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GAMA Gas-Fired Furnace User's Information Manual

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INSTALLATION AND SERVICING
INSTRUCTIONS
AND
USER'S INFORMATION MANUAL
**INSTALLER — AFFIX THIS INSTRUCTION
PACKET ADJACENT TO THE FURNACE.
**HOMEOWNER — RETAIN THESE
INSTRUCTIONS FOR FUTURE REFERENCE.
INSTRUCTIONS D'ENTRETIEN ET
INSTALLATION
ET
MANUEL DE L'USAGER
**INSTALLATEUR -- PLACEZ LA POCHETTE
D'INSTRUCTIONS À COTÉ DU GÉNÉRATEUR
D'AIR CHAUD.
**PROPRIÉTAIRE -- CONSERVEZ CES
INSTRUCTIONS POUR Y RÉFÉRER PLUS TARD.
LITERATURE BOOKLET NO. 20557401
ISSUE 0442
20536912

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  • Page 1 INSTALLATION AND SERVICING INSTRUCTIONS USER'S INFORMATION MANUAL **INSTALLER — AFFIX THIS INSTRUCTION PACKET ADJACENT TO THE FURNACE. **HOMEOWNER — RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE. INSTRUCTIONS D'ENTRETIEN ET INSTALLATION MANUEL DE L'USAGER **INSTALLATEUR -- PLACEZ LA POCHETTE D'INSTRUCTIONS À COTÉ DU GÉNÉRATEUR D'AIR CHAUD.
  • Page 2 Owner Record Furnace Model # Serial # Installation Date INSTALLED BY: Dealer Address Telephone # License # Contact Person Other Equipment Installed: Equipment Type Model # Serial # Installation Date Equipment Type Model # Serial # Installation Date Equipment Type Model # Serial # Installation Date...

  • Page 3: Table Of Contents

    • Do not touch any electrical switch; do GAMA Certified not use any phone in your building. • Leave the building immediately. The Gas Appliance Manufacturers Association (GAMA) • Immediately call your gas supplier from symbol verifies that Annual Fuel Utilization Efficiency a neighbor's phone.

  • Page 4: Safety

    Do not use this furnace if any part has been under water. For your safety - A flood-damaged furnace is extremely dangerous. Read before operating Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect Here are a few "Do's and Don'ts"...

  • Page 5: Temperature Control

    11. Set the thermostat to the desired setting. Fan Operation You may wish to increase your comfort by setting your 12. If the furnace will not operate, follow the instructions system for continuous air circulation of the indoor air. in "To Turn Off Gas to Furnace" and call your The fan switch on the thermostat permits you to do this.

  • Page 6: Maintenance Of Your Furnace

    authorized dealer at once to obtain a qualified service Maintenance Of Your Furnace inspection: • Rust, flakes, or other deposits • Coatings • Corrosion Always shut off all power to the unit before attempting any of the following maintenance Even if no unusual rust or other conditions are observed, procedures.

  • Page 7: Cleaning/Replacing The Filter

    Your furnace may use either a disposable filter, permanent filter, electronic or high efficiency media air cleaner. Consult filter/cleaner manufacturer In all direct vent (two pipe) instances, the vent maintenance service and static pressure drop for air outlet shall be installed so as to be in the same moving requirements.

  • Page 8: Parts Replacement Information Guide

    Make sure the condensate drain line does not become blocked or plugged. Visual inspection of condensate flow can easily be made while the furnace is operating. Use a flashlight to illuminate discharge end of the condensate drain that is placed in the sewer opening. The furnace will not operate properly if condensate drain line becomes blocked or plugged.
  • Page 9 AFFIX LABEL HERE INSTALLATION INSTRUCTIONS UPFLOW OR LEFT HORIZONTAL TWO STAGE HEAT VARIABLE SPEED GAS-FIRED CONDENSING WARM AIR FURNACE Issue 0442 TABLE OF CONTENTS Safety ......... . . Gas Connections .

  • Page 10: Safety

    See page 11 for Ducting. 9. A gas-fired furnace for installation in a residential garage must be installed as specified in The Location / Placement section on page 6 of these instructions.

  • Page 11: Furnace Specifications

    FURNACE SPECIFICATIONS AIR INLET UNIT DIMENSIONS DUCT MAX. OVER MAX. ELECTRICAL TEMPERATURE DUCT SUPPLY & VENT RETURN CURRENT UNIT SUPPLY MIN. RISE WEIGHT OPENING CONNECTION MODEL LENGTH WIDTH HEIGHT OPENING PROTECTION AMPS WIRE SIZE(AWG) RANGE DIA.* EV050U3 29 1/2 13 1/2 47 3/8 11 1/2 18 15/16 21 5/8...
  • Page 12 BLOWER MOTOR SPECIFICATIONS AND AIRFLOW ADJUSTING DATA Adjusting Airflow HEAT SETTING COOL SETTINGS MOTOR BLOWER MODEL ADJUST HEAT COOL CFM @ .50 STATIC WHEEL HEATING CFM ADJUSTMENT SETTING "A" SETTING "B" SETTING "C" SETTING "D" NORM NORM 1200 1000 EV050U3 10 X 6 ( + ) 1380...

  • Page 13: Furnace Wiring Specifications

    FURNACE WIRING SPECIFICATIONS 20558801 Issue 0442 Page 5 of 32...

  • Page 14: Introduction

    The furnace cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. The unit must also be electrically grounded in accordance with local codes, or in the absence of local codes, with the latest edition of the (U.S.) National Electrical Code ANSI/NFPA No. 70 or CSA Standard C22.1;...
  • Page 15 If furnace is tilted back condensate will collect in the Failure to comply with all of the clearances will secondary heat exchanger which will result in create a fire hazard. improper combustion, fire hazard, or other unsafe conditions which could result in property damage, personal injury or death.

  • Page 16: Air For Combustion And Ventilation

    AIR FOR COMBUSTION AND VENTILATION Contaminated Combustion Air: allows for the combustion air to be supplied directly If the furnace is to be installed in a structure defined to the furnace from the outdoors. Ventilation needs as having contaminated combustion air, the furnace must only to be considered when furnace is installed as use the direct vent (two pipe) configuration using non- direct vent (two pipe).
  • Page 17 If ventilation and/or combustion air must be supplied to the "Confined Space" from inside the building structure, two permanent openings to an additional room of sufficient volume as to combine the volumes of the spaces to meet the criteria for an "Unconfined Space" must be created. Each opening must have a free area of not less than one square inch per 1000 Btu per hour of total input of all appliances within the "Confined Space"...
  • Page 18 Figure 4 When horizontal ducts are used to supply air from the outdoors, they must be of the same cross sectional area CONFINED SPACE / OUTDOOR AIR as the free area of the openings to which they connect. FROM ATTIC The minimum dimension of rectangular air ducts must not be less than 3 inches.

  • Page 19: Ducting

    DUCTING The proper sizing of warm air ducts is necessary to insure satisfactory heating operation. Ductwork should be in accordance with the latest editions of (U.S.) NFPA-90A (Air Conditioning Systems) and NFPA-90B (Warm Air Heating and Air Conditioning Systems) or Canadian equivalent. viewed for possible openings using light assistance or Ductwork Recommendation: The supply duct work should be attached to the...

  • Page 20: Venting

    When installing the furnace with cooling equipment for year round operation, the following recommendations The coil MUST be installed on the air discharge must be followed for series or parallel air flow: side of the furnace. Under no circumstances 1. In series flow applications, the coil is mounted after should the air flow be such that cooled, conditioned the furnace in an enclosure in the supply air stream.
  • Page 21 Figure 8 VENT TERMINATION CLEARANCES...
  • Page 22 Horizontal (Side Wall) Vent Termination: The optional concentric vent termination kit (2" To prevent blockage of the combustion air and diameter Part No. 20280901 / Cat. No. 87L83 or 3" exhaust vent by snow, vent termination must be made 12" diameter Part No.
  • Page 23 The vertical vent system can be installed through an Figure 16 existing chimney provided that: CONCENTRIC VENT VERTICAL MOUNTING a. No other appliance is vented into the chimney. b. The vent system does not terminate within the chimney and the termination clearances shown in Figure 14 are maintained.
  • Page 24 TABLE 4 4. All pipe should be supported using clamps and/or straps. These supports should be at least every four Allowable Max Vent Lengths for 3" Diameter Venting (4) feet, or as required by local codes. 5. All horizontal vent runs must be sloping upwards to * Allowable Max Vent Lengths of 3"...
  • Page 25 Installation of Air Inlet Connector: 2. Remove horizontal condensate opening knockout The air inlet connector must be installed on the top from left side of cabinet as shown in Figure 22 panel of the furnace (See Figure 19). The connector and mounting screws are shipped in the vestibule of the 3.
  • Page 26 Figure 21 Condensate Disposal Drain: This furnace must use the condensate trap supplied UPFLOW TRAP with the unit (See Figures 17 and 18) for proper drain installation. The drain must terminate at a floor drain, sewer system, or drain vent for proper condensate removal.

  • Page 27: Electrical Connections

    ELECTRICAL CONNECTIONS When installed, the furnace must be electrically Single Stage Thermostat Operation: grounded in accordance with local codes or, in the The automatic heat staging option allows a single stage absence of local codes, with the (U.S.) National Electrical thermostat to be used with a two stage furnace.
  • Page 28 This furnace is manufactured for use with Natural gas and must be converted using the proper LP conversion kit FIRE OR EXPLOSION HAZARD for use with LP (Propane) gas. For LP (Propane) gas, a tank regulator is required to reduce supply pressure to Failure to follow the safety warnings exactly could 12"-13"w.c.

  • Page 29: Control Board & Variable Speed Motor Features

    CONTROL BOARD & VARIABLE SPEED MOTOR FEATURES Other features of this variable speed motor include: Humidifier Connections: Terminals are provided on the blower control board for connections to a 120-volt optional humidifier. The "HUM" Soft Start: terminal is energized whenever the thermostat calls for The variable speed motor will slowly ramp up to normal heat.

  • Page 30: Unit Sequence Of Operation

    UNIT SEQUENCE OF OPERATION Here's How Your Heating System Works: Standby Mode When the control is in standby mode, it continually Should overheating occur, or the gas supply fail to monitors thermostat input, rollout switch, and flame shut OFF, turn OFF the manual gas valve to the sense.
  • Page 31 STARTUP AND OPERATIONAL CHECKOUT 6. The hot-surface ignitor will heat-up to an "orange" glow, the main burners will ignite. Do not use this furnace as a construction heater. Use of this furnace as a construction heater Figure 28 exposes the furnace to abnormal conditions, TYPICAL FLAME APPEARANCE contaminated combustion air and the lack of air (MAIN BURNERS)
  • Page 32 10.0" w.c. (2 stage). After proper adjustments, Example: reconnect violet wire and furnace should go up to 2 3.50"w.c. Gas valve outlet pressure tap reading stage high fire. Turn OFF gas, replace manifold pressure -.15"w.c. Burner box inlet pressure (hose not connected) 3.65"w.c.
  • Page 33 4. Calculate the furnace input using the following Altitude Derating: formula: The following information is provided as guidelines for altitude derating and is not meant to supersede any state BTUH = Cubic Ft/Hr x BTU/Cubic Foot or local codes. Local codes have priority over any others and in some case might limit your options in dealing with The local gas supplier should be able to provide the an altitude derate situation.
  • Page 34 The switch is located behind the burner access door. Removing the burner access panel from the furnace, and Hand drilling of orifices is never acceptable since it reset by pushing in the button in the middle of the switch could lead to delayed ignition, overfiring, improper (between the two wire connections - See Figure 31).
  • Page 35 the homeowner how to operate the furnace system before Figure 32 leaving the job site. PRESSURE SWITCH LOCATION AND CONNECTION If the pressure switch activates to shut the furnace down, the vent and drain systems must be checked and cleared. Failure to do so may result in serious bodily harm or nuisance furnace shutdown and/or a hazardous condition that may lead to property damage, personal injury or death.

  • Page 36: Sequence Of Operation

    SEQUENCE OF OPERATION DIRECT IGNITION SYSTEM CONTROL 20558801 Issue 0442 Page 28 of 32...

  • Page 37: Servicing The Furnace

    SERVICING THE FURNACE 7. Turn on utilities and check for leaks using soapy water and a brush. ELECTRICAL SHOCK, FIRE OR EXPLOSION 8. A visual check of the main burner should be made at HAZARD the beginning of each heating season. 9.
  • Page 38 4. Remove the burner access panel by removing the necessary to disconnect the electrical supply and seven (7) No. 10 sheet metal screws that secure the thermostat wiring from the control board. 6. Remove the blower retaining screws from the front of panel to the cabinet.

  • Page 39: Control System Diagnostics

    CONTROL SYSTEM DIAGNOSTICS Troubleshooting Table 9 Make the following visual checks before toubleshooting: Failure Codes - Red LED 1. Check to see that the power to the furnace and the integrated ignition/blower control board is ON. Fault Description Status 2. The manual shutoff valves in the gas line to the No power to control or control hardware fault LED Off detected...

  • Page 40: Wiring Diagram

    WIRING DIAGRAM 20558801 Issue 0442 Page 32 of 32...

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