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USER'SINFORMATIONMANUAL ] CONDENSINGGASFURNACE Fire or explosion hazard . Information in this manual MUST be followed exactly . Failure to follow the information in this manual exactly could result in property damage , bodily injury , or death . Do not store or use gasoline or other flammable vapors and liquids in the vi - 0 cinity of this or any other appliance . _ m WHAT TO DO IF YOU SMELL GAS Q Do not try to light any appliance . Q Do not touch any electrical switch ; do not use any phone in your building . Q Immediately evacuate the building and call your gas supplier from a phone outside the building . Follow the gas supplier's instructions . If you cannot reach your gas supplier , call the fire department . 25 - 20 - 66 Installation and service must be performed by a qualified installer , service agency or the gas supplier . Design Certified by A . G . A . 441 02 1301 01 ( 8 / 12 / 97 ) Replaces 441 02 1301 O0 Printed in U . S . A , International Comfort Products Corporation ( USA ) I anufactured by : I LP2 Lewisburg , TN USA 37091
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CondensingGas Furnace User's InformationManual Contents Danger , Warning and Caution . . . . . . . . . . . . . . . . 2 OperatingYour Unit . . . . . . . . . . . . . . . . . . . . . . . 5 Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Combustion Air ( Your safety ) . . . . . . . . . . . . . . . . 3 Danger Label Danger , Warning and Caution White lettering on a black background except the word DANGER which is white with a red background . The signal words DANGER , WARNING and CAUTION are used to identify levels of hazard seriousness . The sig - nal word DANGER is only used on product labels to signify an immediate hazard . The signal words WARNING and CAUTION will be used on product labels and throughout this manual and other manuals that may apply to the prod - uct . Signal Words DANGER - Immediate hazards which WILL result in se - vere personal injury or death . Warning Label WARNING - Hazards or unsafe practices which COULD White lettering on a black background except the word result in severe personal injury or death . WARNING which is black with an orange background . CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property dam - age . Signal Words in Manuals The signal word WARNING is used throughout this manu - al in the following manner : Caution Label White lettering on a black background except the word CAUTION which is black with a yellow background . The signal word CAUTION is used throughout this manual in the following manner : CAUTION ProductLabeling Signal words are used in combination with colors and / or pictures on product labels . Following are examples of product labels with explanations of the colors used . E3
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User's InformationManual CondensingGas Furnace 2 . Do not use this unit if any part has been under water . Immediately call a qualified service techni - Readthis manualandfollowits instructionsandadhere cian to inspect the unit and to replace any part of the to all Cautionsand Warningsinthe manualandon the control system and any gas control which has been unit . Consulta qualifiedservicetechnicianfor installa - under water . tion , adjustmentandmaintenance . 3 . Never obstruct the vent grilles , or any ducts that Failureto observeand followCautions , Warningsandry provide air to the unit . Air must be provided for instructionsmayresultinpropertydamage , bodilyinju or death . proper combustion and ventilation of flue gases . 4 . Familiarize yourself with the possible air starva - tion signals . These are outlined in the Combustion Air section . SafetyRules 5 . Check the combustion air supply . Some models Your unit is built to provide many years of safe and de - use air drawn from outside . Other models and other appliances use combustion air from inside the struc - pendable service providing it is properly installed and ture . Air starvation signals are listed in section titled maintained . However , abuse and / or improper use can " Combustion Air " . If any of the signals are noticed , shorten the life of the unit and create hazards for you , the perform a combustion air check as shown in section owner . titled " Combustion Air Checks " or call a service tech - nician . If you add weather stripping , storm windows , A . The U . S . Consumer Product Safety Commission insulation , an additional fuel burning appliance , or recommends that users of gas - burning appliances remodel the structure , a combustion air check install carbon monoxide detectors . There can be MUST be accomplished after the addition . various sources of carbon monoxide in a building or . Maintain safety and service clearances from the dwelling . The sources could be gas - fired clothes unit . These are listed on the Rating Plate on the unit dryers , gas cooking stoves , water heaters , furnaces , and in the " Installation Manual " . Keep the unit area gas - fired fireplaces , wood fireplaces , and several other items . Carbon monoxide can cause serious clean and free of combustible materials at all times . bodily injury and / or death . Therefore , to help alert Never store gasoline , paint , aerosol cans , waxes , people of potentially dangerous carbon monoxide bleaches , dry cleaning fluid or items such as paper levels , you should have carbon monoxide detectors or rags near the unit . listed by a nationally recognized agency ( e . g . Un - 7 . Familiarize yourself with all controls . Make sure derwriters Laboratories or International Approval you know how to shut off the gas and the electrical Services ) installed and maintained in the building or power to the unit . If the unit is to be shut down for an dwelling ( see Note below ) . extended length of time ( example ; remodeling proj - B . There can be numerous sources of fire or smoke in a ect ) , turn off both the gas and the electrical power . building or dwelling . Fire or smoke can cause seri - For safety , always turn them off before performing ous bodily injury , death , and / or property damage . service or maintenance on the unit . Therefore , in order to alert people of potentially dan - . Establish a regular service and maintenance gerous fire or smoke , you should have fire and schedule . This will ensure efficient and safe opera - smoke detectors listed by Underwriters Laborato - ries installed and maintained in the building or dwell - tion of the unit . It is recommended that you have a qualified service agency perform a complete check ing ( see Note below ) . on the unit before each heating season . See unit Maintenance " Service Technician Checks " . Note : The manufacturer of your furnace does not test any detectors and makes no representations regarding . Inspect insulation . Insulation is combustible . If any brand or type of detector . your furnace is located in an attic or other space near insulation , periodically inspect to insure space C . To ensure safe and efficient operation of your unit , around furnace is free and clear of insulating materi - you should do the the following : al . If furnace is newly installed , make a through check around furnace . If adding insulation to a space with a furnace , also check that furnace is free Thoroughly read this manual and labels on the and clear of insulating material . unit . This will help you understand how your unit op - erates and the hazards involved with gas and elec - 10 . Keep air openings clear . Do not block any air tricity . openings on the furnace , openings connecting to furnace area , and spaces around the furnace .
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CondensingGas Furnace User's InformationManual appliance , or remodel the structure , a combustion air CombustionAir ( Your Safety ) check MUST be accomplished after the addition . Makethe inspectionas follows : 1 . Close all doors and windows . If you have a fireplace , All fuel - burning appliances must be provided with start a fire and wait until flames are burning vigorous - enough fresh air for proper combustion and ventilation ly . of flue gases . 2 . Turn on all exhausting devices , such as : kitchen and Some models use air from the space in which they are bathroom exhaust fans and dryers ( gas or electric ) . located , and other appliances in the same space may 3 . Turn on all vented gas appliances , such as : heating also be using indoor air for ventilation and / or combus - tion . equipment ( includes any room heaters ) and water heaters . Lack of combustion air will result in carbon monoxide 4 . Wait ten ( 10 ) minutes for drafts to stabilize . gas which could cause serious bodily injury or death . 5 . On appliances with a draft hood , check for spillage by holding a lighted match 2 inches from the draft New materials and methods are being used in construc - hood opening . Reference Figure 1 which shows a tion and remodeling which result in lower energy costs for water heater draft hood . heating and cooling . It may also mean your appliances may not be getting enough air for combustion and ventila - Figure 1 1 Water Heater Draft Hood tion of flue gases . The use of exhaust fans , fireplaces , clothes dryers , and other appliances consume air or vent it outside . Vent Pipe ' ' _ I . . . . Draft If the appliances or heating unit can't get enough air , two Typical Gas _ - - _ Hood conditions may result : Water Heater 1 . The appliance or heating unit may produce carbon Match monoxide gas . Carbon monoxide or " CO " is a colorless and odor - less gas produced when fuel is not burned com - A . Match flame pulls toward draft hood . pletely or when the flame does not receive sufficient This indicates no spillage and that appliance is get - oxygen . ting enough air for combustion . Return exhausting 2 . The appliance may not vent flue gases properly . devices and appliances to the condition you found The following are signs that your appliances may not be them . getting enough air for proper combustion . B . Match goes out or flame wavers away from draft hood . This indicates spillage and that appliance is Be aware of these signals ; not getting enough air for combustion . 1 . Headaches - Nausea - Dizziness 2 . Excessive humidity - Heavily frosted windows or a moist " clammy " feeling in the structure . Draft hood spillage means there is not enough air for proper combustion and carbon monoxide may 3 . Smoke from the fireplace won't draw up the be present . chimney . Keepa window open ( aminimum of 2 " ) near the ap - pliance until a permanentair duct is installed . Con - tact a qualified service agency . If you experience headaches , nausea , or dizziness , Carbon monoxide poisoning can result in serious carbon monoxide may be present . bodily injury or death from asphyxiation . Leavethe house immediately andcall your gas sup - plier . Carbon monoxide poisoning can result in serious If draft hood spillage is indicated : bodily injury or death from asphyxiation . 1 . Check for plugged flue connectors and chimneys . Repair stoppage and test again . CombustionAir Checks 2 . If you have a fireplace , open a window or door near If any of the signals are noticed , perform a combustion air the fireplace and then check for spillage . If spillage check or call a service technician . If you add weather strip - stops , do not use the fireplace until you can supply fresh air by a permanent duct . ping , storm windows , insulation , an additional fuel burning
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User's InformationManual CondensingGas Furnace 3 . If you have kitchen and bathroom exhaust fans , turn air intakes must be installed to provide air directly to them OFF and check for spillage . the area around the unit . These MUST comply with If spillage stops , do not use exhaust fans until you local and state building codes or in their absence can supply fresh air by a permanent duct . Circuit with the National Fuel Gas Code NFPA 54 / ANSI breakers for fans should be turned off . Z223 . 1 , current edition or in Canada the National Standard CAN / CGA 1 - B149 . 4 . Spillage means air starvation and a fresh air duct or Component Locations Figure 2 Representative drawing only , some models may vary in appearance . Furnace Vent Pipe Air Intake Pipe ( Outside Air ) White Rodgers Gas Valve Rubber _ Optional on all models • _ / Fan / Delay Control CoSDupwohoitnrcIghn _ _ terloc _ _ k _ _ _ _ J _ _ J , _ _ . _ " / ' / _ / . _ Mounted on Blower ) _ _ - 02 / _ _ j Pressure _ 4L _ Switch _ - - _ " / Manual Gas ' _ - ' > _ , , . _ I / _ / Shut - off Honeywell _ _ j / _ Gas Valve _ Combustion / _ > : _ Air Blower f / * _ " ' _ - . . * _ 7 _ . Condensate / _ _ _ Trap _ _ _ GasValve Sight Glass / _ / 25 - 21 - 13A TurningOff The Unit OperatingYour Unit Set the thermostat to the lowest setting or set System Se - Keep the blower access door and all access panels in lect Switch to OFF if equipped . place except for inspection or maintenance . If furnace is to be turned off for an extended period of time , Before starting your unit be sure you read and understand electricity and gas should be turned off to furnace . all of the procedures in this manual . Check to make sure Please refer to label on unit for detailed instructions to turn the unit filter is clean and correctly installed . off gas to appliance . Should overheating occur or the gas supply fail to shut off , shut off the manual gas valve to the unit be - L P ModelUnits fore shutting off the electrical supply . Ifyour L . P . ( liquefied petroleum ) gas unit is installed in a an excavated or low lying area , we recommend that you con - tact your L . P . supplier about installing a warning device Carbon monoxide Poisoning Hazard . that would alert you of a gas leak . Provisions for combustion and ventilation air must be provided for in accordance with installa - tions instructions supplied with unit . Failure to provide adequate combustion and ven - Fire or explosion hazard . tilation air can result in personal injury and / or L . P . gas is heavierthan air . Leaking gas can settle in death . lowareas such as a crawlspace . If yoususpect the presence of gas , follow the instructions onthe cov - er of this manual . StartingUnit Please refer to " lighting instructions " or " operating Failure to observe could result in property damage , instructions " label on furnace for detailed instruc - bodily injury or death . tions on starting the furnace .
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CondensingGas Furnace User's InformationManual Air Filters FreezingTemperaturesAnd Your Structure Your unit is equipped with safety devices that may keep it The air filter ( s ) should be inspected at least monthly and from operating if sensors detect abnormal conditions such cleaned or replaced as required . There are two types of fil - as clogged exhaust flues . ters that are commonly used . The most widely used is the If your unit remains shut off during cold weather the water Fiberglass disposable type which should be REPLACED pipes could freeze and burst , resulting in serious water before it becomes clogged . The other type is the washable damage . type constructed of aluminum mesh , foam , or reinforced fibers . Washable filters may be cleaned by soaking in mild Ifthe structure will be unattended during cold weather you detergent and rinsing with water . should take these precautions . 1 . Turn off main supply water into the structure and drain the water lines if possible . Open faucets in ap - propriate areas . Fire hazard from dust and lint buildup on internal 2 . Have someone check the structure frequently dur - unit parts . ing cold weather to make sure it is warm enough to Never operate unit without a filter installed . prevent pipes from freezing . Suggest they call quali - fied service agency , if required . Failure to observe could result in bodily injury or death . Unit Maintenance Remember that dirty filters are the most common cause of Have your unit inspected and serviced on an annual basis inadequate heating or cooling performance . ( before the heating season ) by a qualified service techni - cian . Electrical shock hazard . Turn off electric power to unit before performing any maintenance or removing panels or doors . Failure to observe could result in bodily injury or death . Recommended Filter Sizes Figure 3 Recommended Filter Sizes Unit Size Nominal Air Flow Sq . In . Surface Area / Nominal Size ( inches ) Cubic Feet Heating Input 1000 x Btuh per Minute ( CFM ) Cleanable Filters Disposable Filters 40 - 50 800 - 900 500 or 20 x 25 350 or 14x25 40 - 50 , 75 , and 100 900 - 1100 600 or 20 x 30 350 or 14x25 1100 - 1300 350 or 14x25 40 - 50 , 75 , and 100 350 or 14 x 25 ( 2Req , ) 1300 - 1500 75,100 , and 125 400 or 16 x 25 ( 2Req . ) 400 or 16 x 25 ( 2Req . ) 100 and 125 1500 - 1700 500 or 20 x 25 500 or 20 x 25 ( 2 Req . ) 125 1900 - 21 O0 500 or 20 x 25 600 or 20 x 30 ( 2 Req . ) 150 2300 - 2500 720 or 24 x 30 600 or 20 x 30 ( 2 Req . ) ReplacementFilters Figure 3 lists recommended sizes and types of filters that or on the outside on either side of the unit . A plastic end - cap is inserted in the filter rack after the filter is installed . may be used with your unit , based on the input rating and Btuh . The endcap keeps air from escaping around the open end of the filter rack . See Figure 4for filter rack , filter and end - Replacement filters should be of the same type and size cap locations . as the originals , to ensure adequate air flow and filtering . Filter racks attached to the unit are made so the filter sim - A disposable low velocity filter though , can be replaced with a washable high velocity type . Do not replace a high ply slides out one side for removal . velocity filter with a disposable low velocity filter . 1 . Remove the endcap from the filter rack . 2 . Slide the filter out of the filter rack . Filter Replacement - Upflow and Horizontal 3 . Inspect the filter ( s ) and replace or clean washable These units come with a filter rack and filter . The filter rack types . If filter is aluminum mesh it should be re - may be installed in the bottom of the blower compartment , coated with filter coating spray .
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User's InformationManual CondensingGas Furnace Reinstall the filter in the filter rack . 5 . Inspect the filter ( s ) and replace or clean washable types . If filter is aluminum mesh it should be re - Some filters are marked with an arrow to indicate coated with filter coating spray . the proper direction of air flow through the filter . The air flow direction will be towards the blower 6 . Reinstall the filter in the filter rack . motor . Make sure filter is installed correctly . Some filters are marked with an arrowto indicate the proper direction of air flow through the filter . Figure 4 Filter Racks The air flow direction will be towards the blower motor . Make sure filter is installed correctly . 7 . Reinstall compartment door . Side Mounted Filter Rack 8 . Turn on the gas and electrical power to the furnace . Return Air Duct Figure 6 l Main Burner Filter Endcap Filter in bottom of Unit Endcap X 10 - 10 - 78 5 . Reinstall the endcap in the filter rack . PilotFlame Filter Replacement - Counterflow While the main burner is ON , the flame should envelop the These units come with a filter rack and filters . The filter upper part of the Flame Sensor , as shown in FIGURE 6A . rack should be installed in the top of the unit . To remove filter , refer to Figure 5 for the following steps . Contact a qualified service agency at once if an abnor - mal flame appearance is identified . I Figure 5 [ Counterflow Filter Replacement Figure 6A J Pilot Burner for Honeywell Left Flame Sensor Pilot Burner Right Side 10 - 10 - 74a 25 21 16 Lubrication 1 . Turn off the gas and electrical power to the furnace . The circulating blower motor and combustion air blower 2 . Remove compartment door . do not require lubrication . 3 . Reach up above right side of blower and lift dirty fil - ters out of rack at top of furnace . Monthly Inspection A properly adjusted gas unit should not require cleaning at 4 . Straighten up filters and pull straight down at side of blower . Pull out through right side of door opening . frequent intervals , but it should be inspected regularly to
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CondensingGas Furnace User's InformationManual 7 . Inspect pilot flame ( if equipped ) . While main burner ensure safe and efficient operation . A brief monthly in - is on , the flame should envelop the upper part of the spection is recommended that does not require disassem - flame sensor as shown in Fig ure 6A . Contact a qual - bly . In addition you should have the unit inspected , and ified service technician if an abnormal flame appear - cleaned if required , by a qualified service technician annu - ance is identified . ally . . Inspect the drain line and overflow line monthly . If a Note : Step 7 is only required for furnaces equipped with a condensate neutralizer cartridge is used and be - pilot . Your unit may or may not have a pilot . Furnaces with comes plugged , the condensate will flow through the overflow line . If this happens , clean both cartridge a pilot will have a metal tube attached to the gas valve . Fol - and drain lines . To clean , disconnect and unscrew low the metal tube to the pilot . The pilot is located between end cap from cartridge . Pour the neutralizer out and two of the burners . flush neutralizer and inside of cartridge with water . 1 . Check the vents to be sure they are clear and free of Pour neutralizer back , adding neutralizer if cartridge obstructions . is less than 3 / 4 full . See replacement parts for neutralizer . 2 . Check that the vent connector is in place , slopes up - ward away from furnace , and is physically sound ServiceTechnicianChecks without holes or excessive corrosion . 3 . Check return air duct to make sure it is sealed to unit When the unit is being inspected for condition and opera - casing , terminates outside the space containing the tion have the Service Technician check the following furnace , and that it is in good physical condition . items . 4 . Inspect the unit base . All supports for furnace should 1 . Check that adequate combustion air is being sup - be structurally sound without sags , cracks , gaps , plied to the unit by the air openings into or from the etc . between the furnace and the base . unit . 5 . Remove the front panel and use a flashlight to in - 2 . Check all flue gas passages including main and pilot spect the visible part of the heat exchanger and main burners , heat exchanger , and vent . burners . Check for loose soot and give particularor attention to obvious deterioration from corrosion 3 . Check gas pipe and all connections inside and lead - other sources . If soot or deterioration is found inside ing to the unit for leaks . the unit DO NOT OPERATE UNIT ; call a qualified 4 . Check electrical wiring and connections . service technician . 5 . Check supply and return air ducts for leakage , block - 6 . Inspect main burner flames for the following : age and connections to unit . • Stable and blue flames . Dust may cause orange 6 . Check circulating air blower wheel and motor . Clean tips or wisps of yellow , but flames must not have them if required . solid yellow tips . 7 . Perform an operational checkout on the unit to be • Flames extending directly from burner into sure safety controls function and that unit operates heat exchanger . properly . • Flames do not touch sides of heat exchanger . For additional information the Service Technician Ifabnormal flame appearance is identified do not op - can consult the Installation Instructions and applica - erate unit ; call a qualified service technician . ble Technical Support Manual for the unit .