background image

24

IO-242

      5/04

XIII. OPERATIONAL CHECKS

WARNING

T

O AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL

COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. 

E

LECTRICAL

COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. 

C

ONTACT A

QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
SHOULD DEVELOP.

B

URNER

 F

LAME

The burner flames should be inspected with the burner compartment
door installed.  Flames should be 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 fla m es for: 
1. G ood  adju stm ent
2. Stable, soft and  blu e 

3. N ot curling, flo atin g, o r lifting  off. 

 Burner Flame

A

UXILIARY

 L

IMIT

 C

ONTROL

Auto reset limits are located on or near the blower. To access this
auxiliary limit, disconnect the electrical power and remove the blower
door. If the limit control opens, the air circulation blower will run
continuously. The diagnostic light will flash four times. These
symptoms are identical to a trip of the primary limit control. The
auxiliary limit control is designed to prevent furnace operation in
case of main blower failure on horizontal and counterflow
installations. It may also open if the power supply is interrupted
while the furnace is firing. The auxiliary limit control is suitable for
both horizontal right and horizontal left installations. Regardless of
airflow direction, it does not need to be relocated.

WARNING

T

O AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL

COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. 

E

LECTRICAL

COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS. 

C

ONTACT A

QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE
PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, 

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
furnace has been operating (burners firing) for approximately ten
minutes.  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 be de-energized 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.

WARNING

T

O PREVENT PREMATURE FAILURE OF HEAT EXCHANGER, PROPERTY DAMAGE,

PERSONAL INJURY OR DEATH, DO NOT ADJUST THE LIMIT CONTROL (FACTORY

SET).

IMPORTANT NOTE: 

This unit must not be used as a construction

heater during the finishing phases of construction of a new structure.
This type of use may result in premature failure due to extremely
low return air temperatures and exposure to corrosive or very dirty
atmospheres.

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.

XIV. SAFETY CIRCUIT DESCRIPTION

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 abnormal 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 controls
all furnace operations.  Responding to the thermostat, the module
initiates and controls normal furnace operation, and monitors and
addresses all safety circuits.  If a potential safety concern is
detected, the module will take the necessary precautions and
provide diagnostic information through an LED.

P

RIMARY

 L

IMIT

The primary limit control is located on the partition panel and
monitors heat exchanger compartment temperatures.  It is an
automatic reset, temperature sensor.  The limit guards against the
overheating as a resulting of insufficient air passing over the heat
exchanger.

A

UXILIARY

 L

IMIT

The auxiliary limit control is located either on or near the circulator
blower and monitors heat exchanger compartment temperatures.
The control is a  temperature sensor.  It guards against overheating
resulting from insufficient air passing over the heat exchanger.

R

OLLOUT

 L

IMITS

The rollout limit controls are mounted on the burner/manifold
assembly and monitor the burner flame.  They are   manual-reset,
temperature sensors.  This limit guards against burner flames not
being properly drawn into the heat exchanger.

P

RESSURE

 S

WITCHES

The pressure switches are normally-open, negative air pressure-
activated switches.  They monitor the airflow (combustion air and

Summary of Contents for GDS8

Page 1: ...en 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 s...

Page 2: ...ETE THE INSTALLATION 13 FIX 1 LINER TERMINATION 13 FIX 2 CHANGE VENTING ARRANGEMENTS 13 FIX 3 REBUILD THE CROWN 13 FIX 4 RELINING 13 VIII Electrical Connections 14 WIRING HARNESS 14 115 VOLT LINE CONN...

Page 3: ...5 FILTER MAINTENANCE 25 FILTER REMOVAL 26 UPRIGHT FILTER REMOVAL 26 INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS 26 FLAME SENSOR QUALIFIED SERVICER ONLY 26 IGNITER QUALIFIED SERVICER ONLY 26 BURNERS 26...

Page 4: ...ponent failures could result in heating system operational problems TO THE INSTALLER Before installing this unit please read this manual thoroughly to familiarize yourself with specific items which mu...

Page 5: ...ring 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 d...

Page 6: ...lking compound or cement grout Counterflow Installation over a combustible floor If installation over a combustible floor becomes necessary use an accessory subbase see Product Data Book applicable to...

Page 7: ...HE FURNACE POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMVOAL HOLD DOWN NUTS SUPPORT NUTS 2 x2 x3 8 ANGLE IRON 3 PLACES Suspended Furnace EXISTING FURNACE REMOVAL NOTE...

Page 8: ...furnished with doors are considered a part of the unconfined space 5 3 3 Equipment Located in Confined Spaces a All Air from Inside the Building The confined space shall be provided with two permanen...

Page 9: ...rtical 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 Furnace Water Heater Outlet Air Chimney or Gas...

Page 10: ...ada the furnaces must be vented in accordance with the National Standard of Canada CAN CSA B149 1 and CAN CSA B149 2 latest editions and amendments NOTE The vertical height of the Category I venting s...

Page 11: ...OD EQUIPPED APPLIANCE THE POTENTIAL FOR CONDENSATIO N DAM AG E MAY STILL EXIST WITH EXTREMELY COLD CONDITIO NS LONG VENT CONNECTORS EXTERIOR CHIM NEYS OR ANY CO MBINATION OF THESE CONDITIONS THE RISK...

Page 12: ...CHECK 5 LINER CONDITION If a metal liner is present it must be checked It cannot be assumed that all existing metal liners are correctly installed and in good condition Remove the lowest existing vent...

Page 13: ...CSA B149 2 latest editions and amendments assume interior chimneys If in the judgment of the local gas utility installer and or local codes one or more of the above factors is likely to present a prob...

Page 14: ...requirements If a flexible liner is to be used it must be made of the proper materials For most residential applications an aluminum liner should be acceptable If the combustion air supplied to the fu...

Page 15: ...rminal strip as shown in Figure 12 IMPORTANT NOTE To avoid possible equipment malfunction route the low voltage wires to avoid interference with filter removal or other maintenance Integrated Ignition...

Page 16: ...minals TWINNING A twin terminal located on the thermostat terminal strip can be used to twin two furnaces This twin terminal synchronizes the circulation blowers of the two furnaces Furnaces must be s...

Page 17: ...The actual firing rate of the furnace is Input 1 000 heating value of the gas X 3600 constant 52 6 meter time for 1 ft3 of gas Input 3 600 000 52 6 Input 68 400 Btu h METER TIME IN MINUTES AND SECONDS...

Page 18: ...minimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace Use two pipe wrenches when making...

Page 19: ...ely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence of gas is suspected follow the instructions on Page 4 of this manual All...

Page 20: ...is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the airstream The access panel must be ma...

Page 21: ...ubleshooting Chart for further explanation of the lighting codes Follow the start up and adjustment items refer to further information in Section XIII Operational Checks FURNACE OPERATION Purge gas li...

Page 22: ...e the number of seconds per cubic foot sec ft3 of gas being delivered to the furnace If the dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one If the dial is a two cu...

Page 23: ...ng ends During normal heating operation the circulator fan will come on approximately 37 seconds after the gas valve opens ON OFF ON OFF ON OFF ON OFF 1 2 1 2 1 2 1 2 90 SECON D DELAY 120 SECON D DELA...

Page 24: ...valve to close and extinguish flame The induced draft blower to be de energized after a fifteen second postpurge and The circulator blower to remain energized continuously until limit control resets 3...

Page 25: ...he red LED If the furnace is in lockout it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume norma...

Page 26: ...cleaned by a qualified servicer using emery cloth or steel wool Following cleaning the flame sense signal should be as indicated in the Specifications Sheet IGNITER QUALIFIED SERVICER ONLY If the igni...

Page 27: ...SHES Induced draft blower pressure switch contacts sticking Shorts in pressure switch circuit Inspect pressure switch hose Repair if necessary Inspect flue for blockage proper length elbows and termin...

Page 28: ...er if necessary Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check induced draft blower for proper performa...

Page 29: ...IR CLEANER ELECTRONIC BLWR CIRCULATOR BLWR ID HUMIDIFIER FLAME SENSOR 115 VAC TRANSFORMER 40 VA 24 VAC C2 GND VALVE GAS CONTROL LIMIT PRIMARY AUTO RESET LIMIT CONTROL S MANUAL RESET ROLLOUT RO1 5 RO2...

Page 30: ...of product failure They are simple to service and forgiving to operate We use quality materials and components Finally every unit is run tested before it leaves the factory That s why we know There s...

Reviews: