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Integrated control module monitors flame presence.  Gas
valve will remain open only if flame is sensed.

Circulator blower is energized on heat speed following a fixed
thirty second blower on delay.  Electronic air cleaner terminals
are energized with circulator blower.

Furnace runs, integrated control module monitors safety
circuits continuously.

R and W thermostat contacts open, completing the call for
heat.

Gas valve closes, extinguishing flame.

Induced draft blower is de-energized following a fifteen
second post purge. Humidifier terminals are de-energized.

Circulator blower is de-energized following the heat off delay
period (selectable 90, 120, 150, 180; factory set at 150).
Electronic air cleaner terminals are de-energized.

Furnace awaits next call from thermostat.

C

OOLING

 M

ODE

The normal operational sequence in cooling mode is as follows:

R and Y thermostat contacts close, initiating a call for cool.

Integrated control module performs safety circuit checks.

Outdoor fan and compressor are energized.

Circulator blower is energized on cool speed following a fixed
five second on delay.  Electronic air cleaner terminals are
energized with circulator blower.

Furnace circulator blower and outdoor cooling unit run,
integrated control module monitors safety circuits
continuously.

R and Y thermostat contacts open, completing the call for
cool.

Outdoor fan and compressor are de-energized.

Circulator blower is de-energized following a fixed forty five
second cool off delay period.  Electronic air cleaner terminals
are de-energized.

Furnace awaits next call from thermostat.

F

AN

 O

NLY

 M

ODE

The normal operational sequence in fan only mode is as follows:

R and G thermostat contacts close, initiating a call for fan.

Integrated control module performs safety circuit checks.

Circulator blower is energized on heat speed.  Electronic air
cleaner terminals are energized.

Circulator blower runs, integrated control module monitors
safety circuits continuously.

R and G thermostat contacts open, completing the call for
fan.

Circulator blower is de-energized.  Electronic air cleaner
terminals are de-energized.

Furnace awaits next call from thermostat.

XVI. OPERA

XVI. OPERA

XVI. OPERA

XVI. OPERA

XVI. OPERATI

TI

TI

TI

TIO

O

O

O

ONAL CHECK

NAL CHECK

NAL CHECK

NAL CHECK

NAL CHECKS

S

S

S

S

B

URNER

 F

LAME

The burner flames should be inspected with the burner compart-
ment door installed.  A sight glass is provided for inspection pur-

poses.  Flames should stable, quiet, soft, and blue (dust may cause
orange tips but they must not be yellow).  Flames should extend
directly outward from the burners without curling, floating, or lifting
off.  Flames must not impinge on the sides of the heat exchanger
firing tubes.

Check the burner flames for: 
1. Good adjustment
2. Stable, soft and blue 
3. Not curling, floating, or lifting off. 

Burner Flame

P

RIMARY

 L

IMIT

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 fur-
nace has been operating (burners firing) for approximately ten min-
utes.  Check the control as follows:

1.

Allow the furnace to operate with burners firing continuously
for approximately ten minutes.

2.

Gradually block the return air to furnace.  Remove airflow
blockage when limit control is activated and turns off burners.
Airflow blockage causes unit overheating and will produce
the following reactions:

• The gas valve to close and extinguish flame,
• The induced draft blower to deenergized after a fifteen

second postpurge, and

• The circulator blower to remain energized continuously

until limit control resets.

3.

Remove the return air blockage to clear overheating condition.
After an acceptable temperature is reached during the cool
down period, the limit control will reset and allow the furnace
to resume normal operation.

These checks establish that the primary limit control is functioning
and will respond to a restriction in the return air, or a circulator blower
failure.  If the primary limit control does not function during this test,
the cause must be determined and corrected.

XVII. SAFET

XVII. SAFET

XVII. SAFET

XVII. SAFET

XVII. SAFETY CIR

Y CIR

Y CIR

Y CIR

Y CIRCUIT DESCRIPTI

CUIT DESCRIPTI

CUIT DESCRIPTI

CUIT DESCRIPTI

CUIT DESCRIPTIO

O

O

O

ON

N

N

N

N

G

ENERAL

A number of safety circuits are employed to ensure safe and proper
furnace operation.  These circuits serve to control any potential safety
hazards and serve as inputs in the monitoring and diagnosis of ab-
normal function.  These circuits are continuously monitored during
furnace operation by the integrated control module.

I

NTEGRATED

 C

ONTROL

 M

ODULE

The integrated control module is an electronic device which, if a
potential safety concern is detected, the module will take the neces-
sary precautions and provide diagnostic information through an LED.

P

RIMARY

 L

IMIT

The primary limit control is located on the partition panel and moni-
tors heat exchanger compartment temperatures.  It is a normally-
closed (electrically), automatic reset, temperature-activated sensor.
The limit guards against the overheating as a result of insufficient
conditioned air passing over the heat exchanger.

Summary of Contents for GCS9

Page 1: ...rself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install 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 specific good safety practices follow them The precautions listed in this Install...

Page 2: ...ND JOINING METHODS 13 PROPER 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 PIPE PIPING 16 DIRECT VENT DUAL PIPE PIPING 17 VENT INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES 18 CONCENTRIC VENT TERMINATION 18 X Condensate Drain L...

Page 3: ...tion 30 GENERAL 30 INTEGRATED CONTROL MODULE 30 PRIMARY LIMIT 30 AUXILIARY LIMIT 31 ROLLOUT LIMIT 31 PRESSURE SWITCHES 31 FLAME SENSOR 31 XVIII Troubleshooting 31 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 31 DIAGNOSTIC CHART 31 RESETTING FROM LOCKOUT 31 XIX Maintenance 31 ANNUAL INSPECTION 31 FILTERS 32 BURNERS 32 INDUCED DRAFT AND CIRCULATOR BLOWERS 32 CONDENSATE TRAP AND DRAIN SYSTEM QUALIFIED SER...

Page 4: ...r warranty certificate is also supplied with the unit Read the warranty carefully and note what is covered Keep the warranty certificate in a safe location for future reference If additional information or operating instructions are required con tact the dealer where the purchase was made Homeowner Notice If the residence is left unattended for an extended period of time i e 4 hours or greater hav...

Page 5: ...0 Coil Front Cover Drain Port 21 Drain Line Penetrations 22 Drain Trap 23 Blower Door Interlock Switch 24 Capacitor 25 Integrated Control Module with fuse and diagnostic LED 26 24 Volt Thermostat Connections 27 Transformer 40 VA 28 Circulator Blower 29 Auxiliary Limit 30 Junction Box 31 Electrical Connection Inlets 32 Coil Front Cover 33 Combustion Air Inlet Pipe Upflow Horizontal Counterflow Hori...

Page 6: ...ughly read this manual for specifics pertaining to the installation and application of this product WARNING POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSTAION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT II SAFET II SAFET II SAFET II SAFET II SAFETY Y Y Y Y Please adhere to the...

Page 7: ...ners fire horizontally into the heat exchanger Do not install the unit with the access doors on the up top or down bottom side of the furnace WARNING TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE To ensure proper furnace operation install operate and maintain the furnace in accordance with these installa...

Page 8: ...LITY Installations must adhere to the clearances to combustible materi als which this furnace has been design certified to The minimum clearance information for this furnace is provided on the unit s clear ance label These clearances must be permanently maintained Clearances must also accommodate an installation s gas electri cal and drain trap and drain line connections If the alternate com busti...

Page 9: ...HIND DOORS IN CORNERS UNDER CABINETS Thermostat Influences Consult the instructions packaged with the thermostat for mounting instructions and further precautions V V V V V CO CO CO CO COMBUSTI MBUSTI MBUSTI MBUSTI MBUSTIO O O O ON VENTIL N VENTIL N VENTIL N VENTIL N VENTILA A A A ATI TI TI TI TIO O O O ON AIR REQUIREMENTS N AIR REQUIREMENTS N AIR REQUIREMENTS N AIR REQUIREMENTS N AIR REQUIREMENTS...

Page 10: ... equip ment in the enclosure but not less than the sum of the areas of all vent connectors in the confined space Alternate Opening Location Equipment Located in Confined Spaces All Air from Outdoors Single Air Opening See 5 3 3 b Furnace Water Heater Opening Chimney or Gas Vent Opening NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating o...

Page 11: ...L APPLI AL APPLI AL APPLI AL APPLIC C C C CA A A A ATI TI TI TI TIO O O O ONS CO NS CO NS CO NS CO NS CONSID NSID NSID NSID NSIDERA ERA ERA ERA ERATI TI TI TI TIO O O O ONS NS NS NS NS GENERAL Horizontal applications in particular may dictate many of the installation s specifics such as airflow direction ductwork connec tions flue and combustion air pipe connections etc The basic ap plication of t...

Page 12: ...ce 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 Press...

Page 13: ...AND EXCESSIVE HEAT AS THEY ARE COMBUSTIBLE LIQUIDS AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND OR EYES Two or three inch nominal diameter PVC Schedule 40 pipe meet ing ASTM D1785 PVC primer meeting ASTM F656 and PVC sol vent cement meeting ASTM D2564 specifications must be used Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311 Carefully follow the manufacturer s instr...

Page 14: ...NSTALLATIONS On upflow units secure the combustion air intake pipe directly to the air intake coupling On counterflow units secure the combus tion air intake pipe to the air intake coupling using the rubber cou pling and worm gear hose clamps provided with the unit The coun terflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment NOTE Because o...

Page 15: ...d vent flue piping to the rubber elbow using a worm gear hose clamp NOTE Use of the alternate vent flue location for upright installations requires the drain trap be installed on the same side of the unit as the flue pipe 8 Upflow and Counterflow units For horizontal installations externally secure the field supplied vent flue pipe directly to the vent flue coupling using a PVC or ABS coupling or ...

Page 16: ...e should be the wall thickness plus the depth of the socket fittings to be in stalled on the inside and outside of the wall The wall penetration should be sealed with silicone caulking material In a basement installation the vent flue pipe can be run between joist spaces If the vent pipe must go below a joist and then up into the last joist space to penetrate the header two 45 elbows should be use...

Page 17: ... elbows and or tees in each Vent Flue Combustion Air Intake pipe Elbows and or tees used in the terminations must be included when determining 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 objection able insulation of the combustion air pipe may be required Use 1 2 thick cl...

Page 18: ...op maintain the same minimum clearances be tween the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit If more than one direct vent furnace is to be installed horizontally through a common side wall maintain the clearances as in the fol lowing figure Always terminate all exhaust vent outlets at the same elevation and al...

Page 19: ...LAMPS QTY 3 Hose and Tube Identification 1 Remove the rubber plug from the front cover drain port right or left side depending on the intended drain trap mounting 2 Secure HoseAto front cover drain port with a red hose clamp Route hose to rear side panel grommet hole NOTE For left side drainage grommets will have to be relocated to left side panel DRAIN TRAP FRONT COVER DRAIN PORT TUBE S 2 GREEN H...

Page 20: ...over drain port and the rubber elbow drain port NOTE On counterflow models relocation of the front cover pressure switch hose is required Make connections as follows 1 Remove the rubber plug from the coil front cover drain port Counterflow furnaces Relocate the front cover pressure switch hose connection from the left side pressure tap to the right down side tap The pressure switch hose must be co...

Page 21: ...Y PROPER OPERATION AFTER SERVICING WIRING HARNESS The wiring harness is an integral part of this furnace Field alter ation to comply with electrical codes should not be required Wires are color and number coded for identification purposes Refer to the wiring diagram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material ...

Page 22: ...AVOID INJURY ELECTRICAL SHOCK OR DEATH DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING The furnace s integrated control module is equipped with line volt age accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows Humidifier 1 0 Amp maximum at 120 VAC Electronic ...

Page 23: ... The appropriate manufacturer s propane gas conversion kit must be applied for pro pane gas installations Refer to the Section VIII Propane Gas High Altitude Installations section for details GAS VALVE This unit is equipped with a 24 volt gas valve controlled during fur nace operation by the integrated control module As shipped the valve is configured for natural gas The valve is field convertible...

Page 24: ...OW MODEL MANUAL SHUT OFF VALVE UPSTREAM FROM GROUND JOINT PIPE UNION DRIP LEG GROMMET IN STANDARD GAS LINE HOLE DRAIN TRAP ALTERNATE GAS LINE LOCATION MANIFOLD PLUG IN ALTERNATE GAS LINE HOLE GAS VALVE GROUND JOINT PIPE UNION BURNERS GROMMET IN STANDARD GAS LINE HOLE COUNTERFLOW MANUAL SHUT OFF VALVE UPSTREAM FROM GROUND JOINT PIPE UNION ALTERNATE GAS LINE LOCATION PLUG IN ALTERNATE GAS LINE HOLE ...

Page 25: ... joints to reduce noise transmission To prevent the blower from interfering with combustion air or draft when a central return is used a connecting duct must be installed between the unit and the utility room wall A room closet or alcove must not be used as a return air chamber When the furnace is used in connection with a cooling unit the fur nace should be installed in parallel with or on the up...

Page 26: ... propane gas high altitude etc have been appropriately installed FURNACE STARTUP 1 Close the manual gas shutoff valve external to the furnace 2 Turn off the electrical power to the furnace the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the...

Page 27: ...piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following procedure OUTLET INLET Pressure Regulator Adjustment Under Cap Screw Gas Valve On Off Selector Switch Inlet Pressure Tap Side of Valve Outlet Manifold Pressure Tap White Rodgers Model 36F22 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the fur...

Page 28: ...GAS VALVE This valve is shipped from the factory with the regulator preset see control label Consult the appliance rating plate to ensure burner manifold pres sure is as specified If another outlet pressure is required follow these steps 1 Turn OFF all electrical power to the system 2 Using a 3 32 inch hex wrench loosen outlet pressure tap screw one turn Do not remove screw 3 Connect a calibrated ...

Page 29: ...cable to your model provides an airflow table showing the relationship between airflow CFM and external static pressure E S P for the proper selection of heating and cooling speeds The cooling blower speed is shipped set on HIGH and the heating blower speed is set as indicated in the Product Data Book applicable to your model These blower speeds should be adjusted by the in staller to match the in...

Page 30: ...from the burners without curling floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes Check the burner flames for 1 Good adjustment 2 Stable soft and blue 3 Not curling floating or lifting off Burner Flame PRIMARY LIMIT The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger If the p...

Page 31: ...fore removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object DIAGNOSTIC CHART WARNING TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE Refer to the Troubleshooting Chart at the end of this manual...

Page 32: ...ME 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 insu lator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense flame and will lock out The flame sensor should be carefully cleaned by a qualified servicer using emery cloth or steel ...

Page 33: ...rature packet near furnace X X X X XXII REP XII REP XII REP XII REP XII REPAIR REPL AIR REPL AIR REPL AIR REPL AIR REPLACEMENT PAR ACEMENT PAR ACEMENT PAR ACEMENT PAR ACEMENT PARTS TS TS TS TS When ordering any of the listed functional parts be sure to provide the furnace model manufacturing and serial numbers with the order Although only functional parts are shown in the parts list all sheet meta...

Page 34: ...drain system Correct as necessary Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain system or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning switch contacts Loose or improperly connected wiring Pressure switch circuit no...

Page 35: ...FLASHES Flame sensor is coated oxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to improper gas pressure or combustion air Induced draft blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 flashes Flame sensed with no call for heat Correct short at flame sensor or in flame sensor wiring Turn power OFF prior to ...

Page 36: ...ED AND CONFORM TO N E C AND LOCAL CODES PK PINK 115 VAC HOT AND PARK TERMINALS LINE H FLAME SENSOR FRONT COVER PRESSURE SWITCH SINGLECONTROLON45KBTU NO C GY BK PLUG CONNECTION FIELD SPLICE SWITCH TEMP OR 24V THERMOSTAT CONNECTIONS BU GN GND 115 VAC 24 VAC BLOWER COMPARTMENT DOOR SWITCH OPEN WHEN DOOR OPEN DOOR SWITCH BK GND D IS C O N N EC T L N WH JUNCTION BOX 1 OR ID BLOWER PRESSURE SWITCH HEAT ...

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