the original, registered homeowner for as long as you own your home -A 10-Year Unit Replacement Limited Warranty*on the heat exchanger for the original,registered homeowner -A 10-Year Parts Limited Warranty*on all functional parts To receive the Lifetime Heat Exchanger Limited Warranty,10-Year Unit Replacement Limited Warranty and 10-Year Parts Limited Warranty,online registration must be completed within 60 days of installation Online registration is not required in California or Quebec. Full warranty details available at wwwamana-hac com ©2009 Goodman Company,L R Amana is a registered trademark of Maytag Corporation f ENERGY STAR ratings are dependent upon conditions beyond equipment or its related companies and is used under license to Goodman Company,L.R,Houston,TX installation.To make certain your HVAC equipment qualities for the ENERGY All rights reserved. STAR designation,get complete information at wwwenergystargov CB-DGMH95 GMH9 S/GCH9 S/GME9 S/GCH9 GAS—FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS Installer: Affix all manuals adjacent to the unit. (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirements a embodied in the American National Stan- dard / National Standard of Canada ANSI C US Z21.47-CSA-2.3 Gas Fired Central Fur- n aces. [Ism° Intertek A RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION. ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer. This includes all safety precautions and related items. Prior to actual installation,thoroughly familiarize yourself with this Instruction Manual Pay special attention to all safety warnings.Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation. Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use. Safety is a matter of common sense...a matter of thinking before acting Most dealers have a list of specific good safety practices...follow them. The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual,the precautions listed here take precedence NOTE:Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual. Goodman Manufacturing Company, L.P. N ,� 10-299P 5151 San Felipe, Suite 500, Houston,TX 77056 10/2012 www.cioodmanmtg.com ©2006-2012 Goodman Manufacturing Company, L.P. Table of Contents IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY............................................................................................4 I. Component Identification ...............................................................................................................................................5 II. Safety .............................................................................................................................................................................. 6 ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS.....:.............................................................................................................. 6 III. Product Application ...................................................................................................................................................... 6 IV. Location Requirements &Considerations................................................................................................................. 7 GENERAL .........................................................................................................................................................................7 CLEARANCESAND ACCESSIBILITY.......................................................................................................................................... 8 FURNACESUSPENSION....................................................................................................................................................... 8 EXISTINGFURNACE REMOVAL............................................................................................................................................... 8 THERMOSTATLOCATION........................................................................................................................................................ 9 V.Combustion&Ventilation Air Requirements ............................................................................................................... 9 VI.Installation Positions ...................................................................................................................................................11 VII.Horizontal Applications&Considerations ................................................................................................................11 GENERAL ....................................................................................................................................................................... 11 DRAINTRAP AND LINES .................................................................................................................................................... 11 LEVELING...................................................................................................................................................................... 11 ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS.................................................................................................. 11 ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS............................................................................................................ 12 DRAINPAN..................................................................................................................................................................... 12 FREEZEPROTECTION........................................................................................................................................................ 12 FURNACESUSPENSION..................................................................................................................................................... 12 VIII. Propane Gas/High Altitude Installations............................................................................................................... 12 IX. Vent/Flue Pipe &Combustion Air Pipe ..........................:.......................................................................................... 12 GENERAL ....................................................................................................................................................................... 12 DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT.................................................................................................................. 13 MATERIALS AND JOINING METHODS ..................................................................................................................................... 13 PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES............................................................................................... 13 TERMINATIONLOCATIONS ................................................................................................................................................... 13 CANADIAN VENTING REQUIREMENTS..................................................................................................................................... 15 STANDARDFURNACE CONNECTIONS .................................................................................................................................... 15 ALTERNATEFURNACE CONNECTIONS.................................................................................................................................... 16 NON-DIRECT VENT SINGLE PIPE) PIPING ........................................................................................................................... 17 DIRECTVENT DUAL PIPE) PIPING ..................................................................................................................................... 18 VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES ................................................................ 19 CONCENTRICVENT TERMINATION........................................................................................................................................ 19 SIDEWALL VENT KIT...................................................................................................................................................... 20 X. Condensate Drain Lines&Drain Trap........................................................................................................................ 20 STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS .................................................................................................. 21 UPRIGHTINSTALLATIONS-TRAP ON LEFT SIDE........................................................................................................................ 23 HORIZONTALINSTALLATIONS................................................................................................................................................ 24 XI.Electrical Connections................................................................................................................................................ 26 WIRINGHARNESS............................................................................................................................................................ 26 115 VOLT LINE CONNECTIONS........................................................................................................................................... 26 JUNCTIONBOX RELOCATION .............................................................................................................................................. 26 24 VOLT THERMOSTAT WIRING........................................................................................................................................... 27 GME95 FURNACE WITH 2-STAGE CONDENSER FIELD WIRING ................................................................................................ 27 115 VOLT LINE CONNECTION OF ACCESSORIES (ELECTRONIC AIR CLEANER) ........................................................................... 27 24 VOLT HUMIDIFIER........................................................................................................................................................ 28 XII. Gas Supply and Piping.............................................................................................................................................. 28 GENERAL ....................................................................................................................................................................... 28 GAS PIPING CONNECTIONS................................................................................................................................................ 28 PROPANEGAS TANKS AND PIPING ...................................................................................................................................... 31 XIII. Circulating Air& Filters............................................................................................................................................ 31 DUCTWORK-AIR FLOW CHECKINGDUCT STATIC ................................................................................................................................................... 32 BOTTOMRETURN AIR OPENING[UPFLOW MODELS] .............................................................................................................. 32 FILTERS-READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK..................................................................... 33 UPRIGHTINSTALLATIONS .................................................................................................................................................... 33 HORIZONTALINSTALLATIONS................................................................................................................................................ 33 2 1 l t Table of Contents XIV. Startup Procedure&Adjustment.......................... ................................... 33 HEATANTICIPATOR SETTING ............................................................................................................................................... 33 DRAINTRAP PRIMING....................................................................................................................................................... 33 FURNACEOPERATION ........................................................................................................................................................ 33 GAS SUPPLY PRESSURE MEASUREMENT............................................................................................................................... 34 GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT.......:........................................................................................... 35 GAS INPUT RATE MEASUREMENT(NATURAL GAS ONLY)............................................................................................................ 35 TEMPERATURERISE.......................................................................................................................................................... 36 CIRCULATOR BLOWER SPEEDS........................................................................................................................................... 36 CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ................................................................................................................... 36 SETTING FURNACE OPERATING MODE.................................................................................................................................. 37 XV. Normal Sequence of Operation................................................................................................................................ 37 POWERUP..................................................................................................................................................................... 37 HEATINGMODE................................................................................................................................................................ 37 (MODE DIP SWITCH IS SET TO"1 STG" POSITION) .............................................................................................................. 37 (MODE DIP SWITCH IS SET TO"2 STG" POSITION) .............................................................:................................................ 37 COOLINGMODE .............................................................................................................................................................. 38 FANONLY MODE............................................................................................................................................................. 38 XVI. Operational Checks................................................................................................................................................... 38 BURNERFLAME............................................................................................................................................................... 38 XVII.Safety Circuit Description ....................................................................................................................................... 38 GENERAL ....................................................................................................................................................................... 38 INTEGRATED CONTROL MODULE.......................................................................................................................................... 38 PRIMARYLIMIT ................................................................................................................................................................ 38 AUXILIARYLIMIT.............................................................................................................................................................. 38 ROLLOUTLIMIT............................................................................................................................................................... 38 PRESSURESWITCHES ...................................................................................................................................................... 39 FLAMESENSOR............................................................................................................................................................... 39 XVIII.Troubleshooting..................................................................................................................................................... 39 ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS.................................................................................................................. 39 DIAGNOSTICCHART.......................................................................................................................................................... 39 FAULTRECALL ................................................................................................................................................................ 39 RESETTINGFROM LOCKOUT......................................:........................................................................................................ 39 XIX. Maintenance............................................................................................................................................................. 39 ANNUALINSPECTION......................................................................................................................................................... 39 FILTERS ......................................................................................................................................................................... 40 BURNERS.......................................................................................................................................................................40 INDUCED DRAFT AND CIRCULATOR BLOWERS........................................................................................................................ 40 CONDENSATE TRAP AND DRAIN SYSTEM(QUALIFIED SERVICER ONLY) .......................................................................................40 FLAME SENSOR(QUALIFIED SERVICER ONLY)....................................................................................................................... 40 IGNITER(QUALIFIED SERVICER ONLY)................................................................................................................................. 40 FLUEPASSAGES(QUALIFIED SERVICER ONLY)...................................................................................................................... 40 XX. Before Leaving an Installation ................................................................................................................................. 41 XXI. Repair& Replacement Parts ................................................................................................................................... 41 TroubleshootingChart...................................................................................................................................................... 42 Blower Performance Data ............................................................................................................................................... 44 WiringDiagram ................................................................................................................................................................ 47 Special Instructions for Products Installed ..................................................................................................................... 50 in the State of Massachusetts....................................................................................................................................... 50 A WARNING GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES. IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT,YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT. 3 SHIPPING INSPECTION - AWARNING All units are securely packed in shipping containers tested accord- ing to International Safe Transit Association specifications. The car- IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED ton must be checked upon arrival for external damage If damage Is EXACTLY,A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY found, a request for inspection by carrier's agent must be made In DAMAGE,PERSONAL INJURY OR LOSS OF LIFE. writing immediately. -DO NOT'STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS The furnace must be carefully inspected on arrival for damage and AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. -WHAT TO DO IF YOU SMELL GAS: bolts or screws which may have come loose in transit In the event •DO NOT TRY TO LIGHT ANY APPLIANCE. of damage the consignee should- *DO NOT TOUCH ANY ELECTRICAL SWITCH;DO NOT USE 1. Make a notation on delivery receipt of any visible damage to ANY PHONE IN YOUR BUILDING. shipment or container. •IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A 2. Notify carrier promptly and request an Inspection. NEIGHBORS PHONE,FOLLOW THE GAS SUPPLIERS 3. With concealed damage,carrier must be notified as soon as INSTRUCTIONS. •IF YOU CANNOT READCH YOUR GAS SUPPLIER,CALL THE possible- preferably within five days. FIRE DEPARTMENT. 4. File the claim with the following support documents within a -INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED nine month statute of limitations. INSTALLER,SERVICE AGENCY OR THE GAS SUPPLIER • Original or certified copy of the Bill of Lading,or indemnity bond. AWARNING Original paid freight bill or indemnity In lieu thereof. • Original or certified copy of the Invoice,showing trade and SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT other discounts or reductions OFF,TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY. Copy of the inspection report issued by carrier's representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection of damage DANGERand for a thorough investigation of each claim The distributor or # manufacturer will not accept claims from dealers for transportation damage. Keep this literature in a safe place for future reference. IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WAR- RANTY Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty cer- CARBON MONOXIDE POISONING HAZARD tificate carefully to determine what is and Is not covered and keep the warranty certificate In a safe place. If you are unable to locate Special Warning for Installation of Furnace or Air Handling Units in the warranty certificate please contact your installing contractor or Enclosed Areas such as Garages,Utility Rooms or Parking Areas contact customer service (877-254-4729) to obtain a copy. Carbon monoxide producing devices(such as an automobile,space To receive the Lifetime Heat,Exchanger Limited Warranty(good for heater,gas water heater,etc.)should not be operated In enclosed areas as long as you own your home) and the 10-year Parts Limited such as unventilated garages,utility rooms or parking areas because of Warranty, online registration must be completed within 60 days of the danger of carbon monoxide(CO)poisoning resulting from the exhaust emissions. If a furnace or air handler Is Installed in an enclosed area such installation. Online registration is not required In California or Que- as a garage,utility room or parking area and a carbon monoxide producing bec. Complete warranty details available from your local dealer or device Is operated therein,there must be adequate,direct outside ventilation. at www goodmanmfg com To register your Goodman®brand unit,go to www.goodmanmfg com This ventilation is necessary to avoid the danger of CO poisoning which and click "Warranty Registration" Complete registration as can occur if a carbon monoxide producing device continues to operate In prompted. the enclosed area. Carbon monoxide emissions can be(re)circulated throughout the structure if the furnace orair handler isoperating in any mode. Product limited warranty certificates for models currently in produc- tion can be viewed at www goodmanmfg com. If your model is not CO can cause serious illness including permanent brain damage or death. currently in production or does not appear On the website, please 810259-216 contact your installing contractor or contact customer service(877- 254-4729)to obtain a copy of your warranty certificate Each product overview page contains a Product Warranty link; by TO THE INSTALLER clicking on it you will be able to view the limited warranty coverage . Before installing this unit, please read this manual thoroughly to for that specific product To view warranty registration information, familiarize yourself with specific items which must be adhered to, click on the Product Warranty text on the left navigation panel on the Including but not limited to: unit maximum external static pressure, home page of each website.The Online Product Registration pages gas pressures, BTU input rating, proper electrical connections, clr- are located In this same section. culating air temperature rise, minimum or maximum CFM, and mo- tor speed connections. 4 1 t ` j I. COMPONENT IDENTIFICATION 5 6 7 $ 7 10 5 7 1 11 z z 4 11 U.1 Q 2 ® 12 a 2 0 m 13 4 1 Of o z e 16 100 15 ,J ® m of CIO 18 18 14 17 19 19 0 1 w w 20 00- 31 0 2 18 19 2 8 19 a. a. 0 8 v 1 w CZ 0 3 1Of 2 1 Jill m � 5 CIO 9 7 8 7 6 4 O 6 4 Upflow/Horizontal Counterflow/Horizontal 1 Gas Valve 22 Blower Door Interlock Switch 2 Gas Line Entrance (Alternate) 23 Capacitor 3 Pressure Switch 24 Integrated Control Module 4 Gas Manifold (with fuse and diagnostic LED) 5 Combustion Air Intake Connection ! "Coupling" 25 24-Volt Thermostat Connections 6 Hot Surface Igniter 26 Transformer(40 VA) 7 Rollout Limit 27 Circulator Blower 8 Burners 28 Auxiliary Limit 9 Flame Sensor 29 Junction Box 10 Flue Pipe Connection/"Coupling" 30 Electrical Connection Inlets 11 Flue Pipe (Internal) 31 Cod Front Cover 12 Primary Limit 13 Gas Line Entrance 14 Flue Pipe Connection (Alternate) 15 Rubber Elbow 16 Induced Draft Blower 17 Electrical Connection Inlets (Alternate) 18 Coil Front Cover Pressure Tap 19 Coil Front Cover Drain Port 20 Drain Line Penetrations 21 Drain Trap 5 II.SAFETY' or shuffle your feet, do not touch ungrounded objects, etc) Please adhere to the following warnings and cautions when in- If you come in contact with an ungrounded object, repeat stalling, adjusting, altering, servicing, or operating the furnace step 2 before touching control or wires. 4 Discharge your body to ground before removing a new ®WARNING control from its container Follow steps 1 through 3 If installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER object INSTALLATION,ADJUSTMENT,ALTERATION,SERVICE OR MAINTENANCE,REFER TO THIS MANUAL.FOR ADDITIONAL III.PRODUCT APPLICATION ASSISTANCE OR INFORMATION,CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile ®WARNING homes,trailers or recreational vehicles This unit is NOT designed or certified for outdoor applications. The furnace must be installed THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS indoors(i.e , attic space, crawl space, or garage area provided the WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE garage area is enclosed with an operating door). KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER,BIRTH This furnace can be used in the following non-industrial commer- DEFECTS OR OTHER REPRODUCTIVE HARM. cial applications Schools,Office buildings,Churches,Retail stores ® Nursing homes,Hotels/motels,Common or office areas WARNING In such applications , the furnace must be installed with the follow- ing stipulations* HIGH VOLTAGEI It must be Installed per the Installation instructions TO AVOID PROPERTY DAMAGE,PERSONAL INJURY OR provided and per local and national codes DEATH DUE TO ELECTRICAL SHOCK,THE FURNACE MUST It must be Installed indoors in a building constructed on BE LOCATED TO PROTECT THE ELECTRICAL site COMPONENTS FROM WATER. • It must be part of a ducted system and not used in a free air delivery application. ®WARNING It must not be used as a "make-up" air unit. • It must be installed with two-pipe systems for combustion DO NOT UTILIZE THE HEATING UNIT WITHOUT REASONABLE ROUTINE air, especially if VOC's or other contaminants are present INSPECTION,MAINTENANCE AND SUPERVISION.IF THE UNIT IS IN A in the conditioned space BUILDING THAT IS OR WILL BE VACANT,CARE SHOULD BE TAKEN TO All other warranty exclusions and restrictions apply This ROUTINELY INSPECT,MAINTAIN AND MONITOR THE UNIT.IN THE furnace is an ETL dual-certified appliance and is EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING appropriate for use with natural or propane gas(NOTE: If TEMPERATURES AND WILL BE VACANT,DRAIN ALL WATER-BEARING using propane, a propane conversion kit is required). PIPES,PROPERLY WINTERIZE THE BUILDING,AND TURN OFF ALL WATER SOURCES.IN THE EVENT THAT THE BUILDING IS EXPOSED TO Dual certification means that the combustion air inlet pipe is op- FREEZING TEMPERATURES AND IS VACANT,ANY HYDRONIC COIL tional and the furnace can be vented as a. UNITS SHOULD ALSO BE DRAINED AND AN ALTERNATIVE HEAT Non-direct vent (single pipe) central forced air furnace in SOURCES UTILIZED. Iwhich combustion air Is taken from the installation area or from air ducted from the outside or, ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS Direct vent(dual pipe)central forced air furnace in which all combustion air supplied directly to the furnace burners NOTE: Discharge static electricity accumulated In the body before through a special air intake system outlined in these touching the unit An electrostatic discharge can adversely affect instructions. electrical components. This furnace may be used as a construction site heater ONLY if the Use the following precautions during furnace Installation and ser- following conditions are met vicing to protect the integrated control module from damage. By The vent system is permanently installed per these putting the furnace,the control,and the person at the same electro- installation Instructions. static potential, these steps will help avoid exposing the integrated A room thermostat Is used to control the furnace. Fixed control module to electrostatic discharge This procedure Is apple- jumpers that provide continuous heating CANNOT be cable to both installed and non-installed (ungrounded) furnaces used 1. Disconnect all power to the furnace Do not touch the Return air ducts are provided and sealed to the furnace. Integrated control module or any wire connected to the control A return air temperature range between 60°F (16°C) and prior to discharging your body's electrostatic charge to 80°F (27°C) is maintained. ground. Air filters are installed In the system and maintained 2 Firmly touch a clean, unpainted, metal surface of the during construction, replaced as appropriate during furnaces near the control Any tools held in a person's hand construction, and upon completion of construction are during grounding will be discharged replaced 3 Service integrated control module or connecting wiring The input rate and temperature rise are set per the furnace following the discharge process in step 2 Use caution not rating plate. to recharge your body with static electricity;(i.e.,do not move 6 • 100% outside air Is provided for combustion air The rated heating capacity of the furnace should be greaterthan or requirements during construction.Temporary ducting can equal to the total heat loss of the area to be heated. The total heat be used. loss should be calculated by an approved method or In accor- NOTE: Do not connect the temporary duct directly to the dance with"ASHRAE Guide"or"Manual J-Load Calculations"pub- furnace. The duct must be sized according to the lished by the Air Conditioning Contractors of America. instructions under Section V, Combustion and Ventilation IV. LOCATION REQUIREMENTS &CONSIDERATIONS Air Requirements, Section 5.3.3 • The furnace heat exchanger, components, duct system, GENERAL air filters and evaporator coils are thoroughly cleaned following final construction clean up. A WARNING • All furnace operating conditions (including ignition, input rate, temperature rise and venting)are verified according TO PREVENT POSSIBLE EQUIPMENT DAMAGE,PROPERTY DAMAGE, to these installation Instructions. PERSONAL INJURY OR DEATH,THE FOLLOWING BULLET POINTS MUST NOTE: The Commonwealth of Massachusetts requires that the BE OBSERVED WHEN INSTALLING THE UNIT. following additional requirements must also be met: Follow the Instructions listed,below when selecting a furnace loca- • Gas furnaces must be Installed by a licensed plumber or tion. Refer also to the guidelines provided In Section V, Combus- gas fitter tion and Ventilation Air Requirements. • A T-handle gas cock must be used. Centrally locate the furnace with respect to the proposed or existing air distribution system. • If the unit is to be Installed in an attic,the passageway to Ensure the temperature of the return air entering the and the service area around the unit must have flooring. furnace is between 55°F and 100°F when the furnace is heating. To ensure proper installation and operation, thoroughly read this Provide provisions for venting combustion products manual for specifics pertaining to the Installation and application outdoors through a proper venting system. Special of this product consideration should be given to vent/flue pipe routing and combustion air Intake pipe when applicable. Refer A WARNING to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for appropriate termination POSSIBLE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH DUE TO locations and to determine If the piping-system from FIRE,EXPLOSION,SMOKE,SOOT,CONDENSATION,ELECTRICAL furnace to termination can be accomplished within the SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER guidelines given. NOTE: The length of,flue and/or INSTALLATION,REPAIR,OPERATION,OR MAINTENANCE OF THIS combustion air piping can be a limiting factor In the PRODUCT. location of the furnace • Locate the furnace so condensate flows downwards to A WARNING the drain. Do not locate the furnace or Its condensate drainage system in any area subject to below freezing TO PREVENT PERSONAL INJURY,PROPERTY DAMAGE OR DEATH DUE temperatures without proper freeze protection Refer to TO FIRE,DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, Section X, Condensate Drain Lines and Trap for further TRAILER OR RECREATIONAL VEHICLE. details • Ensure adequate combustion air Is available for the To ensure proper furnace operation, install, operate and maintain furnace Improper or Insufficient combustion air can the furnace in accordance with these installation and operation expose building occupants to gas combustion products instructions, all local building codes and ordinances. In their ab- that could Include carbon monoxide. Refer to Section V, sence, follow the latest edition of the National Fuel Gas Code Combustion and Ventilation Air Requirements (NFPA 54/ANSI Z223 1),and/or CAN/CSA 8149.1-05 1-05 Installa- Set the furnace on a level floor to enable proper tion Codes, local plumbing or waste water codes, and other apple- condensate drainage. If the floor becomes wet or damp cable codes at times, place the furnace above the floor on a concrete A copy of the National Fuel Gas Code(NFPA 54/ANSI Z223 1)can base sized approximately 1-1/2" larger than the base of be obtained from any of the following: the furnace. Refer to the Section VII, Horizontal American National Standards Institute Applications and Considerations for leveling of horizontal 1430 Broadway furnaces. New York, NY 10018 • Ensure upflow or horizontal furnaces are not installed National Fire Protection Association directly on carpeting, or any other combustible material. 1 Batterymarch Park The only combustible material allowed is wood. Quincy,MA 02269 A special accessory subbase must be used for upright CSA International counterflow unit Installations over any combustible 8501 East Pleasant Valley - material (including wood) Refer to subbase instructions Cleveland, OH 44131 for installation details. (NOTE: A subbase will not be required if an air conditioning coil Is located beneath the A copy of the CAN/CSA B149.1-05 1-05 Installation Codes can also furnace between the supply air opening and the be obtained from. combustible floor CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1 R3 7 • Exposure to contaminated combustion air will result in TOP safety and performance-related problems Do not installc TOP the furnace where the combustion air is exposed to the t= following substances: SIDE SIDE SIDE 00 chlorinated waxes or cleaners 11 chlorine-based swimming pool chemicals water softening chemicals BOTTOM deicing salts or chemicals BOTTOM carbon tetrachloride Upflow Counterflow Horizontal halogen type refrigerants A furnace installed in a confined space(i.e.,a closet or utility room) cleaning solutions (such as perchloroethylene) must have two ventilation openings with a total minimum free area printing inks of 0.25 square inches per 1,000 BTU/hr of furnace input rating paint removers Refer to the Specification Sheet applicable to your model for mini- varnishes mum clearances to combustible surfaces. One of-the ventilation hydrochloric acid openings must be within 12 inches of the top; the other opening cements and glues must be within 12 inches of the bottom of the confined space In a antistatic fabric softeners for clothes dryers typical'construction,the clearance between the door and doorframe is usually adequate to satisfy this ventilation requirement. and masonry acid washing materials • Seal off a non-direct vent furnace if it is Installed near an area frequently contaminated by any of the above FURNACE SUSPENSION substances. This protects the non-direct vent furnace If suspending the furnace from rafters or joists, use 3/8" threaded from airborne contaminants To ensure that the rod and 211x2"x1/8" angle Iron as shown below. The length of rod enclosed non-direct vent furnace has an adequate supply will depend on the application and the clearances necessary. of combustion air, vent from a nearby uncontaminated PROVIDE r MIWUM CLEARANCE BETWEEN room or from. outdoors. Refer to the Section V,' *TOZ= ENTERRODANDFURNACECASINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL Combustion and Ventilation Air Requirements for details • If the furnace is used in connection with a cooling unit, R D ASSURE FURNACE IS LEVEL FROM install the furnace upstream or in parallel with the cooling END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT unit. Premature heat exchanger failure will result if theOF THE FURNACE - BELOW THE BACK OF THE FURNACE cooling unit is placed ahead of the furnace HOL For vertical (upflow or downflow) applications, the SUPPORc� �,minimum cooling coil width shall not be less than furnace NUTS width minus 1". Additionally, a coil installed above an upflow furnace or under a counterflow furnace may be the same width as the furnace or may be one size larger than the furnace Example: a "C"width cod may be installed with a `B"width furnace %2 1lN(3POSITION AS CLOSE AS POSSIBLE TILT OUTWARD TO ALLOW FOR TO BLOWER DECK TO ALLOW FOR DOOR AND CIRCULATOR BLOWER For upflow applications, the front of the coil and furnace CIRCULATOR SLOWER REWCAL REMOVAL must face the same direction Suspended Furnace • If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are EXISTING FURNACE REMOVAL located not less than 18 inches(457 mm)above the floor NOTE:When an existing furnace is removed from a venting system Protect the furnace from physical damage by vehicles. serving other appliances, the venting system may be too large to • If the furnace Is installed horizontally, the furnace access properly vent the remaining attached appliances doors must be vertical so that the burners fire horizontally The following vent testing procedure is reproduced from the American into the heat exchanger Do not install the unit with the National Standard/National Standard of Canada for Gas-Fired Cen- access doors on the "up/top" or "down/bottom" side of tral Furnaces ANSI 221.47-Latest Edition,CSA-2.36--Latest Edition the furnace. Section 1.23.1. CLEARANCES AND ACCESSIBILITY Installations must adhere to the clearances to combustible mate- The following steps shall be followed with each appliance connected to the rials to which this furnace has been design certified The mini- venting system placed in operation,while any other appliances connected mum clearance information for this furnace is provided on the unit's to the venting system are not in operation: clearance label. These clearances must be permanently main- a. Seal any unused openings in the venting system; tained. Clearances must also accommodate an installation's gas, b. Inspect the venting system for proper size and horizontal pitch,as electrical, and drain trap and drain line connections. If the alternate required by the National Fuel Gas Code,ANSI Z223.1 or the CSA vent/flue connection is used, additional clearance must be pro- 13149.1-05.1-05 Installation Codes and these instructions. Deter- vided to accommodate these connections Refer to Section IX, mine that there is no blockage or restriction,leakage,corrosion and Vent Flue Pipe and Combustion Air Pipe for details NOTE: In other deficiencies which could cause an unsafe condition; addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit *NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual 8 0 t � c. In so far as practical,close all building doors and windows and all V.COMBUSTION&VENTILATION AIR REQUIREMENTS doors between the space in which the appliance(s)connected to the venting system are located and other spaces of the building.Turn on ®WARNING clothes dryers and any appliance not connected to the venting sys- tem.Turn on any exhaust fans,such as range hoods and bathroom exhausts,so they shall operate at maximum speed.Do not operate a POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF summer exhaust fan.Close fireplace dampers; THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE d. Follow the lighting instructions.Place the appliance being inspected OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA. in operation.Adjust thermostat so appliance shall operate continu- ously; Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around e. Test for draft hood equipped spillage at the draft hood relief opening doors and windows. These changes have helped in reducing after 5 minutes of main burner operation.Use the flame of a match heating/cooling costs but have created a problem supplying com- or candle; bustion and ventilation air for gas fired and other fuel burning apple- f. After it has been determined that each appliance connected to the ances Appliances that pull air out of the house (clothes dryers, venting system properly vents when tested as outlined above,re- exhaust fans, fireplaces, etc) Increase the problem by starving turn doors,windows,exhaust fans,fireplace dampers and any other appliances for air. gas burning appliance to their previous conditions of use; House depressurization can cause back drafting or improper com- bustion of gas-fired appliances, thereby exposing building occu- g. If improper venting is observed during any of the above tests,the pants to gas combustion products that could include carbon mon- common venting system must be corrected. oxide Corrections must be in accordance with the latest edition of the If this furnace is to be Installed In the same space with other gas National Fuel Gas Code NFPA 54/ANSI Z223 1 and/or CSA B149 1- appliances, such as a water heater, ensure there Is an adequate 05.1-05 Installation Codes supply of combustion and ventilation air for the other appliances If resizing is required on any portion of the venting system, use the Refer to the latest edition of the National Fuel Gas Code NFPA 54/ appropriate table In Appendix G in the latest edition of the National ANSI Z223 1 (Section 5.3), or CSA 8149 1-05 Installation Codes Fuel Gas Code ANSI Z223.1 and/or CSA B149 1-05.1-05 Installa- (Sections 7 2, 7 3, or 7.4), or applicable provisions of the local tion Codes, building codes for determining the combustion air requirements for the appliances THERMOSTAT LOCATION Most homes will require outside air be supplied to the furnace area The thermostat should be placed approximately five feet from the by means of ventilation grilles or ducts connecting directly to the floor on a vibration-free, inside wall In an area having good air outdoors or spaces open to the outdoors such as attics or crawl circulation. Do not install the thermostat where it may be influ- spaces enced by any of the following The following information on air for combustion and ventilation is repro- duced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section • Drafts, or dead spots behind doors, in corners, or under 5.3. cabinets 5.3.1 General: • Hot or cold air from registers. (a)The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion,ventilation and dilu- • Radiant heat from the sun. tion of flue gases from within the building.They do not apply to(I) • Light fixtures or other appliances. direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all • Radiant heat from a fireplace. flue gases are discharged to the outside atmosphere,or(2)enclosed • Concealed hot or cold water pipes, or chimneys furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases. • Unconditioned areas behind the thermostat, such as an (b)Equipment shall be installed in a location in which the facilities for outside wall ventilation permit satisfactory combustion of gas,proper venting and the maintenance of ambient temperature at safe limits under JF 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. (c)In addition to air needed for combustion,process air shall be pro- vided as required for:cooling of equipment or material,controlling COLD dew point, heating, drying, oxidation or dilution, safety exhaust, )) odor control,and air for compressors. (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. Thermostat Influences (e)While all forms of building construction cannot be covered in detail, Consult the instructions packaged with the thermostat for mount- air for combustion, ventilation and dilution of flue gases for gas ing Instructions and further precautions. utilization equipment vented by natural draft normally may be ob- tained by application of one of the methods covered in 5.3.3 and 5.3.4. 9 i (f)Air requirements for the operation of exhaust fans,kitchen ventila- chimney or Gas vent tion systems,clothes dryers,and fireplaces shall be considered in Ventilation louvers determining the adequacy of a space to provide combustion air (each end of attic) requirements. NOTE:The inlet and outlet air re q openings must each have a free 5.3.2 Equipment Located in Unconfined Spaces: area of not less than one square Inch per 4000 BTU of the hi unconfined spaces(see definition below)in buildings,infiltration may total input rating of all equipment be adequate to provide air for combustion ventilation and dilution of to the enclosure. flue gases.However, in buildings of tight construction(for example, Outlet Au weather stripping,heavily insulated,caulked,vapor barrier,etc.),addi- tional air may need to be provided using the methods described in 5.3.3- = Hater b or 5.3.4 Furnace Inlet Air Space, Unconfined. Aftemate au inlet ❑ 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 Ventilation louvers for the space in which the appliances are installed through openings not unheated crawl space furnished with doors,are considered a part of the unconfined space. Equipment Located in Confined Spaces; All Air from Outdoors— Inlet Air from Ventilated Crawl Space and Outlet Air to Ventikited 5.3.3 Equipment Located in Confined Spaces: Attic. See 5.3.3-b (a)All Air from Inside the Building:The confined space shall be pro- 2.When communicating with the outdoors through vertical ducts, vided with two permanent openings communicating directly with each opening shall have a minimum free area of 1 square inch per an additional room(s) of sufficient volume so that the combined 4,000 BTU per hour of total input rating of all equipment in the volume of all spaces meets the criteria for an unconfined space.The enclosure. total input of all gas utilization equipment installed in the combined space shall be considered in making this determination.Each open- cnimney or cas vent in shall have a minimum free area of 1 square inch per 1,000 BTU (each enVentilation louvers g q p (each and of attic) per hour of the total input rating of all gas utilization equipment in NOTE,The Inlet and outlet air the confined space,but not less than 100 square inches.One open- openings must each have a free ing shall be within 12 inches of the top and one within 12 inches of area of not less than one square inch per 4000 BTU of the the bottom of the enclosure. total Input rating of all equipment in the enclosure .--Chimney or Gas Vent NOTE:Each opening must have outlet Air a free area of not less than one square inch per 1000 BTU of — Water the total input rating of all equip- Furnace Heater ment in the enclosure,but not Inlet air duct less than 100 square inches, o lends I fl(300 mm) above floor] .--Opening neaterrEquipment Located in Confined Spaces; All Air from Outdoors umce Through Ventilated Attic. See 5.3.3-b. 3.When communicating with the outdoors through horizontal ducts, .—Opening 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. Equipment Located in Confined Spaces; All Air from Inside Chimney or Gas Vent Building. See 5.3.3-a. (b)All Air from Outdoors:The confined space shall be provided with two permanent openings,one commencing within 12 inches of the NOTE:The air duct openings top and one commencing within 12 inches of the bottom of the must have a free area of not enclosure.The openings shall communicate directly,or by ducts, less than one square Inch per 2000 BTU of the total Input with the outdoors or spaces(crawl or attic)that freely communicate rating of all equipment in the with the outdoors. outlet air duct enclosure*. 1 When directly communicating with the outdoors,each opening shall have a minimum free area of 1 square inch per 4,000 BTU Fumace Heater per hour of total input rating of all equipment in the enclosure. _ Inlet air duct 'Ifthe appliance room is located against an outsidewall and the airopenings communicate directly wil h the outdoors,each opening shall have a free area of not less than one square inch per4,000 BTU per hour of the total Input rating of all appliances in the enclosure Equipment Located in Confined Spaces; All Air from Outdoors. See 5.3.3-b. 10 d 4. When ducts are used,they shall be of the same cross-sectional "Recommended Installation Positions" figure for appropriate in- area as the free area of the openings to which they connect.The stallation positions, ductwork connections, and resulting airflow minimum dimension of rectangular air ducts shall not be less arrangements. than 3 inches. VII.HORIZONTAL APPLICATIONS&CONSIDERATIONS NOTE:The single opening must have GENERAL a free area of not less than one —Chimney or Gas Vent square Inch per 3000 BTU of the total Input rating of all equip- Horizontal applications, in particular, may dictate many of the mentInthe enclosure,but notlessthan installation's specifics such as airflow direction, ductwork connec- the sum of the areas of all vent connectors in the confined space. tions, flue and combustion air pipe connections, etc The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, .—Opening additional consideration must be given to the following FURNACE MUST BE LEVEL ALTERNATE ALTTRNA E 4 FROM END TO END water Alternate VENLOCATION FURNACE MUST BE LEVEL Heater Opening OR SLIGHTLY TILTED FORWARD Furnace Location WITH THE DOORS 0"-3/4" - BELOW THE BACK PANEL a m Equipment Located in Confined Spaces; All Air from Outdoors - 4 3/4"MINIM Single Air Opening. See 5.3.3-b. GAS LINE WITH DRAIN TRAP DRIP LE CLEARANCE 5.When directly communicating with the outdoors,the single open- (3"MINIMUM) ing shall have a minimum free area of 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclo- sure. DRAIN DRAIN LINE WITH PAN 114"PER FOOT 5.3.4 Specially Engineered Installations: DOWNWARD SLOPE The requirements of 5.3.3 shall not necessarily when special FURNACE MUST BE SUPPORTED 6"MINIMUM SERVICE q y g over° en p AT BOTH ENDS AND MIDDLE CLEARANCE REQUIRED engineering,approved by the authority having jurisdiction,provides an adequate supply of air for combustion,ventilation,and dilution of flue Horizontal Furnace gases. DRAIN TRAP AND LINES 5.3.5 Louvers and Grilles: In horizontal applications the condensate drain trap Is secured to In calculating free area in 5.3.3,consideration shall be given to the block- the furnace side panel, suspending It below the furnace A mint- ing effect of louvers,grilles or screens protecting openings.Screens used mum clearance of 4 3/4 Inches below the furnace must be pro- shall not be smaller than 1/4 inch mesh.If the area through a design of vided for the drain trap. Additionally, the appropriate downward louver or grille is known, it should be used in calculating the size of piping slope must be maintained from the drain trap to the drain opening required to provide the free area specified.If the design and free location Refer to Section X, Condensate Drain Trap and Lines for area is not known,it may be assumed that wood louvers will have 20-25 further details. If the drain trap and drain line will be exposed to percent free area and metal louvers and grilles will have 60-75 percent temperatures near or below freezing, adequate measures must free area. Louvers and grilles shall be fixed in the open position or be taken to prevent condensate from freezing. interlocked with the equipment so that they are opened automatically during equipment operation. LEVELING 5.3.6 Special Conditions Created by Mechanical Exhausting or Fire- Leveling ensures proper condensate drainage from the heat ex- places: changer and Induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace Operation of exhaust fans,ventilation systems,clothes dryers,or fire- should also be level from back to front or have a slight tilt with the places may create conditions requiring special attention to avoid unsat- access doors downhill (approximately 3/4 inches) from the back isfactory operation of installed gas utilization equipment. Air from panel. The slight tilt allows the heat exchanger condensate, gen- Inside Building.See 5.3.3-a, erated in the recuperator coil,to flow forward to the recuperator coil front cover. VI.INSTALLATION POSITIONS This furnace may be Installed in an upright position or horizontal ALTERNATEVENT/FLUE AND COMBUSTIONAIRCONNECTIONS on either the left or right side panel. Do not Install this furnace on In horizontal installations, provisions for alternate vent/flue piping its back. For upright upflow furnaces, return air ductwork may be is available for upflow furnaces with left air discharge Counterflow attached to the side panels) and/or basepan For horizontal up- furnaces include provisions for both alternate vent/flue and com- flow furnaces, return air ductwork must be attached to the basepan bustion air piping with right air discharge These configurations For both upright or horizontal counterflow furnaces, return duct- allow the flue and combustion air piping to be run vertically through work must be attached to the basepan(top end of the blower com- the furnace. Refer to the "Recommended Installation Positions" partment), NOTE: Ductwork must never be attached to the back of figure for further detail The standard piping connections may also the furnace For upflow installations requiring 1,800 CFM or more, be used in these positions. Refer to Section IX, VentlF/ue Pipe use either two side returns or a bottom return or a combination of and Combustion Air Pipe for details concerning the conversion to side and bottom. Contact your distributor for proper airflow require- the alternate vent/flue air connections ments and number of required ductwork connections. Refer to 11 • When using the horizontal alternate vent configuration, you must FREEZE PROTECTION use the RF000142 vent drain kit. See following illustration Refer to Section VII, Horizontal Applications and Conditions-Drain Trap and Lines. "FIELD SUPPLIED VENT-DRAIN DRAIN HOSE" AIRFLOW FURNACE SUSPENSION FROM VENT-DRAINIf the furnace is Installed in a crawl space It must be suspended CONNECTED TO CONDENSATE from the floor joist or supported by a concrete pad Never Install the DRAIN LINE WITH furnace on the ground or allow it to be exposed to water Refer to "FIELD SUPPLIED Section IV, Location Requirements and Considerations - Furnace CONNECTOR" /I, o Q - Suspension for further details NOTE:MAKE SMALL VIII.PROPANE GAS/HIGH ALTITUDE INSTALLATIONS LOOP IN HOSE TO SERVE AS "P-TRAP". ®WARNING ALTERNATE FLUENENT LOCATION POSSIBLE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH MAY AIR n ALTERNATE FLUE AND OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED.THE DISCHARGE LJ ALTERNATE FLUE PIPE Reum COMBUSTION AIR PIPE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER a LO�N Duct LOCATIONS O conneGlo FURNACE OPERATION.ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY. C �cl This furnace is shipped from the factory configured for natural gas ' at standard altitude Propane gas Installations require an orifice LRe,turmn o change to compensate for the energy content difference between ° natural and propane gas. t my AIR High altitude Installations may require both a pressure switch and ctio V DISCHARGE UPFLOW COUNTERFLOW an orifice change These changes are necessary to compensate UPRIGHT UPRIGHT for the natural reduction in the density of both the gas fuel and the ALTERNATE FLUE AND combustion air at higher altitude. ALTERNATE FLUE COMBUSTION AIR PIPE For installations above 7000 feet, please refer to your distributor LOCATIONS PIPE LOCATION for required kit(s) Bottom GMH95,GCH95,GCH9 GAS ORIFICE CHART Return AIR OaRl'I'mDuctn Ducl ° AIR Manifold Pressure DISCHARGEnectto Connectlo DISCHARGE Altitude Gas Kit Orifice Pressure Switch UPFLOW HORIZONTAL COUNTERFLOW HORIZONTAL LEFT AIR DISCHARGE RIGHT AIR DISCHARGE Natural None 443 3 5"w c. 0-7000None Propane LPM-05*Z #55 10 0"w c "'emLPM-06* P1 a °O RDud �/ AIR AIR Connecllo DISCHARGE DISCHARGE GME95 GAS ORIFICE CHART [C=onnedio UPFLOW HORIZONTAL COUNTERFLOW HORIZONTAL Altitude Gas Kit Orifice Manifold Pressure RIGHT AIR DISCHARGE LEFT AIR DISCHARGE Pressure Switch Recommended Installation Positions Natural None #45 3 5"w c NOTE:Alternate"vertical"piping connections can not be used when 0-7000 None an upflow furnace is installed with supply air discharging to the Propane LPM-06i2 #5s io o^w c right, or when a counterflow furnace Is Installed with supply air discharging to the left In either case, use the standard flue and z LPM-O5'supports White-Rodgers 2-stage valve only combustion air piping connections LPM-06*supports both Honeywell and White-Rodgers 2-stage valves NOTE: In Canada,gas furnaces are certified to 4500 feet ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS Contact the distributor for a tabular listing of appropriate This furnace has provisions allowing for electrical and gas line manufacturer's kits for propane gas and/or high altitude installa- connections through either side panel. In horizontal applications tions. The indicated kits must be used to insure safe and proper the connections can be made either through the"top"or"bottom"of furnace operation All conversions must be performed by a quali- the furnace. fied installer, or service agency. DRAIN PAN IX.VENT/FLUE PIPE&COMBUSTION AIR PIPE A drain pan must be provided if the furnace is installed above a GENERAL conditioned area The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable) ®WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH.CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION. 12 1 S , As an alternative to PVC pipe, primer, solvent cement, and fittings, AWARNING ABS materials which are in compliance with the following specifi- cations may be used. Two-or-three-Inch ABS Schedule 40 pipe UPON COMPLETION OF THE FURNACE INSTALLATION,CAREFULLY must meet ASTM D1527 and, if used in Canada, must be CSA INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF listed. Solvent cement for ABS to ABS joints must meet ASTM THE FURNACE TO ASSURE IT IS PROPERLY SEALED.LEAKS IN THE D2235 and, if used in Canada, must be CSA listed. The solvent FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH cement for the PVC to ABS transition joint must meetASTM D3138. DUE TO EXPOSURE'TO FLUE PRODUCTS,INCLUDING CARBON Fittings must be DWV type fittings meeting ASTM D2661 and ASTM MONOXIDE. f D3311 and, if used in Canada, must be CSA listed Carefully A condensing gas furnace achieves Its high level of efficiency by follow the pipe manufacturers' Instructions for cutting, cleaning, extracting almost all of the heat from the products of combustion and solvent cementing PVC and/or ABS. and cooling them to the point where condensation takes place. All 90° elbows must be medium radius (1/4 bend DWV) or long Because of the relatively low flue gas temperature and water con- radius (Long sweep 1/4 bend DWV) types conforming to ASTM densation requirements, PVC pipe is used as venting material. D3311 A medium radius (1/4 bend DWV) elbow measures 3 1/ This furnace must not be connected to Type B,BW,or L vent or vent 16"minimum from the plane of one opening to the centerline of the connector,and must not be vented Into any portion of a factory built other opening for 2" diameter pipe, and 4 9/16" minimum for 3" or masonry chimney except when used as a pathway for PVC as Pipe. described later in this section Never common vent this appliance PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES with another appliance or use a vent which is used by a solid fuel appliance Do not use commercially available "no hub connec- Adhere to these instructions to ensure safe and proper furnace tors" other than those shipped with this product performance The length, diameter, and number of elbows of the It Is the responsibility of the installer to follow the manufacturers' vent/flue pipe and combustion air pipe (when applicable) affects recommendations and to verify that all vent/flue piping and con- the performance of the furnace and must be carefully sized All nectors are compatible with furnace flue products. Additionally, it piping must be installed in accordance with local codes and`these is the responsibility of the installer to ensure that all piping and instructions. connections possess adequate structural integrity and support to Piping must be adequately secured and supported to prohibit sag- prevent flue pipe separation, shifting, or sagging during furnace ging,point separation, and/or detachment from the furnace Hori- operation zontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back DUAL CERTIFICATION:NON-DIRECT/DIRECT VENT towards the furnace,to properly return condensate to the furnace's This furnace is dual certified and may be installed as a non-direct drain system. Allowances should be made for minor expansion vent(single pipe)or direct vent(dual pipe)appliance. A non-direct and contraction due to temperature variations. For this reason, vent installation requires only a vent/flue pipe, while a direct vent particular care must be taken to secure piping when a long run is installation requires both a vent/flue pipe and a combustion air followed by a short offset of less than 40 Inches intake pipe Refer to the appropriate section for details concerning Precautions should be taken to prevent condensate from freez- piping size, length, number of elbows, furnace connections, and ing inside the vent/flue pipe and/or at the vent/flue pipe termina- terminations. tion It is our recommendation that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should be MATERIALS AND JOINING METHODS insulated with 1/2"thick closed cell foam Also all vent/flue piping exposed outdoors In excess of the terminations shown in this AWARNING manual (or in unheated areas)should be insulated with 1/2"thick closed cell foam. Inspect piping for leaks prior to installing insu- lation. TO AVOID BODILY INJURY,FIRE OR EXPLOSION,SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES(I.E.,SPARKS, TERMINATION LOCATIONS OPEN FLAMES,AND EXCESSIVE HEAT)AS THEY ARE COMBUSTIBLE LIQUIDS.AVOID BREATHING CEMENT VAPORS OR CONTACT WITH NOTES: Refer to Section IV, Location Requirements and SKIM AND/OR EYES. Considerations for Combustion air Contaminant restrictions. Two-or three-inch nominal diameter PVC Schedule 40 pipe meet- The following bullets and diagram describe the restrictions con- ing ASTM D1785, PVC primer meeting ASTM F656, and PVC sol- cerning the appropriate location of vent/flue pipe and combustion vent cement meeting ASTM D2564 specifications must be used air intake pipe (when applicable) terminations. Refer to Non-Di- Fittings must be DWV type fittings meeting ASTM D2665 and ASTM rect Vent (Single Pipe) Piping and Direct Vent(Dual Pipe) Piping D3311. Carefully follow the manufacturer's Instructions for cutting, located in this section for specific details on termination construc- cleaning, and solvent cementing of PVC. 'tion. The use of Schedule 40 PVC or ABS cellular core (Foam Core) All terminations (flue and/or intake) must be located at plastic pipe is also acceptable as a flue/vent and intake pipe ma- least 12 inches above ground level or the anticipated terial PVC primer meeting ASTM F656 and PVC solvent cement snow level. meeting ASTM D2564 specifications must be used Fittings must Vent terminations (non-direct and direct vent) must be DWV type fittings meetingA'STM D2665 and ASTM D3311.Care- terminate at least 3 feet above any forced air Inlet located fully follow the manufactures instructions for cutting, cleaning and within 10 feet. solvent cementing of PVC NOTE: This provision does not apply to the combustion For Canadian installations, all PVC pipe, fittings and joining mate- air Intake termination of a direct vent application. rials must be UL S636 listed. 13 Inside ❑V VENT TERMINAL Corner Detail QX AIR SUPPLY INLET C7 ®AREA WHERE TERMINALIS NOT PERMITTED V a A �H �y B-i B V IJCr CLOSED V OPERABLE CLOSEED I N X OPERABLE � B-( X o F �B �—j K I B DIRECT VENT TERMINAL CLEARANCES Canadian Installations' US Installations' Canadian Installatlans+ US Installations' A= Clearance above grade, 12 in(30 cm) 12 in(30 cm) 1= Clearance to service 3 ft(91 cm) ' veranda,porch,deck or regulator vent outlet balcony(See 1 24 6-i(9)b) J= Clearance to nonmechanical air 6,n(15 cm)br appliances 10,000 6n(15 an)for appliances 10000 B=Clearance to window or 6In(15 cm)for apphances 61n(15 cm)for appliances supply mletto budding or the BNh(3 WN)12m(30 an)for Btuh(3 kW),9 in(23 cm)for door that may be opened 10,000 Btuh(3 K✓h,12 In(30 cm)for 10,000 Btuh(3 kW),9 in(23 cm)for combustion or Inlet to any other appllances>10,000 Bbih(3WN)and appliances>10000 Btuh(31,W)and eppliances>10,000 Btuh(3 kW)and appliances>10,000 BNh(3 kW)and appliance 100,000 Btuh(30 kW),361.(91 em) 50,000 BWh(15 k",12 In(30 cm)for 100,000 Btuh(30 kW),36 in(91 cm) 50,000 Bluth(15 M),12 in(30 cm)for for appliances>100,000 Btuh(30 kW) appliances>50,000 Blur,(15 W) for appliances>100,000 Btuh(30 appliances>500,000 Btuh(15 kW) kW) K= Clearance to a mechanical 6 R(1 83 m) 3 R(91 cm)above it within C=Clearance to permanently airsupply inlet 10 It.(3 m)ho—anally closed window L= Clearance above paved sidewalk or 7it(213m)$ D=Vertical clearance to ventilated soffit paved driveway located on public located above the terminal within a property horizontal distance of 2 feet(61 cm) from the center line of the terminal M=Clearance under veranda,porch, 121n(30 cm); deck or balcony E= Clearance to unvenblaled soffit ' F= Clearance to outside comer 1 In accordance with the current CSA 81491,Nafura/Gas endPmpene Installation Code G=Clearance to inside comer 2 In accordance with the current ANSI Z22311NFPA 54,Natrona/Fuel Gas Code H=Clearance to each side of center 3 It(91 cm)with,.a height 15 R ' ndtshall velingstterrrunate rLrectly above as,dewalkorpaved tlnvewaythatis locatedbetween two snglefanlly dwellings and serves line extended above meter/regulator (45 m)above the meter/regulator t both assembly assembly $ Permitted only if veranda,porch,deck or balcony is fully open on a minimum of to sides beneath the floor ' For clearances not speafied in ANSI Z2231/NFPA 54 or CSA B 1491,the following statement shall bemcluded •Clearance In accordance wbh local Installation codes and tha requirements of Ne gas supplier and the manufacturers installation InabLction' OTHER THAN DIRECT VENT TERMINAL CLEARANCES Canadian Installations+ US Installations x Canadian Installations' U S Installations' A= Clearance above grade, 12 in SO—) 12,n(30 cm) I= Clearance to sevice 3 R(91 cm) ' veranda,porch,deck or regulator vent outlet balcony(See 1 24 6-i(9)b) J= Clearance to nonmechanical air 6 in(15 cm)for appliances 10,000 4 It(1 2 m)below or to side of B= Clearance to windowor 6,n(15 an)forapphancos 4 R(1 2 m)below or to aide of supply Inlet to building or the Btuh(3 kW),12 in(30 cm)for opening,1 It(300 m)above opening door that may be opened 10,000Btuh(3 kW)12 in(30 cm)for opening,l It(300 m)above opening combustion air inlet to any other appliances>10,000 Btuh(3kW)and appliances>10,000 Built(3 kW)and appliance 100,000 Btuh(30 kW),361n(91 cm) 100,000 Btuh(30 kW),36 in(91 cm) for appliances>100,000 Btuh(30 kW) for apphances>100,000 Btuh(30 kW) K=Clearance to a mechanical 611(1 83 m) 3 fl(91 cm)above if wthin C=Clearance to permanently air supply Inlet 10 It(3 m)honzontaly closed window L= Clearance above paved sidewalk or 7 R(2.13m)t 7 R(213m) D=Vertical clearance to ventilated mffit paved driveway located on public located above the terminal within a property horizontal distance of 2 feet(61 cin) M=Clearance under veranda,porch, 12 in(30 cm)$ from the tamer line of the terminal deck or balcony E= Clearance to unventilated soffit ' F= Clearance to outside comer 1 In accordance with the current CSA 81491,Natural Gas and Propene Installation Code G=Clearance to Inside corner 2 In accordance with the current ANSI Z2231/NFPA 54 National Fuel Gas Code H=Clearance to each sloe afconter 3 It(91 an)within a height ISR t Avent shall nottenninate directly above a sidewalk orpaveable cinvewaythat is located between two single family dxellingsand line extended above meter/regulator (45 m)above the meterlregulator servesboth dwelling ase—biy assembly $ Permitted only if veranda,porch,deck or balcony is fully open on a minimum oftwo sides beneath the floor • Forclearances notspeafied In ANSIZ2231/1VFPA 54 or CSA B1491,the following statement shall be included 'Clearance In accordance wth local installation codes and the requirements of the gas supplier and the manufacturer s Installabon Instruction' 14 • The vent termination of a non-direct vent application must terminate at least 4 feet below,4 feet horizontally from,or 1 foot above any door,window,or gravity air inlet into any building. • The vent termination of a direct vent application must ' terminate at least 12 inches from any opening through E which flue gases may enter a budding (door, window, or N gravity air inlet). T • The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line ' (or the anticipated rsnow level) and be at least 12 inches 45 DEGREE r� ' from any vertical wall (including any anticipated snow LONG-SWEEP ;y ELBOWS build up) • A vent termination shall not terminate over public walkways or over an area where condensate or vapor couldcreate a nuisance or hazard or could be detrimental to the operation of regulators, relief valves,'or other equipment. • The combustion air intake termination of a direct vent application should not terminate in an area which is Increased Clearance Configuration frequently dusty or dirty. 1. NOTE: Do not use other commercially available"no hub connec- NOTE:In Canada,the Canadian Fuel Gas Code takes precedence tors" due to possible material conflicts The vent/flue pipe can over the preceding termination restrictions. also be secured using a PVC or ABS elbow or coupling using the CANADIAN VENTING REQUIREMENTS appropriate glue (see Sectlon IX, Materials and Joining Methods) In Canada, venting must conform to the requirements of the cur- NOTE:For non-direct vent installations,a minimum-of one 90° rent CAN/CSA-6149 1-05 Installation Code Use only CSA-listed, elbow should be installed on the combustion air intake coupling ULC-S636 compliant two-or three-inch diameter PVC orABS pipe, to guard against inadvertent blockage. solvent cement,and fittings throughout. The certified piping should COMBUSTION AIR PIPE be clearly marked with the ULC Std"S636"on the pipe and fittings DIRECT,VENT1 TALLAT/ONS Carefully follow the pipe manufacturers' instructions for cutting, On upf/ow units secure the combustion air intake pipe directly to cleaning, and solvent cementing PVC and/or ABS the air intake coupling. On counterflow units secure the combus- The vent can be run through an existing unused chimney provided tion air intake pipe to the air intake coupling using the rubber cou- the space between the vent pipe and the chimney is insulated and pling and worm gear hose clamps provided with the unit The closed with a weather-tight, corrosion-resistant flashing. counterflow rubber coupling allows service removal of air intake STANDARD FURNACE CONNECTIONS piping internal to the furnace blower compartment. NOTE: Be- cause of probable material conflicts, do not use other commer- It is the responsibility of the installer to ensure that the piping dally available "no hub connectors" The combustion air intake connections to the furnace are secure, airtight, and adequately pipe can also be secured directly to the counterflow unit air intake supported. pipe coupling As shipped, attachment "couplings" for vent/flue and combustion air intake pipe connections are provided on the furnace's top cover NON-DIRECT VENTINSTALLATIONS (upflow) or basepan (counterflow). To use the standard connec- A minimum of one 90° elbow should be installed on the combus- tions, field supplied vent/flue pipe and combustion air intake pipe tion air intake "coupling" to guard against inadvertent blockage (when applicable) should be secured directly to the furnace atCOMIUSTION COMBUSTION VENTIFLUE IP AIR PE VENTIFLUE AIR PIPE PIPE these locations. (DIRECT VENT ONLY) PIPE (DIRECT VENT ONLY) n 4R BEER VENTIFLUE PIPE Mw owe ERn Va Mom YE Vent/flue pipe can be secured to the vent/flue coupling using they;; Gy rubber coupling and worm gear hose clamps provided with this ..... °R _ OR furnace (see"Standard Connections"figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc If necessary, clearances may be O increased by utilizing two 45 deg. Long-Sweep Elbows and creat- ing an 'IS" joint to provide additional space at connection loca- UPFLOW COUNTERFLOW tions. This joint can be rotated on the fitting to establish maxi- STANDARD CONNECTIONS mum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg elbow when considering elbow count 15 r ALTERNATE FURNACE CONNECTIONS 5. Remove plastic plug from alternate vent/flue location. If the standard locations are undesirable for a specific installation, Relocate and Install plug in standard vent/flue location (topcover) alternate side panel locations are available on the upflow models Counted/ow units. for the vent/flue. Counterflow furnaces include provisions for both Remove plastic plug from alternate vent/flue location. alternate vent/flue and combustion air piping.These locations may ate and install plug in standard vent/flue location be of particular benefit to upright upflow installations requiring ad- Relocate Plug remaining hole in blower deck with plastic ditional access to an A coil, or to upright counterflow Installations (basepplug included the drain kit bag requiring additional access to a filter or electronic air cleaner, or to horizontal installations desiring vent/flue (upflow and counterflow) 6. Upflow and Counterflow units. and combustion air intake (counterflow only) piping run vertically Insert cut section of vent/flue pipe and coupling into alternate from the side of the cabinet vent/flue location. Using a rubber coupling and worm gear NOTE: Standard and alternate locations can be combined(I e , an hose clamps from the drain kit bag, attach the vent/flue pipe installation may use the standard combustion air Intake location and coupling to the induced draft blower. Secure the but use the alternate vent/flue location), if needed. coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8" #8 self drilling screws A WARNING _ A WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP.USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS. THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD.WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED VENT/FLUE PIPING,AS DAMAGE CAN RESULT IN ALTERNATE VENTIFLUE LOCATION LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES,INCLUDING CARBON MONOXIDE. The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To us&the alternate vent/flue loca- 7. Upflow and Counterflow units. tion refer to the following steps, the "Vent/Flue Pipe Cuts" figure, For upright installations,externally mountthe rubberelbow and the"Alternate Vent/Flue Location"figure to the vent/flue coupling using a worm gear hose clamp. NOTE: Counterflow instructions follow the upflow Instructions Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate 1 Remove and save the four screws securing the vent/flue_ vent/flue location for upright installations, requires the drain coupling to the furnace top panel trap be installed on the same side of the unit as the flue Counterflow units. pipe. 1 Remove and save the four screws securing the vent/flue 8. Upflow and Counterflow units. coupling to the furnace basepan. Also remove the three For horizontal installations, externally secure the field- screws securing the furnace's internal vent/flue piping to supplied vent/flue pipe directly to the vent/flue coupling using the blower deck a PVC or ABS coupling or elbow 2 Upflow and Counterflow units. Loosen the worm gear hose clamps on the rubber elbow REMOVE REMOVE REMOVE and detach it from both the induced draft blower and the REMOVE 4 SCREWS 4 sCREWs o PIPE f �PE CUT PIPE PER vent/flue pipe. VENT/FLUE PIPE CUTS CUT PIE PER DIAGRAM 3. Upflow and Counterflow units VENT/FLUE O v PIPE CUTS REMOVE Remove the vent/flue pipe from the furnace DIAGRAM Q /3SCREWS 4 Cut the vent/flue pipe 3.75 inches from the flanged end of "V\ e0O 5 the pipe See Vent/Flue Pipe Cuts figure. The section of REMOVE REMOVE pipe attached to the coupling will reach through the side AND RELOCATE AND RELOCATE z o panel to the induced draft blower Discard remaining pipe p ® DET CH BBER and elbows. IDBLOWERAND ® DETACH RUBBER VENT/FLUE ELBOW FROM Counterflow units. PIPE ID BLOWER AND Cut the vent/flue pipe 3 75 inches from,the blower deck VEPIPE See Vent/Flue Pipe Cuts figure.Save vent/flue pipe UPFLOW COUNTERFLOW attached to blower deck coupling for use In the alternate location. Discard remaining pipe and elbows FLANGE—� — �9'!S CUT HERE-m-------- Vent/Flue -------Vent/Flue Pipe Cuts 16 ADDITIONAL PLUG GMH95/GCH95iGME95 Direct Vent(2-Pipe)and Non-Direct Vent(1-Pipe)(6) FROM DRAIN KIT Maximum Allowable Length of Vent/Flue Pipe&Combustion Air Pipe(ft)Iq(2) Pipe Number of Elbows(6)(6) 4 EXTERNALLY Un(Btu) Input Btu) Size( (4I MOUNT in.) 0 1 1 2 3 4 5 6 7 8 RUBBER ELBOW © 40,000 or 2 1/2 100 95 90 85 80 75 70 65 60 SECURE TO ® ID BLOWER WITH RUBBER COUPLING 45,000 or 2 1/ 2 250 245 240 235 230 225 220 215 210 AND HOSE CLAMPS 60,000 or 1/2 110 105 100 95 90 85 80 75 70 COUNTERFLOW UPRIGHT (UPFLOW SIMILAR) 70,000 2 220 215 210 205 200 195 190 185 180 © or 2 1/2 ID BLOWER WITH © 80,000 or 2 1/2 35 30 25 20 15 10 N.otApplicable RUBBER COUPLING SECURE TO AND HOSECABINET WITH 80,000 3 132 125 118 111 104 97 90 83 76 CLAMPS SCREWS - 90,000 or 2 1/2 45 40 35 30 25 20 NotApp€€cable 90,000 3 147 140 133 126 119 112 105 98 91 ® 100,000 3 98 91 84 77 70 63 56 49 42 b 115,000 1 3 140 1 133 126 119 112 105 98 1 91 1 84 UPFLOW/HORIZONTAL 1) Maximum allowable limits listed on Individual lengths for Inlet and flue (COUNTERFLOW SIMILAR) and NOT a combination 2) Minimum requirement for each vent pipe Is five(5)feet In length and Alternate Vent/Flue Location one elbow/tee 3) Tee used in the vent/flue termination must be included when determin- ing the number of elbows In the piping system NON-DIRECT VENT SINGLE PIPE)PIPING 4) 2 1/2"or 3"diameter pipe can be used In place of 2"diameter pipe. Non-direct vent installations require only a vent/flue pipe The 5) Increased Clearance Configurations using (2) 45 deg Long Sweep vent pipe can be run horizontally with an exit through the side of elbows should be considered equivalent to one 90 deg. elbow. t6) One 90° elbow should be secured to the combustion air Intake con- he building or run vertically with an exit through the roof of the nection building The vent can also be run through an existing unused chimney, however, it must extend a minimum of 12 Inches above VENTIFLUE PIPE TERMINATIONS the top of the chimney The space between the vent pipe and the NOTE: If either a 90 degree or 45 degree elbow is used for termi- chimney must be closed with a weather-tight, corrosion-resistant nation, it must be pointed downward. ' flashing For details concerning connection of the vent/flue pipe The vent/flue pipe may terminate vertically, as through a roof, or to the furnace,refer to Section IX, Vent/Flue Pipe and Combustion horizontally, as through an outside wall. Air- Standard Furnace Connections or Alternate Furnace Con- Vertical vent/flue pipe terminations should be as shown in the nections for specific details. Refer to the following Non-Direct following figure Refer to Section IX, Vent/Flue Pipe and Com- Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for spe- cific details on termination construction. bustion Air Pipe - Termination Locations for details concerning Although non-direct vent Installations do not require a combus- location restrictions The penetration of the vent through the roof tion air intake pipe, a minimum of one 900 elbow should be at- must be sealed tight with proper flashing such as is used with a tached to the furnace's combustion air Intake IF an upright instal- plastic plumbing vent. lation uses the standard intake location This elbow will guard Horizontal vent/flue pipe terminations should be as shown In the against Inadvertent blockage of the air Intake following figure Refer to Section IX, Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations for details concerning loca- VENTIFLuE PIPE LENGTHS AND DIAMETERS tion restrictions. A 2 3/8"diameter wall penetration is required for Refer to the following table for applicable length, elbows, and 2" diameter pipe. A 3" diameter hole is required for a 2 1/2" pipe pipe diameter for construction of the vent/flue pipe system of a and a 3 1/2" diameter hole is required for 3" diameter pipe. To non-direct vent installation In addition to the vent/flue pipe, a secure the pipe passing through the wall and prohibit damage to single 90° elbow should be secured to the combustion air Intake piping connections, a coupling should be installed on either side to prevent inadvertent blockage The tee used in the vent/flue of the wall and solvent cemented to a length of pipe connecting termination must be included when determining the number of the two couplings The length of pipe should be the wall thick- elbows in the piping system ness plus the depth of the socket fittings to be installed on the Inside and outside of the wall. The wall penetration should be sealed with silicone caulking material In a basement installation, the vent/flue pipe can be run between Joist spaces If the vent pipe must go below a Joist and then up into the last Joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows 17 TEE(OPTIONAL) Direct vent installations require both a combustion air Intake and a vent/flue pipe The pipes may be run horizontally and exit through Min To Roofthe side of the building or run vertically and exit through the roof of est Anticipated the building. The pipes may be run through an existing unused now Level chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resis- tant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. For details concerning connection of pipes to the furnace, refer to the Section 1X, VentlF/ue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections. Vertical Termination(Single Pipe) VENTIFLUE AND COMBUSTION AIR PIPE LENGTHS AND DIAMETERS 90°or45' MEDIUM EL OWSIUS Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of'a direct vent(dual pipe) installation The number 12-Ma of elbows tabulated represents the number of elbows and/or tees TOE—F..NIONEBT R �,�° in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or °W LEVE tees used in the terminations must be included when determining the number of elbows in the piping systems. If the combustion air intake pipe is to be installed above a finished 51— ceiling or other area where dripping of condensate will be oblec- Alternate Vertical Termination(Single Pipe) tionable, insulation of the combustion air pipe may be required. Use 1/2" thick closed cell foam insulation such as Armaflex or Insultube where required WALL VENTIFLUE AND COMBUSTION AIR PIPE TERMINATIONS INSIDE OUTSIDE TEE OPTIONAL) The vent/flue and combustion air pipes may terminate vertically, as 45 ELBOW TURNED through a roof, or horizontally, as through an outside wall DOor WN Vertical pipe terminations should be as shown in the following TUR EDW figure Refer to Section IX, Vent/Flue Pipe and Combustion Pipe- 1 COUPLING DOWN Termination Locations for details concerning location restrictions. MIN. The penetrations through the roof must be sealed tight with proper ELBOW OR FROM 12"TO GROUND OR COUPLING WALL HIGHEST ANTICIPATED flashing such as is used with a plastic plumbing vent. SNOW LEVEL TEE(OPTIONAL) , Horizontal Termination(Single Pipe) VENTIFLUE COMBUSTION AIR INTAKE 12"MIN 901 or 45° 12"MIN. MEDIUM RADIUS ELBOWS VENTIFLUE TEE(OPTIONAL) - or SCREE 46'ELBOW O TIO L TURNED DOWN or 90'ELBOW TURNED DOWN 24"MAX. / 3"MIN. 12"MIN ABOVE /� 12"MIN.TO ROOF HIGHESTANTICIPATED SNOW LEVEL Y OR HIGHEST ANTICIPATED SNOW LEVEL Vertical Terminations(Dual Pipe) y�•w'� Horizontal terminations should be as shown in the following fig- ure Refer to Section /X, Vent/Flue Pipe and Combustion Pipe - Horizontal Termination(Single Pipe) Termination Location for location restrictions. A 2 3/8" diameter Above HighestAnticipated Snow Level wall penetration Is required for 2"diameter pipe. A 3"diameter hole DIRECT VENT DUAL PIPE) PIPING is required for a 2 1/2" pipe and a 3 1/2"diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall The inlet air screens provided in the installation instruction packet and prohibit damage to piping connections, a coupling should be are available for the installer to use in the inlet of the combustion installed on either side of the wall and solvent cemented to a pipe air pipe to prevent animals from building nests in the combustion connecting the two couplings. The pipe length should be the wall air pipe Installation of screens, while strongly recommended, is thickness plus the depth of the socket fittings to be Installed on the not required and will not affect performance of the unit inside and outside of the wall The wall penetration should be sealed with silicone caulking material 18 _ c / BU' Vent edlum Radius Elbow —*-12"MIN 3"MIN V- 24"MA 12"Min... - VEE Screelf - 24"Max./ TEE(OPTIONAL) '(Optional) 3"Min. �=-24"Max. 24"MAX // / Air Intake COMBUSTION � • AIR INTAK 90°or 45° 12"MIN ABOVE MEDIUM RADIUS12"Min.Above HIGHEST ANTICIPATED ELBOWS Highest Anticipated Yi SNOW LEVEL now Level 12"MIN.ABOVE SCREE HIGHANTICIPATED SNOWL OPTIONAL) SNOW LEVEL 'JA- ' Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) Standard Horizontal Terminations(Dual Pipe) In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows SS, VENT VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE MEDIUM RADIUS DIRECT VENT FURNACES ELBOW If more than one direct vent furnace is to be installed vertically 12•NiN through a common roof top, maintain the same minimum clear- ,� ances between the exhaust vent and air Intake terminations of :`"MAX adjacent units as with the exhaust vent and air intake terminations 24"MAX J"MIN of a single unit. �r If more than one direct vent furnace is to be Installed horizontally through a common side wall, maintain the clearances as in the AIR following figure. Always terminate all exhaust vent outlets at the NTAKE J�., �—SCREEN same elevation and alwa s terminate all air Intakes at the same 4~12'MIN ABOVE (OPTIONAL) Y HIGHEST ANTICIPATED elevation SNOW LEVEL X Alternate Horizontal Vent Termination(Dual Pipe) gp° Vents Medium 12"MIN Radius Elbows 3"MIN SUPPORT 24"MAX Min STRAPS 12" VENTIFLUE TEE(OPTIONAL) / 3"Min '24"Max. 3"Mm. 24„ 24"Max. 3"Min COMBUSTION AIR INTAKE Air SCREEN 12"MIN ABOVE Intakes HIGHEST ANTICIPATED (OPTIONAL) 12'MI :ABOVE-- r o screen SNOW LEVEL O tional /HIGHEST ANTICIPATED _ 1r MW ABovE 7�. ( P ) SNOW LEVEL IGHESTANTtlPATED 80°Or 45° :NOW LEVEL ---ME RADIUS V� � LBOWS �� }r Horizontal Venting Of Multiple Units 1 Standard Horizontal Terminations Above Anticipated Snow CONCENTRIC VENTTERMINATION Level(Dual Pipe) Referto the directions provided with the Concentric Vent Kit(DCVK) for installation specifications. 19 SIDE WALL VENT KIT Do not trap the drain line in any other location than at This kit is to be used with 2"or 3"direct vent systems.The vent kit the drain trap supplied with the furnace must terminate outside the structure and may be Installed with the Do not route the drain line outside where it may freeze. intake and exhaust pipes located side-by-side or with one pipe If the drain line is routed through an area which may above the other This kit is NOT intended for use with single pipe see temperatures near or below freezing, precautions (indirect vent) installations. must be taken to prevent condensate from freezing Refer to the directions furnished with the Side Wall Vent Kit(p/n within the drain line 0170KOOOOOS)for installation specifications. If an air conditioning coil is installed with the furnace, a common drain may be used An open tee must be X.CONDENSATE DRAIN LINES&DRAIN TRAP installed in the drain line, near the cooling coil, to A condensing gas furnace achieves its high level of efficiency by relieve positive air pressure from the coil's plenum. extracting almost all of the heat from the products of combustion This is necessary to prohibit any interference with the and cooling them to the point where condensation takes place. function of the furnace's drain trap The condensate which is generated must be piped to an appropri- NOTE:In vertical installations,air conditioning coil condensate may ate drain location. drain into the furnace trap as long as there is a trap between the coil In upright Installations, the furnace's drain hoses may exit either and the furnace trap and the drain pipe is not terminating below the the right or left side of the furnace NOTE: If the alternate vent/flue water level of the furnace trap outlet is utilized in an upright Installation, the drain trap and drain connections must be located on the same side as the alternate vent/flue outlet. In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended be- neath the furnace. The field-supplied drain system must be in accordance with all local codes and the instructions in the follow- ing sections. Follow the bullets listed below when Installing the drain system. Refer to the following sections for specific details concerning fur- nace drain trap installation and drain hose hook ups. • The drain trap supplied with the furnace must be used • The drain line between furnace and drain location must be constructed of 3/4" PVC. • The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain 20 STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS 1. Remove the rubber plug from the right side of the front cover All installations positions require the'use of the drain trap, hoses, drain port tubes, and clamps The following quantity of hoses, tubes, and 2. Secure Hose A to front cover drain port with a red hose hose clamps are provided with the unit. clamp. Route hose to rear side panel grommet hole. 3. Cut and remove 1/4 inch from the end of the drain port on the rubber elbow. HOSE A 4. Insert Tube 1 into rubber elbow drain port and secure with Qom'1 silver hose clamp. Angle tube outward toward front of furnace. HOSE B 5. Cut 17 3/4 inches from the long end of Hose B and discard QTY' 1 Secure the remaining hose to Tube 1 with a green hose DRAIN TRAP TUBE 1 clamp. Route the other end of Hose B to front right side QTY:1 CITY:1 panel grommet hole. GREEN TUBE 2 For details concerning mounting of the drain trap, refer to Vertical bb" HOSE CLAMPS QTY:2 Drain Trap Mounting QTY'3 SILVER 6 Insert short end of each of tube 2 through side panel RED HOSE CLAMP grommet holes. Secure tubes to hoses A and B with green HOSE CLAMP QTY:1 hose clamps Ensure hoses and tubes maintain a QTY:1 downward slope for proper drainage and that they are not Hose and Tube Identification kinked or binding. In a upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator cod front cover The drain lines are then routed through the right side panel and Into the drain trap secured to the outside of the cabinet. NOTE: Refer to Alternate Vent/Flue Hose Connections for upright installations using an alternate vent/flue outlet. RIGHT SIDE PANEL RUBBER ELBOW o RUBBER ELBOW DRAIN PORT SILVER HOSE CLAMP o TUBE 1 ® HOSE SIDE PANEL o GROMMET HOLES TUBE(S) 2 0 FRONT RED HOSE HOSE DRAIN COVER CLAMP A GREEN TRAP DRAIN PORT HOSE CLAMPS (3 PLACES) 21 ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS 5 Insert Tube 1 into rubber elbow drain port and secure with a silver hose clamp. Angle tube toward trap Upright installations using the alternate vent/flue outlet will require 6. Cut 17 3/4 inches from the long end of Hose B and discard "right-side only" drain hoses to be connected as follows. Refer to Venf/Flue Pipe and Combustion Air Pipe for details on alternate 7 Secure straight end of Hose B to exposed end of Tube 1 vent/flue pipe connection. with a green hose clamp Route hose toward right side 1 Remove the rubber plug from the right-side drain port on panel grommet holes. the front cover Save for use in step 3. 8 Insert short end of one Tube 2 through rear right side panel 2 Secure Hose A to front cover drain port with a red hose grommet drain hole. Secure tube to Hose A with a green clamp. Route hose to rear right side panel grommet hole hose clamp 3 Remove grommet from front right-side panel drain hole. 9• Insert short end of remaining Tube 2 into Hose B from Seal hole in grommet with large end of plug. Reinstall rubber elbow and secure with green hose clamp Ensure grommet and plug into side panel drain hole hoses and tubes maintain a downward slope for proper 4 Cut 1/4 inch from the end of the drain port on the externally drainage and are not kinked or binding. mounted rubber elbow. Discard cut portion RUBBER ELBOW (EXTERNALLY MOUNTED) RUBBER FRONTELBOW COVER ° ° ' DRAIN PORT DRAIN HOSE B PORT ® SILVER HOSE CLAMP a TUBE 1 0 GREEN HOSE CLAMPS (3 PLACES) 0 0 0 0 RED HOSE HOSE A CLAMP DRAIN TRAP TUBE(S) 2 Upright"Alternate:Connections-Right Side Only (UpflowShown,CounterflowSimilar) 22 UPRIGHT INSTALLATIONS-TRAP ON LEFT SIDE 5. Cut "X" inches from the long end of Hose B and discard. Refer to table for appropriate length to cut. Secure remaining NOTE: For left side trap installation,grommets must be moved to hose to Tube 1 with a green hose clamp. Route other end the left side of the furnace and the plugs installed on the right side of Hose B to front left side panel grommet hole. of the furnace. 1 Remove the rubber plug from the left side drain port on the NOTE: Long hose "B" must always be connected to Tube 1 and the elbow and not on the front cover. front cover 2 Secure Hose A to front cover drain port with a red hose 6. Insert short end of each Tube 2 through side panel grommet clamp. Route hose to rear side panel grommet hole. holes. Secure tubes to Hose A and Hose B with green hose 3. Cut and remove 1/4 inch from the end of the drain port on clamps. Ensure hoses and tubes maintain a downward the rubber elbow. slope for proper drainage and that they are not kinked or 4 Insert Tube 1 into rubber elbow drain port and secure with binding. silver hose clamp. Angle tube outward toward front of furnace. LEFT SIDE PANEL � . FRONT COVER RUBBER DRAIN PORT ELBOW • o e RED HOSE RUBBER CLAMP ELBOW HOSE A ® DRAIN PORT SIDE PANEL o —° SILVER HOSE DRAIN CLAMP HOLES o TUBE 1 TUBE(S) 2 � GREEN HOSE ° ° ° CLAMP DRAIN TRAP GREEN HOSE B HOSE CLAMP Upright"Standard"Connections-Left Side (UpflowShown,CounterflowSimilar) 23 I. Remove the rubber plug from right side of the front cover Cabinet Width Models "X"Length to Cut From Long drain port (inches) (kBTU_Tons) End of Hose B Counterfiow furnaces (inches) Relocate the front cover pressure switch hose connection 17112 0403, 045_30, 7 from the left side pressure tap to the right (down) side tap 060_3 The pressure switch hose must be connected to the down 21 07040,0805 31/2 side to guard against blocked drain conditions Cut hose 090_50, 100 5 to appropriate length to minimize sagging Plug left(unused) 2412 11550 None pressure tap with plug removed from right side 2. Secure Hose Ato front cover drain tap with a red hose clamp UPRIGHT DRAIN TRAP MOUNTING LEFT OR RIGHT SIDE PANEL) Route hose to rear right(down) side panel grommet holes 3 Cut 1/4 inch from the end of the drain port on the rubber 1 Insert drain tubes into drain trap and position the drain trap elbow and discard against the side panel. NOTE: Drain tubes must reach the 4 Insert Tube 1 into rubber elbow drain port and secure with a bottom of the drain trap. silver hose clamp Angle tube outward toward front of furnace 2 Secure drain trap to side panel at the mounting holes 5 Cut 17 3/4 inches from the long end of Hose B and discard (dimples or crosshairs on counterflow models) located below the grommet drain holes 6 Secure remaining end of Hose B to exposed end of Tube 1 3 Attach PVC drain line to drain trap outlet with either a 90° with a green hose clamp. Route hose to front right down elbow or coupling. side panel grommet holes 7 Cut 5 1/2 inches straight length from the long end of each HORIZONTAL INSTALLATIONS Tube 2 and discard the radius pieces. 8. Insert approximately one inch of each Tube 2 through the RIGHT SIDE DOWN right down side panel grommet holes. Secure tubes to Horizontal installations with the right side down require that the Hose A and Hose B using green hose clamps. Ensure drain hoses be connected to the right side front cover drain port hoses and tubes maintain a downward slope for proper and the rubber elbow drain port. drainage and are not kinked or bound For details concerning mounting of the drain trap, refer to Conden- NOTE: On counterflow models,relocation of the front cover pressure sate Drain Lines and Drain Trap-Horizontal Drain Trap Mounting switch hose is required. Make connections as follows: ® o 0 0 o FRONT COVER DRAIN PORT RED HOSE HOSE A CLAMP n FRONT HOSE NB COVER PRESSURE ® TAP RUBBER ® ELBOW 0 RIGHT SIDE TUBES 2 PANEL RUBBER ELBOW GREEN DRAIN PORT HOSE TUBE 1 SILVER HOSE DRAIN TRAP� CLAMP CLAMP (3 PLACES) Horizontal Connections-Right Side Down (Upflow Shown,Counterflow Similar) 24 LEFT SIDE DOWN 4 Remove the rubber cap from the side drain port on the rubber elbow. Horizontal installations with the left side panel down will require 5. Secure the short end of Hose B to rubber elbow side drain drain hoses to be connected to the left side front cover drain port port using a green hose clamp.NOTE: For left side drainage, and the side drain port on the rubber elbow. route hose to far left (down) side panel grommet holes. 1 Remove the rubber plug from the front cover left (down) NOTE: Horizontal left side connections (when using new side drain port side port drain elbow) does not require connecting a hose 2 Relocate the front cover pressure switch hose connection to the induced draft blower housing. from the right side (as shipped) pressure tap to the left 6 Cut 5 1/2 inches straight length from the long end of each (down) side tap. The pressure switch hose must be Tube 2 and discard radius ends. connected to the down side to guard against blocked drain 7 Insert approximately one inch of each Tube 2 through left conditions. Cut hose to appropriate length to minimize side panel grommet hole Secure tubes to Hose A and sagging Plug right (unused) pressure tap with plug Hose B with a green hose clamps. NOTE: Tube must removed from left side reach bottom of trap. Ensure hoses and tubes maintain a 3 Secure Hose A to front cover drain port with a red hose downward slope for proper drainage and that they are not clamp. Route hose to rear left (down) side panel grommet kinked or binding. holes. NOTE: For left side drainage, grommets must be For details concerning mounting of the drain trap, refer to Conden- relocated to left side panel. sate Drain Lines and Drain Trap-Horizontal Drain Trap Mounting GREEN HOSE CLAMP C ° 0 (D @ HOSE B 0 (D FRONT HOSE A COVER PRESSURE TAP GREEN HOSE ® CLAMP LEFT SIDE TUBE(S) 2 PANEL FRONT COVER DRAIN PORT RED HOSE CLAMP DRAIN TRAP SIDE PANEL GROMMET HOLES Horizontal Connections-Left Side Down (UpflowShown,CounterflowSimilar) HORIZONTAL DRAIN TRAP MOUNTING(LEFT OR RIGHT SIDE PANEL) 1. Position the drain trap against side panel with drain tubes inserted into trap. Note that the trap may be orientated with the outlet facing either the furnace's top cover or base pan. 2 Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes. 3. Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding. 4. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling. 25 XI.ELECTRICAL CONNECTIONS Line polarity must be observed when making field connections Line voltage connections can be made through either the right or A WARNING left side panel. The furnace is shipped configured for a left side (right side for counterflows) electrical connection with the junction box located inside the burner compartment. To make electrical HIGH VOLTAGE! connections through the opposite side of the furnace, the junction TO AVOID THE RISK OF ELECTRICAL SHOCK,WIRING TO box must be relocated to the other side of the burner compartment THE UNIT MUST BE POLARIZED AND GROUNDED. prior to making electrical connections. To relocate the junction box, observe the following steps AWARNING JUNCTION BOX RELOCATION HIGH VOLTAGE! A WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK,DISCONNECT ELECTRICAL POWER EDGES OF SHEET METAL HOLES MAY BE SHARP.USE GLOVES AS A BEFORE SERVICING OR CHANGING ANY ELECTRICAL PRECAUTION WHEN REMOVING HOLE PLUGS. WIRING. 1 Remove the burner compartment door. 2. Remove and save the two screws securing the junction box ACAUTION to the side panel. 3 Relocate junction box and associated plugs and grommets LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING to opposite side panel Secure with screws removed In CONTROLS.WIRING ERRORS CAN CAUSE IMPROPER AND step 2. DANGEROUS OPERATION.VERIFY PROPER OPERATION AFTER SERVICING. O F+ WIRING HARNESS The wiring harness is an integral part of this furnace Field alter- STANDARD °w JUNCTION ATE JUNCTION BOX ation to comply with electrical codes should not be required Wires LOCATION LOCATION are color coded for identification purposes Refer to the wiring _ _ OX diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring - material having a temperature rating of at least 105°C Any re- placement wiring must be copper conductor. Junction Box Relocation 115 VOLT LINE CONNECTIONS Before proceeding with electrical connections,ensure that the sup- A WARNING ply voltage, frequency, and phase correspond to that specified on the unit rating plate Power supply to the furnace must be N E C. HIGH VOLTAGE! Class 1, and must comply with all applicable codes The furnace TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR must be electrically grounded In accordance with local codes or, In DEATH,THE FURNACE MUST BE ELECTRICALLY their absence,with the latest edition of The National Electric Code, GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. THEIR ABSENCE,WITH THE LATEST EDITION OF THE Use a separate fused branch electrical circuit containing properly NATIONAL ELECTRIC CODE. sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent pro- To ensure proper unit grounding, the ground wire should run from tection specified on the unit rating plate An electrical disconnect the furnace ground screw located inside the furnace junction box must be provided at the furnace location all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground To confirm proper unit grounding, NOTE: Line polarity must be observed when making field turn off the electrical power and perform the following check. connections 1. Measure resistance between the neutral (white) connection Connect hot, neutral, and ground wires as shown in the wiring and one of the burners diagram located on the unit's blower door For direct vent applica- 2. Resistance should measure 10 ohms or less This furnace tions, the cabinet opening to the junction box must be sealed air is equipped with a blower door interlock switch which tight using either a UL approved bushing such as Heyco Liquid interrupts unit voltage when the blower door is opened for Tight or by applying a UL approved non-reactive sealant to bush- servicing Do not defeat this switch. ing. 26 r , 24 VOLT THERMOSTAT WIRING NOTE: Wire routing must not interfere with circulator blower ECO-TECH operation, filter removal, or routine maintenance MOTOR - T3 Tb Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located in the Ta Tz I blower compartment. Wire routing must not to interfere with circu- lator blower operation, filter removal, or routine maintenance Re- _ = U c fer to the following figure for thermostat connections to the Inte- Furnace a a I Field grated control module terminal strip. Control I (Supplied Relay O Y Y W R G C I Y Y R R R C Y1 W R G C Y2 Heating/Cooling © Room Thermostat c HEATING HEATING AND REMOTE Y1 R C Y2 ROOM FURNACE COOLING ROOM FURNACE CONDENSING THERMOSTAT THERMOSTAT UNIT Remote Condensing Unit Thermostat Diagram This furnace Is equipped with a 40 VA transformer to facilitate use Field Wiring for GME95 Furnacewith 2-Stage Condenser with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 115 VOLT LINE CONNECTION OF ACCESSORIES (ELECTRONIC 24 Volt wiring AIR CLEANER GME95 FURNACE WITH 2-STAGE CONDENSER FIELD WIRING ®WARNING The GME95 model furnaces may be used with a 2-stage outdoor air conditioner.A two stage cooling/single stage gas heat thermo- stat Is required, in addition to a field supplied relay.The relay must HIGH VOLTAGE, have a 24VAC coil and contacts rated for up to 1 horse power at TO AVOID PERSONAL INJURY OR DEATH DUE TO 125VAC. ELECTRICAL SHOCK,DISCONNECT ELECTRICAL POWER i BEFORE SERVICING OR CHANGING ANY ELECTRICAL 1 Install the field supplied relay on the control mounting panel WIRING. near the furnace ignition control. The relay should be The furnace's Integrated control module is equipped with line volt- installed such that the motor leads will reach the relay age accessory terminals for controlling power to an optional field- contact terminals. supplied electronic air cleaner. 2 Connect the "Y2" (high stage cool) thermostat terminal to The accessory load specifications are as follows. one coil terminal of the field supplied relay. Connect the Electronic Air Cleaner 1 1.0 Amp maximum at 120 VAC other field supplied relay coil terminal to the"C"terminal on the furnace Ignition control. Typical 18AWG thermostat wire Turn OFF power to the furnace before Installing any accessories may be used. Follow the air cleaner manufacturers' Instructions for locating, 3. Connect the common terminal of the field supplied relay to mounting, grounding, and controlling these accessories Acces- the "LINE-H" terminal on the furnace Ignition control Use sory wiring connections are to be made through the 1/4" quick wiring having copper conductors only and a temperature connect terminals provided on the furnace integrated control mod- rating of at least 105°C. ule. The electronic air cleaner hot terminal is Identified as EAC-H 4 Using the GME95 airflow tables in this manual, determine The electronic air cleaner neutral terminal Is Identified as LINE the motor speed tap needed to deliver the required high NEUTRAL. All field wiring must conform to applicable codes Con- stage cooling airflow. Connect the selected motor speed nections should be made as shown below. tap to the normally open terminal on the field supplied relay. OPTIONAL Use wiring having copper conductors only and a temperature ACCESSORIES rating of at least 105°C. AIR CLEANER 5 See the following wiring schematic. J 120 VAC m� HOTAND z� PARK —� JW TERMINALS Z 120 VAC INTEGRATED NEUTRAL CONTROL TERMINALS MODULE 12 PIN CONNECTOR Accessories Wiring 27 If it is necessary for the installer to supply additional line voltage In some areas the gas supplier may artificially derate the gas In an wiring to the inside of the furnace, the wiring must conform to all effort to compensate for the effects of altitude. If the gas is artifi- local codes, and have a minimum temperature rating of 105°C All cially derated, the appropriate orifice size must be determined line voltage wire splices must be made Inside the furnace junction based upon the BTU/ft3 content of the derated gas and the altitude box Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223 1, and The integrated control module electronic air cleaner terminals(EAC) information provided by the gas supplier to determine the proper are energized with 115 volts whenever the circulator blower Is en- orifice size. ergized A different pressure switch may be required at high altitude regard- 24 VOLT HUMIDIFIER less of the BTU/ft3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and correspond- The yellow wire connected to the I D Blower pressure switch is Ing manufacturer's pressure switch kits. powered anytime the pressure switch is closed and provides 24 PROPANE GAS CONVERSION VAC humidifier control Remove the yellow wire and connect a field supplied jumper wire with a "piggyback" terminal to the pressure switch terminal Reconnect the yellow wire to the "piggyback" ter- AWARNING minal on the dumper wire and then connect the 24 VAC line of the humidifier to the stripped end of the jumper wire. Using a wire nut POSSIBLE PROPERTY DAMAGE,PERSONAL INJURY OR DEATH MAY or a field-supplied quick connect terminal can make this connec- OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED.THE tion.The wiring must conform to all local and national codes. Con- APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER nect the COM side of the humidifier to the BIC terminal on the FURNACE OPERATION.ALL CONVERSIONS MUST BE PERFORMED BY furnace Control board (or t0 the COM side of the 24 VAC trans- A QUALIFIED INSTALLER OR SERVICE AGENCY. former).DO NOT CONNECT 115V HUMIDIFIER TO THESE TERMI- NALS. This unit is configured for natural gas The appropriate manufacturer's propane gas conversion kit, must be applied for XII.GAS SUPPLY AND PIPING propane gas installations Refer to the Section VIII, Propane Gas GENERAL /High Altitude Installations section for details The furnace rating plate includes the approved furnace gas input Consult the furnace Specification Sheet for a listing of appropirate rating and gas types The furnace must be equipped to operate on kits. The indicated kits must be used to insure safe and proper the type of gas applied This includes any conversion kits required furnace operation All conversions must be performed by a quali- for alternate fuels and/or high altitude. fied Installer or service agency GAS VALVE ®CAUTION This unit is equipped with a 24 volt gas valve controlled during furnace operation by the Integrated control module As shipped, TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE,THE the valve is configured for natural gas. The valve is field convertible INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT for use with propane gas by replacing the regulator spring with a RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES propane gas spring from an appropriate manufacturer's propane OPERATING. I gas conversion kit Taps for measuring the gas supply pressure Inlet gas supply pressures must be maintained within the ranges and manifold pressure are provided on the valve specified below. The supply pressure must be constant and avail- The gas valve has a manual ON/OFF control located on the valve able with all other household gas fired appliances operating The Itself This control may be set only to the "ON" or"OFF" position minimum gas supply pressure must be maintained to prevent Refer to the lighting instructions label or Section XIV, Startup Pro- unreliable Ignition The maximum must not be exceeded to pre- cedure&Adjustment for use of this control during start up and shut vent unit overfiring down periods Inlet Gas Supply Pressure GAS PIPING CONNECTIONS Natural Gas Minimum 4 5"w c IMaximurn 10.0"w c GENERAL Propane Gas Iminimum. 11 0"w c Maximum- 13 0"w c HIGH ALTITUDE DERATE ®CAUTION When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE natural reduction In the density of both the gas fuel and combus- DUE TO UNDERFIRING OF EQUIPMENT,USE THE PROPER SIZE OF tion air as altitude increases. The kit will provide the proper design NATURALIPROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE certified input rate within the specified altitude range METERITANK TO THE FURNACE. High altitude kits are purchased according to the Installation alts- When sizing a trunk line, be sure to include all appliances which tude and usage of either natural or propane gas Contact your will operate simultaneously. distributor for a tabular listing of appropriate altitude ranges and The gas piping supplying the furnace must be properly sized based corresponding manufacturer's high altitude(Natural, Propane Gas, on the gas flow required, specific gravity of the gas, and length of and/or Pressure Switch) kits. the run The gas line installation must comply with local codes, or Do not derate the furnace by adjusting the manifold pressure to a in their absence, with the latest edition of the National Fuel Gas lower pressure than specified on the furnace rating plate The Code, NFPA 54/ANSI Z223 1 combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner This may cause incomplete combustion, flash- back, and possible yellow tipping 28 Natural Gas Capacity of Pipe • Use ground joint unions In Cubic Feet of Gas Per Hour(CFH) Length of Nominal Black Rpe Size • Install a drip leg to trap dirt and moisture before it can enter Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2" the gas valve. The drip leg must be a minimum of three 10 132 278 520 1050 1600 inches long 20 92 190 350 730 1100 30 73 152 285 590 980 • Install a 1/8"NPT pipe plug fitting, accessible for test gauge 40 63 130 245 500 760 connection, immediately upstream of the gas supply 50 1 56 115 215 440 670 connection to the furnace. 60 50 105 1 195 1 400 610 70 46 96 180 1 370 560 Always use a back-up wrench when making the connection 80 43 90 170 350 530 to the gas valve to keep It from turning. The orientation of 90 40 84 160 320 490 the gas valve on the manifold must be maintained as 100 38 79 150 305 460 shipped from the factory. Maximum torque for the gas valve (Pressure 0 5 psig or less and pressure drop of 0 3"W C,Based on connection is 375 in-lbs; excessive over-tightening may 0 60 Specific Gravely Gas) damage the gas valve. CFH= BTUH Furnace Input Install a manual shutoff valve between the gas meter and Heating Value of Gas(BTU/Cubic Foot) unit within six feet of the unit If a union is Installed, the To connect the furnace to the building's gas piping, the Installer union must be downstream of the manual shutoff valve, must supply a ground joint union, drip leg, manual shutoff valve, between the shutoff valve and the furnace. and line and fittings to connect to gas valve. In some cases, the . Tighten all joints securely. installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size • Connect the furnace to the building piping by one of the The following stipulations apply when connecting gas piping. Re- following methods. fer to Gas Piping Connections figure for typical gas line connec- — Rigid metallic pipe and fittings. tions to the furnace • Gas piping must be supported external to the furnace cabinet — Semi-rigid metallic tubing and metallic fittings. so that the weight of the gas line does not distort the burner Aluminum alloy tubing must not be used In exterior rack, manifold or gas valve. locations. In order to seal the grommet cabinet • Use black iron or steel pipe and fittings for building piping. penetration, rigid pipe must be used to reach the Where possible, use new pipe that is properly chamfered, outside of the cabinet. A semi-rigid connector to the reamed, and free of burrs and chips. If old pipe is used, be gas piping may be used from there. sure It is clean and free of rust, scale, burrs, chips, and old . Use listed gas appliance connectors In accordance with pipe joint compound. their instructions. Connectors must be fully In the same • Use pipe joint compound on male threads ONLY. Always room as the furnace. use pipe joint compound (pipe dope) that Is APPROVED • Protect connectors and semi-rigid tubing against physical FOR ALL GASES. DO NOT apply compound to the first two and thermal damage when installed. Ensure aluminum- threads alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water(except rain water), detergents, or.sewage. 29 MANUAL SHUT OFF VALVE ,UPSTREAM FROM GROUNDJOINr GAS VALVE PIPE UNION) ALTERNATE MANJAL GAS LINE MANIFOLD BURNERS L( ATM SHUT OFF VALVE UPSTREAM FROM �3 I ALTERNATC r GRX DJOINT I`----d GAS LINE NPEUNION) LOCATIO� PLUG IN 1 HEIGHT REQUIRED PLUG IN ALTERNATE BY LOCAL CODELIN. ALTERNATE -L GAS LINE GAS INE Q HEIUITREOLIRED HOLE HOLE L-� BY LOC LLGODE CSTANDAR ) V IN STANDARD GAS LINE HOLE • � GROMM ET GA6VALVE DRIPLEG INSTANDARD AS UNE HOLE MANIFOLD PIPEUNION DRIP LEG GROUND JO IN7 3..RNER3 PIPF UNTO N COUNTERFLOW UPFLOW / MANUAL HUT-OFFVALVE (UPSTREAM FROM GROUND MANUAL M IROM F VALVE r// JOINT PIPE UNION) / NPSTREAMFROM GROUND GRJLVC JUWT �/ JONTPPE UNION) PP_UVION GROUNDJOINT PIPE UNION DRIP LEG /DRIP LEG GROMMET IN STANDARD GAS VALVE f GROP IMET IN STANDARD GAS VALVE BURNERS GAS LINE HOLE BURNERS / GAS UNE HOLE Imo/ DRAINTRAP (GJ II -- �� +4 'DRAIN TRAP MANIFOLD PLUG I ,J ALTERNATE GAS UNE UNE HOLE MOLE MANIFOLD PLUG IN ALTERNATE GASUNELOCATION ALTERNATE GAS GAS LINE HOLE LINE LOCATION HORIZONTAL[COU NTERF LOW MODEL] HORIZONTAL[UPFLOW MODEL] HORIZONTAL[COUNTERFLOW NOTES 1 WHEN GAS LINE IS IN THE ALTERNATE LOCATION, 2 DRIP LEG MAY TERMINATE WITH A 1/2"X 1/8"PIPE PLUG SWAP THE POSITION OF THE PLUG AND GROMMET. TOACCOMMODATE LINE GAS PRESSURE MEASUREMENT Gas Piping Connections • (1) Close nipple ®WARNING ° (1) 90 degree street elbow EDGES OF SHEET METAL HOLES MAY BE SHARP.USE GLOVES AS A • (1) 2 1/2" pipe nipple PRECAUTION WHEN REMOVING HOLE PLUGS. • (1) 90 degree elbow DIRECTI$TANDARD INLET PIPING • Straight Pipe When gas piping enters directly to the gas valve through the stan- • The straight pipe must be long enough to reach the outside dard inlet hole,the installer must supply straight pipe with a ground of the cabinet so as to seal the grommet cabinet penetration joint union to reach the exterior of the furnace. The rigid pipe must and to install the ground point union outside the cabinet.A be long enough to reach the outside of the cabinet to seal the semi-rigid connector to the gas piping can be used outside grommet cabinet penetration. A semi-rigid connector to the gas the cabinet per local codes piping can be used outside the cabinet per local codes INDIRECTIALTERNATE INLET PIPING When gas piping enters indirectly to the gas valve through the alternate gas Inlet hole, the following 1/2 Inch pipe fittings (starting from the gas valve) to reach the outside of the cabinet must be supplied: 30 , y GAS PIPING CHECKS First Stage 6 to 16 PSIG Regu ntor (2g PSIG Max( Continuous Before placing unit In operation, leak test the unit and gas connec- 11-WC tions 200 M PSIG econd Stage ®WARNING Regulate TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE,NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. Propane Gas Installation(Typ.) Check for leaks using an approved chloride-free soap and water Sizing Between First and Second Stage Regulator* Solution, an electronic combustible gas detector, or other approved Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting testing methods. Capacities in 1,000 BTU/hour Pipe or Nominal Pipe Size Tubing Tubing Size,O D.Type L Schedule 40 NOTE: Never exceed specified pressures for testing. Higher Length, 3/8" 1/2" 5/8" 3/4" 7l8" 1/2" 314" pressure may damage the gas valve and cause subsequent Feet Overfiring, resulting In heat exchanger failure. 10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 2,200 3,700 5,800 2,200 4,200 Disconnect this unit and shutoff valve from the gas supply piping 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 950 1,700 2,700 4,100 1, 00 3,700 system before pressure testing the SUPPIY piping system with Pres- 50 330 770 1,500 2,400 3,700 1,500 3,400 sures In excess of 1/2 psig (3 48 kPa). 60 300 700 1,300 2,200 3,300 1,300 3,100 Isolate this unit from the gas supply piping system by closing its 80 260 610 1,200 1,900 2,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 external manual gas shutoff valve before pressure testing supply 125 200 490 900 1,400 2,300 900 2,100 piping system with test pressures equal to or less than 1/2 psig 150 190 430 830 1,300 2,100 830 1,900 (3 48 kPa). 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500 PROPANE GAS TANKS AND PIPING To convert to capacities at 15 psig settings-multiply by 1 130 To convert to capacities at 5 psig settings-multiply by 0.879 A WARNING Propane Gas Piping Chart 1 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 IF THE GAS FURNACE IS INSTALLED IN A BASEMENT,AN EXCAVATED Capacities in 1,000 BTU/hour AREA OR A CONFINED SPACE IT IS STRONGLY RECOMMENDED TO PIPs or Nominal Pipe Size 1 Tubing Tubing Size,O.D Type L Schedule 40 CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING Length, 318" 1/2" 518" 3W' 718" 1-118" 1/2" 3/4" 1" 1.114" 1.1/2' WARNING DEVICE IN CASE OF A GAS LEAK. Feet 10 39 92 199 329 501 935 275 567 1,071 2,205 3,307 •SINCE PROPANE GAS IS HEAVIER THAN AIR,ANY LEAKING AS CAN 20 26 62 131 216 346 630 189 393 732 1,496 2,299 SETTLE IN ANY LOW AREAS OR CONFINED SPACES. 30 21 50 107 181 277 500 152 315 590 1,212 1,858 •PROPANE GAS ODORANT MAY FADE,MAKING THE GAS 40 19 41 90 145 233 427 129 237 4504 48 1 1 559 448 50 18 37 79 131 198 376 114 237 91136 3 1,417 UNDETECTABLE EXCEPT FOR WITH A WARNING DEVICE. 1 60 16 35 72 121 187 340 103 217 409 634 1,275 80 13 29 62 104 155 289 89 185 346 724 1,066 A gas detecting warning system is the only reliable way to detect a loo 11 26 55 90 138 255 78 162 307 630 976 120 10 za as e1 ,zz 24 69 las 275 567 ass propane gas leak. Rust can reduce the level of odorant in propane 10 2 635 9 21 43 72 109 202 132 252 511 787 gas. Do not rely on your sense of smell Contact a local propane 200 a 19 39 660 187 54 112 209 439 665 ' gas supplier about Installing a gas detecting warning system. If 250 a 17 36 so 10s3 172 4a ino 185 390 590 the presence of gas Is suspected, follow the instructions on Page 'Data In accordance With NFPA pamphlet NO 54 4 of this manual. Propane Gas Piping Chart II All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. XIII.CIRCULATING AIR&FILTERS For satisfactory operation, propane gas pressure must be 11 inch w.c. at the furnace manifold with all gas appliances In operation DUCTWORK-AIRFLOW Maintaining proper gas pressure depends on three main factors. 1. Vaporization rate, depending on temperature of the liquid, ®Wi4RNING and "wetted surface" area of the container or containers 2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency) NEVER ALLOW THE PRODUCTS OF COMBUSTION,INCLUDING CARBON 3 Pressure drop In lines between regulators, and between MONOXIDE,TO ENTER THE RETURN DUCT WORK OR CIRCULATION second stage regulator and the appliance. Pipe size will AIR SUPPLY. depend on length of pipe run and total load of all appliances. Duct systems and register sizes must be properly designed for the Complete information regarding tank sizing for vaporization, rec- CFM and external static pressure rating of the furnace. Design the ommended regulator settings, and pipe sizing is available from ductwork in accordance with the recommended methods of "Air most regulator manufacturers and propane gas suppliers. Conditioning Contractors of America" Manual D Since propane gas will quickly dissolve white lead and most stan- dard commercial compounds, special pipe dope must be used. Install the duct system in accordance with Standards of the Na- Shellac-based compounds resistant to the actions of liquefied tlonal Board of Fire Underwriters for the Installation of Air Condi- petroleum gases such as Gasola&, Stalacti&, Clyde's® or John tioning, Warm Air Heating and Ventilating Systems Pamphlets No Crane® are satisfactory. 90A and 90B. Refer to the following illustration for typical propane gas installa- tions 31 r . A closed return duct system must be used, with the return duct SUPPLY connected to the furnace.NOTE: Ductwork must never be attached AIR to the back of the furnace Flexible points may be used for supply and return connections to reduce noise transmission To prevent CUTAWAY OF DUCTWORK the blower from interfering with combustion air or draft when a .TO EXPOSE COIL central return is used, a connecting duct must be installed be- tween the unit and the utility room wall. Never us a room,closet,or alcove as a return air chamber. When the furnace is used in connection with a cooling unit, the �� furnace should be Installed in parallel with or on the upstream side INCLINED of the cooling unit to avoid condensation in the heating element MANOMETER With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled �� m; air from entering the furnace and, if manually operated, must be Ea equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position. RETURN When the furnace is installed without a cooling coil, it is recom- AIR mended 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 Checking Static Pressure viewed for visual light inspection or such that a sampling probe (80%Furnace Shown,90%Similar) can be inserted into the airstream The access panel must be made to prevent air leaks when the furnace is in operation. When the furnace is heating, the temperature of the return air en- BOTTOM RETURN AIR OPENING[UPFLOW MODELS] tering the furnace must be between 55°F and 1007 The bottom return air opening on upflow models utilizes a "lance and cut" method to remove sheet metal from the duct opening in CHECKING DUCT STATIC the base pan. To remove, simply press out the lanced sections by Refer to your furnace rating plate for the maximum ESP (external hand to expose the metal strips retaining the sheet metal over the duct static) rating duct opening Using tin snips, cut the metal strips and remove the Total external static refers to everything external to the furnace cabi- sheet metal to free the duct flanges. Using the scribe line along net. Cooling coils, filters, ducts, grilles, registers must all be con- the duct flange as a guide, unfold the duct flanges around the sidered when reading your total external static pressure The sup- perimeter of the opening using a pair of seamer pliers or seamer ply duct pressure must be read between the furnace and the cool- tongs NOTE:Airflow area will be reduced by approximately 18%if ing coil This reading is usually taken by removing the "A" shaped duct flanges are not unfolded. This could cause performance is- block off plate from the end on the coil; drilling a test hole in it and sues and noise issues. reinstalling the block off plate Take a duct static reading at the test hole Tape up the test hole after your test is complete The negative A WARNING pressure must be read between the filter and the furnace blower. Too much external static pressure will result in insufficient air that EDGES OF SHEET METAL HOLES MAY EIE SHARP.USE GLOVES AS A can cause excessive temperature rise. This can cause limit switch PRECAUTION WHEN REMOVING HOLE PLUGS. tripping and heat exchanger failure To determine total external duct static pressure, proceed as fol- lows, CUT<SHEET 1 With clean filters in the furnace, use a draft gauge (inclinedPRESS OUT BY HAND manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure) 2 Measure the static pressure of the supply duct. (Positive Pres- sure) 3 The difference between the two numbers is .4"w.c. Example: static reading from return duct=-1"W C. CUT static reading from supply duct= .3"W.C. AFTME total external static pressure on this system = 4"w c NOTE: Both readings may be taken simultaneously and read di- scRIBELINEsouTLINING rectly on the manometer if so desired If an air conditioner coil or Duct Flange Cut Outs DUCT FLANGES Electronic Air Cleaner Is used in conjunction with the furnace, the readings must also include theses components, as shown in the When the furnace is used in connection with a cooling unit, the following drawing. furnace should be Installed in parallel with or on the upstream side 4 Consult proper tables for the quantity of air If the total external of the cooling unit to avoid condensation in the heating element static pressure exceeds the maximum listed on the furnace With a parallel flow arrangement, the dampers or other means rating plate, check for closed dampers, registers, undersized used to control the flow of air must be adequate to prevent chilled and/or oversized poorly laid out duct work 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 When the furnace is 32 Installed without a cooling coil, It is recommended that a remov- able access panel be provided in the outlet air duct. This opening Ac E s shall be accessible when the furnace is installed and shall be of DOOR 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 MRFMW RETURN CENTRAL when the furnace is in operation When the furnace is heating,the UR Q Ducr — - GRILLE temperature of the return air entering the furnace must be between MERETUM o SUPPORT O O EXTERN RLTER Q _ Q 55*F and 100 F. RACKMT BRACKET (ERHERs10 I (PROVIDED) FILTERS-READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK 1: �:3 Filters must be used with this furnace. Discuss filter maintenance O O with the building owner Filters do not ship with this furnace, but must be provided by the Installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace Is installed without fil- AIR FLOW ters, the warranty will be voided Possible Upright Upflow Possible Upright Counterflow On upflow units, guide dimples locate the side return cutout locations. Use a straight edge to scribe lines connecting the FilterLocations dimples. Cut out the opening on these lines. NOTE: Internal filter retention is not provided on this furnace. If an NOTE:An undersized opening will cause reduced airflow. internal installation is desired, an internal filter retention kit is avail- Refer to Minimum Filter Area tables to determine filter area re- able as an accessory. Please see your distributor for details. q u i re m e nts. HORIZONTAL INSTALLATIONS COOLING AIRFLOW REQUIREMENT(CFM) Filters must be Installed in either the central return register or in the 600 900 1000 1200 1400 1600 2000 return air duct work. o4o_3BXA 194• 194• 240 zea - — -- 0453BXA XIV.STARTUP PROCEDURE&ADJUSTMENT 060 38XA — 324• 324• 324• 336 -- — Furnace must have a 115 VAC power supply properly connected 0703BXA and grounded Proper polarity must be maintained for correct op- 0704CXA — -- 291• 291• 336 384 a - eration. In addition to the following start-up and adjustment Items, gl 0904CXA --- 432• 432' 432• 432• refer to further information In Section XVI, Operational Checks a 080_5CXA --- 388' 388• 388• 480 osoSoxA -- -- HEAT ANTICIPATOR SETTING 10155DXA -' "' 486' 496• 486• 486• The heat anticipator in the room thermostat must be correctly ad- *Minimum filter area dictated by heating airflow requirement. justed to obtain the proper number of cycles per hour and to pre- Permanent Minimum Filter Area(sq.in) vent"overshooting"of the setting. Set the heat anticipator setting to [Based on a 600 f1mm filter face velocity] 0 7 amps. Follow the thermostat manufacturer's instructions on how to adjust the heat anticipator setting COOLING AIRFLOW REQUIREMENT(CFM) DRAIN TRAP PRIMING 600 800 1000 1200 1400 1600 2000 The drain trap must be primed prior to furnace startup To prime,fill 040-3BX` 389• 398• 490 576 — — --- the drain trap with water. This ensures proper furnace drainage 0453BXA O6o_3Bxaupon startup and prohibits the possibility of flue gases escaping 0 0703BXA — sa7• sal• sar s7z -- - through the drain system 0704CXA 583• 583* 672 768 al FURNACE OPERATION Is 0904CXA — — 863• 863• 863* 863• -- oeo_ScxA Purge gas lines of air prior to startup Be sure not to purge lines 0905DXA --- -- -' 777• 777• 777• 960 Into an enclosed burner compartment. 100_5DXA ___ 971* 971• 971, 971. Check for leaks using an approved chloride-free soap and water 1155DXA solution,an electronic combustible gas detector,or other approved *Minimum filter area dictated by heating airflow requirement method. Verify that all required kits (propane gas, high altitude, Disposable Minimum Filter area(sq.in) etc) have been appropriately installed (Based on 300 ft/min filter face velocity] FURNACE STARTUP UPRIGHT INSTALLATIONS 1. Close the manual gas shutoff valve external to the furnace. Depending on the Installation and/or customer preference, differ- 2 Turn off the electrical power to the furnace ing filter arrangements can be applied. Filters can be installed In 3. Set the room thermostat to the lowest possible setting the central return register or a side panel external filter rack kit 4 Remove the burner compartment door. (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. NOTE: This furnace is equipped with an ignition device which The following figure shows possible filter locations. automatically lights the burner. Do not try to light the burner by hand. 33 5. Move the furnace gas valve manual control to the OFF Open to Manometer position Atmosphere Hose I 6 Wait five minutes then smell for gas. Be sure to check near i High Fire Regulator the floor as some types of gas are heavier than air. Outlet Adj st ul 7. If you smell gas after five minutes, immediately follow the Pressure Boss ReVenttor instructions on page 4 of this manual If you do not smell gas after five minutes, move the furnace gas valve manual o control to the ON position �o 8 Replace the burner compartment door. 9 Open the manual gas shutoff valve external to the furnace p Low Fire 10. Turn on the electrical power to the furnace Regulator 11. Adjust the thermostat to a setting above room temperature au 6 aAdjust 12. After the burners are lit, set the thermostat to desired Inlet 0 o O w o o 00 temperaturePressure 'lull, Boss High Fire Coil Coaxial Cod FURNACE SHUTDOWN Manometer Terminal(HI) Terminal(M) 1 Set the thermostat to the lowest setting The Integrated On/Off Switch Common control will close the gas valve and extinguish flame Terminal(C) Following a 15 second delay, the induced draft blower will White-Rodgers Model 36G54 Connected to Manometer be de-energized After a 100 or 150 second delay period (field selectable),the circulator blower will be de-energized. High Fare 2. Remove the burner compartment door and move the furnace Regulator Regulator p Vent Adjust gas valve manual control to the OFF position. 3 Close the manual gas shutoff valve external to the furnace 4 Replace the burner compartment door ® ® o o O GAS SUPPLY PRESSURE MEASUREMENT ® O p O oo-� goo A CAUTION Gas Valve On/Off Low Fare To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE,THE Selector Swatch Regulator INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT Adjust RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING. Common The lane pressure supplied to the gas valve must be within the Open to Manometer Terminal(C) Atmosphere Hose High Fare Coil range specified below The supply pressure can be measured at Terminal(HI) the gas valve inlet pressure boss or at a hose fitting installed in the 1 Low Fire Coal gas piping drop leg The supply pressure must be measured with ' Terminal(LO) the burners operating To measure the gas supply pressure, use I the following procedure I O � a ` Inlet Pressure Tap ® �v� 1/8 NPT �0 INLET 0 OUTLET ®o Manometer O ® O M°GM 003 Gas Valve On/Off ®O® Selector Switch Outlet Pressure Tap 1/8 NPT White-Rodgers Model 36G54(Two-Stage) Honeywell Model VR9205 Connected to Manometer 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer(or appropriate gas pressure gauge)at either the gas valve inlet pressure boss or the gas piping drip leg.See Honeywell VR9205 gas valve figure or White-Rodgers 36G54 gas valve figure for location of Inlet pressure boss 34 NOTE: If measuring gas pressure at the drip leg or Honeywell 3 Outlet pressure tap connections VR9205 gas valve,a field-supplied hose barb fitting must be Installed a. Honeywell VR9205 valve: Remove the outlet pressure prior to making the hose connection. If using the inlet pressure boss plug Install an 1/8" NPT hose barb fitting Into the boss on the White-Rodgers 36G54 gas valve, then use the 36G outlet pressure tap Valve Pressure Check Kit, Goodman Part No 0151 K00000S b. White-Rodgers 36G54 valve: Back outlet pressure test 3. Turn ON the gas supply and operate the furnace and all screw (inlet/outlet pressure boss) out one turn other gas consuming appliances on the same gas supply (counterclockwise, not more than one turn). line. 4. Attach a hose and manometer to the outlet pressure barb 4. Measure furnace gas supply pressure with burners firing. fitting (Honeywell valve) or outlet pressure boss (White- Supply pressure must be within the range specified in the Rodgers valve) Inlet Gas Supply Pressure table. 5 Turn ON the gas supply. 6 Turn on power and close thermostat"R" and "W1" contacts Inlet Gas Supply Pressure to provide a call for low stage heat Natural Gas Minimum: 4.5"w.c JMaximum. 10 0"w c 7. Measure the gas manifold pressure with burners firing. Propane Gas Minimum: 11 0"w.c IMaximum 13 0"w c. Adjust manifold pressure using the Manifold Gas Pressure If supply pressure differs from table, make the necessary adjust- table shown below. ments to pressure regulator, gas piping size, etc, and/or consult 8 Remove regulator cover screw from the low (LO) outlet with local gas utility. pressure regulator adjust tower and turn screw clockwise 5 Turn OFF gas to furnace at the manual shutoff valve and to increase pressure or counterclockwise to decrease disconnect manometer Reinstall plug before turning on pressure Replace regulator cover screw gas to furnace. 9. Close thermostat"R"and"W2"contacts to provide a call for 6 Turn OFF any unnecessary gas appliances stated in step high stage heat. 3. 10. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw clockwise Gate to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw. Gas Shuto11. Turn off all electrical power and gas supply to the system Valve 12. Remove the manometer hose from the hose barb fitting or outlet pressure boss. 13. Replace outlet pressure tap: me Furnace a. Honeywell VR9205 valve.Remove the 1/8"NPT hose barb fitting from the outlet pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread pen To sealer tmosphere b. White-Rodgers 36G54 valve- Turn outlet pressure test Dnp Lscrew in to seal pressure port (clockwise, 7 in With F minimum). 14. Turn on electrical powerand gas supply to the system. Manometer Hose 15 Close thermostat contacts"R"and"W1/W2"to energize the valve. Using a leak detection solution or soap suds, check for leaks at outlet pressure boss plug(Honeywell valve)or screw(White-Rodg- Manometer ers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND Measuring Inlet Gas Pressure(Alt.Method) REPAIRALL LEAKS IMMEDIATELY' NOTE: For gas to gas conversion, consult your dealer for GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT appropriate conversion. A CAUTION Manifold Gas Pressure TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE,THE Gas Rate Ran-e Nominal GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE.ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING Natural Low Stage 1.7 to 2.3"W.C. 2 0"W.C. THE GAS VALVE PRESSURE REGULATOR. HI h Sta a 3.2 to 3.8"w.c. 3.5"W.C. Only small variations in gas pressure should be made by adjust- propane Low Stage 5.7 to 6.3"w.c. 6.0"w.c. ing the gas valve pressure regulator The manifold pressure must High Stage 9.7 to 10.3"W.0 10.0"w C be measured with the burners operating To measure and adjust the manifold pressure, use the following procedure. GAS INPUT RATE MEASUREMENT(NATURAL GAS ONLY) 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. The gas input rate to the furnace must never be greater than that 2. Turn off all electrical power to the system. specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure 1. Turn OFF the gas supply to all other gas-burning appliances except the furnace 35 2 While the furnace is operating, time and record one CIRCULATOR BLOWER SPEEDS complete revolution of the smallest gas meter dial 3. Calculate the number of seconds per cubic foot(sec/ft3)of ®WARNING gas being delivered to the furnace If the dial Is a one cubic foot dial, divide the number of seconds recorded In step 2 by one. If the dial is a two cubic foot deal,divide the number TO PREVENT PREMATURE FAILURE OF HEAT EXCHANGER, PROPERTY of seconds recorded in step 2 by two DAMAGE,PERSONAL INJURY OR DEATH,DO NOT ADJUST THE LIMIT CONTROL(FACTORY-SET). 4 Calculate the furnace Input in BTUs per hour(BTU/hr) Input This furnace is equipped with a multi-speed circulator blower. This equals the Installation's gas heating value multiplied by a blower provides ease in adjusting blower speeds The Specifica- conversion factor(hours to seconds),divided by the number tion Sheet applicable to your model provides an airflow table,show- of seconds per cubic foot. The measured Input must not be ing the relationship between airflow(CFM)and external static pres- greater than the Input indicated on the unit rating plate sure(E S.R),for the proper selection of heating and cooling speeds EXAMPLE: The cooling blower speed is shipped set on HIGH, and the heating Installation's gas heating (HTG) value. 1,000 BTU/ft3 blower speed is set as Indicated in the Specification Sheet appll- (Obtained from gas supplier) cable to your model These blower speeds should be adjusted by Installation's seconds per cubic foot: 34 sec/ft3 the Installer to match the Installation requirements so as to provide Conversion Factor (hours to seconds): 3600 sec/hr the correct heating temperature rise and correct cooling CFM Input = (Htg value x 3600)—seconds per cubic foot To adjust the circulator blower speed, proceed as follows- Input=(1,000 BTU/ft3 x 3600 sec/hr)_34 sec/ft3 1 Turn OFF power to the furnace. 2 Select the heating and cooling blower speeds that match Input= 106,000 BTU/hr the Installation requirements from the airflow table In the This measured Input must not be greater than the input Specification Sheet Indicated on the unit rating plate. 3 Relocate desired motor leads to the circulator blower heat 5 Turn ON gas and relight appliances turned off In step 1. and cool speed terminals on the integrated control module Ensure all the appliances are functioning properly and that (Terminals are identified as LO HEAT-H, HI HEAT-H and all pilot burners are operating COOL-H (hot)) If a heating speed and the cooling blower TEMPERATURE RISE speed are the same, a jumper wire must be used between the heat and cool terminals. Temperature rise must be within the range specified on the unit 4 Connect all unused blower motor leads to the "PARK" rating plate An incorrect temperature rise may result in condens- terminals on the Integrated control module. Any leads not Ing In or overheating of the heat exchanger. An airflow and tem- connected to the "PARK"terminals must be taped. perature rise table Is provided In the Specification Sheet applicable 5. Turn ON power to furnace to your model. 6. Verify proper temperature rise as outlined in Section XIV, Determine and adjust temperature rise as follows: Startup Procedure and Adjustment- Temperature Rise 1. Operate furnace with burners firing for approximately ten minutes. Ensure all registers are open and all duct dampers are In their final (fully or partially open) position. GMH95,GCH95,GCH9 2 Place thermometers In the return and supply ducts as close Circulator Blower Speeds to the furnace as possible. Thermometers must not be LOW RED influenced by radiant heat by being able to "see" the heat MEDIUM LOW ORANGE exchanger MEDIUM LOW BLUE HIGH BLACK HEAT EXCHANGER COMMONINEUTRAL WHITE RADIATION"LINE OF SIGHT' SUPPLY GME 95 AIR Circulator Blower Speeds �T6uPPLY T1-LOW YELLOW T2-MED-LOW RED T3-MED ORANGE OO RISE'TSuPPLY-TRETURN T4-MED-HI BLUE D T5-HI BLACK I/1I COMMOMNEUTRAL WHITE TRETURN RETURN CIRCULATOR BLOWER FAN TIMING ADJUSTMENT AIR NOTE: Items in this section refer to the air circulator blower fan Temperature Rise Measurement NOT to the Induced draft blower. The induced draft blower timing 3 Subtract the return air temperature from the supply air sequence is not adjustable The circulator blower fan timing Is temperature to determine the air temperature rise Allow adjustable only on models with optional "heating fan OFF delay" adequate time for thermometer readings to stabilize. adjustment pins or switches. It Is NOT adjustable In any other 4 Adjust temperature rise by adjusting the circulator blower circumstances speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise. Refer to Section XIV, Startup Procedure andAdjustment-Circulator Blower Speeds for speed changing details 36 As shipped, the circulator blower fan will remain on for 150 sec- • Integrated control module LED will light. onds after the gas valve closes When a call for cooling occurs,the . Integrated control module monitors safety circuits circulator fan comes on and remains on for 45 seconds after the call for cooling ends During normal heating operation, the circula- tor fan will come on approximately 34 seconds after the gas valve • Furnace awaits call from thermostat opens. HEATING MODE ® 1 SECOND Z LL SEcoND Z LL MODE DIP SWITCH IS SET TO "7 STG"POSITION) DELAY O LL DELAY O LL O O The normal operational sequence in heating mode is as follows: Switch viewed in an upflow installation. . R and W thermostat contacts close, initiating a call for heat. Adjustment Switch • Integrated control module performs safety circuit checks SETTING FURNACE OPERATING MODE . Induced draft blower is energized for 15 second pre-purge period causing pressure switch contacts to close. This furnace is designed to operate with either a single gas Input . Igniter warm up begins after 15 second prepurge expires rate or with two distinct gas input rates. The Mode DIP switch is used to select the single gas input rate or two distinct input rates. . Low and high stage gas valves open at end of igniter warm up period, delivering gas to burners and establishing flame Setting the Mode switch to 1 STG"forces the furnace to operate at . Integrated control module monitors flame presence. Gas the furnace's highest input rate only. Operation Is as described valve will remain open only if flame is detected. under Sequence of Operation (Integrated Ignition Control)—Mode DIP Switch is set to "1 STG"position • Circulator blower is energized on high heat speed following a fixed thirty second blower on delay Electronic air cleaner Setting the Mode switch to"2 STG"allows the furnace to operate at terminals are energized with circulator blower the furnace's highest input AND at an input rate that is 75% of the . Furnace operates; integrated control module monitors highest input rate For this mode of operation, the furnace oper- safety circuits continuously ates at the low Input rate for a pre-determined time period then steps to the high input rate. Operation Is as described under Se- ' R and W thermostat contacts open, completing the call for quence of Operation(Integrated Ignition Control)—Mode DIP Switch heat. is set to"2 STG"position. • Gas valve closes, extinguishing flame. The time period is determined by the 2nd Stg Dly DIP switch. Setting ' Induced draft blower is de-energized following a fifteen the 2nd Stg Dly DIP switch to 5 minutes fixes the delay period at 5 second post purge. minutes. Setting the 2nd Stg Dly DIP switch to Auto enables an • The circulator blower remains at high heat speed for thirty algorithm that calculates a delay period based on the heating cycle seconds. The circulator blower then switches to low heat time and the total cycle time The delay period can range from 1 speed for the remainder of the selected heat off delay period minute to 12 minutes For example, the selected heat off delay period is 150 seconds. The circulator blower operates at high heat for 30 NOTE:The AMH, GCH, GDH, GMH and GME hybrid furnaces re- seconds and at low speed for 150- 30 = 120 seconds. quire a single stage thermostat These furnaces utilize a control MODE DIP SWITCH IS SET TO "2 STG"-PosIT►oN) board with single stage or two stage capability. The second stage feature is established by setting dip switch#2 on the board, either The normal operational sequence in sequence is as follows one stage or two stage All of the second stage timing is then • R and W thermostat contacts close, initiating a call for heat. ` controlled by dipswitch 3 on the circuit board. • Integrated control module performs safety circuit checks • Induced draft blower is energized for 15 second prepurge p' period causing pressure switch contacts to close HEAT OFF SECOND ® SECOND DAY DELAY u, z0 DELAY • Igniter warm up begins after 15 second prepurge expires O • Low and high-stage gas valves open at end of igniter warm N 2-STAGE 7sTAGE up period, delivering gas to burners and establishing flame. MODE LL Z O • High-stage gas valve closes after five seconds; low-stage gas valve remains open 7S�ACNP 6 �, n • Integrated control module monitors flame presence. Gas ONLY MINUTES V„ Z AUTO LL O valve will remain open only if flame is detected O • Circulator blower is energized on low heat speed following a fixed thirty second blower on delay. Electronic air cleaner XV.NORMAL SEQUENCE OF OPERATION terminals are energized with circulator blower POWER UP • Furnace is now operating in low-stage heating mode. The normal power up sequence is as follows- 0 115 VAC power applied to furnace • Integrated control module performs internal checks 37 • Furnace operates; integrated control module monitors • Circulator blower is de-energized. Electronic air cleaner safety circuits continuously. terminals are de-energized • If low-stage delay period expires, control will shift operation • Furnace awaits the next call from thermostat. from low-stage heating mode operation to high-stage heating mode operation. Control will energize circulator XVI.OPERATIONAL CHECKS blower high heat speed and high stage gas valve Furnace is now operating in high-stage heating mode BURNER FLAME • The burner flames should be inspected with the burner compart- • R and W thermostat contacts open, completing the call for ment door installed A sight glass is provided for inspection pur- heat. poses Flames should be stable, quiet, soft, and blue (dust may • Induced draft blower is de-energized following a fifteen cause orange tips but they must not be yellow) Flames should second post purge, extend directly outward from the burners without curling,floating,or • Circulator blower is de-energized following a heat off delay lifting off. Flames must not impinge on the sides of the heat ex- period (selectable 100 or 150 seconds, factory set at 150 changer firing tubes. seconds) If the furnace is operating in the low-stage heating mode 9 „ when thermostat contacts open, circulator remains at low heat speed for the selected delay off period If the furnace is operating in high-stage heating mode when Check the the thermostat contacts open, the circulator blower remains 1 Stable, Flames for at high heats speed for thirty seconds. The circulator blower 1 Stable,soft and blue. g p y 2 Not curling,floating then switches to low heat speed for the remainder of the or lifting off selected heat off delay period. For example, the selected heat off delay period is 150 seconds The circulator blower operates at high heat for 30 seconds and at low speed for Burner Flame 150 - 30 = 120 seconds. • Furnace awaits the next call from thermostat. XVII.SAFETY CIRCUIT DESCRIPTION COOLING MODE GENERAL The normal operational sequence in cooling mode is as follows: A number of safety circuits are employed to ensure safe and proper • R and Y thermostat contacts close, initiating a call for cool. furnace operation These circuits serve to control any potential • Integrated control module performs safety circuit checks. safety hazards and serve as inputs in the monitoring and diagno- sis of abnormal function. These circuits are continuously moni- • Outdoor fan and compressor are energized tored during furnace operation by the integrated control module • Circulator blower is energized on cool speed following a INTEGRATED CONTROL MODULE fixed five second on delay. Electronic air cleaner terminals The integrated control module is an electronic device which, if a are energized with circulator blower potential safety concern is detected, the module will take the nec- • Furnace circulator blower and outdoor cooling unit run, essary precautions and provide diagnostic information through an integrated control module monitors safety circuits LED. continuously PRIMARY LIMIT • R and Y thermostat contact open, completing the call for cool The primary limit control is located on the partition panel and moni- tors heat exchanger compartment temperatures It is a normally- • Outdoor fan and compressor are de-energized closed (electrically), automatic reset, temperature-activated sen- • Circulator blower is de-energized following a fixed forty five sor The limit guards against the overheating as a result of insuffi- second cool off delay period.Electronic air cleaner terminals cient conditioned air passing over the heat exchanger are de-energized AUXILIARY LIMIT • Furnace awaits the next call from thermostat The auxiliary limit control(s) are located on or near the circulator FAN ONLY MODE blower and monitors heat exchanger compartment temperatures They are a normally-closed (electrically), manual-reset, tempera- The normal operational sequence in fan only mode is as follows: ture activated sensors These limits guard against overheating as • R and G thermostat contacts close, initiating a call for fan a result of insufficient conditioned air passing over the heat ex- • Integrated control module performs safety circuit checks. changer • Circulator blower is energized on low heat speed. Electronic ROLLOUT LIMIT air cleaner terminals are energized. The rollout limit control(s) are mounted on the burner/manifold • Circulator blower runs, integrated control module monitors assembly and monitor the burner flame They are normally-closed safety circuits continuously (electrically), manual-reset, temperature-activated sensors. These limits guard against burner flames not being properly drawn into • R and G thermostat contacts open, completing the call for the heat exchanger. fan. 38 PRESSURE SWITCHES FAULT RECALL The pressure switches are normally-open (closed during opera- The ignition control is equipped with a momentary pushbutton tion), single-pole single-throw, negative air pressure-activated switch that can be used to display on the diagnostic LED the last switches. They monitor the airflow (combustion air and flue prod- five faults detected by the control.The control must be in Standby ucts)through the heat exchanger via pressure taps located on the Mode (no thermostat inputs) to use the feature. Depress the induced draft blower and the coil front cover. These switches guard pushbutton switch for approximately 2 seconds Release the switch against insufficient airflow (combustion air and flue products) when the LED is turned off. The diagnostic LED will then display through the heat exchanger and/or blocked condensate drain con- the flash codes associated with the last five detected faults. The ditions order of display is the most recent fault to the least recent fault. FLAME SENSOR RESETTING FROM LOCKOUT The flame sensor is a probe mounted to the burner/manifold as- Furnace lockout results when a furnace is unable to achieve igni- sembly which uses the principle of flame rectification to determine tion after three attempts during a single call for heat. It is character- the presence or absence of flame. ized by a non-functioning furnace and a one flash diagnostic LED XVIII.TROUBLESHOOTING code. If the furnace is in"lockout", it will(or can be)reset in any of the following ways. ELECTROSTATIC DISCHARGE(ESD)PRECAUTIONS 1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal NOTE: Discharge body's static electricity before touching unit. An operations following a one hour lockout period. electrostatic discharge can adversely affect electrical components 2 Manual power interruption. Interrupt 115 volt power to the Use the following precautions during furnace installation and ser- furnace for 1 -20 seconds vicing to protect the integrated control module from damage. By 3. Manual thermostat cycle Lower the thermostat so that putting the furnace,the control,and the person at the same electro- there is no longer a call for heat then reset to previous setting static potential, these steps will help avoid exposing the integrated Interrupt thermostat signal to the furnace for 1 -20 seconds. control module to electrostatic discharge. This procedure is appli- NOTE: If the condition which originally caused the lockout still cable to both installed and uninstalled (ungrounded) furnaces. exists, the control will return to lockout. Refer to Section XVlll, 1 Disconnect all power to the furnace. Do not touch the Troubleshooting-Diagnostic Chart for aid in determining the cause. integrated control module or any wire connected to the control prior to discharging your body's electrostatic charge to XIX.MAINTENANCE ground. 2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control Any tools held in a person's A WARNING hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process In step 2. Use caution not HIGH VOLTAGE1 to recharge your body with static electricity;(i.e,do not move TO AVOID PERSONAL INJURY OR DEATH DUE TO or shuffle your feet, do not touch ungrounded objects, etc.) ELECTRICAL SHOCK,DISCONNECT ELECTRICAL POWER If you come in contact with an ungrounded object, repeat BEFORE PERFORMING ANY MAINTENANCE.IF YOU MUST Step 2 before tOUChlcontrol a Or wires. HANDLE THE IGNITER,HANDLE WITH CARE.TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS,ROUGH 4. Discharge your body to ground before removing a new HANDLING OR VIBRATION COULD DAMAGE THE IGNITER control from its container Follow steps 1 through 3 if RESULTING IN PREMATURE FAILURE.ONLY A QUALIFIED installing the control on a furnace. Return any old or new I SERVICER SHOULD EVER HANDLE THE IGNITER. controls to their containers before touching any ungrounded object ANNUAL INSPECTION DIAGNOSTIC CHART The furnace should be Inspected by a qualified Installer, or service agency at least once per year.This check should be performed at A WARNING the beginning of the heating season. This will ensure that all fur- nace components are In proper working order and that the heating system functions appropriately Pay particular attention to the fol- HIGH VOLTAGEI lowing items. Repair or service as necessary. TO AVOID PERSONAL INJURY OR DEATH DUE TO Flue pipe system Check for blockage and/or leakage. Check ELECTRICAL SHOCK,DISCONNECT ELECTRICAL POWER �A BEFORE PERFORMAING ANY SERVICE OR MAINTENANCE. to the outside termination and the connections at and internal to the furnace. Refer to the Troubleshooting Chart at the end of this manual for * Heat exchanger. Check for corrosion and/or buildup within assistance in determining the source of unit operational problems. the heat exchanger passageways The red diagnostic LED blinks to assist in troubleshooting the unit. • Burners Check for proper ignition, burner flame, and flame The number of blinks refers to a specific fault code. sense. 39 t � • Drainage system. Check for blockage and/or leakage BURNERS Check hose connections at and Internal to furnace Visually Inspect the burner flames periodically during the heating • Wiring Check electrical connections for tightness and/or season Turn on the furnace at the thermostat and allow several corrosion Check wires for damage minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance Flames should be stable, quiet, • Filters soft, and blue (dust may cause orange tips but they must not be FILTERS yellow). They should extend directly outward from the burners with- out curling, floating, or lifting off Flames must not Impinge on the sides of the heat exchanger firing tubes ®CAUTION INDUCED DRAFT AND CIRCULATOR BLOWERS TO ENSURE PROPER UNIT PERFORMANCE,ADHERE TO THE FILTER The bearings in the Induced draft blower and circulator blower SIZES GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR motors are permanently lubricated by the manufacturer No further SPECIFICATION SHEET APPLICABLE TO YOUR MODEL" lubrication is required Check motor windings for accumulation of *NOTE Please contact your distributor or our website for the dust which may cause overheating. Clean as necessary. applicable Specification Sheet referred to in this manual CONDENSATE TRAP AND DRAIN SYSTEM(QUALIFIED SERVICER MAINTENANCE ONLY) Improper filter maintenance is the most common cause of inad- Annually inspect the drain tubes,drain trap,and field-supplied drain equate heating or cooling performance. Filters should be cleaned line for proper condensate drainage. Check drain system for hose (permanent) or replaced (disposable) every two months or as re- connection tightness, blockage, and leaks. Clean or repair as quired When replacing a filter, it must be replaced with a filter of necessary. the same type and size. FLAME SENSOR(QUALIFIED SERVICER ONLY) FILTER REMOVAL Under some conditions, the fuel or air supply can create a nearly Depending on the installation, differing filter arrangements can be invisible coating on the flame sensor. This coating acts as an applied. Filters can be installed in either the central return register insulator causing a drop in the flame sense signal If the flame or aside panel external filter rack(upflow only) A media air filter or sense signal drops too low the furnace will not sense flame and electronic air cleaner can be used as an alternate filter Follow the will lock out. The flame sensor should be carefully cleaned by a filter sizes given in the Recommended Minimum Filter size table to qualified servicer using emery cloth or steel wool Following clean- ensure proper unit performance ing, the flame sense signal should be 1 to 6 microamps at 115 To remove filters from an external filter rack in an upright upflow volts. Installation, follow the directions provided with external filter rack IGNITER(QUALIFIED SERVICER ONLY kit HORIzONTAL UmjFILTERREMOVAL If the Igniter and the surrounding air are at about 70°F and the igniter wires are not connected to any other electrical components, Filters in horizontal installations are located in the central return the resistance of the igniter should not exceed 75 ohms If It does, register or the ductwork near the furnace the igniter should be replaced To remove: 1 Turn OFF electrical power to furnace. FLUE PASSAGES(QUALIFIED SERVICER ONLY) 2 Remove filter(s)from the central return register or ductwork. The heat exchanger flue passageways should be inspected at the 3 Replace filter(s) by reversing the procedure for removal. beginning of each heating season If necessary, clean the pas- 4 Turn ON electrical power to furnace. sageways as outlined below. MEDIA AIR FLLTERORELECTRowcAIR CLEANERRFmoVAL 1 Turn OFF the electrical power and gas supply to the furnace 2. Disconnect the gas line and remove the burner/ manifold Follow the manufacturer's directions for service. assembly by removing the screws securing the assembly to the partition panel 3. Disconnect the flue pipe system from the induced draft blower 4. Remove the induced draft blower and, drain and pressure tap hoses from the recuperator coil front cover 5 Remove the recuperator coil front cover to expose the coil tubes and turbulators. 40 ! Y 6. Remove the recuperator coil turbulators individually by slowly XX.BEFORE LEAVING AN INSTALLATION pulling each turbulator forward firmly. Cycle the furnace with the thermostat at least three times 7. Clean the recuperator cod tubes using a long handle wire Verify cooling and fan only operation. brush, such as a gun cleaning brush. 8. Clean the primary heat exchanger tubes using a wire brush ' Review the Owner's Manual with the homeowner and attached to a length of high grade stainless steel cable, discuss proper furnace operation and maintenance. such as drain cleanout cable. Attach a variable speed • Leave literature packet near furnace. reversible drill to the other end of the cable. Slowly rotate the cable with the drill and insert it into one of the heat XXI.REPAIR&REPLACEMENT PARTS exchanger tubes. While reversing the drill, work the cable • When ordering any of the listed functional parts, be sure to in and out several times to obtain sufficient cleaning. Repeat provide the furnace model, manufacturing, and serial for each tube. numbers with the order. 9 Clean residue from furnace using a vacuum cleaner. 0 Although only functional parts are shown in the parts list, all 10 Replace the parts removed in the previous steps in reverse sheet metal parts,doors,etc.may be ordered by description order. 11 Turn on electrical power and gas to furnace Check for ' Parts are available from your distributor. leaks and proper unit operation 12. Severe heat exchanger fouling is an indication of an Functional Parts List- operational problem. Perform the checks listed in Section Gas Valve Blower Motor XIV, Startup Procedure and Adjustments to reduce the Gas Manifold Blower Wheel chances of repeated fouling. Natural Gas Orifice Blower Mounting Bracket Propane Gas Orifice Blower Cutoff Igniter Blower Housing Flame Sensor Capacitor -Rollout Limit Switch Heat Exchanger Primary Limit Switch Coil Front Cover Auxiliary Limit Switch Integrated Control Module Pressure Switch Transformer Induced Draft Blower Door Switch 41 1 TROUBLESHOOTING CHART SymptomsAbnormal Operation ..- •Furnace fads to operate NONE •No 115 volt power to •Manual disconnect switch •Assure 115 and 24 volt •Turn power OFF •Integrated control module furnace,or no 24 volt OFF,door switch open,or power to furnace prior to repair. diagnostic LED provides power to integrated 24 volt wires improperly integrated control module .Replace integrated no signal. control module. connected or loose. •Check integrated control control module •Blown fuse or circuit •Blown fuse or circuit module fuse(3A) fuse with 3A breaker breaker Replace if necessary. automotive fuse •Check for possible shorts •Read precautions •Integrated control in 115 and 24 volt circuits in"Electrostatic module has an •Integrated control module Repair as necessary. Discharge"section internal fault. has an internal fault .Replace bad integrated of manual control module. •LED is Steady On. ON •Normal Operation -Normal Operation •None -Normal Operation CONTINUOUS CN •Furnace fads to operate •Furnace lockout due •Failure to establish flame •Locate and correct gas •Turn power •Integrated control module —( 1 )— to an excessive Cause may be no gas to interruption. OFF prior to diagnostic LED is �-'� number of ignition burners,front cover •Check front cover repair. flashing ONE(1)flash. t FLASH "retries" (3 total)'. pressure switch stuck open, pressure switch bad igniter or igniter operation(hose,wiring, alignment,improper orifices, contact operation). or coated/oxidized or Correct if necessary. improperly connected flame .Replace or realign sensor •Igniter is igniter. fragile,handle •Loss of flame after establish 'Check flame sense with care ment.Cause may be signal.Sand sensor if .Sand flame interrupted gas supply,lazy coated and/or oxidized sensor with burner flames(improper gas •Check flue piping for emery cloth pressure or restriction in flue blockage,proper •See"Vent/Flue and/or combustion air length,elbows,and Pipe"section piping),front cover pressure termination. for piping switch opening,or improper •Verify proper induced details. induced draft blower draft blower perfor- performance. mance. •Furnace fails to operate Pressure switch •Induced draft blower •Replace induced draft •Turn power OFF •Integrated control module 2 circuit is closed. pressure switch contacts blower pressure switch. prior to repair diagnostic LED is Induced draft sticking. •Replace pressure, flashingTWO 2 flashes. blower is not •Shorts in pressure switch switch with proper ( ) 2 FLASHES P •Repair short. P P operating circuit replacement part •Induced draft blower runs Pressure switch •Pressure switch hose •Inspect pressure •Turn power continuously with no 3 circuit not closed blocked,pinched or switch hose.Repair,if OFF prior to further furnace operation. Induced draft blower connected improperly necessary, repair •Integrated control module 3 FLASHES is operating •Blocked flue and/or inlet air •Inspect flue and/or inlet •Replace diagnostic LED is pipe,blocked drain system, air piping for blockage, pressure flashing THREE(3) or weak induced draft proper length,elbows, switch with flashes. blower and termination.Check proper •Incorrect pressure switch drain system.Correct replacement setpoint or malfunctioning as necessary. part. switch contacts. •Correct pressure switch •Loose or improperly setpoint or contact connected wiring. motion •Tighten or correct wiring connection. 'Integrated control module will automatically attempt to reset from lockout after one hour. 2LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch 42 t Y TROUBLESHOOTING CHART Symptoms Possible Causes Corrective Action Abnormal Operation LED Code' Description(s) & Notes •Circulator blower runs •Primary limit •Insufficient conditioned air •Check primary limit. •Turn power OFF over the heat exchanger. Replace if necessary. P P prior to repair continuously No furnace 4 circuit is open ger. operation Blocked filters, restrictive •Check filters and •Replace primary •Integrated control module ductwork, improper ductwork for blockage. switch with proper diagnostic LED is flashing. 4 FLASHES circulator blower speed, or Clean filters or remove replacement part. FOUR(4)flashes faded circulator blower. obstruction. •Replace blower •Faulty primary limit switch. •Check circulator blower with correct •Loose or improperly speed and performance. replacement part. connected wiring. Correct speed or replace blower,if necessary -Tighten or correct wiring connection. •Induced draft blower and •Flame sensed •Short to ground in flame •Correct short at flame •Turn power OFF circulator blower runs 5 with no call for sense circuit. sensor or in flame prior to repair continuously No furnace heat. sensor wiring. operation. 5 FLASHES •Integrated control module diagnostic LED is flashing FIVE (5) flashes. •Furnace fads to operate. •Rollout limit open •Flame rollout. •Check burners for proper •See"Vent/Flue alignment. Pi •Integrated control module 6 •Integrated control •Misaligned burners, Pipe"section for diagnostic LED is flashing module fuse is blocked flue and/or air •Check flue and air inlet piping details. SIX (6) flashes. s FLASHES blown. inlet pipe,or failed piping for blockage, •Replace induced induced draft blower. proper length, elbows, draft blower with •No furnace operation. � and termination.Correct ro •Loose or improperly as necessary. p lace- per re p connected wiring. •Check rollout limit.Replace ment part. •Short in 24 volt AC if necessary. •Replace inte- control circuits or safety •Check induced draft grated control circuits. blower for proper module fuse with -Faulty rollout limit performance. Replace, if 3A automotive necessary. fuse •Tighten or correct wiring •Read precautions connection. in"Electrostatic •Repair short in 24 volt AC Discharge" control/safety circuit(s). section of manual. •Replace integrated control .Replace rollout module fuse (3A). limit with correct replacement part. •Normal furnace •Flame sense •Flame sensor is coated/ •Sand flame sensor. •Turn power OFF operation. microamp signal is oxidized •Inspect for proper sensor Prior to repair •Integrated control module low. •Flame sensor incorrectly alignment. •Clean flame sensor diagnostic LED is 7 FLASHES positioned in burner •Compare current gas with steel wool: flashing SEVEN(7) flame pressure to rating plate 'See"Vent/Flue ue flashes •Lazyburner flame due to info. Adjust as needed. Pipe"section for 1 piping details. improper gas pressure or •See rating plate for combustion air. proper gas pressure. •Furnace not operating •Problem with •Improperly connected •Check and correct wiring •Turn power OFF iter. •Integrated control module $ igniter circuit. ignfrom integrated control prior to repair •Bad igniter. module to igniter. Replace igniter diagnostic LED is •Poor unit ground. flashing EIGHT(S) -Replace bad igniter with proper flashes. s FLASHES •Poor burner ground. replacement art. •Faulty integrated control -Check and correct unit re P P module. ground wiring. •Read precautions •Replace bad integrated in "Electrostatic Discharge" control module. section of manual •Induced draft blower runs •Polarity of 115 •Polarity of 115 volt AC •Review wiring diagram to •Turn power OFF power to furnace or correct polarity.continuously No furnace C or 24 volt P Y• prior to repair. operation. power is integrated control module •Ven proper round. p is reversed. -Verify P P 9 •Integrated control module reversed •Red and blue wires to Correct if necessary. diagnostic LED Is flashing CONTINUOUS FLASHING transformer are reversed. •Reverse red and blue continuously. •Poor unit ground. wires connected to transformer. •LED is steady on STEADY •Normal operation. ' LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. 43 J j BLOWER PERFORMANCE DATA G M H95 BLOWER PERFORMANCE (CFM &Temperature Rise vs. External Static Pressure) Model Tons AC EXTERNAL STATIC PRESSURE (Inches Water Column) Motor at 0 5" 0.1 0.2 0.3 04 0.5 0.6 0.7 0.8 Heating Speed Speed As Shipped ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM HIGH 3.0 1352 29 1318 30 1260 31 1202 33 1128 35 1044 955 853 GMH950453BX* MED 25 1214 32 1172 34 1123 35 1064 37 1012 39 938 ' 859 741 (MED-HI) MED-LO 20 997 40 994 40 960 41 923 43 884 45 817• 741 611 LOW 1 5 757 52 753 52 734 54 704 56 674 59 620, 524 438 HIGH 30 1449 41 1409 42 1326 45 1273 47 1201 49 1194 1136 1018 GMH950703BX* MED 25 1192 50 1172 51 1141 52 1094 54 1046 57 973 904 793 (MED-HI) MED-LO 20 981 61 962 62 943 63 917 65 888 67 830 764 665 LOW 15 750 79 730 81 714 83 692 86 657 90 620 570 502 HIGH 4.0 2069 29 1965 30 1871 32 1756 34 1661 36 1549 1415 1275 GMH950704CX* MED 35 1752 34 1724 34 1667 36 1603 37 1488 40 1402 1290 1082 (MED-HI) MED-LO 3.0 1437 41 1437 41 1417 42 1369 43 1320 45 1256 1140 984 LOW 25 1184 50 1177 50 1161 51 1132 52 1095 54 1047 928 837 HIGH 40 1970 40 1874 342 1757 45 1667 48 1566 51 1431 1334 1182 GMH950904CX* MED 35 1713 46 1650 48 1572 50 1510 52 1418 56 1313 1211 1079 (MED-HI) MED-LO 3.0 1439 55 1412 56 1370 58 1327 60 1260 63 1166 1078 956 LOW 2.5 1183 67 1155 69 1122 74 1108 72 1062 75 1.011 931 816 HIGH 50 2058 39 1997 40 1928 42 1852 43 1777 45 1682 1600 1487 GMH950905CX* MED 40 1718 47 1685 48 1632 49 1586 51 1520 53 1458 1369 1281 (MED-HI) MED-LO 3.5 1502 54 1464 55 1429 56 1380 58 1319 61 1272 1200 1137 LOW 3.0 1305 62 1277 63 1253 64 1212 , 66 1175 69 1127 1081 1010 HIGH 50 2147 37 2114 37 2057 39 2030 39 1978 40 1889 1784 1713 GMH950905DX* MED 40 1675 47 1686 47 1640 48 1623 49 1557 51 1501 1455 1360 (MED-HI) MED-LO 35 1489 53 1470 54 1436 55 1409 56 1361 58 1318 1243 1130 LOW 30 1307 61 1265 63 1234 64 1203 66 1168 68 1096 1053 991 HIGH 5.0 2134 46 2103 47 2029 48 1941 51 1906 51 1818 1733 1625 GMH951155DX* MED 40 1678 58 1643 60 1643 60 1577 62 1527 64 1489 1423 1339 (MED-Hp MED-LO 3.5 1453 68 1440 68 1426 69 1363 72 1349 73 1314 1253 1205 LOW 30 1259 78 1239 79 1220 80 1181 83 1159 85 1118 1082 101.5 1 CFM in chart is without filters(s) Filters do not ship with this furnace,but must be provided by the installer If the furnace requires two return filters,this chart assumes both filters are installed 2 All furnaces ship as high speed cooling and medium-speed heating Installer must adjust blower cooling&heating speed as needed 3 For most jobs,about 400 CFM per ton when cooling is desirable 4 INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE 5 The chart is for information only For satisfactory operation,external static pressure must not exceed value shown on rating plate The shaded area indicates ranges in excess of maximum external static pressure allowed when heating The data for 0 6"w c to 0 8"w c is shown for air conditioning purposes only 6 The above chart is for U S furnaces installed at 0-2000 feet At higher altitudes,a properly de-rated urntwill have approximately the same temperature rise at a particular CFM,while the ESP at that CFM will be lower 44 L " � BLOWER PERFORMANCE DATA GCH95 / GCH9115 BLOWER PERFORMANCE (CFM &Temperature Rise vs.Extemal Static Pressure) Model Tons AC EXTERNAL STATIC PRESSURE(Inches Water Column) Motor at 0 5" 0.1 0.2 0.3 0.4 0.5 0.6 0.7 . 0.8 Heating Speed Speed As Shipped ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM^ CFM CFM HIGH 3.0 1415 28 1352 30 1290 31 1196 34 1127 36 1035 936 825 GCH950453BX* MED 25 1221 33 1178 34 1127 36 1073 38 1007 40 932 834 733 (MED-HI) MED-LO 20 1034 39 1000 40 976 41 935 43 881 46 819' 733, 662' LOW 1.5 860 47 845 48 812 50 783 51 740 54 682 619, 534 HIGH 30 1431 42 1368 44 1296 47 1228 49 1150 53 1055 962 860 GCH950703BX* MED 2.5 1212 50 1182 51 1138 53 1091 55 1019 59 944 871 769 (MED-HI) MED-LO 2.0 1002 60 978 62 956 63 921 66 878 69 825 ' 738 647 LOW 15 813 74 805 75 790 76 759 80 726 83 689 644 605 HIGH 4.0 1755 34 1674 36 1632 37 1510 40 1423 42 1325 .1241 1116 GCH950704CX* MED 35 1656 36 1585 38 1536 39 1429 42 1355 45 1268 1145" 1059 (MED-HI) MED-LO 3.0 1551 39 1488 41 1427 42 1353 45 1290 47 1195 1100 1017 LOW 2.5 11286 47 11258 48 112411 49 11851 51 11121 54 11067 983 1 886, HIGH 4.0 1734 46 1652 49 1578 51 1508 53 1413 57 1336 1248 1154 GCH950904CX* MED 35 1642 49 1558 52 1487 54 1418 57 1336 60 1243 1,164 1039 (MED-HI) MED-LO 30 1522 53 1458 55 1396 58 1321 61 1253 64 1182 110f 986' LOW 25 1287 63 1244 65 1184 68 1148 70 1098 73 1034 953 ,1 849 HIGH 5.0 2189 37 2109 38 2025 40 1948 41 1862 43 1767 1644 1537 GCH950905DX* MED 4.0 1885 43 1831 44 1776 45 1711 47 1637 49 1539 1453 1346 (MED-HI) MED-LO 3.5 1665 48 1627 50 1584 51 1524 53 1462 55 1400„ 1323 .1220 LOW 3.0 1474 55 1440 56 1401 57 1356 59 1310 61 1255 1193 1109 HIGH 5.0 2134 46 2103 47 2029 48 1941 51 1906 51 1818 1733 1625 GCH91155DX* MED 40 1678 58 1643 60 1643 60 1577 62 1527 64 1489 1423 1339 (MED-HI) MED-LO 35 1453 68 1440 68 1426 69 1363 72 1349 73 1314 1253 1205 LOW 30 1259 78 1239 79 1220 80 1181 83 1159 85 1118.1,1082 1015 1. CFM in chart is without filters(s) Filters do not ship with this furnace,but must be provided by the installer If the furnace requires two return filters,this chart assumes both filters are installed 2 All furnaces ship as high speed cooling and medium-speed heating Installer must adjust blower cooling&heating speed as needed 3 For most fobs,about 400 CFM per ton when cooling is desirable. 4 INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE 5 The chart is for information only For satisfactory operation,external static pressure must not exceed value shown on rating plate The shaded area indicates ranges in excess of maximum external static pressure allowed when heating The data for 0 6"w c to 0 6"w c.is shown fo air conditioning purposes only 6 The above chart is for U S.furnaces installed at 0-2000 feet At higher altitudes,a properly de-rated unitwill have approximately the same temperature rise at a particular CFM,while the ESP at that CFM will be lower 45 BLOWER PERFORMANCE DATA G M E95 (CFM&TEMPERATURE RISE VS.EXTERNAL STATIC PRESSURE) Model Tons EXTERNAL STATIC PRESSURE(Inches Water Column) --------- Motor AC at Heating Speed Speed 05" 01 0.2 03 0.4 0.5 0.6 0.7 0.8 As Shipped ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM T1 -YELLOW 15 726 48 670 53 617 57 553 64 490 72 429 378 336 T2-RED 20 905 39 860 41 812 43 761 46 712 49 663 610 . 574 GM T3-ORANGE 2.5 1121 31 1074 33 1039 34 998 35 959 37 923 882 839 (MED-HI) -HI) T4-BLUE 30 1274 28 1239 28 1199 29 1166 30 1 129 31 1096, 1059 1021 T5-BLACK 30 1306 27 1261 28 1232 29 1195 29 1162 30 1132 1090 1057 T1 -YELLOW 1 5 714 80 667 79 604 87 548 96 484 109 422 367° 325 T2-RED 20 904 58 851 62 804 66 761 69 708 75 664 •612 572 GME950603BX* T3-ORANGE 25 1125 47 1075 49 1045 51 999 53 956 55 921 877 839 (MED-HI) T4-BLUE 30 1312 40 1271 42 1228 43 1202 44 1165 45 1127. 1087' 1044 T5-BLACK 35 1423 37 1386 38 1354 39 1321 40 1278 41 1210 1134 1032 T1 -YELLOW 3.0 1297 54 1253 56 1209 58 1161 61 1111 63 1067 1022-1974 T2-RED 35 1507 47 1455 48 1422 49 1377 51 1334 53 1296 1251, 1195 GME950805CX* T3-ORANGE 40 1677 42 1637 43 1602 44 1562 45 1526 46 1484 1441 1324 (MED-HI) T4-BLUE 4.0 1879 37 1842 38 1800 39 1762 40 1700 41 1566 1437 1319 T5-BLACK 50 2044 35 1967 36 1894 37 1795 39 1702 41 1578 1452 1320 T1 -YELLOW 30 1331 66 1275 69 1206 73 1145 77 1080 81 1021 953 889 T2-RED 3.5 1512 58 1452 60 1392 63 1336 66 1279 69 1219 1175 1115 GME95100T3-ORANGE 4.0 1713 51 1666 53 1614 57 1569 56 1513 58 1468 1414 1364 (MED-HI) T4-BLUE 40 1892 46 1845 48 1802 49 1752 50 1707 52 1656„ 1614 1577 T5-BLACK 50 2080 42 2038 43 2005 44 1960 45 1920 46 1879 1843 -1791 1 CFM in chart is without filters(s) Filters do not ship with this furnace,but must be provided by the installer If the furnace requires two return filters,this chart assumes both filters are installed 2 All furnaces ship as high speed cooling and medium-speed heating Installer must adjust blower cooling&heating speed as needed 3 For most jobs,about 400 CFM per ton when cooling is desirable 4. INSTALLATION IS TO BE ADJUSTED TO OBTAIN TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE 5 The chart is for information only For satisfactory operation,external static pressure must not exceed value shown on rating plate The shaded area indicates ranges in excess of maximum external static pressure allowed when heating The data for 0 6"w c to 0 8"w c is shown fo air conditioning purposes only 6 The above chart is for U S furnaces installed at 0-2000 feet At higher altitudes,a properly de-rated umtwill have approximately the same temperature rise ata particular CFM,while the ESP at that CFM will be lower 46 WIRING DIAGRAM GMH95[0453,0704,0905D] GMH95[0703,0904,1155] --- ----- 24 VACR� 4!OVA BLOWER r,---- HUMIDIFIEJ�-- INTEGRATED HUMIDIFIERGY COMPARTMENT t--- I CONTROLMODULE DOOR SWITCH I OPEN WHEN 24 VAC (DOOR OPEN I IGNOTR B(B) GND I MVC(9)SFORME C 24V THERMOSTAT I 115 VAC I MVH(12) I HI VALVE CONNECTIONS^I I PM C G R W Y BK WH m I I MFR(ONTCOVER C I PRESSURE D BLOWER 2: PRESSURE SWITCH SWITCH m G PB(10) C NO Q FUSE OR x j' MICRO Lll MI Pso(4 Gy 1 I I HU(/) PK INTEGRATED 4 HLo(1) CONTROL 5 5 ' OR I II I MANUAL RTROLSU)ULIARYAUTORESE MODULE > BL R PRIMARY 10 YL GR IRo2(11) CONTROL oanv* OR R01(Sy �s " OR MANUAL RESET ROLLOUT NacE* GY BR LIMIT CONTROL(S) RD (SINGLE CONTROL ON 45K BTU) TH(3) 24 VAC F }Q .e T 4OR _ Z 2 —"* 40VA i *FACTORY SETTINGS TRANSFORMER (/J h S-H(OyW}N XFMR-H 115VAC F O T 25 FLAME SENSOR _ Z O DIAGNOSTIC NNWEG OLEO ib FG WHI" = 115 VAC NOTANDPARK IERNINALI HOTSURFACE W IGNITER a a/ a COOLH HEAT41 IGN BK V1 J Q SEE -" R'LL O GND NOTE 4 WH m 0 r m C7 Z BL(MED RD PK o m ND BLWR z ? W OR((MEDLOW) i r I y 40 $ 1. U WZ RD(LOW) BK I STN o xa Q CIRCULATOR I�v�IJ m p j COOL•H CIRCULATOR N o (Wq W Z BR BR BLOWER YL m BLWR W m O CAPACITOR I 't a -- W NPU /ELECTRONIC 00 W QW BLOWER COMPARTMENT EACH 1 AIR CLEANER r I W BURNER COMPARTMENTCD MAN UAL RESET LINE-H I AUXILIARY LIMITS O O Q - (1 J IN UPFLOW JUNCTION BOX IL y rp GND BLOWER DECK LOUJ W r BK (2)IN CTLOW DOOR BLOWER HOUSING SWITCH 9 a3 � ~ O IL HINDUCED DRAFT WH ®WARNING' I I OW W 12 BLOWER WH DISCONNECTPOWE I I' DISCONNECT - Z J a _ BEFORE SERVICING I Z a W AUTO RESET / \ WIRING TO UNIT (7 NO F V) PONTRO LIMIT L-Q�'-r�PU MUST BE I I I 'D 7 CONTROL, I \�J PROPERLY I I a BL POLARIZED I y I _ U AND GROUNDED YL L GND N f 1� RD OR OR TO 115VAC/1 0/60 HZ POWER SUPPLY WITH V OVERCURRENT PROTECTION DEVICE t Z PKC-�"•Q---- D WH I `IJ AWARNING DISCONNECT POWER BEFORE Z ID BLOWER MANUAL RESET ROLLOUT LIMIT CONTROL(S) JUNCTION BE WIRING TO UNIT MUST BE M PRESSURE 24 VAC (SINGLE CONTROL ON 45K BTU) BL BOX PROPERLY POLARIZED AND GROUNDED Q SWITCH HUMIDIFIER FRONT COVER N PRESSURE SWITCH /-T r1 r -1 S V2CIRCUIT EC' GY ° Gy— CONNECTOR Y CONNECTOR GNOU ' —GR ----�---- -JIIGND ® SORFACE BR BK --�-0�8-I- -LIGNTER 2 OR SFLA AE EN1 LSCONNE�T GAS VALVE(HONEYWELL) SOR 0 STEADY ON:NORMAL OPERATION J OFF =CONTROLFAILURE LOW VOLTAGE(24V) EQUIPMENTGND !77 1c1 -.- 1 FLASH =SYSTEM LOCKOUT(RETRIES EXCEEDED) LOW VOLTAGE FIELD --- FIELD GND 2 2 FLASHES=PRESSURE SWITCH STUCK CLOSED HI VOLTAGE(115V) — FIELD SPLICE 3 3 FLASHES=PRESSURE SWITCH STUCK OPEN HI VOLTAGE FIELD --- 4 4 FLASHES=OPEN HIGH LIMIT JUNCTION y SWITCH(TEMP) o-ra -F 1� 5 5 FLASHES=FLAME SENSE WITHOUT GAS VALVE IGNITER �� 6 6 FLASHES= OPEN ROLLOUT OR OPEN FUSE TERMINAL -O' � INTERNAL TO SWITCH(PRESS) r G V 7 7 FLASHES=LOW FLAME SIGNAL INTEGRATED CONTROL - B 8 FLASHES =CHECK IGNITER OR IMPROPER GROUNDING OVERCURRENT CONTINUOUS/RAPID FLASHES=REVERSED 115 VAC POLARITY PLUG CONNECTION -EZD- PROT DEVICE COLOR CODES PK PINK NOTES 1 SET HEATNTIGPATOR ON ROOM THERMOSTATAT 0 TAMPS _ YLYELLOW BRBROWN 2 MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING OR ORANGE WH WHITE 31FNY OFTHE ORIGINALWIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED,ITMUST BE REPLACED WITH WIRING MATERIAL PU PURPLE BLBLUE HAVING ATEMPERATURE RATING OF AT LEAST 105*C USE COPPER CONDUCTORS ONLY GREEN GYGRAY 4 IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME,DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS UNUSED GN GI BLACK RD RED BLOWER LEADS MUST BE PLAGEDON'PNK'TERMINALS OF INTEGRATED CONTROL OR TAPED 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES RECN OBYNO FLAT INPUTS) 0140FOO663 REV.A 6 BOTANHE AST 5 FAULTS 5T RECENT TO LEAST RECENT,DEPRESS SWITCH FOR MORE THAN i SECONDS WHILE IN Wiring Is subject to change.Always refer to the wiring diagram on the unit for the most up-to-date wiring. 47 V R J WIRING DIAGRAM GCH95 / GCHQ GMH950905CX r {IdFlEP , INTEGRATED 1 CONTROLMOOULE TR(SI C GND(S) GND GAS MVC(9) HI ALVE I MVH(12) PM V VAC OR COOPER ANGIMYWTC(M�S I 4UMIDIFIER GY DOOR OMPARTMEN- I 24 VAC Ip PEN WHEN I I MV1I2) NO O 10 VA v FRONT COVEfR I TRANSFORMER <JG PS 110) PRESSURE SWITCH 24V THERMOSTAT 1 iiS VAC �(�II TO P8O q J CONNECTIONS J `r I MICRO HLI(7)' r— C O R W V N HLO(1) NO BK m AUIDRFSELPiMAw G i UMTCONRi0. m R ID ELOPER R02(11) PRESSURE FUSE OR " swlrcH __GY_ g R01 I6) PU MNAINRESET—JT f" } INTEGRATED GR LMITCON7RO0) Z_ Ca CONTROL TM(S) 151NGLECONIROLON/50TUI MODULE c H IF ri GR 40 VA TRANSFORMER F0 oEufk n GY OR DR XFMR41 115VAC UI C3 .E* RD BR —� FLAME SENSOR _Z O �FSATGY J = DE"* OR FSI HOT SURFACE LLI Q *FACTORYSETTINGS IGNITER r W SHOWN FS ,,, WH LGN , DIAGNOSTIC LL O IS g O LEo WH [ $ ID m >. Fil ND MUIR Z W = + LXxor NEr'.- M 13 S I 14,0 EA GSEE uxE-n g I r o U W ? ND NOTE Wa J WH 111) ;o COOLJI CIRCULATOR 8 0, DB O BL(MED) RD P�@ GY A 5 N BLwR I � Ix } M OR(MED LOW) S p in Q RD(LOW) Y O W BK /ELECTRONIC LL a CELI1LER m J i AIR CLEANER F l� m Ln W BR BR ELOVVEP YL A EACH W V UI jf^�j\ LINE-H W = M OAPACITOR A JUNCTION BOX 0 D@-GY rrE L', a BLOWER COMPARTMENT SWITCH J W Fr = QBURNER COMPARTMENT A,WARNING Q W DISCONNECT POWER DISCONNECT f- O a GND BEFORE SERVICING J U a O WIRINGTO UNIT LLI W W. BK MUSTBE Z a a H WH PROPERLY = O )- U) POLARIZED INDUCED DRAFT AND GROUNDED E V J BLOWER L GND Q WH TO 115VAC/10/SO HZ POWER SUPPLY WITH _ V UTO RESET LIMIT ENI Y y Y OVERCURRT PROTECTION DEVICE PRIM RIrLQ\`+'lam—PU CONTROL BL Z YL RD OR �OR �Z \% PKD li WH N c l AYlARNING DISCONNECT POWER BEFORE Q IO BLOWER MANUAL RESET ROLLOUT LIMIT CON-ROL(S) SERVICING WIRING TO UN IT MUST BE PRESSURE 24 VAC (SINGLECONTROLON 45K BTU) 9L BOX UNCJU TION PROPERLY POLARIZED AND GROUNDED SWITCH HUMIDIFIER FRONTCOVER _ PRESSURE SW ITCH .�.++ r , zm�, ® CONNECTOR T PM GY GY H�qq�L �f I� N _ CONNECTOR GND —GR ty T T-1II GND m HOT HI R BKA r ��F L SURFACE IGNITER C BR FLAME - I Dom.I 11 GAS VALVE (HONEYWELL) ENSOR L J STEADY ON NORMAL OPERATION LOW VOLTAGE(24V) EQUIPMENT GND 147 OFF =CONTROL FAILURE LOW VOLTAGE FIELD L FIELD GND 1FLASH =SYSTEM LOCKOUT(RETRIESEXCEEDEO) 2FLASHES=PRESSURE SWITCH STUCK CLOSED HI VOLTAGE(115V) FIELD SPLICE LL/ 3FLASHES=PRESSURE SWITCH STUCK OPEN HI VOLTAGE FIELD SWITCH(TEMP) D-ZV a 4 FLASHES=OPEN HIGH LIMIT JUNCTION 4- r�1 5FLASHES=FLAME SENSE WITHOUT GAS VALVE TERMINAL -0- IGNITER�n- BFLA SHIES =OPEN ROLLOUT OR OPEN FUSE INTERNAL TO SWITCH(PRESS.) rGV T 7 FLASHES=LOW FLAME SIGNAL e FLASHES=CHECK IGNITER OR IMPROPER GROUNDING INTEGRATED CONTROL OVERCURRENT PLUG CONNECTION �- PROT DEVICE S CONTINUOUSARAPID FLASHES REVERSED 115 VAC POLARITY COLOR CODES' PK PINK YL YELLOW SR BROWN ISETHEAT ArvnaP 1104RCOMTHERMOSTATAT-FE OR ORANGE WH WHITE ]MANUfACIURER55FELIRED REPLACEMENT PARTS MUST BE USED WHEN EERNCMG BL BLUE IFAWOFTHEOWGINALWIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED,R MUST BE REPLACED WITH WWNG MATERIAL HAVING ATEMPEPATURE PU PURPLE WING OFATLEAST�OS'G USE COPPERCONDLCTORS ONLY GN GREEN GY GRAY 4 PHEATMGMD000HNGBLOWERSPEEDSARENOTTH MEOISCARDJUMPERBEFOREWNNECTINOBLOWERLEADSUMISFDBLOWERLEADSMUWBE BK BLACK RD RED PL 80 ON'PARK'TERMINALS OF NREGRATED CONTROL OR TAPED 0140F0102 -B S UNRMUST BE PERMANENTLY GROUNDED AND CONFORM TO N E G AND LOCAL CODES Wiring is subject to change.Always refer to the wiring diagram on the unit for the most up-to-date wiring. 48 i WIRING DIAGRAM GME95 BLOWER 24 VAC OR coMPARH.�NT r — — �IDIFIER INTEGRATED HUMIDIFIER GV DOCRSNITCH 1 CONTROL MODULE (OPEN WHEN ITR(6) 24 VAC DOOR OPEN) ND C GAS 40 VA GNE 8 HI VALVE 24V THERMOSTAT TRANSFORMER MVC(B) CONNECTIONS 1115 VAC MVH(12) PM -J ID BLOWER C G R W Y IMVL(2)N C PRESSURE BK H FRONT COVER SWITCH mA PRESSURE SW ITCH < I PS 10 C NO O FUSE a PKR Gy— T TO HLI(7) NLO(1) INTEGRATED 6 5 4 OR y l I CONTROL y •MANUALRESETO AUTO SET MODULE s s BL O PRIMPftY ON OFF GR i IRO2(11) UMB 12 11 1 VL STAGE OR IR �RO1(5) CONTROL �v IM DELAY OR MANUALRESETROLLOUT OY i LBJITCOMROL(5) NODE BR 0 TH(3) (SINGLE24VACL ON45K BTU) O OFF OR Gv DELAY 40 VA I'^ } 'k FACTORY SETTINGS TRANSFORMER S.KOf'•�(W.N FS W XFMR+I 115 VAC DIAONOS7Ic sa ; FLAME SENSOR U) LED NOTED A 2 S—WH-1FS F Q 115 VAC HOT AND PARK TERMINALS 1 I HOT SURFACE 1GNIlE ZOO corn-n HEAT-H BK AGN SEE LINE-H z J F = GND W NOTE 4 G) Q Q 0 D z J D BK(HI) PK o z n IND I BLW Z ? Q 0: BL(MED HI) 55 O C'LL Q OR(MED) 3 p NFO Q F } RD(MED LOW) BK O I dry V1 Z YL(LOW) 3 O OOL-H CIRCULATOR U y Z dRLL1MIXt >7 c �V BLWR > Q' BLOWER B' CL Q p V) PU I �ELECTRONIC� O Q BLOWER COMPARTMENT— EACH 4R CLEAN_E5 BURNER COMPARTMENT LINE-H I.L. U) CL MANUAL RESET JUNCTION BOX G' W U ONTOAUXILIARYLIMITS r,T r, ) G' MU L (1)IN UPFLOW DOOR ` 8K BLOWER DECK SWITCH 1 QQQ WH 0. N INDUCED DRAFT A WARNING W J W } BLOWER DISCONNECT POWER UE J LU F WH BEFORE SERVICING DISCONNECT Q Q �j Lou: AUTO RESET WiRNGTOUNIT < F O a PRIMARY UNIT PU MUSTBE J (,) CL Q CONTROL PROPERLY z a ED a BL ANDGGR UUNDED L GNO I Q F to RD OR YL�OR TO 116VACI 10160 HZ POWER SUPPLY WITH (7 j N F( /y OVERCURRENT PROTECTION DEVICE 15 2WH A I MANUAL RESET ROLLOUT LIMIT CONTROLIS MWARNWG DISCONNECT POWER BEFORE ID BLOWER ) SERVICING WIRING TO UNIT MUST BE v PRESSURE 24 VAC I SINGLE CONTROL ON 45K BTU) BL UONXTION PROPERLY POLARIZED AND GROUNDED, Z SWITCH HUMIDIFIER FRONT COVER a fi NO PRESSURE SWITCH 2 CIRCUIT JPMGY GV HCONNECTOR � T-ill GNDHOTSURFACE Oct K ��F LIGNITER OR ETNSOR DISCONNECT VALVE HONEYWELL 0 STEADY ON=NORMAL OPERATION OFF =CONTROL FAILURE LOW VOLTAGE(24V) EQUIPMENT ONO I 1FLASH = SYSTEM lOCKOUTSRETRIES EXCEEDED) LOW VOLTAGE FIELD FIELD ONO { 2 FLASHES=PRESSURE SWITCH STUCK CLOSED HI VOLTAGE(115V) FIELD SPLICE CJ 3 FLASHES=PRESSURE SWITCH STUCK OPEN HI VOLTAGE FIELD a 4 FLASHES=OPEN HIGH LIMB JUNCTION 4. SWITCH(TEMP) Or--CO SPLASHES=FLAME SENSE WITHOUT GAS VALVE IGNITER -Z"n'2- s 6FLASHES= OPEN ROLLOUT OR OPEN FUSE TERMINAL -0-7FLASHES=LOW FLAME SIGNAL INTERNAL TO SWITCH(PRESS) --Jr. s 6 FLASHES=CHECK IGNITER OR IMPROPER GROUNDING INTEGRATED CONTROL OVERCUR ,�, PLUG CONNECTION •-m- PROT.DEVICE C CONTINUOUS/RAPID FLASHES v REVERSED 115 VAC POLARITY COLOR CODES PK PINK NOTES YL YELLOW BRBROWN 1,SET HEAT ANTICIPATOR ON ROOM THERMOSTATAT O.T AMPS OR ORANGE WH WHITE 2,MANUFACTURERS SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING PU PURPLE BL BLUE 3 IFANY OF THE ORIGINAL WIREAS SUPPLIED WITH THE FURNACE MUST BE REPLACED,IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105'C USE COPPER ON GREEN GY GRAY CONDUCTORS ONLY BK BLACK RD RED 4 BLOWER SPEEDS SHOULD SEADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE CORRECT CFM(SEE SPEC SHEET FOR AIR FLOW CHART) 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES 6 TO RECALL THE LAST 5 FAULTS,MOST RECENT TO LEAST RECENT,DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY(NO THERMOSTAT INPUTS) 0140F01115 REV A Wiring is subject to change Always refer to the wiring diagram on the unit for the most up-to-date wiring. 49 SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight(8)feet above grade directly In line VENT/FLUE with the exhaust vent terminal for the horizontally vented TEE gas fueled heating appliance or equipment The sign shall read, in print size no less than one-half(1/2) inch In size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 4 INSPECTION. The state or local gas Inspector of the side COMBUSTION DISTANCE BETWEEN wall horizontal) vented as fueled equipment shall not AIR Y 9 KE. VENT AND GRADE approve the installation unless, upon inspection, the DISTANCE BETWEEN/ Inspector observes carbon monoxide detectors and signage COMBUSTION AIR INTAKE AND GRADE Installed in accordance with the provisions of 248 CMR ,i� 5 08(2)(a)1 through 4. EXEMPTIONS The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4• 1. The equipment listed in Chapter 10 entitled "Equipment For all side wall horizontally vented gas fueled equipment Installed Not Required To Be Vented" in the most current edition of in every dwelling, budding or structure used in whole or In part for NFPA 54 as adopted by the Board, and residential purposes, Including those owned or operated by the 2 Product Approved side wall horizontally vented gas fueled Commonwealth and where the side wall exhaust vent termination • equipment installed In a room or structure separate from is less than seven (7) feet above finished grade in the area of the the dwelling, building or structure used in whole or in part venting, including but not limited to decks and porches, the follow- for residential purposes Ing requirements shall be satisfied: (c) MANUFACTURER REQUIREMENTS-GASEQUIPMENT VENTING SYSTEM PROVIDED.When the manufacturer 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At of Product Approved side wall horizontally vented gas the time of Installation of the side wall horizontal vented gas equipment provides a venting system design or venting fueled equipment, the installing plumber or gasfitter shall system components with the equipment, the instructions observe that a hard wired carbon monoxide detector with provided by the manufacturer for installation of the an alarm and battery back-up is installed on the floor level equipment and the venting system shall include where the gas equipment is to be installed. In addition, the 1. Detailed Instructions for the Installation of the venting system installing plumber or gasfitter shall observe that a battery design or the venting system components, and operated or hard wired carbon monoxide detector with an 2. A complete parts list for the venting system design or venting alarm Is installed on each additional level of the dwelling, system. building or structure served by the side wall horizontal vented (d) MANUFACTURER REQUIREMENTS-GAS EQUIPMENT gas fueled equipment It shall be the responsibility of the VENTING SYSTEM NOT PROVIDED When the property owner to secure the services of qualified licensed manufacturer of a Product Approved side wall horizontally professionals for the installation of hard wired carbon vented gas fueled equipment does not provide the parts monoxide detectors for venting the flue gases, but identifies "special venting a. In the event that the side wall horizontally vented gas fueled systems", the following requirements shall be satisfied equipment is installed In a crawl space or an attic, the by the manufacturer. hard wired carbon monoxide detector with alarm and 1. The referenced "special venting system" instructions shall battery back-up may be installed on the next adjacent be included with the appliance or equipment installation floor level Instructions, and b In the event that the requirements of this subdivision can 2 The "special venting systems" shall be Product Approved not be met at the time of completion of installation, the by the Board, and the Instructions for that system shall owner shall have a period of thirty (30) days to comply include a parts list and detailed installation instructions with the above requirements; provided, however, that during said thirty(30)day period,a battery operated carbon (e) A copy of all installation instructions for all Product monoxide detector with an alarm shall be installed. Approved side wall horizontally vented gas fueled 2 APPROVED CARBON MONOXIDE DETECTORS Each equipment, all venting instructions, all parts lists for carbon monoxide detector as required in accordance with venting instructions, and/or all venting design instructions the above provisions shall comply with NFPA 720 and be shall remain with the appliance or equipment at the ANSI/UL 2034 listed and IAS certified completion of the installation. 50 THIS PAGE LEFT INTENTIONALLY BLANK 51 NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE. Quality Makes the Difference! "All of our systems are designed and manufactured with the same high quality standards regard- less of size or efficiency. We have designed these units to significantly reduce the most frequent causes of product failure. They are simple to service and forgiving to operate. We use quality materials and components. Finally, every unit is run tested before it leaves the factory. That's why we know. . . There's No Better Quality." Visit our web sites at www.goodmanmfg.com or www.amana-hac.com forinformation on: • Products • Warranties • Customer Services • Parts • Contractor Programs and Training • Financing Options ©2006-2012 Goodman Manufacturing Company, L.P. 52