background image

12

AIR

 DISCHARGE

AIR

 DISCHARGE

AIR

 DISCHARGE

Bottom 
Return 

Duct 

Connection

Bottom 

Return 

Duct 

Connection

Bottom 

Return 

Duct 

Connection

Side

Return

Duct 

Connection

Side

Return

Duct 

Connection

UPFLOW
UPRIGHT

UPFLOW HORIZONTAL

RIGHT AIR DISCHARGE

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

ALTERNATE FLUE
PIPE LOCATION

ALTERNATE FLUE PIPE
LOCATION

AIR

 DISCHARGE

AIR

 DISCHARGE

AIR

 DISCHARGE

Bottom 

Return 

Duct 

Connection

Bottom 

Return 

Duct 

Connection

Bottom 
Return 

Duct 

Connection

COUNTERFLOW

UPRIGHT

COUNTERFLOW HORIZONTAL

RIGHT AIR DISCHARGE

COUNTERFLOW HORIZONTAL

LEFT AIR DISCHARGE

ALTERNATE FLUE AND
COMBUSTION AIR PIPE
LOCATIONS

ALTERNATE FLUE AND
COMBUSTION AIR PIPE
LOCATIONS

Recommended Installation Positions

NOTE:

 Alternate “vertical” piping connections can not be used when

an upflow furnace is installed with supply air discharging to the
right, or when a counterflow furnace is installed with supply air
discharging to the left.  In either case, use the standard flue and
combustion air piping connections.

A

LTERNATE

 E

LECTRICAL

 

AND

 G

AS

 L

INE

 C

ONNECTIONS

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.

D

RAIN

 P

AN

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).

F

REEZE

 P

ROTECTION

Refer to 

Section VII, Horizontal Applications and Conditions - Drain

Trap and Lines.

F

URNACE

 S

USPENSION

If the furnace is installed in a crawl space it must be suspended
from the floor joist or supported by a concrete pad.  Never install the
furnace on the ground or allow it to be exposed to water.  Refer to

Section IV, Location Requirements and Considerations - Furnace
Suspension

 for further details.

VIII. PR

VIII. PR

VIII. PR

VIII. PR

VIII. PRO

O

O

O

OP

P

P

P

PANE GA

ANE GA

ANE GA

ANE GA

ANE GAS /HI

S /HI

S /HI

S /HI

S /HIGH  AL

GH  AL

GH  AL

GH  AL

GH  ALTITUD

TITUD

TITUD

TITUD

TITUDE INST

E INST

E INST

E INST

E INSTALL

ALL

ALL

ALL

ALLA

A

A

A

ATI

TI

TI

TI

TIO

O

O

O

ONS

NS

NS

NS

NS

WARNING

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF

THE CORRECT CONVERSION KITS ARE NOT INSTALLED. 

T

HE APPROPRIATE KITS

MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. 

A

LL

CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE

AGENCY.

This furnace is shipped from the factory configured for natural gas
at standard altitude.  Propane gas installations require an orifice
change to compensate for the energy content difference between
natural and propane gas.
High altitude installations may require both a pressure switch and
an orifice change.  These changes are necessary to compensate
for the natural reduction in the density of both the gas fuel and the
combustion air at higher altitude.
For installations above 7000 feet, please refer to your  distributor
for required kit(s).

Altitude

Gas

Kit

Orifice

Manifold
Pressure

Pressure

Switch 

NOTE:  In Canada, gas furnaces are certified to 4500 feet.

0-7000

None

LPM-05

#43

#55

3.5" w.c.

10.0" w.c.

None

HIGH ALTITUDE GAS ORIFICE CHART

Natural

Propane

Contact the distributor for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude installa-
tions.  The indicated kits must be used to insure safe and proper
furnace operation.  All conversions must be performed by a quali-
fied installer, or service agency.

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

IX. VENT/FLUE PIPE & COMBUSTION AIR PIPE

G

ENERAL

WARNING

F

AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR

DEATH.  

C

AREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS

SECTION.

WARNING

U

PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE

ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT

IS PROPERLY SEALED.  

L

EAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS

PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS,

INCLUDING CARBON MONOXIDE.

A condensing gas furnace achieves its high level of efficiency by
extracting almost all of the heat from the products of combustion
and cooling them to the point where condensation takes place.
Because of the relatively low flue gas temperature and water con-
densation requirements, PVC pipe is used as venting material.
This furnace must not be connected to Type B, BW, or L vent or vent
connector, and must not be vented into any portion of a factory built
or masonry chimney except when used as a pathway for PVC as
described later in this section.  Never common vent this appliance
with another appliance or use a vent which is used by a solid fuel
appliance.  Do not use commercially available “no hub connec-
tors” other than those shipped with this product.
It is the responsibility of the installer to follow the manufacturers’
recommendations and to verify that all vent/flue piping and connec-
tors are compatible with furnace flue products.  Additionally, it is the
responsibility of the installer to ensure that all piping and connec-
tions possess adequate structural integrity and support to prevent
flue pipe separation, shifting, or sagging during furnace operation.

Summary of Contents for GCH9

Page 1: ...tall 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 s...

Page 2: ...ER VENT FLUE AND COMBUSTION AIR PIPING PRACTICES 13 TERMINATION LOCATIONS 13 CANADIAN VENTING REQUIREMENTS 14 STANDARD FURNACE CONNECTIONS 14 ALTERNATE FURNACE CONNECTIONS 14 NON DIRECT VENT SINGLE PI...

Page 3: ...XVIII Troubleshooting 32 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 32 DIAGNOSTIC CHART 32 FAULT RECALL 32 RESETTING FROM LOCKOUT 32 XIX Maintenance 32 ANNUAL INSPECTION 32 FILTERS 32 BURNERS 33 INDUCED...

Page 4: ...warranty certificate is also supplied with the unit Read the warranty carefully and note what is covered Keep the warranty cer tificate in a safe location for future reference If additional informatio...

Page 5: ...e 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...

Page 6: ...The input rate and temperature rise are set per the furnace rating plate 100 outside air is provided for combustion air requirements during construction Temporary ducting can be used II SAFETY II SAF...

Page 7: ...ly air opening and the combustible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is exposed t...

Page 8: ...tions of use g If improper venting is observed during any of the above tests the common venting system must be corrected halogen type refrigerants cleaning solutions such as perchloroethylene printing...

Page 9: ...ipping heavily insulated caulked vapor barrier etc addi tional air may need to be provided using the methods described in 5 3 3 b or 5 3 4 Space Unconfined For purposes of this Code a space whose volu...

Page 10: ...directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed...

Page 11: ...ropriate in stallation positions ductwork connections and resulting airflow arrangements VII HO VII HO VII HO VII HO VII HORIZO RIZO RIZO RIZO RIZONT NT NT NT NTAL APPLI AL APPLI AL APPLI AL APPLI AL...

Page 12: ...s require an orifice change to compensate for the energy content difference between natural and propane gas High altitude installations may require both a pressure switch and an orifice change These c...

Page 13: ...nt flue pipe and a combustion air intake pipe Refer to the appropriate section for details concerning piping size length number of elbows furnace connections and terminations MATERIALS AND JOINING MET...

Page 14: ...rd against inadvertent blockage COMBUSTION AIR PIPE DIRECT VENT INSTALLATIONS On upflow units secure the combustion air intake pipe directly to the air intake coupling On counterflow units secure the...

Page 15: ...LT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE 7 Upflow and Counterflow units For upright installations externally mount the rubber elbow to the ven...

Page 16: ...r of elbows in the piping system Pipe Size 4 inc 2 3 4 5 6 7 8 045_3 2 68 65 62 59 56 53 50 070_3 2 68 65 62 59 56 53 50 070_4 2 46 43 40 2 16 13 10 3 68 65 62 59 56 53 50 090_5 3 68 65 62 59 56 53 50...

Page 17: ...ter pipe can be used in place of 2 diameter pipe 4 Increased Clearance Configurations using 2 45 deg Long Sweep elbows should be considered equivalent to one 90 deg elbow VENT FLUE AND COMBUSTION AIR...

Page 18: ...furnace NOTE If the alternate vent flue 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 horizon...

Page 19: ...Hose B with green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to S...

Page 20: ...ht down side panel grommet holes Secure tubes to Hose A and Hose B using green hose clamps Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound For details...

Page 21: ...must be sized in accordance with the maximum overcurrent pro tection specified on the unit rating plate An electrical disconnect must be provided at the furnace location NOTE Line polarity must be ob...

Page 22: ...Blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control Remove the yellow wire and connect the supplied brown jumper wire to the pressure switch...

Page 23: ...plying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of the run The gas line installation must comply with local codes or in their absence wi...

Page 24: ...ctors and semi rigid tubing against physical and thermal damage when installed Ensure aluminum alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry...

Page 25: ...ne gas leak Rust can reduce the level of odorant in propane gas Do not rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence...

Page 26: ...uipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recom mended that a removable ac...

Page 27: ...bility of flue gases escaping through the drain system FURNACE OPERATION Purge gas lines of air prior to startup Be sure not to purge lines into an enclosed burner compartment Check for leaks using an...

Page 28: ...NT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR...

Page 29: ...rtially open position 2 Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchange...

Page 30: ...MODE DIP SWITCH IS SET TO 2 STG POSITION The normal operational sequence in sequence is as follows R and W thermostat contacts close initiating a call for heat Integrated control module performs safet...

Page 31: ...Y CIRCUIT DESCRIPTION XVII SAFETY CIRCUIT DESCRIPTION XVII SAFETY CIRCUIT DESCRIPTION XVII SAFETY CIRCUIT DESCRIPTION GENERAL A number of safety circuits are employed to ensure safe and proper furnace...

Page 32: ...e least recent fault RESETTING FROM LOCKOUT Furnace lockout results when a furnace is unable to achieve igni tion after three attempts during a single call for heat It is character ized by a non funct...

Page 33: ...AME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame...

Page 34: ...E LEA RE LEA RE LEAVIN VIN VIN VIN VING AN INST G AN INST G AN INST G AN INST G AN INSTALL ALL ALL ALL ALLA A A A ATI TI TI TI TIO O O O ON N N N N Cycle the furnace with the thermostat at least three...

Page 35: ...kage proper length elbows and termination Check drain system Correct as necessary Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Pressure switch hose blocked p...

Page 36: ...e due to improper gas pressure or combustion air Induced draft blower and circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 flashes F...

Page 37: ...NT COVER PRESSURE SWITCH N O C GY BK PLUG CONNECTION FIELD SPLICE SWITCH TEMP OR 24V THERMOSTAT CONNECTIONS GR GND 115 VAC 24 VAC BLOWER COMPARTMENT DOOR SWITCH OPEN WHEN DOOR OPEN DOOR SWITCH BK GND...

Reviews: