background image

3

T

O

 

PREVENT

 

PERSONAL

 

INJURY

 

OR

 

DEATH

 

DUE

 

TO

 

IMPROPER

 

INSTALLATION

ADJUSTMENT

ALTERATION

SERVICE

 

OR

 

MAINTENANCE

REFER

 

TO

 

THIS

 

MANUAL

. F

OR

 

ADDITIONAL

 

ASSISTANCE

 

OR

 

INFORMATION

CONSULT

 

A

 

QUALIFIED

 

INSTALLER

SERVICER

 

AGENCY

 

OR

 

THE

 

GAS

 

SUPPLIER

.

WARNING

I

F

 

THE

 

INFORMATION

 

IN

 

THESE

 

INSTRUCTIONS

 

IS

 

NOT

 

FOLLOWED

 

EXACTLY

A

 

FIRE

 

OR

 

EXPLOSION

 

MAY

 

RESULT

 

CAUSING

 

PROPERTY

DAMAGE

PERSONAL

 

INJURY

 

OR

 

LOSS

 

OF

 

LIFE

.

D

O

 

NOT

 

STORE

 

OR

 

USE

 

GASOLINE

 

OR

 

OTHER

 

FLAMMABLE

 

VAPORS

 

AND

 

LIQUIDS

 

IN

 

THE

 

VICINITY

 

OF

 

THIS

 

OR

 

ANY

 

OTHER

 

APPLIANCE

.

D

O

 

NOT

 

TRY

 

TO

 

LIGHT

 

ANY

 

APPLIANCE

.

D

O

 

NOT

 

TOUCH

 

ANY

 

ELECTRICAL

 

SWITCH

DO

 

NOT

 

USE

 

ANY

 

PHONE

 

IN

 

YOUR

 

BUILDING

.

I

MMEDIATELY

 

CALL

 

YOUR

 

GAS

 

SUPPLIER

 

FROM

 

A

 

NEIGHBOR

S

 

PHONE

. F

OLLOW

 

THE

 

GAS

 

SUPPLIER

S

 

INSTRUCTIONS

.

I

F

 

YOU

 

CANNOT

 

REACH

 

YOUR

 

GAS

 

SUPPLIER

CALL

 

THE

 

FIRE

 

DEPARTMENT

.

I

NSTALLATION

 

AND

 

SERVICE

 

MUST

 

BE

 

PERFORMED

 

BY

 

A

 

QUALIFIED

 

INSTALLER

SERVICE

 

AGENCY

 

OR

 

THE

 

GAS

 

SUPPLIER

.

WHAT TO DO IF YOU SMELL GAS:

WARNING

T

HIS

 

PRODUCT

 

CONTAINS

 

OR

 

PRODUCES

 

A

 

CHEMICAL

 

OR

 

CHEMICALS

 

WHICH

 

MAY

 

CAUSE

 

SERIOUS

 

ILLNESS

 

OR

 

DEATH

 

AND

 

WHICH

 

ARE

 

KNOWN

 

TO

 

THE

 S

TATE

 

OF

 C

ALIFORNIA

 

TO

 

CAUSE

 

CANCER

BIRTH

 

DEFECTS

 

OR

 

OTHER

 

REPRODUCTIVE

 

HARM

.

WARNING

H

EATING

 

UNIT

 

SHOULD

 

NOT

 

BE

 

UTILIZED

 

WITHOUT

 

REASONABLE

ROUTINE

INSPECTION

MAINTENANCE

 

AND

 

SUPERVISION

. I

F

 

THE

 

BUILDING

 

IN

 

WHICH

 

ANY

 

SUCH

 

DEVICE

 

IS

 

LOCATED

 

WILL

 

BE

 

VACANT

CARE

 

SHOULD

 

BE

 

TAKEN

 

THAT

 

SUCH

 

DEVICE

 

IS

 

ROUTINELY

 

INSPECTED

MAINTAINED

 

AND

 

MONITORED

IN

 

THE

 

EVENT

 

THAT

 

THE

 

BUILDING

 

MAYBE

 

EXPOSED

 

TO

 

FREEZING

 

TEMPERATURES

 

AND

 

WILL

 

BE

 

VACANT

ALL

 

WATER

-

BEARING

 

PIPES

 

SHOULD

 

BE

 

DRAINED

THE

 

BUILDING

 

SHOULD

 

BE

 

PROPERLY

 

WINTERIZED

AND

 

THE

 

WATER

 

SOURCE

 

CLOSED

IN

 

THE

 

EVENT

 

THAT

 

THE

 

BUILDING

 

MAY

 

BE

 

EXPOSED

 

TO

 

FREEZING

 

TEMPERATURES

 

AND

 

WILL

 

BE

 

VACANT

ANY

 

HYDRONIC

 

COIL

 

UNITS

 

SHOULD

 

BE

 

DRAINED

 

AS

 

WELL

 

AND

IN

 

SUCH

 

CASE

ALTERNATIVE

 

HEAT

 

SOURCES

 

SHOULD

 

BE

 

UTILIZED

.

WARNING

T

O

 

PREVENT

 

POSSIBLE

 

PROPERTY

 

DAMAGE

PERSONAL

 

INJURY

 

OR

 

DEATH

 

DUE

 

TO

 

ELECTRICAL

 

SHOCK

THE

 

FURNACE

 

MUST

 

BE

 

LOCATED

 

TO

 

PROTECT

 

THE

 

ELECTRICAL

 

COMPONENTS

 

FROM

 

WATER

.

WARNING

Drain trap must be primed at time of installation.  Trap is
internally partitioned; add water to both inlet ports until wa-
ter appears at both sides of the outlet opening. Failure to
prime trap at time of installation may have a negative ef-
fect on combustion quality and pressure switch action.

S

AFETY

  C

ONSIDERATIONS

Adhere to the following warnings and cautions when install-
ing, adjusting, altering, servicing, or operating the furnace.
To ensure proper installation and operation, thoroughly read
this manual for specifics pertaining to the installation and
application of this product.

This furnace is manufactured for use with natural gas. It
may be field converted to operate on L.P. gas by using the
appropriate L.P. conversion kit listed in the

 PROPANE GAS/

HIGH ALTITUDE INSTALLATIONS section

 of this manual

Install this furnace only in a location and position as speci-
fied in 

LOCATION REQUIREMENTS & CONSIDERATIONS sec-

tion and INSTALLATION POSITIONS section 

of this manual.

Provide adequate combustion and ventilation air to the fur-
nace as specified in 

COMBUSTION & VENTILATION AIR RE-

QUIREMENTS section of this manual.

Combustion products must be discharged to the outdoors.
Connect this furnace to an approved vent system only, as
specified in 

VENT/FLUE PIPE & COMBUSTION AIR PIPE

 sec-

tion of this manual.

Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the detec-
tion of leaks to check all connections, as specified in 

GAS

SUPPLY AND PIPING

 section of this manual.

Always install a furnace to operate within the furnace’s in-
tended temperature-rise range with a duct system which has
external static pressure within the allowable range, as speci-
fied on the furnace rating plate and 

OPERATIONAL CHECKS

section

 of these instructions.

When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space contain-
ing the furnace, the return air shall also be handled by duct(s)
sealed to the furnace casing and terminating outside the
space containing the furnace.

A gas-fired furnace for installation in a residential garage
must be installed as specified in the 

LOCATION REQUIRE-

MENTS AND CONSIDERATIONS

 

section

 of this manual.

This furnace may be used as a construction site heater only
if certain conditions are met. These conditions are listed in
the 

PRODUCT APPLICATION

 

section

 of this manual.

FROZEN AND BURST WATER PIPE HAZARD
F

AILURE

 

TO

 

PROTECT

 

AGAINST

 

THE

 

RISK

 

OF

 

FREEZING

 

MAY

 

RESULT

 

IN

 

PROPERTY

 

DAMAGE

.

S

PECIAL

 

PRECAUTIONS

 MUST 

BE

 

MADE

 

IF

 

INSTALLING

 

FURNACE

 

IN

 

AN

 

AREA

 

WHICH

  

MAY

 

DROP

 

BELOW

 

FREEZING

. T

HIS

 

CAN

 

CAUSE

 

IMPROPER

 

OPERATION

 

OR

 

DAMAGE

 

TO

 

EQUIPMENT

.  I

F

 

THE

 

FURNACE

 

ENVIRONMENT

 

HAS

 

THE

 

POTENTIAL

 

OF

 

FREEZING

THE

 

DRAIN

 

TRAP

 

AND

 

DRAIN

 

LINE

 

MUST

 

BE

 

PROTECTED

. T

HE

 

USE

 

OF

 

ACCESSORY

 

DRAIN

 

TRAP

 

HEATERS

ELECTRIC

 

HEAT

 

TAPE

 

AND

/

OR

 RV 

ANTIFREEZE

 

IS

 

RECOMMENDED

 

FOR

 

THESE

 

INSTALLATIONS

.

CAUTION

Summary of Contents for *CSS920402BN

Page 1: ...ETY PRECAUTION is a registered trademark of Maytag Corporation or its related companies and is used under license All rights reserved TABLE OF CONTENTS SAFETY CONSIDERATIONS 3 SHIPPING INSPECTION 4 EL...

Page 2: ...RAP PRIMING 33 FURNACE OPERATION 33 GAS SUPPLY PRESSURE MEASUREMENT 34 GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT 34 GAS INPUT RATE MEASUREMENT NATURAL GAS ONLY 35 TEMPERATURE RISE 36 CIRCULATOR...

Page 3: ...ns when install ing adjusting altering servicing or operating the furnace To ensure proper installation and operation thoroughly read this manual for specifics pertaining to the installation and appli...

Page 4: ...ome loose in transit In the event of damage the consignee should 1 Make a notation on delivery receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspectio...

Page 5: ...for use with natural or propane gas NOTE If using propane a propane conversion kit is required Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as...

Page 6: ...ing combustion products outdoors through a proper venting system Special consideration should begiventovent fluepiperoutingandcombustionairintakepipewhenapplicable Referto Vent FluePipeandCombustion A...

Page 7: ...snecessary useanaccessory subbase seeSpecificationSheetapplicableforyourmodelfordetails Aspecialaccessorysubbasemustbeusedforupright counterflow unit installations over any combustible material includ...

Page 8: ...any unused openings in the venting system 2 Inspect the venting system for proper size and horizontal pitch as required by the National Fuel Gas Code ANSI Z223 1 or the Natural Gas and Propane Install...

Page 9: ...back drafting or improper combustion of gas fired appliances thereby exposing building occupants to gas combustion products that could include carbon monoxide If this furnace is to be installed in th...

Page 10: ...tothefurnacesidepanel suspendingitbelowthefurnace Aminimum clearance of 5 5 below the furnace must be provided for the drain trap Additionally the appropriate downward piping slope must be maintained...

Page 11: ...all vent flue piping and connectorsarecompatiblewithfurnaceflueproducts Additionally itistheresponsibilityoftheinstallertoensurethatallpipingand connections possess adequate structural integrity and s...

Page 12: ...n from a 2 to 3 pipe in a horizontal section of pipe as this may create a water trap PREFERRED TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE TO AVOID CREATING A WATER TRAP IN VENT PIPING ACCE...

Page 13: ...orted Vent FluePipe The vent pipe outlet is sized to accept 2 pipe Secure vent flue pipe directly into the furnace fitting with the appropriate glue Alternately a small section of 2 pipe may be glued...

Page 14: ...r outlet 5 Install cut end of the flanged section and connect to inducer with rubber coupling supplied with furnace 6 Install screws removed in step 1 securing flange to cabinet THE RUBBER ELBOW IS NO...

Page 15: ...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 NOTE Terminate both pipes in the...

Page 16: ...Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal Combustion Air Pipe Vent Pipe All piping and fittings must be joined per material manufacturer s s...

Page 17: ...termining the number of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable insu...

Page 18: ...Refer to the directions furnished with the Side Wall Vent Kit p n 0170K00000S or 0170K00001S for installation specifica tions CONDENSATE DRAIN LINES DRAIN TRAP A condensing gas furnace achieves its hi...

Page 19: ...ed horizontally require the trap to be relocated Many drain hoses have a built in grommet which will provide a cabinet seal when installed See instructions below for your model and installation positi...

Page 20: ...Remove the trap and two hoses from the blower deck 4 Remove the two plugs from the right side of the cabinet and install them in the blower deck 5a Draining the Vent Elbow Locate hose 2 factory instal...

Page 21: ...e the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side o...

Page 22: ...clamps 7 Fasten the drain trap to the cabinet with two screws removed in step 2 8 Refer to Field Supplied Drain section for instructions on field supplied installed drain on outlet of furnace trap COU...

Page 23: ...e observed when making field connections Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a left side right side for counterflows...

Page 24: ...ig ured for a left side electri cal connection To make electrical connections through the opposite side of the furnace the junction box must be relocated to the left side prior to making electrical co...

Page 25: ...The 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...

Page 26: ...valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size Thefollowingstipulationsapplywhenconnect...

Page 27: ...rd Gas Line Hole Ground Joint Pipe Union Ground Joint Pipe Union NOTE Union may be inside furnace cabinet where allowed by local codes COUNTERFLOW Figure 32 Drip Leg Plug in Main Gas Line Hole Alterna...

Page 28: ...sulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kP...

Page 29: ...g plate for the maximum ESP ex ternal duct static rating Total external static refers to everything external to the fur nace cabinet Cooling coils filters ducts grilles registers must all be considere...

Page 30: ...s retaining the sheet metal over the duct opening Using tin snips cut the metal strips and remove the sheet metal covering the duct opening In the corners of the open ing cut the sheet metal along the...

Page 31: ...BN 2 10 X 20 or 1 16 X 25 Top Return CSS9 0804CN 2 10 X 20 or 1 16 X 25 Top Return CSS9 1005CN 2 14 X 20 or 1 20 X 25 Top Return CSS961205DN 2 14 X 20 or 1 20 X 25 Top Return Other size filters of equ...

Page 32: ...11 5 2 X 1600 CFM 2 16 in X 25 in x 5 AM11 3225 5 AM11 3225 AM11 5PP AM11 5 AM11 5RA AM11 5PP Family Family Family Upright Installations Depending on the installation and or customer preference differ...

Page 33: ...uipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Move the furnace gas valve manual control to the OFF position 6 Wait five minutes then sme...

Page 34: ...2 gas valve then use the 36G J Valve Pressure Check Kit Part No 0151K00000S 3 TurnONthegassupplyandoperatethefurnaceandallothergasconsuming appliances on the same gas supply line 4 Measure furnace gas...

Page 35: ...s to gas conversion consult your dealer for appropriate conversion GAS INPUT RATE MEASUREMENT NATURAL GAS ONLY The actual gas input rate to the furnace must never be greater than that specified on the...

Page 36: ...stalled with the furnace If the cooling capacity is in BTU hr divide it by 12 000 to convert capacity to tons Example Cooling Capacity of 30 000 BTU hr 30 000 12 000 2 5 Tons 2 Determine the proper ai...

Page 37: ...rol module monitors flame presence Gas valve will remain open only if flame is detected Circulator blower is energized on heat speed following a thirty 30 second blower on delay 96 models 115 VAC EAC...

Page 38: ...rmally closed electrically automatic reset temperature activated sensor The limit guards against overheating as a result of insufficient conditioned air passing over the heat exchanger AUXILIARY LIMIT...

Page 39: ...e control is in standby mode no call for heat or cool press the FAULT RECALL switch for five to ten seconds or until the diagnostic LED begins to rapid flash When the switch is released the LED will t...

Page 40: ...e To remove 1 Turn OFF electrical power to furnace 2 Remove filter s from the central return register or ductwork 3 Replace filter s by reversing the procedure for removal 4 TurnONelectricalpowertofur...

Page 41: ...should be as indicated in the Specifications Sheet FLUE PASSAGES QUALIFIED SERVICER ONLY The heat exchanger flue passageways should be inspected at the beginning of each heating season BEFORE LEAVING...

Page 42: ...Loose or improperly connected wiring Pressure switch circuit not closed Induced draft blower is operat ing Induced draft blower runs continuously with no further furnace operation Integrated control m...

Page 43: ...5 5 FLASHES Short to ground in flame sense circuit Furnace fails to operate Integrated control module diagnostic LED is flashing SIX 6 flashes No furnace operation Rollout limit open Integrated contro...

Page 44: ...5 1084 1005 HIGH 5 0 2284 30 2231 31 2170 31 2103 32 2037 33 1945 1836 1750 MED 4 0 1865 37 1869 36 1775 38 1732 39 1684 40 1619 1548 1480 MED LO 3 5 1594 43 1571 43 1530 45 1492 46 1454 47 1414 1355...

Page 45: ...N A 610 N A 604 571 519 HIGH 5 0 2233 32 2159 33 2086 34 2024 35 1941 37 1850 1753 1651 MED 4 0 1820 39 1778 40 1742 41 1695 42 1638 43 1551 1485 1384 MED LO 3 5 1571 45 1535 46 1497 48 1446 49 1402...

Page 46: ...TIONS N E C CLASS 2 WIRE GR GND 115 VAC 24 VAC BLOWER COMPARTMENT DOOR SWITCH OPEN WHEN DOOR OPEN DOOR SWITCH WARNING DISCONNECTPOWER BEFORE SERVICING WIRING TO UNITMUSTBE PROPERLY POLARIZED AND GROUN...

Page 47: ...GND 115 VAC 24 VAC BLOWER COMPARTMENT DOOR SWITCH OPEN WHEN DOOR OPEN DOOR SWITCH WARNING DISCONNECTPOWER BEFORE SERVICING WIRING TO UNITMUST BE PROPERLY POLARIZEDAND GROUNDED BK GND DISCONNECT L N PO...

Page 48: ...tly mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or...

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