Heating & Air Conditioning ® C om fort. Q uality. Tru st. GAS FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS *GUCA/GCCA/GULA Installer: Affix all manuals adjacent to the unit. *Type FSP Category IV Direct or Non Direct Vent Forced Air Furnace. These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces. Part No. 10318740 Printed in USA DESIG N CE R T I F I E D CE R TI FIE D Goodman Company, L.P.
Table of Contents I. Component Identification .......................................................................................................................................... 5 II. Safety .......................................................................................................................................................................... 6 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ...................................................................................................
Table of Contents XII. Gas Supply and Piping ......................................................................................................................................... 27 GENERAL ........................................................................................................................................................................................................... 27 High Altitude Derate ..........................................................................................
WARNING If additional information or operating instructions are required, contact the dealer where the purchase was made. If the information in these instructions is not followed exactly, fire or explosion may result causing property damage, personal injury or loss of life.
I.
2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4.
WARNING IV. Location Requirements and Considerations Possible death, personal injury or property damage due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, repair, operation, or maintenance of this product. GENERAL WARNING To prevent possible death, personal injury, equipment damage, or property damage the following bullet points must be observed when installing the unit.
• • • • • Exposure to contaminated combustion air will result in safety and performance-related problems.
The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47-1998, CSA-2.3-M98 Section 1.23.1. The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation: DRAFTS OR DEAD SPOTS -BEHIND DOORS -IN CORNERS -UNDER CABINETS a.
The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section 5.3. 5.3.3 Equipment Located in Confined Spaces: (a) All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. 4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.
VI. Installation Positions LEVELING Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.
IX. Vent/Flue Pipe & Combustion Air Pipe ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace. GENERAL WARNING DRAIN PAN A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).
Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.
provided with this furnace (see “Standard Connections” figure). The rubber coupling allows separation of the vent/ flue pipe from the furnace during servicing. NOTE: Do not use other commercially available “no hub connectors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see Section IX, Materials and Joining Methods.
5. Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover). Counterflow units. Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (basepan). Plug remaining hole in blower deck with plastic plug included in the drain kit bag. 6. Upflow and Counterflow units. Insert cut section of vent/flue pipe and coupling into alternate vent/flue location.
3 REMOVE PIPE 1. REMOVE 4 SCREWS 1 REMOVE 4 SCREWS 3 REMOVE PIPE 3. Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (top cover). Counterflow units. Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (basepan). Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag. 4. Upflow and Counterflow units.
NON-DIRECT VENT (SINGLE PIPE) PIPING Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing.
12" MIN. Direct Vent (Dual Pipe) Maximum Allowable Length of Vent/Flue & Combustion Air Intake Pipe (ft) VENT/FLUE TEE or 90° ELBOW TURNED DOWN Unit Input (Btu) 45,000 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL 70,000 90,000 115,000 Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level 115,000 In a basement installation, the vent/flue pipe can be run between joist spaces.
90° Medium Radius Elbow 12" MIN Vent 3" MIN 24" MAX VENT/FLUE TEE 12" Min. 3" MIN 24" MAX Screen 24" Max. COMBUSTION AIR INTAKE 90º MEDIUM RADIUS ELBOW 24" Max. 3" Min. Air Intake 12" MIN 12" MIN SCREEN 12" Min. Above Highest Anticipated Snow Level Standard Horizontal Terminations (Dual Pipe) Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) In a basement installation, the pipes may be run between the joist spaces.
X. Condensate Drain Lines & Drain Trap UPRIGHT INSTALLATIONS In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet.
LEFT SIDE PANEL FRONT COVER DRAIN PORT RUBBER ELBOW RED HOSE CLAMP RUBBER ELBOW DRAIN PORT HOSE A RED HOSE CLAMP SIDE PANEL GROMMET HOLES Alternate Vent/Flue Drain Hose Connections Upright installations using the alternate vent/flue outlet will require “right-side only” drain hoses to be connected as follows. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection. TUBE 1 TUBE(S) 2 GREEN HOSE CLAMPS (3 PLACES) DRAIN TRAP HOSE B 1.
the following section. FRONT COVER DRAIN PORT Upright Drain Trap Mounting (Left or Right Side Panel) 1. Insert drain tubes into drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap. 2. Secure drain trap to side panel at the mounting holes (dimples or crosshairs on Counterflow models) located below the grommet drain holes. 3. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling.
3. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear left (down) side panel grommet holes. NOTE: For left side drainage, grommets must be relocated to left side panel. Hose B Tube 1 INDUCED DRAFT BLOWER DRAIN PORT HOSE B FRONT COVER PRESSURE TAP LEFT SIDE PANEL HOSE A Junction Box GREEN HOSE CLAMPS (3 PLACES) TUBE(S) 2 FRONT COVER DRAIN PORT Tube Installation with Green Hose Clamps DRAIN TRAP RED HOSE CLAMP Counterflow Units with a 16 1/2” cabinet width.
WARNING XI. Electrical Connections In upright upflow installations, the drain trap must be mounted on the opposite side of the unit from the junction box. This will reduce the risk of water reaching the junction box in the event of a blocked drain condition. WARNING To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) WARNING To avoid electrical shock, injury or death, disconnect electrical power before servicing, or changing any electrical wiring. * ALTERNATE JUNCTION BOX LOCATION * * * * * * * * STANDARD JUNCTION BOX LOCATION The furnace’s integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner.
XII. Gas Supply and Piping A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or an distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits. GENERAL The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied.
MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) GAS VALVE MANIFOLD MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) BURNERS ALTERNATE GAS LINE LOCATION PLUG IN ALTERNATE GAS LINE HOLE HEIGHT REQUIRED BY LOCAL CODE HEIGHT REQUIRED BY LOCAL CODE * * * * * * * * * GROUND JOINT PIPE UNION * * * * * GROMMET IN STANDARD GAS LINE HOLE * * * PLUG IN ALTERNATE GAS LINE HOLE ALTERNATE GAS LINE LOCATION * * * GAS VALVE GROMMET IN STANDARD GAS LINE HOLE MANIFOLD
Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size Pipe in Feet 1/2" 3/4" 1" 1 1/4" 10 132 278 520 1050 20 92 190 350 730 30 73 152 285 590 40 63 130 245 500 50 56 115 215 440 60 50 105 195 400 70 46 96 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.
Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or Nominal Pipe Size Tubing Tubing Size, O.D.
XIII. Circulating Air & Filters Propane Gas Tanks and Piping WARNING DUCTWORK - AIR FLOW Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D.
XIV. Startup Procedure & Adjustment UPRIGHT INSTALLATIONS Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Review and follow the filter sizes given in the Specifications Sheet to ensure proper unit performance.
Furnace Shutdown 1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. After a 60, 90, 120, or 180 second delay period (field selectable), the circulator blower will be de-energized. 2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position. 3. Close the manual gas shut-off valve external to the furnace. 4.
White-Rodgers 36G22 Gas Valve GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the unit OFF. To measure the gas supply inlet pressure, use the following procedure.
3. Connect a calibrated water manometer and 5/16 inch hose to the gas valve outlet pressure tap. Hose should overlap tap by 3/8 inch. 3. Turn ON system power and set thermostat to a call for heat. 4. Using a leak detection solution or non-chlorine soap suds, check for leaks at hose connection. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY! 5. Remove regulator screw cover. Turn regulator screw either clockwise to increase pressure or counterclockwise to decrease.
To adjust the circulator blower speed, proceed as follows: HEAT EXCHANGER RADIATION "LINE OF SIGHT" 1. Turn OFF power to the furnace. 2. Select the heating and cooling blower speeds that match the installation requirements from the airflow table in the Specification Sheet. 3. Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module. (Terminals are identified as HEAT and COOL (hot)).
Timing Chart for Normal Heating Mode CIRCULATOR BLOWER ON OFF GAS VALVE OPEN CLOSED IGNITER ON OFF PRESSURE SWITCH CLOSED OPEN CONTACTS INDUCED DRAFT BLOWER ON OFF THERMOSTAT ON OFF SECONDS t ign 0 IGNITER WARM UP PERIOD (see note) t circ 0 FIXED HEAT ON DELAY: 30 SECONDS 15 [ 60,90, 120 or 180 WR50T55 HAS A FIXED 90-SECOND OFF DELAY NOTE: WHITE-RODGERS 50A55 or 50T55 INTEGRATED CONTROL MODULE HAS A VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN A 17-SECOND MAXIMUM AND A FIVE-SECOND M
• Furnace circulator blower and outdoor cooling unit run, XV. Normal Sequence of Operation • POWER UP The normal power up sequence is as follows: • • • • • • • 115 VAC power applied to furnace. Integrated control module performs internal checks. Integrated control module flashes LED one time. Integrated control module monitors safety circuits continuously. Furnace awaits call from thermostat.
PRIMARY LIMIT The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger. If the primary limit control does not function during this test, the cause must be determined and corrected. Function of this control should be verified by gradually blocking the furnace return air after the furnace has been operating (burners firing) for approximately ten minutes. Check the control as follows: XVII.
3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 0 - 20 seconds. NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to Section XVIII, Troubleshooting - Diagnostic Chart for aid in determining the cause. XVIII.
Troubleshooting Chart Symptoms of Abnormal Operation Associated LED Code2 • Furnace fails to operate. • Integrated control module diagnostic LED provides no signal. NONE Fault Description(s) • No 115 volt power to • Manual disconnect switch furnace, or no 24 volt OFF, door switch open, or power to integrated 24 volt wires improperly control module. connected or loose. • Blown fuse or circuit • Blown fuse or circuit breaker. breaker. • No signal from thermostat. • Furnace fails to operate.
Troubleshooting Chart Symptoms of Abnormal Operation Associated LED Code2 • Circulator blower runs continuously. No furnace 4 operation. • Integrated control module diagnostic LED 4 FLASHES is flashing FOUR (4) flashes. Fault Description(s) • Primary or auxiliary limit circuit is open. Possible Causes • Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower. • Loose or improperly connected wiring.
Filter Removal Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register, the bottom of the blower compartment (upflow only) or a side panel external filter rack (upflow only). A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Specifications Sheet must be followed to ensure proper unit performance. Refer to the following for removal and installation of filters.
XX. Before Leaving an Installation CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) Annually inspect the drain tubes, drain trap, and fieldsupplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary. • Cycle the furnace with the thermostat at least three • FLAME SENSOR (QUALIFIED SERVICER ONLY) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor.
