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Permit M99-0060 - BRUMMETT THOMAS
M99 -0060 4517 So. 137t'' St. Thomas Brummett City of Tukwila c: �. (206) 431-3670 Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 MECHANICAL PERMIT Permit No: M99 -0060 Type: B -MECH Category: RES Address: 4517 S 137 ST Location: Parcel #: 734760 -0305 Contractor License No: TENANT THOMAS BRUMMETT 4517 S 137 ST, TUKWILA WA 98168 OWNER BRUMMEL THOMAS 4517 S 137TH ST, SEATTLE WA 98168 CONTACT ANNE SCHMIDT 2800 THORNDYKE AV W, SEATTLE WA 98199 **** k******* k*** k**.*** k***** k*************' k*k** ** * *'k * **•k * *'k'k*'k* * *'k k ** * ** *** Permit Description: Status: ISSUED Issued: 03 /31/1999 Expires: 09/27/1999 Phone: Phone: 206- 282 -4700 INSTALL ONE .GAS FURANCE, 52 B FURNACE. IS AT 15 AMP 120 V UMC Edition: 1997 U, 1 AWH 40 GALLON, Valuation: Total Permit Fee: 1,000.00. 46.50 ** * * * *'k'kk * * **:k **• kl******.******. i4*.k*** * * *'k* *k * * * ** * *k•k*li klek*Iciv'k*:k * *** ***** 3 1 -q Permit' Center ®authorized 5lgnature. Date I hereby certify that "I have..r.ead and examined this permit and know the same tobe,true and correct. All provisions of law and ordinances governing this work will be complied with, whether specif.ied,her.ein or not. The granting"..of this permit does not" p,resume to give authority to violate or cancel the :prov,isions of any other state or local laws 'regulating c:onstru'p,tion or. the performance of work. Tam authorized to sign for and obtain this by-ig permit. Signature, Print Name: This permit shall.become null and void if the work.iS:not commenced within 180 days from the date '.of issuance, or if'the work is suspended or abandoned for a period`':of "180 days from the j'as:t •inspection. CITY OF TUKWILA Address: 4517 S 137 ST uite: Tenant: THOMAS BRUMMETT Type: B-MECH Parcel 734760-0305 Permit No: M99-0060 Status: ISSUED Appl ied: 03/19/1999 Issued: 03/31/1999 Ot144(***AA*k**A****4********kk***kh**M***Akk***4,A444t******k*****%***4?A*A***** Permit Conditions: 1, Plumbing permits shall be obtained through the Seattle-King County Department of Public Heal,th,Plumb ing will be Inspected by that agencr,":rjhOiai4*q.':9*;;;. piping - (296-4722). No changes willbei„.Made to,%tpe plans uniesS-,aPpiNyed by the Engineer and tfle7r6kwilaaUtiding:':tivisio. 3. All permitsnSpectlonireordS,--.and,appro'Ved:'plans....::shall be availablee r tthe.'job site prio to the startt'of,':;andOp- struction'.,These *cuments-are to be mainal66:1 able untit f:Inaj':J.nspection approval is granted.. :, H 4. All cOstruCtion to he done in confo rmance With-approved plansarid requirements of :,the Uniform Building.Code.,(1997,,A EditiO) isameh0-ed, UhiforM Mechanical Code (1997 EdftionY and WaShing.ton State Energy Code '(1997 Edition). Valialtx:'of-PerMit. The issOance- of a permit or approval Of-A plans Specffications; and .66mputatiOns shall not be cOn- strued to be a'perpttfor, ,Or :an apprOVal-of, any vlolatAon.,:,, of:4ny of the proV),sionS of the-b4lidling code or 01 any other orAinance'.of_the furfsdiction.H:,,No permit preSuripg.;t0„'„'H, giVeaOthOritv to violate, ar cance 1 the provisions of this • r . codeishalj be vIid 6. Man'UfactUrers: lnta 1 lation initruct ions required on • si te„. for :the building inspectors revew CITY OF IKWILA Permit Center 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 Fr ' STAFF USE ONLY Project Number: Permit Number: 44- oaPo Miscellaneous Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through Mu mail or facsimile. Project Name/Tenant: ��S � 7,�%�/�1 ` City ate /Zip:. , 4. d ,, , Value of Constru ■ Above Ground Tanks ■ Antennas /Satellite Dishes ■ Bulkhead /Docks ■ Commercial Reroof ❑ Demolition ❑ Fence Mechanical ❑ Manufactured Housing- Replacement only ❑ Parking Lots ❑ Retaining Walls Temporary Pedestrian Protection /Exit Systems ❑ Temporary Facilities ❑ Tree Cutting CLJ� CL� ��( (2 .: . Tax • .rc- �% tuber: . A Site Address: IN Property Owner: / .. City State /Zip: Phon Fax dt: co 0 Sewer 2_ Street Address: ,.L'ontact Person:, rtE- `�`; `„ Ul 4 /'--- Phone: Street Address: City State /Zip: Fax #: Contractor: / , , i Phone: 20 4 Woe:3 Street Address:, 0 14..1: i . i t State/ ' • /. I'w`l Fax #: Architect: Phone: Street Address: City State /Zip: Fax #: Engineer: Phone: Street Address: City State /Zip: Fax #: MISCELLANEOUS PERMIT REVIEW AND APPROVAL REQUESTED:. (TO BE FILLED OUT BY APPLICANT):., Description 47f/4'// fi (-- / we/ v � sz/ ' % t I �1<� 40D-11 1 I ' (se) 154-m f Will there be storage of flammable/combustible hazardous material iii the building? ❑ yes ❑ no (ZAv Attach list of materials and storage location on se.arate 8 1/2 X 11 .a.erindicatin. • uantities & Material Safet Data Sheets ■ Above Ground Tanks ■ Antennas /Satellite Dishes ■ Bulkhead /Docks ■ Commercial Reroof ❑ Demolition ❑ Fence Mechanical ❑ Manufactured Housing- Replacement only ❑ Parking Lots ❑ Retaining Walls Temporary Pedestrian Protection /Exit Systems ❑ Temporary Facilities ❑ Tree Cutting ' APPLICANT ,REQUEST.FOR`MISCELLANEOUS PUBLIC WORKS PERMITS.` ❑ Channelization /Striping ❑ Flood Control Zone ❑ Landscape Irrigation ❑ Storm Drainage ❑ Water Meter /Exempt # El Water Meter /Permanent # ❑ Water Meter Temp # ❑ Miscellaneous ❑ Curb cut/Access /Sidewalk ❑ Fire Loop /Hydrant (main to vault)#: Size(s): ❑ Land Altering: 0 Cut cubic yards 0 Fill cubic yards 0 sq. ft.grading /clearing El Sanitary Side Sewer #: ❑ Sewer Main Extension 0 Private 0 Public ❑ Street Use ❑ Water Main Extension Size(s): Size(s): Sizes : Est. quantity: Moving Oversized Load /Hauling 0 Private 0 Public 0 Deduct 0 Water Only gal Schedule: MONTHLY'SERVICE.BILLINGS.TO:. i ... _ Name: Phone: Address: City /State /Zip: 0 Water 0 Sewer 0 Metro 0 Standby WATER METER DEPOSIT /REFUND :BiLLING:. ' Name: Phone: Address: City /State /Zip: Value of Construction - In all cases, a value of construction amount should be entered by the applicant. This figure will be reviewed and is subject to possible revision by the Permit Center to comply with current fee schedules. Expiration of Plan Review - Applications for which no permit Is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 180 days upon written request by the applicant as defined in Section 107.4 of the Uniform Building Code (current edition). No application shall be extended more than once. / Date application accepted: MISCPMT.DOC 7/11/96 Date application expires: ALL MISCELLANEOUS F; MIT APPLICATIONS MUST BE SU TED WITH THE FOLLOWING: ➢ ALL DRAWINGS SHALL BE AT A LEGIBLE SCALE AND NEATLY DRAWN • BUILDING SITE PLANS AND UTILITY PLANS ARE TO BE COMBINED ➢ ARCHITECTURAL DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED ARCHITECT STRUCTURAL CALCULATIONS AND DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED STRUCTURAL ENGINEER > CIVIUSITE PLAN DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED CIVIL ENGINEER (P.E.) d Copy of Washington State Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued, unless the homeowner will be the builder OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent If the applicant is other than the owner, registered ; architect /engtneer,.ot contractor.liconsed. by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT: Blab SUBMIT APPLICATION AND REQUIRED CHECKLISTS FOR PERMIT REVIEW 7 Above Ground Tanks/Water Tanks - Supported ,directly; upon grade , exceeding 5,000 gallons and, a' ratio of height to diameter or,width: which exceeds 2:1. Submit checklist .: No : M -9 0 Antennas /Satellite Dishes Submit checklist` No..'M 1 EJ Awnings /Canopies - No signage Commercial Tenant Improvement Permit" 71 Bulkhead /Dock Submit checklist No M 10 .:' il Commercial Reroof Submit'checklist' No ' M 6 ri Demolition Submit checklist: No : M 3, 1111 3a: 0 Fences - Over 6 feet.in Height Submit checklist.` No:" M -9'' 0 Land Altering /Grading /Preloads Submit checklist ,No:;;M =2 • Loading Docks Commercial T errant Improvement. Permit:'.Submitch'ecklist No: H 17, 0 Mechanical (Residential & Commercial) Submit ;checklist ,No. :M -8" Residential onl'.- H -6, H 16'.: 0 Miscellaneous Public Works Permits Submit checklist No ::H -9 E Manufactured Housing (RED INSIGNIA ONLY); Submit checklist No: , "M -5 - 0 Moving Oversized Load /Hauling Submit checklist' No: M-5 ' in Parking Lots Submit checklist : No: 'M -4; 0 Residential Reroof - Exempt with following exception: If. roof structure to be repaired or replaced Residential:Buliding Permit:. Submit :checklist No:, M -6,: 0 Retaining Walls - Over 4 feet in height Subunit checklist ' No: .M 1 • Temporary Facilities Submit checklist . •No :: M-7 E Temporary Pedestrian Protection/Exit.Systems Submit checklist No:, M-4 E Tree Cutting Submit checklist No: 1‘.&:,2 d Copy of Washington State Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued, unless the homeowner will be the builder OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent If the applicant is other than the owner, registered ; architect /engtneer,.ot contractor.liconsed. by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT: Blab NER OR AUT ORIZE A� 1Date: /a'( nt-narne" - ) Phone,� Fax it: Address:: r]%n`n �/4,1 , (j„ Ll ie ( i City /Stale /Zip:' o n WA ' -Ir -g� MISCPMT.DOC 7/11/96 ik* Ak: 4** hli* AA•, 1* Ak** A1.4AA4h * *t*A**,lkA A,tA*•A • k .•.4 #**•.l•**1*A.•s.1t***•. *hh ;A:TY OF TUKWl L.A.t WA ¼ h•k *kk * ***•k•A*** * *Nr**, * *:4k*k* •A A *A**k** *It **** *A*A***A 4650 03/31/;•x'.•1' 12;06 1 R(N.EiMI:T ' TRANSMIT' .Number: R9800042 Amount: Payment Method .CHI.CIC Not;a•t iariz WDF IUCORP0R1 Tl:t1 In i t« TLO Pei'oe1t Not M9a -0060 .Types N•-MECH MECHANICAL PERMIT Parcel No: ' 73476.0-.03( ?5. Site Addre i '4317 3 137 ST Total . FOs':, . 46.50 This Payment 46,x0 Total ALL F`mts'. 46.50 13 a 1 anCe A. ** *** *Ak***kA *.4 A * **fik•A*•*•.***k. *>F.k* ?k*•k. *Afi*A **Aof *�1A ** * *•:'t1vks.* *1.* Account Cade • 000/344.830 000/322.100 Description PLAN CHECK - pE3 MECHANICAL RF6 Amount; 3.30 37,;20. INSPECTION NO. INSPECTION RECORD Retain a copy with perm; CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, 400, Tukwila, W, PERMIT NO. (206)431 -3670 tom: yiM y.Q -cif Inspe,ion: Acdr 1-1.7 (5-7 sf: ate •` i q9 Special instructions: Da& t5a. n . r , a.m. i ®ques ( . W � amat rev Approved per applicable codes. CCorrections required prior to approval. OA To ' /1L1A[,, $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection, Receipt No: Date: installation, start -up, 333BAV and operating instructions 333JAV UPFLOW /HORIZONTAL Series A TWO- STAGE, VARIABLE -SPEED GAS FURNACE M.itlWYhh►tMMW+4N«, maywnw.+.M.a••- _- __ FILE COPY NOTE: Read the entire instruction manual before starting the installation. This symbol —> indicates a change since the last issue. Index Page SAFETY CONSIDERATIONS 1 -2 Clearances to Combustibles 1 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE 2 INTRODUCTION 2 Dimensional Drawing 3 LOCATION 2 -3 General 2 -3 Location Relative to Cooling Equipment 3 Hazardous Locations AIR FOR COMBUSTION AND VENTILATION Unconfined Space Confined Space INSTALLATION Upflow Installation 5 Horizontal Attic Installation 5 Horizontal Crawlspace Installation 5 FILTER ARRANGEMENT 5 LEVELING LEGS (IF REQUIRED) 7 GAS PIPING 7 -8 ELECTRICAL CONNECTIONS 8 -10 115 -v Wiring 8 24 -v Wiring 8 -10 Accessories 10 VENTING 10 START -UP, ADJUSTMENT, AND SAFETY CHECK General Sequence of Operation Adaptive Heating Mode Non - Adaptive Heating Mode Cooling Mode Continuous Blower Mode Heat Pump Mode Defrost Mode 3 4 -5 4 4 -5 5 10 -20 10 10 -14 11 12 12 12 13 13 13 -14 14 14 -19 14 -18 18 19 19 -20 20 ilEcEN so VILA arY'•OF• Set -Up Procedures Start-Up Procedures Adjustments Set Gas Input Rate Set Temperature Rise Set Thermostat Heat Anticipator Check Safety Controls Checklist )'r PEPOI'T'CEidFEft SAFETY CONSIDERATIONS Installation and servicing of heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on —1— Cancels: 11 333B-60-1 rC a4 rnr.� 001 0 dP2 TABLE 1— MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS (IN.) 11 333B-60-2 3 -96 aEFFICIENCY RATING CERTIFIED ama i UNIT SIZE 1 060 1 080 -120 • UPFLOW Single -Wall Vent 1 0 Furnace Sides Type B -1 Double -Wall Vent 0 0 Furnace Back 0 0 Plenum Top 1 1 Furnace Front Single -Wall Vent 6 8 (See Notes) Type B -1 Double -Wall Vent 3 3 Single -Wall Vent 6 6 Vent Type 13-1 Double -Wall Vent 1 1 HORIZONTAL POSITION (IN ALCOVE, ATTIC, AND CRAWLSPACE) SIdes'$ 1 1 Back 0 0 Single -Wall Vent 1 1 Top Type B -1 Double -Wall Vent 1 1 Furnace Frontt Single -Wall Vent 6 6 (See Notes) Type B•1 Double -Wall Vent 3 3 Single -Wall Vent 6 8 Vent Type B -1 Double -Wall Vent 1 1 HORIZONTAL POSITION (IN CLOSET)** SIdes'$ 1 1 Back 0 0 Single -Wall Vent 2 2 Top Type B -1 Double -Wall Vent 2 2 Furnace Front Single -Wall Vent 6 6 (See Notes) Type B -1 Double -Wall Vent 3 3 Single -Wall Vent 8 8 Vent Type B -1 Double -Wall Vent 1 1 The supply side must maintain 6 -in. clearance from flux to combustible materials when using single -wall vent. t 18 -in. front clearance required for alcove. $ Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible between lines formed by intersection of top and two sides of furnace casing, and building Joints, stud, or framing. Clearance 10 return side is a minimum of zero in. J -box must be installed on lower (bottom) inside of furnace. NOTES: 1. Provide 30 -in. front clearance for servicing. An open door in front of the furnace can meet this requirement. 2. A minimum clearance of 3 in. must be provided In front of the furnace for combustion air and proper operation. heating equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply. -4 Follow all safety codes. In the United States, refer to the National Fuel Gus Code (NFGC) NFPA No. 54 -1992 /ANSI Z223.1 -1992. In Canada, refer to the current edition of the National Standard of Canada CAN /CGA- B 149.1- and .2 -M95 Natural Gus and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have tare extinguisher available during start-up and adjustment procedures servic lls. Recognize safety information. This is the safety -alert symbol p, . When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAU- TION. These words are used with the safety -alert symbol. DAN- GER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residen- tial construction practices. We require these instructions as a minimum for a safe installation. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE A CAUTION: Electrostatic discharge can affect electronic components, Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electro- static potential. 1. Disconnect all power to the furnace. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND. 2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person's hand during grounding will be satisfactorily discharged. 3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (For example: DO NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.). 4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touch- ing control or wires. 5. Use this procedure for installed and uninstalled (un- grounded) furnaces. 6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1. through 5. before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects. 7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage. INTRODUCTION The models 333BAV and 333JAV Series A Furnaces are available in sizes 60,000 through 117,000 Btuh input capacities. These furnaces use variable -speed motors manufactured by Gen- eral Electric (GE) and known as ICM2+ motors. They are integrated control motors, which include a pre - programmed micro- processor -based control to precisely control the selected airflow rotes. The motor will be referred to as ICM2+ in the rest of this document. —2— The design of the upflow/horizontal gas -fired furnace is A.G.A. and C.G.A. design - certified for use with natural and propane gases and for installation on combustible wood flooring, in alcoves, attics, basements, closets, or utility rooms. The design of this furnace line is not A.G.A. and C.G.A. design- certified for instal- lation in mobile homes, recreation vehicles, or outdoors. Before installing the furnace, refer to the current edition of the NFGC. Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction. For further information, the NFGC is available from National Fire Protection Association Inc. Batterymarch Park, Quincy, MA 02269; Ameri- can Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209; or from Literature Distribution. Installation must conform to the regulations of the serving gas supplier and the local building, heating, and plumbing codes in effect in the area in which the installation is made, or in the absence of local codes with the requirements of the NFGC or NSCNGPIC. A CAUTION: Application of this furnace should be in- doors with special attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause prema- ture component failure. WARNING: Improper installation, adjustment, alter- ation, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory - authorized and listed kits or accessories when modifying this product. A failure to follow this warning can cause electrical shock, fire, personal injury, or death. This furnace is designed for a minimum continuous retum -air temperature of 60 °F db or intermittent operation down to 55 °F db such as when used with a night setback thermostat, Return-air temperature must not exceed 85 °F db. To aid in installation, troubleshooting, and service, a status code label is located on the blower compartment door. This label explains how to use the LED status indicator on the furnace control which is viewed through the sight glass on the door. For high - altitude installations, the high - altitude conversion kit MUST be installed at or above 5500 ft above sea level. For accessory installation details, refer to the applicable installa- tion literature. NOTE: Remove all shipping brackets and materials before oper- ating the furnace. I. LOCATION A. General CAUTION: Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met. 39 gib" 1 28 12" FLUE COLLAR Y 2 1/46" + lib -IN. DIA HOLE POWER ENTRY �� fib -IN. DIA �° ACCESSORY Q 1 3/4-IN. DIA HOLE p! GAS ENTRY 1/2-IN. DIA HOLE THERMOSTAT WIRE ENTRY SIDE INLET a d 5 t" t 1 12 s /18" 13(18" 1 I.— 24 5/1 s" ----1.— 3 "--N-1 11/18" AIR INLET 2 3%" A D 11, ‘f I 1 1 1 I 1 I 1 1 1 1 1 O I 1 O I 1 = 1 1 = 1 1 I 1 1 11/18" —►-I 4 E -•-.13/16" 21 /is" 1„ 5 3/8" 2 11/18" 5 13/18" 2 3/8" 1 TYP 1" 11/18" TY 17.1....... v AIRFLOW 19" OUTLET I gib -IN. DIA + POWER ENTRY 1 12 -IN. DIA R.H. GAS ENTRY gib -IN. DIA ACCESSORY 1/2-IN. DIA THERMOSTAT WIRE ENTRY SIDE INLET 13/16" 1" 231/4" SIDE RETURN DUCT LOCATION NOTES: 1. Two additional 7, -in. dia knockouts are located in the top plate. 2. Minimum return -air opening at furnace: a. For 800 CFM- 16 -In. round or 1412 x 12 -in. rectangle. b. For 1200 CFM- 20 -in. round or 1412 x 1912 -in. rectangle. c. For 1600 CFM- 22 -in. round or 1412 x 231/4 -in. rectangle. d. For airflow requirements above 1800 CFM, use both side inlets, a combination of 1 side inlet and the bottom, or the bottom only. Fig. 1— Dimensional Drawing TABLE 2— DIMENSIONS (IN.) 1 1412" _____Irj ” A88387 UNIT SIZE A D E FLUE COLLAR SHIP. WT 060 -12 14-3/16 12-9/16 12-11/16 4 134 080.16 21 19 -3/8 19 -1/2 4 154 100-20 24-1/2 22-7/8 23 4 184 120-20 24-1/2 22 -7/8 23 5 194 CAUTION: Do not use this furnace during construction when adhesives, sealers, and/or new carpets are being installed and curing. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine, when burned in combustion air, form acids which will cause corrosion of the heat exchangers and metal vent system. Some of these compounds are released from paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems. This furnace must be installed so the electrical components are protected from water. Locate the furnace as near the center of the air distribution system and chimney or vent as possible. The furnace should be installed as level as possible. When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. —3— Provide ample space for servicing and c caning. Always comply with the minimum tire protection clearances shown on the unit clearance label. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring. B. Location Relative to Cooling Equipment The cooling coil must be installed parallel with or on the downstream side of the furnace to avoid condensation in the heat exchangers. When installed parallel with a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full -heat or full -cool position. C. Hazardous Locations When the furnace is installed in u residential garage, it must be installed so that the burners and ignition source are located at least 18 in. above the floor. The furnace should be protected from physical damage by vehicles. When a furnace is installed in public garages, airplane hangars, or other buildings having hazardous atmospheres, the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association, Inc. VENT THROUGH ROOF INTERIOR HEATED SPACE 12" MAX �1SQIN. PER 1000 BTUH- IN DOOR OR WALL ?w U.0 UNCONFINED Ooo.. SPACE o(1) 1 SO IN. PER 1000 BTUH• IN DOOR OR WALL Minimum opening size Is 100 square in. with minimum dimensions of 3 -In. t Minimum of 3 -In. when type -B1 vent Is used. A89012 Fig. 2— Confined Space: Air for Combustion and Ventilation from an Unconfined Space 11. AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3, Air for Combustion and Ventilation, of the NFGC or applicable provisions of the local building codes. Canadian installations must be in accordance with Section 7 of the NSCNGPIC and all authorities having jurisdiction. CAUTION: Air for combustion must not be contami- nated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. All fuel - burning equipment must be supplied with air for combus- tion of the fuel. Sufficient air MUST be provided to ensure there . will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be mode between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and draft safeguard opening into the circulating air. CAUTION: The operation of exhaust fans, kitchen ven- tilation fans, clothes dryers, or fireplaces could create a negative air pressure condition at the furnace. Make -up air must be provided for these devices, in addition to that required by the furnace. The requirernents for combustion and ventilation air depend upon whether the furnace is located in a CONFINED or UNCONFINED space. 12" MAX 1 PEIN. R 4000 BTUH' 2 1 SO IN. PER 2000 BTUH' 12" MAX 1 SQ IN. PER 4000 BTUH' 12" MAX DUCT 1 SQ IN. TO PER 4000 OUTDOORS BTUH' 'Minimum dimensions of 3 -In. NOTE: Use any of the following combinations of openings: A &B C &D D &E F &G A89013 Fig. 3— Confined Space: Air for Combustion and Ventilation from Outdoors A. Unconfined Space An unconfined space has volume of at least 50 cu ft for each 1000 Btuh of total input for all the appliances (such as furnaces, clothes dryers, water heaters, etc.) in the space. For Example: 333BAV AND 333JAV FURNACES HIGH -STAGE INPUT BTUH MINIMUM SQ FT WITH 7 -1/2 FT CEILING 60,000 400 80,000 534 100,000 667 117,000 780 If the unconfined space is of unusually tight construction, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be sized the same as for a confined space as defined below. Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room. B. Confined Space A confined space has volume of less than 50 cu ft per 1000 Btuh of the total input rating for all appliances installed in that space. A confined space MUST have 2 permanent openings, 1 within 12 in. of the ceiling, and the other within 12 in. of the floor which freely communicate with an unconfined space or the outdoors. (See Fig. 2.) NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free urea. Screens, when used, must not be smaller than 1 /4 -in. mesh. Louvers and grilles must be constructed so they cannot be closed. The size of the openings depends upon whether the air comes from outside of the structure or an unconfined space inside the structure. 1. All air from inside the structure: a. Each opening MUST have at least 1 sq in. of free area per 1000 Btuh of the total input for all equipment within the confined space, but not less than 100 sq in. per opening. (See Fig. 2.) The minimum dimension of air openings shall not be less than 3 in. For Example: COMBUSTION AIR FROM UNCONFINED SPACE 333BAV and 333JAV Furnaces High -Stage Input Btuh Free Area per Opening (Sq In.) 60,000 100 80,000 100 100,000 100 117,000 117 b. If the building is constructed unusually tight, a perma nent opening directly communicating with the outdoors should be provided. This opening shall have a minimum free area of 1 sq in. per 4000 Btuh of total input rating for all equipment in the enclosure. (See Fig. 3,) c. If the furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from the hallway or space adjacent to the furnace, all air for combustion must come from outdoors. (See Fig. 3.) 2. All air from outside the structure: a. If combustion air is taken from outdoors through vertical ducts, the openings and ducts MUST have at least 1 sq in. of free area per 4000 Btuh of the total input for all equipment within the confined space. (See Fig. 3.) For Example: COMBUSTION AIR FROM OUTDOORS THROUGH VERTICAL. DUCTS 333BAV and 333JAV Furnaces HIgh -Stage Input Btuh Free Area per Opening (Sq In.) Round Pipe (In. Dia) 60,000 15.0 5 80,000 20.0 6 100,000 25.0 6 117,000 29.3 7 b. If combustion air is taken from the ou doors through horizontal ducts, the openings and ducts MUST have at least I sq in. of free area per 2000 Btuh of the total input for all equipment within the confined space. (See Fig. 3.) For Example: COMBUSTION AIR FROM OUTDOORS THROUGH HORIZONTAL DUCTS 333BAV and 333JAV Furnaces Hlgh -Stage Input Btuh Free Area per Opening (Sq In.) Round Pipe (In. Dia) 60,000 30.0 7 80,000 40.0 8 100,000 50.0 8 117,000 58.5 9 c. When ducts are used, they must be of the same cross - sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (See Fig. 3.) —5— INSTALLATION I. UPFLOW INSTALLATION A. WARNING: Do not install the furnace on its back. Safety control operation will be adversely affected. Never connect return-air ducts to the sides or back of the furnace. A failure to follow this warning could result in fire, personal injury, or death. NOTE: Door clip on the control door may be removed for upflow installations. I. Position furnace in desired location. 2. Connect gas supply pipe. 3. Connect supply- and return -air ducts. II. HORIZONTAL ATTIC INSTALLATION 0 WARNING: Do not install the furnace on its back; safety control operation will be adversely affected. Never connect return-air ducts to the sides or back of the furnace. A failure to follow this warning could result in fire, personal injury, or death. The furnace can be installed horizontally with either the left -hand (LH) or right -hand (RH) side down. A typical attic installation is shown in Fig. 4. A. Construct a Working Platform Construct working platform on location where all required furnace clearances are met. (See Table 1 and Fig. 4.) B. Install Furnace 1. Position furnace in desired location. 2. Connect gas supply pipe. See Fig. 4 for typical piping entry. 3. Connect supply- and return-air ducts. 4. Install 24- X 24 -in. sheet metal shield on platform in front of louvered control panel as shown in Fig. 4. III. HORIZONTAL CRAWLSPACE INSTALLATION The furnace can be installed horizontally with either the LH or RH side down. In a crawlspace, the furnace can either be hung from the floor joist (See Fig. 5) or installed on suitable blocks or pad. (See Fig. 6.) The furnace can be suspended from each corner by hanger bolts (4 each 3 /8 -in. all- thread rod) cut to desired length. Use 1- X 3 /8 -in. flat washer, 3 /8 -in. lockwasher, and 3 /8 -in. nuts on hanger rods. (See Fig. 5.) Dimples are provided for hole locations. (See Fig. 1.) Since the horizontal crawlspace installation is very similar to the attic, refer to Attic Installation section. The installation of a sheet metal shield in front of the louvered control panel is covered in Attic Installation section. For a crawlspace installation, this same sheet metal shield must be installed above the louvered control panel. Extend the sheet metal shield over the furnace top far enough to cover the gas pipe entry hole. IV. FILTER ARRANGEMENT WARNING: Never operate unit without a filter or with filter access door removed. A failure to follow this warning could result in fire, personal injury, or death. The factory- supplied filter(s) are shipped in the blower compart- ment. Determine location for the filter and move filter retaining hardware, if necessary, before attaching the return-air duct. After the return-air duct has been connected to the furnace, install the filter(s) inside the furnace blower compartment. See Fig. 7 for side return application and Fig. 8 for bottom return application. 1 LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET, BUILDING JOISTS, STUDS, OR FRAMING. MANUAL SHUTOFF GAS VALVE 30•IN. MIN WORK AREA CLEARANCE TO COMBUSTIBLE MATERIALS Fig. 4— Horizontal Attic Installation A95233 ANGLE IRON OR EQUIVALENT ROD LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL NSIONAL 3/8-IN. HEX NUT DWG FOR & WASHER ( ) LOCATIONS) READ PER ROD Fig. 5— Horizontal Crawlspace A bottom closure panel is factory installed in the bottom of the furnace. When bottom return inlet is desired, remove and discard the enclosure panel. Filter retaining brackets, supports, and retainers are factory as- sembled and shipped installed for side return application, with 1 set of all required hardware on each furnace. (See Fig. 7.) 3/e -IN. ROD NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. 2. The entire length of furnace must be supported when furnace Is used in horizontal position. A95234 Installation on Hanger Rods For bottom return applications, remove the front and back brackets and supports from each side. The back bracket(s) are installed in the rear of the furnace casing. Dimples are provided to mark mounting screw locations. The front bracket(s) are installed on the bottom front plate, as shown in Fig. 8, once the bottom enclosure has been removed. 1111IIIIIIIIII$ 1111111111 1111111 1 1 11 J 111111111 11111111111 11111 11111111111 Fig. 6— Horizontal Installation on Blocks FILTER RETAINER WASHABLE FILTER A95235 Fig. 7 —Side Filter Arrangement A95284 Rotate filter side supports 180° so filter will rest on support and reinstall. Install small U- shaped end of filter retaining rod in the rear bracket. Install the front of the filter retainer rod as shown in Fig. 8. Two sets of hardware are needed for furnaces in 24 -1/2 in. casings using 2 filters for bottom return. All hardware is provided for filter installation. WASHABLE FILTER FILTER ALTER RETAINER SUPPORT A93046 Fig. 8— Bottom Filter Arrangement TABLE 3— FILTER INFORMATION (IN.) FURNACE CASING WIDTH FILTER SIZE* FILTER TYPE Side Return Bottom Return 14.3/16$ (1) 16 X 25 X 11. (1) 14 X 25 X 1 Cleanable 21 (1) 16 X 25 X 1 (1) 20 X 25 X 1 t Cleanable 24.1/2 (2) 16 X 25 X 11- (1) 24 X 25 X 1 Cleanable Filters can be field modified by cutting the frame as marked and folding to the desired size. Alternate sizes can be ordered from your distributor or dealer. t Factory•provided with the furnace. $ External side filter rack must be used for upilow right-side return. —7— V. LEVELING LEGS (IF REQUIRED FOR UPFLOW) 5/18': 1 3/4' 5/18" 1 3A" 1 3/4 "y.. A89014 Fig. 9— Leveling Leg Installation When the furnace is used with side inlet(s) and leveling legs are required, refer to Fig. 9 and install field - supplied, corrosion - resistant 5 /16 -in. machine bolts and nuts. NOTE: The length of the bolt should not exceed 1 -1/2 in. 1. Lay furnace on its back. Locate and drill 5 /16 -in. diameter hole in each bottom corner of furnace as shown in Fig. 9. 2. Install nut on bolt and install bolt with nut in hole. (Install flat washer if desired.) 3. Install another nut on other side of furnace base. (Install flat washer if desired.) 4. Adjust outside nut to provide desired height and tighten inside nut to secure arrangement. VI. GAS PIPING CAUTION: Emissions control devices located at the heat exchanger inlets MUST be removed for propane installations (Refer to gas conversion kit for instructions). Gas piping must be installed in accordance with national and local codes. Refer to the NFGC in U.S. Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction. A WARNING: If a flexible connector is required or allowed by the authority having jurisdiction, black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in. outside the furnace casing. A failure to follow this warning could result in fire, personal injury, or death. The gas supply line should be a separate line running directly from the gas meter to the furnace, if possible. Refer to Table 4 for the recommended gas pipe size, Risers must be used to connect to the furnace and the meter. Piping should be pressure tested in accordance with local and national plumbing and gas codes BEFORE the furnace has been attached. If the test pressure exceeds 0.5 psig (14 -in. wc), the gas supply pipe must be disconnected from the furnace and capped before the pressure test. If the test pressure is equal to or less than 0.5 psig (14 -in. wc), close the manual shutoff valve before the test. (See Fig. 10.) It is recommended that the ground joint union be loosened before pressure testing. After all connections have been made, purge the lines and check for leakage with regulated gas supply pressure. Install a sediment trap in the riser leading to the furnace. The trap can be installed by connecting a tee to the riser leading from the furnace. Connect a capped nipple into the lower end of the tee. The capped nipple should extend below the level of the gas controls. (See Fig. 10.) GAS SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION 1/ Fig. 10— Typical Gas Pipe Arrangement TABLE 4— MAXIMUM CAPACITY OF PIPE* A89417 NOMINAL IRON PIPE INTERNAL DIAMETER LENGTH OF PIPE (FT) 10 20 30 40 50 SIZE (IN.) (IN.) 1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151 1 1.049 680 465 375 320 285 1 -1/4 1.380 1400 950 770 660 580 1 -1/2 1.610 2100 1460 1180 990 900 • Cubic It of gas per hr for gas pressures of 0.5 psig (14 -in. wc) or less, and a supply line pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 10.2, NFGC. Apply joint compound (pipe dope) sparingly and only to the male threads of each joint. The compound must be resistant to the action of propane gas. Install an accessible manual shutoff valve upstream of the furnace gas controls and within 72 in. of the furnace. A 1 /8 -in. NPT plugged tapping is provided on the gas valve for test gage connection. Installation of an additional I /8 -in. NPT plugged tapping, accessible for test gage connection, installed immediately upstream of the gas supply connection to the furnace and down- stream of the manual shutoff valve, is not required. Place ground joint union between the gas control manifold and the manual shutoff valve. —8— WARNING: Use the proper length of pipes to avoid stress on the gas control manifold. A failure to follow this warning can cause a gas leak resulting in a fire, explosion, personal injury, or death. CAUTION: Use a backup wrench at the furnace gas control when connecting the gas pipe to the furnace to avoid damaging gas controls or manifold. WARNING: Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap - and -water solution to check for leakage. A failure to follow this warning can cause a fire, explosion, personal injury, or death. VII. ELECTRICAL CONNECTIONS A. 115 -v Wiring Refer to the unit rating plate or Table 5 for equipment electrical requirements. The control system requires an earth ground for proper operation. CAUTION: Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. —4 Make all electrical connections in accordance with the National Electrical Code (NEC) ANSI/NFPA 70 -1996 and local codes or ordinances that might apply. For Canadian installations, all elec- trical connections must be made in accordance with CSA C22.1 Canadian Electrical Code, or authorities having jurisdiction. —4 WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70 -1996 and Canadian Electrical Code, CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. The junction box can be moved to the left -hand side of the furnace when a left -hand side power supply is desired. Remove the 2 screws holding the junction box. Mount the junction box on the left -hand side of the furnace, Holes have been provided in casing. When moved, tuck the wiring harness behind the clip provided to keep extra wire lengths out of the way. NOTE: Proper polarity must be maintained for l 15 -v wiring. If polarity is incorrect, the furnace control status LED will flash rapidly and prevent heating operation. B. 24 -v Wiring Refer to ESD Precautions Procedure before proceeding with 24 -v connections. Make field 24 -v connections at the 24 -v terminal block. (See Fig. 13.) Connect terminal Y /Y2 as shown in Fig. 11 or 12 for proper cooling operation. Use only AWG No. 18 or larger, color -coded copper thermostat wire. The 24 -v circuit contains an automotive -type, 3 -amp fuse located on the tnain control. Any 24 -v electrical shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3 -amp fuse. The control will flash code 24 when the fuse needs replacement. 115 -VOLT FIELD - SUPPLIED FUSED DISCONNECT FIVE WIRE THREE -WIRE HEATING - ONLY NOTE 2 - - -- FIELD 24 -VOLT WIRING ---- FIELD 115 -, 208/230 -, 460 -VOLT WIRING FACTORY 24 -VOLT WIRING FACTORY 115 -VOLT WIRING 1 -STAGE THERMOSTAT TERMINALS FIELD - SUPPLIED FUSED DISCONNECT JUNCTION BOX CONTROL BOX o- o- 24 -VOLT TERMINAL BLOCK ' NOTE 1 FURNACE CONDENSING UNIT 208/230- OR - - 460 -VOLT -- THREE PHASE — 1208/230- lS - - SINGLE -- PHASE NOTES: 1. Connect Y/V2- terminal as shown for proper operation. 2. Some thermostats require a'C' terminal connection as shown. 3. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. A95236 Fig. 11— Heating and Cooling Application Wiring Diagram 1 -Stage Thermostat and Condensing Unit SEVEN WIRE FOUR -WIRE HEATING - ONLY 115 -VOLT FIELD - SUPPLIED FUSED DISCONNECT NOTE 2 tw1 vi c "cP Yt --1.1 I I I 1 - - -- FIELD 24 -VOLT WIRING - - -- FIELD 115 -, 208/230 -, 460 -VOLT WIRING FACTORY 24 -VOLT WIRING FACTORY 115 -VOLT WIRING 2 -STAGE THERMOSTAT TERMINALS FIELD - SUPPLIED FUSED DISCONNECT JUNCTION BOX CONTROL BOX AFS NOTE 1 -4 24 -VOLT TERMINAL BLOCK FURNACE 1Y1 2 -SPEED CONDENSING UNIT 208/230.OR 460 -VOLT 1THREE PHASE -1208/230 - `VOLT - ISINGLE – PHASE NOTES: 1. Connect Y1 and Y/Y2 as shown for proper operation. 2. Some thermostats require a 'C' terminal connection as shown. 3. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. A96060 Fig. 12— Heating and Cooling Application Wiring Diagram 2 -Stage Thermostat and Condensing Unit TABLE 5— ELECTRICAL DATA UNIT SIZE VOLTS— HERTZ— PHASE OPERATING VOLTAGE RANGE MAX UNIT AMPS MIN WIRE GAGE MAX WIRE LENGTH (FT)$ MAX FUSE OR HACR -TYPE CKT BKR AMPSt Max' Min' 060-12 115 -60-1 127 104 10.1 14 36 15 080 -16 115-60-1 127 104 10.6 14 34 15 100-20 115 -60-1 127 104 12.6 14 29 15 120-20 115-60-1 127 104 13.9 14 26 15 Permissible limits o the voltage range at which the unit will operate satisfactorily. t Time -delay fuse Is recommended. # Length shown Is as measured along wire path between unit and service panel for maximum 2 percent voltage drop. —9— EAC - ELECTRONIC AIR CLEANER (115 -VAC 1 AMP MAX) y— D —FU EP LED - DIAGNOSTIC LIGHT TWIN / TEST TERMINAL HUM - HUMIDIFIER (24-VAC MP MAX)5 24 -VOLT THERMOSTAT TERMINALS FURNACE AND BLOWER OFF DELAY SETUP SWITCHES A95231 Fig. 13— Furnace Control C. Accessories I. Electronic air cleaner (EAC) A terminal block (EAC -I [hot] and EAC -2 [neutral]) is provided for EAC connection. (See Fig. 13.) The terminals are energized with 115v, 1 -amp maximum during blower motor operation. 2. Humidifier (HUM) Screw terminals (HUM and Cont 24V) are provided for 24 -v humidifier connection. The terminals are energized with 24v, 0.5 -amp maximum when the gas valve is energized. VIII. VENTING Refer to the enclosed Installation Instructions, GAMA Venting Tables for Category I Furnaces, and Venting for 2 -stage Category I fan - assisted furnaces. In Canada use venting tables found in CAN /CGA B149.1 or .2 -M91 Amendment No. I. The horizontal portion of the venting system shall maintain a minimum of 1 /4 -in. upward slope per linear ft (away from furnace), and it shall be rigidly supported every 5 ft or less with hangers or straps to ensure that there will be no movement after installation. IX. START -UP, ADJUSTMENT, AND SAFETY CHECK A. General The furnace must have a 115 -v power supply properly connected and grounded. Correct polarity must be maintained to enable gas heating operation. The gas service pressure must not exceed 0.5 psig (14 -in. wc), and no Tess than 0.16 psig (4.5 -in. wc). Thermostat wire connections at R and W/W I are the minimum required for gas heating operation. W2 must be connected for 2 -stage heating thermostats. Y/Y2 and G are required to be connected to the furnace for cooling and heat pumps. G is required for continuous -fan. Coht 24V is required for some clock thermo- stats. These connections must be made at the 24 -v terminal block on the furnace control. (See Fig. 13.) 0 is required for heat pumps only. Y1 is required for 2 -stage cooling and 2 -stage heat pumps. The 0 and Y1 connectors must be made to the ICM2+ furnace's orange and blue leads, flagged "O" and "Y1," respectively. This furnace can be installed with either a single -stage heating or a 2 -stage heating thermostat. For single -stage thermostats, connect thermostat R to W/W I at the -10- furnace control terminal block. (See Fig. 11.) For single -stage thermostats, the control will determine, based on length of previ- ous heating on and off cycles, when to operate in low- and high -stage for optimum comfort. Setup switch -2 (SW -2) must be in the factory- shipped OFF position. See Fig. 14 and Tables 6 and 7 for setup switch information. BLOWER - OFF DELAY LOW HEAT (ADAPTIVE ALGORITHM) HIGH HEAT ONLY 4 3 2 1 ON OFF A93377 Fig. 14 —Setup Switches on Furnace Control (Factory Settings) If a 2 -stage heating thermostat is to be used, move SW -2 to the ON position at the end of the furnace installation. This overrides the built -in control process for selecting high- and low -stage and allows the 2 -stage thermostat to select gas heating modes. The W2 from the thermostat must be connected to W2 on the control terminal block. (See Fig. 12.) CAUTION: This furnace is equipped with a manual reset limit switch in the gas control area. The switch will open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switch. Correct inadequate combustion -air supply, component failure, or restricted flue gas passageway before resetting the switch. Before operating the furnace, check each manual reset switch for continuity. If necessary, press and release the button to reset the switch. B. Sequence of Operation Using the schematic diagram in Fig. 16, follow the sequence of operation through the different modes. Read and follow the diagram very carefully. NOTE: The GE ICM2+ BLWM speeds are infinitely variable from 300 to 1400 rpm and are dynamically controlled to precisely control airflow rate (CFM). The ICM2+ motor ramps to speed at a controlled rate to reduce start -up noise perception (4 to 11 sec, depending on the target CFM). The ICM2+ motor ramps down slowly to a stop in the same time as the ramp -up time. ICM2+ ramp -up and ramp -down times are additive to blower -on and -off delays, respectively. The ICM2+ is 115 -v energized whenever power is available at the furnace control, but operates only when the 24 -v motor control input(s) are on. NOTE: If a power interruption occurs during a call for heat (W/W 1 or W/W 1 and W2) and if the thermostat is still calling for gus heating, the control will start a 90 -sec blower only on period 2 sec after power is restored. The red LED will flash code 12 during the 90 -sec period, after which the LED will be on TABLE 6 —SETUP SWITCH DESCRIPTION SETUP SWITCH NO. NORMAL POSITION DESCRIPTION OF USE SW -1 Only High-Gas Heat OFF (Staged Gas Heat) Turn switch on to obtain only high-gas-heat operation on any call for heat regardless of whether R -W/W1, or R -W/W1, -W2 is closed. SW -1 overrides SW -2. SW-2 Low -Gas Heat (Adaptive Mode) OFF (Single -Stage Thermostat) Turn switch off for Installations with single stage thermostats; con- trol selects low - gas -heat or high-gas-heat operation based on pre - vlous cycles. Turn switch on for Installations with 2 -stage thermo• stats to permit only low - gas -heat operation In response to closing R -W/W1. High -gas heat is supplied only when R to W/W1 and W2 are closed. SW -3 and SW4 ON, OFF Switches control gas heating mode blower -off delay. (See Table 7.) TABLE 7— BLOWER -OFF DELAY SETUP SWITCH (SW) POSITION DESIRED HEATING MODE BLOWER -OFF DELAY (SEC) SETUP SWITCH SW -3 SW4 90 OFF OFF 135 OFF ON 180 ON OFF 225 ON ON continuously as long as no faults are detected. The ICM2+ motor will operate at low -gas heat CFM after a power interruption in either low- or high - stage. After the 90 -sec period, the furnace will respond to the thermostat normally. The blower door must be installed for power to be conducted through the blower door interlock switch (ILK) to the furnace control (CPU), transformer (TRAN), inducer motor (IDM), blower motor (BLWM), hot surface ignitor (HSI), and gas valve (GV). 1. Adaptive Heating Mode — Single -Stage Thermostat with 2 -Stage Heating (See Fig. 11 for thermostat connections.) NOTE: In response to thermostat call for heat R to W/W1, the control selects high -stage heating only with HIGH HEAT ONLY switch (SW1) set to ON regardless of the LOW HEAT switch (SW2) setting. With the HIGH HEAT ONLY switch set to OFF, the LOW HEAT switch selects either the low -stage heating only mode when set to ON, or the adaptive heating mode when set to OFF in response to a thermostat call for heat R to W/W1. (See Fig. 14 for description of switch settings or Fig. 16 for control circuit diagram.) This furnace can operate as a 2 -stage furnace with a single -stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low- or high -stage gas heat opera- tion. This selection is based upon the stored history of the lengths of previous gas heating on/off periods of the single -stage thermostat. The furnace will start up in either low- or high -stage gas heat. If the furnace starts up in low- stage, the control CPU determines the low -stage on time (from 0 to 16 minutes) which is permitted before switching to high- stage. If the power is interrupted, the stored history is erased. When this happens, the control CPU selects low -stage for 16 minutes and then switches to high - stage, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the thermostat cycle tirnes. When the thermostat calls for heat, R -W/W1 circuit closes. The furnace control performs a self- check, verifies that the pressure switch contacts for low- and high -stage (LPS and HPS) are open, and starts the IDM in low speed or high speed as appropriate. a. Inducer prepurge period —A 15 sec prepurge period begins when LPS contacts close. For high -stage opera- tion, both LPS and HPS must be closed. For low -stage operation, only LPS must be closed. —11— b. Ignitor warm -up—At the end of the prepurge period, the HSI is energized for a 17 -sec ignitor warm -up period. c. Trial - for - ignition sequence —When the ignitor warm -up period is completed, the main gas valve relay contacts (MGVR -1 and -2) (and high -heat pressure switch relay HPSR for high -stage operation) close to energize low - (and high -) stage the gas valve solenoid(s) (GV) and the humidifier terminal (HUM). The gas valve opens, and 24 -v power is supplied for a field- installed humidifier at terminals HUM and Com 24V. The GV permits gas flow to the burners where it is ignited. After 5 sec, the HSI is de- energized, and a 2 -sec flame - proving period begins. If the HPS fails to close on a call for high -stage gas heat and the LPS closes, the furnace operates at low -stage gas flow rate until the HPS closes. d. Flame- proving —When the burner flame is proved at the flame- proving sensor electrode (FSE), the control CPU begins the blower -on delay period and continues to hold the GV open. If the burner flame is not proved within 2 sec, the control CPU closes the GV, and the control CPU repeats the ignition sequence for up to 3 more trials -for- ignition before going to ignition lockout. The CON- TROL TERMINATES LOCKOUT AUTOMATI- CALLY after 3 hrs, or by momentarily interrupting 115 -v power to the furnace, or by interrupting 24 -v power at SEC l or SEC2 to the control CPU (not at W/W 1, G, R, etc.). Opening the thermostat R -W circuit will not terminate an ignition lockout. If flame is proved when flame should not be present, the control CPU locks out of gas heating mode and operates the IDM on high speed until flame is no longer proved. e. Blower -on delay —If the burner flame is proved, 45 sec after the GV is opened the BLWM is energized at the appropriate heating airflow: low- or high -stage CFM. Simultaneously, the terminals EAC -I and EAC -2 are energized with 115v and remain energized as long as BLWM is energized. f. Switching from low- to high -stage gas heat —If the furnace control CPU switches from low- to high - stage, the control CPU switches the IDM speed from low to high. The high -heat pressure switch relay (HPSR) closes. When the IDM provides sufficient pressure to close the HPS, the high -stage gas valve solenoid GV is energized. The BLWM switches to high -stage airflow 5 sec after the control CPU switches from low -gas heat to high -gas heat. g. Switching from high- to low -stage gas heat —The con- trol CPU will not switch from high- to low -stage while the thermostat R -W circuit is closed when a single -stage thermostat is used. _4 h. Blower -off delay —When the thermostat is satisfied, the R -W circuit is opened, the GV is de- energized, stopping gas flow to the burners, and terminals HUM and CoM 24V are de- energized. The IDM remains energized for a 5 sec post -purge period. The BLWM, which had been operating at low- or high -stage airtlow, will operate at low -stage airflow for 90 sec. (1.) When in low -stage gas heat and the thermostat is satisfied, the blower will continue to operate at the low -stage gas heat CFM until the blower -off delay reaches 90 sec. If the blower -off delay switches (on the 2 -stage furnace control) are set for more than 90 sec, the blower will operate at the selected continu- ous fan CFM for the remaining blower -off delay time. (2.) When in high -stage gas heat and the thermostat is satisfied, the blower will continue to operate at the high -stage gas heat CFM until the blower -off delay expires, for all settings of the gas heat blower -off delay switches on the 2 -stage furnace control. i. The furnace control is factory set for a 135 -sec blower - off delay. 2. Non - Adaptive Heating Mode— Two -Stage Thermostat and 2 -Stage Heating (See Fig. 12 for thermostat connections). NOTE: In response to thermostat call for heat R to W/W I and with HIGH HEAT ONLY switch SWI set to OFF, the control selects low -stage heating only with LOW HEAT switch SW2 set to ON, or the control selects adaptive heating mode with LOW HEAT switch SW2 set to ON. The control selects high -stage heating only with HIGH -HEAT ONLY switch SW 1 set to ON. In response to thermostat call for high -stage heat R to WI and W2, the control selects high -stage heating regardless of switch SW I and SW2 settings. See Fig. 14 for description of switch settings or Fig. 16 for control circuit diagram. The start-up and shutdown functions and delays described in item 1. apply to the 2 -stage heating mode as well, except for switching from low- to high -stage and vice versa. a. When the thermostat calls for heat, the R -W/W I circuit closes for low -stage or the R to W1- and -W2 circuits close for high - stage. The furnace control performs a self - check, verifies pressure switch contacts for low- and high -stage LPS and HPS are normally open, and starts the IDM in low speed or high speed as appropriate. b. Switching from low- to high -stage gas heat —If the thermostat R-W/W1 circuit for low -stage is closed and the R -W2 circuit for high -stage closes, the control CPU switches the IDM speed from low to high. The HPSR closes. When the IDM provides sufficient pressure to close the HPS, the high -stage gas valve solenoid GV is energized. The BLWM switches to high -stage airtlow 5 sec after the R -W2 circuit closes. c. Switching from high- to low -stage gas heat —If the thermostat R -W2 circuit for high -stage opens and the R -W/W 1 circuit for low -stage remains closed, the con- trol CPU switches the IDM speed from high to low. The HPSR opens to de- energize the high -stage gas valve solenoid GV. When the IDM reduces pressure suffi- ciently, the HPS opens. The low -stage gas valve solenoid GV remains energized as long as the LPS remains closed. The BLWM switches to low -stage airflow 5 sec after the R -W2 circuit opens. 3. Cooling Mode a. Single -Speed Cooling Outdoor Unit (See Fig. 11 for thermostat connections.) —12— (1.) The thermostat closes the R to G -and -Y circuits. The R -Y circuit starts the outdoor unit, and the R to G- and -Y/Y2 circuits start the furnace BLWM on cooling speed. (2.) The terminals EAC -1 and EAC -2 are energized with 115v when the BLWM is operating. (3.) When the thermostat is satisfied, the R to G -and -Y circuits are opened. The outdoor unit stops, and the furnace BLWM continues operating at cooling air- flow for an additional 90 sec. b. Two -Speed Cooling Outdoor Unit (See Fig. 12 for thermostat connections.) (1.) The thermostat closes the R to G- and -Y1 circuits for low cooling or closes the R to G- and- Y1 -and- Y/Y2 circuits for high cooling. The R to Y1 circuit operates the outdoor unit on low cooling speed. The R to G- and -Y1 circuit operates the furnace BLWM at low cooling airflow (65% of single -speed cooling airflow; different airflow than for low -gas heat). The R to Y1- and -Y2 circuits operate the outdoor unit on high - cooling airflow, and the R to G -and- Y/Y2- and -Y1 circuits operate the furnace BLWM at high - cooling airflow. Two -speed high - cooling airflow is 105% of single -speed cooling airflow. NOTE: Y1 is found in the outdoor unit. The furnace control CPU controls BLWM airflow by sensing only G- and -Y1 for low - cooling airflow and G- and -Y1- and -Y/Y2 for high - cooling airflow. (2.) Terminals EAC -1 and EAC -2 are energized with 115v when the BLWM is operating on either cooling airflow. (3.) When the thermostat is satisfied, the R to G -and- Y 1 or R to G -and -Y 1- and -Y/Y2 circuits open. The outdoor unit stops, and the furnace blower contin- ues operating on the same cooling airflow for an additional 90 sec. 4. Continuous - Blower Mode a. When the R to G circuit is closed by the thermostat, the BLWM operates at LOW, MED, or HI (50 %, 65%, or 100% of single -speed cooling airflow; different than low -gas heat airflow). LOW, MED, and HI selections are described in Set -up Procedures. Terminals EAC- 1 and EAC -2 are energized with 1 15v as long as the BLWM is operating. b. During a call for heat, the BLWM stops during ignitor warm -up (17 sec), ignition (7 sec), and blower -on delay (45 sec), allowing the furnace heat exchangers to heat up quickly, after which the BLWM operates at the appro- priate gas heating airflow. c. The BLWM reverts to continuous - blower airflow after the heating cycle is completed. In high -stage gas heating, the furnace control CPU and ICM2+ motor control hold the BLWM at low -stage airflow for a 90 -sec blower -off delay period (regardless of selected blower -off delay) before reverting to continuous- blower airflow. d. When the thermostat calls for low - cooling, the BLWM switches to low -cool airtlow or the selected continuous - blower airflow, whichever is greater. Note that a HI selection for continuous - blower airflow will provide more than normal airflow during 2 -speed low - cooling. When the thermostat is satisfied, the BLWM switches to continuous- blower airflow. e. When the thermostat calls for high cooling, the BLWM operates at high -cool airflow. When the thermostat is satisfied, the BLWM operates an additional 2 sec at high -cool airflow before reverting back to continuous - blower airflow. f. When the R -G circuit is opened, the BLWM continues operating for an additional 90 sec, if no other function requires BLWM operation. 5. Heat Pump Mode NOTE: A dual -fuel thermostat or accessory interface kit is required with single -speed heat pumps. See dual -fuel thermostat or interface kit Installation Instructions for single -speed heat pump thermostat and interface connections. No interface kit is needed for 2 -speed heat pumps. See 2 -spced heat pump Installation Instruc- tions to determine whether a standard or dual -fuel heat pump thermostat is required and for thermostat connections. NOTE: See TSTAT Price Page for dual -fuel thermostat ordering number. a. Single -Speed Heat Pump Cooling (1.) The thermostat and interface kit close the R to Y/Y2 -and -G -and -O circuits to operate the furnace BLWM at cooling airflow. The Y /Y2 input to the furnace control is necessary to provide adequate cooling airflow. (2.) Terminals EAC -1 and EAC -2 are energized with 115v when the BLWM is operating. (3.) When the thermostat is satisfied, furnace BLWM continues operating at the cooling airflow for an additional 90 sec. b. Two -Speed Heat Pump Cooling (1.) The thermostat R to G- and -Y1 -and -O circuits op- erate the furnace BLWM at low -cool airflow. The thermostat R to G- and -Y /Y2- and -Y1 -and -O cir- cuits operate the furnace BLWM at high -cool air- flow (105% of single -speed cooling airflow). NOTE: The furnace control CPU controls blower airflow by sensing G, Y1, and 0 for low -cool airflow and G, Y1, Y /Y2, and 0 for 2 -speed high -cool airflow. (2.) Terminals EAC -1 and EAC -2 are energized with I I 5v when the BLWM is operating at either cooling airflow. (3.) When the thermostat is satisfied, the furnace BLWM continues operating at the same cooling airflow for an additional 90 sec. c. Single -Speed Heat Pump Heating (1.) The thermostat (and accessory interface kit) R to G- und-Y/Y2 circuits operate the furnace BLWM at heat pump heating airflow. Heating airflow is the same as cooling airflow for airflow selection HP- EFFY and 90% of cooling airflow for HP -CFMT selection. (2.) Terminals EAC -1 and EAC -2 are energized with I I5v when the BLWM is operating. (3.) When the thermostat is satisfied, the furnace BLWM continues operating at the same heat pump heating airflow for an additional 90 sec. d. Two -Speed Heat Pump Heating (1.) The thermostat closes the R to Y1 -und -G circuits for low heat and operates the furnace BLWM at heat pump low -heat airflow (may not be identical to low- cooling airflow, depending on HP selection at airflow selector). Closing the R -Y/Y2, Y1 and G circuits to the furnace provides BLWM heat pump high -heat airflow. —13— NOTE: The furnace control CPU controls BLWM airflow by sensing G and Y1 for heat pump low- heating airflow, and 0, Y1, and Y/Y2 for heat pump high - heating airflow (105% of single - speed heating airflow). (2.) Terminals EAC -1 and EAC -2 are energized with 1 15v when the BLWM is operating at either heating airflow. (3.) When the thermostat is satisfied, the furnace BLWM continues operating at the same heating airflow for an additional 90 sec. (4.) Opening only the R -Y/Y2 circuit switches the BLWM to heat pump low- heating airflow. 6. Defrost a. When the furnace control R to W/Wl- and -Y/Y2 circuits are closed, the furnace control CPU continues BLWM operation at the heat pump heating airflow until the end of the prcpurge period, then shuts off BLWM until the end of the HSI ignitor -on period (22 sec). b. When installed with a heat pump, the furnace control CPU automatically holds the blower -off time to 22 sec during the HSI ignitor -on period. After 17 sec of the HSI ignitor -on period, a trial- for - ignition sequence occurs as described above for gas heating. After flame is proven and without a blower -on delay, the BLWM then operates at high - gas -heat airflow during defrost. For both single - speed and 2 -speed heat pumps, defrost mode is in high -gas heat only. c. When furnace control R -W/W l circuit is opened, the furnace control CPU begins the normal inducer post - purge period and the BLWM continues operating for the blower -off delay period. If the R -G circuit remains closed, the BLWM reverts to continuous - blower opera- tion. C. Set -up Procedures The ICM2+ blower motor operating mode selections are mode on the airflow selector control with color -coded jumper wires. The factory jumper settings have large bold circles marked around the pins. (See Fig. 16.) NOTE: The ICM2+ furnaces are not approved for twinning. 1. Gas Heating a. The VIOLET wire is factory connected to 1 of 4 pins: A, B, C, or D on airflow selector. The factory pin selection can be checked by noting PIN marking in the lower right -hand corner of furnace rating plate. b. The gas heating air temperature rise is selected on airflow selector (See Fig. 15.) with RED and VIOLET jumper wires. The selections are MID, HI, and MED -HI. MID gives mid point of temperature rise range marked on rating plate. HI gives high end of temperature rise range. MID -HI gives temperature rise about halfway between MID and HI. Select the rise by moving WHITE connectors on RED and VIOLET jumper wires to desired pin positions. These settings select the rise for high and low stages. See Table 8 for air temperature rise. 2. Cooling and Heat Pump Heating a. The cooling and heat pump selections can be determined from Tables 9 and 10, The selections are made by moving the WHITE connector on appropriately colored jumper wire to desired pin position, NOTE: Power must be cycled off and then on for the cool size selection to take effect. Power need not be cycled off and on for the CFM/TON to take effect. O O O P12 0 07 D6 M•HIO M•LOO 0 0 D1 02 -jp F 03 -1 F 04 R3 Off ORN D9 ill Lw�J 010 HI MED 0 O G d COOL z E CO TON PER AC HP ORN HEAT TEMP RISE RED CONTINUOUS CFM • ORN A96061 —> Fi 15— Airflow Selector Control b. The YELLOW COOL SIZE jumper is used to select airflow to match the needed tons for the cooling or heat pump system. The BLUE CFM/TON jumper is used to select a slight adjustment to the airflow. The traditional CFM per ton is 400 for cooling and heat pump airflow. 350 CFM per ton is the airflow used to attain the best efficiency with these units. 315 CFM per ton is the airflow used for improved dehumidification and/or with undersized ducts. Additional humidity control can be attained by using a humidistat (see Set -up Procedures section, item 4.). c. The ORANGE jumper wire selects airflow for cooling - only (AC) or heat pump heating and cooling, and selects heat pump heating best efficiency (HP EFFY) or en- hanced comfort (HP CMFT). HP EFFY provides the same heating airflow as used for cooling. HP CMFT reduces the heating airflow to 90% of the cooling airflow for a higher air temperature rise and better comfort. 3. Continuous -fan The GREEN jumper wire selects the airflow CFM for continuous -fan. LO provides 50% of the airflow used for single -speed cooling or 2 -speed cooling. MED provides 65% of cooling airflow. HI provides 100% of cooling airflow for continuous -fan operation. NOTE: If HI is selected with a 2 -speed cooling or heat pump system, the airflow will remain at 100% of high - cooling/heating when the system is in low- cooling and heat pump low - heating mode. Continuous -fan selection has no effect on gas - heating airflow. 4. As an altemative to selecting 315 CFM per ton for cooling airflow, an active dehumidification mode can be invoked by connecting a humidistat in series with the GREEN wire marked DEHUM connected to the 1/4 quick- connect termi- nal at G on the furnace control. The humidistat contacts should open on a rise in humidity. When the humidistat contacts open, the airflow will be reduced to 80% of the selected airflow, except that this airflow will not be reduced to less than 280 CFM per ton. —14— NOTE: When a humidistat is calling for reduced airflow and the thermostat is satisfied, the blower will not operate on the continuous -fan LOW setting to prevent re- evaporation of conden- sate at the evaporator coil. When continuous -fan MED or HI setting is selected, normal airflow will be reduced to 80 %. D. Start -up Procedures 1. Component test —The furnace features a component test system to help diagnose a system problem in the case of a component failure. To initiate the component test proce- dure, ensure that there are no thermostat inputs to the control and all time delays have expired. Short the TWIN/TEST terminal to ground or CoM 24V for 1 to 4 sec. (See Fig. 13.) NOTE: The component test feature will not operate if the control is receiving any thermostat signals or until all time delays have expired. The ICM2+ blower motor speed ramp -up will slightly delay blower response times. The component test sequence is as follows: u. The furnace control checks itself, operates the inducer motor on low speed for 7 sec and on high speed for 7 sec, then stops. b. The hot surface ignitor is energized for 15 sec, then de- energized. c. The blower motor operates at continuous -fan airflow for 7 sec. d. The blower motor operates at high -gas heat airflow for 7 sec. The gas valve and humidifier terminal HUM are not energized for safety reasons. c. The blower motor operates at single -speed cooling/heat pump heating airflow (or 2 -speed heat pump high - heat/high- cooling) for 7 sec, then stops. NOTE: The EAC terminals are energized when the blower is operating. 2. After all connections have been made, purge gas lines and check for leaks. WARNING: Never purge u gas line into u combustion chamber. Never use matches, candles, flume, or other sources of ignition for the purpose of checking leakage. Use a soap -and -water solution to check for leakage. A failure to follow this warning can cause a fire, explosion, personal injury, or death. 3. To operate furnace, follow procedures on operating instruc- tions label attached to furnace. 4. With furnace operating, set thermostat below room tem- perature and observe that furnace goes off. Set thermostat above room temperature and observe that furnace restarts. E. Adjustments 1, Set gas input rate. The gas input rate must be set for both high- and low -stage heat. Each adjustment is made independently at the gas control regulators. There are 2 methods of adjusting the gas input rate. The preferred method is by using Table 11 and following instructions in item a. The second method is by clocking the gas meter and following instructions in item b. The procedure in item b. MUST be used for altitudes above 2000 ft. The gas valve regulator has been nominally set at 1.5 -in. wc for low -stage and 3.5 -in. wc for high -stage for natural gas. TABLE 8 —GAS HEAT AIRFLOW — NOMINAL CFM (WITH F LTER) FURNACE SIZE GAS HEAT TEMP RISE* GAS HEAT TEMP RISE ( °F)t GAS HEAT AIRFLOW (CFM) Jumper Position High -Stage Low -Stage High -Stage Low -Stage Red Wire Violet Wire 060 HI A 51 45 925 615 M -HI A 46 38 1085 730 MID D 40 30 1250 1135 080 HI A 58 44 970 790 M -HI A 51 39 1140 925 MID D 45 29 1310 1395 100 HI A 51 44 1430 1035 M -HI A 45 39 1685 1215 MID D 40 30 1935 1630 120 HI A 69 49 1330 1240 M -HI A 59 43 1560 1460 MID 0 55 40 1720 1605 Use listed jumper position combinations only. tWilhin t 2 °F --> TABLE 9 —AIR CONDITIONING AND HEAT PUMP COOLING/EFFICIENCY HEATING AIRFLOW NOMINAL CFM (WITH FILTER) AC AIR CONDITIONING, COOLING AIRFLOW AC /HP JUMPER POSITION: HP —EFFY HEAT PUMP — EFFICIENCY, COOLING AND HEATING AIRFLOW HP —CFMT HEAT PUMP — COMFORT, COOLING AIRFLOW Furnace Size Airflow Selection Single -Speed CFM Two -Speed (High/Low) CFM Cool Size Jumper Position Tons Cool CFM Per Ton Jumper Position Cool CFM Per Ton Jumper Position 400 350 315 400 350 315 High Low High Low High Low 060 LO 1 -1/2 600 530 500' 630 500' 550 500' 500' 500' M -LO 2 800 700 630 865 510 735 500" 660 500' M -HI 2 -1/2 1000 880 790 1060 650 920 570 825 510 HI 3 1200 1050 945 1260 780 1100 680 990 585 080 LO 2 -1/2 1000 875 790 1050 660 920 595 830 545 M -LO 3 1215 1050 945 1260 790 1100 700 990 625 M -H1 3-1/2 1400 1225 1100 1470 910 1280 805 1155 715 HI 4 1600 1400 1350 1635 1040 1470 915 1325 820 100 LO 3 1195 1045 950 1260 780 1090 775 990 700' M -LO 3-1/2 1400 1225 1090 1470 910 1285 830 1155 715 M -HI 4 1600 1400 1260 1680 1040 1465 915 1325 820 HI 5 2000 1750 1575 1085 1300 1840 1150 1655 1025 120 LO 3 1160 1050 955 1195 865 1085 785 985 785 M -LO 3-1/2 1400 1220 1090 1420 970 1265 875 1150 845 M -HI 4 1600 1395 1250 1650 1070 1465 975 1315 930 HI 5 2000 1750 1565 2110 1300 1865 1140 1640 1080 ' Minimum airflow is set for use with electronic air cleaner: 060 -500 CFM, 080 -500 CFM, 100 -700 CFM, 120 -700 CFM NOTES: 1. A humidistat can be added to reduce airflow for better dehumidification when needed. This feature reduces the selected cooling airflow by 20% (280 CFM per ton limit). 2. Continuous -fan settings are 50 %, 65 %, or 100% of selected cooling airflow. a. Check gas input rate using Table 11. (1.) Obtain average yearly gas heat value for local gas supply. (2.) Obtain average yearly specific gravity for local gas supply. (3.) Verify furnace model. Table I 1 can only be used for models 333BAV and 333JAV Furnaces. (4.) Check and verify orifice size in furnace. NEVER ASSUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY. (5.) Find natural gas heat value and specific gravity in Table 11. (6.) Follow heat value and specific gravity lines to point of intersection. Find orifice size and manifold pres- -15— sure settings for proper operation at given natural gus conditions on low and high stages. EXAMPLE: Heat value = 980 Btu /cu ft Specific gravity = 0.62 Therefore: Orifice No. 44* Manifold pressure 3.5 -in. we on high stage and I.5 -in. we on low stage. * The furnace is shipped with No. 45 orifices. Therefore, in this example all main burner orifices must be changed and manifold pressure must be adjusted. (7.) Proceed to item c. to adjust manifold pressure. b. Check gas input rate by clocking gas meter for low and high stage. • TABLE 10 —HEAT PUMP COMFORT HEATING NOMINAL CFM (WITH FILTER) AC /HP JUMPER POSITION: HP —CMFT HEAT PUMP — COMFORT, HEATING AIRFLOW Furnace Size Airflow Selection Single -Speed CFM Two -Speed (High/Low) CFM Cool Size Jumper Position Tons Cool CFM Per Ton Jumper Position Cool CFM Per Ton Jumper Position 400 350 315 400 350 315 HIGH LOW HIGH LOW HIGH LOW 060 LO 1 -1/2 540 500' 500* 565 500' 500' 500* 500' 500' M -LO 2 720 630 570 780 500' 660 500' 595 500' M -HI 2-1/2 900 790 710 945 585 830 515 740 500' HI 3 1080 945 855 1135 700 990 610 895 555 080 LO 2.1/2 900 785 710 945 605 825 535 755 500* M -LO 3 1080 945 850 1135 715 990 630 895 560 M -HI 3-1/2 1260 1100 990 1325 830 1150 725 1040 655 HI 4 1440 1260 1135 1510 940 1325 825 1190 740 100 LO 3 1075 940 855 1130 700 980 700 890 700' M -LO 3-1/2 1260 1100 990 1325 820 1155 750 1040 700' M -HI 4 1440 1260 1130 1510 935 1320 825 1190 740 HI 5 1800 1575 1420 1890 1170 1655 1035 1490 920 120 LO 3 1045 945 860 1075 780 975 750 885 750 M -LO 3 -1/2 1260 1100 980 1280 875 1140 790 1035 760 M -HI 4 1440 1255 1125 1485 965 1320 880 1185 835 HI 5 1800 1575 1410 1900 1170 1650 1025 1475 970 ' Minimum airflow is set for electronic air cleane : 060 -500 CFM, 080 -500 CFM, 100 -700 CFM, 120 -700 CFM NOTES: 1. A humidistat can be added to reduce airflow for better dehumidification when 2. Continuous -tan settings are 50 %, 65 %, or 100% of selected cooling airflow. (1.) Obtain average yearly heat value for local gas supply. NOTE: Be sure heating value used for calculations is correct for your altitude. Consult local gas utility for altitude adjustments (if any) of gas heating value. (2.) Check and verify orifice size in furnace. NEVER ASSUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY. (3.) Turn off all other gas appliances and pilots. (4.) Turn SW -2 to ON. Close R -W/W 1 and jumper R to W2 to start furnace in high stage and let run for 3 minutes. (5.) Measure time (in sec) for gas meter to complete 1 revolution. (6.) Refer to Table 12 for gas rate (cubic ft of gas per hr). (7.) Multiply gas rate (cubic ft/hr) by heating value (Btu/ cubic ft). EXAMPLE: Btu/hr heating input = Btu/cu ft X cu ft/hr Heating value of gas = 1070 Btu /cu ft Time for 1 revolution of 2 -cu ft dial = 72 sec Gas rate = 100 cu ft/hr (from Table 12) Btu /hr heating input = 100 X 1070 = 107,000 Btuh (8.) Remove jumper R to W2 and repeat items (5.) through (7.) for low stage. NOTE: High altitude —In the United States, gas input on rating plate is for altitudes up to 2000 ft. for natural and propane gases. Ratings for altitudes over 2000 ft MUST be reduced 4 percent for each 1000 ft above sea level. To obtain the adjusted altitude rating, adjust the manifold pressure (see item c.) and replace the main burner orifices as needed. Refer to NFGC Appendix F, Table F -4 for proper orifice sizing at high altitudes. Installations at altitudes 5500 feet or higher above sea level shall use a factory- supplied high- altitude conversion kit. In Canada, gas input on rating plate is needed. This feature reduces the selected cooling airflow by 20% (280 CFM per ton limit). —16— for altitudes up to 2000 ft for natural and propane gases. High - altitude ratings are from 2000 ft to 4500 ft above sea level. High - altitude rating includes a 10 percent derate as required by Canadian standards. (9.) Measured gas inputs should equal low- and high - stage gas inputs on unit rating plate ± 2 percent. (10.) Proceed to item c. to adjust manifold pressure. Q CAUTION: DO NOT redrill burner orifices. Improper drilling (burrs, out- of- round, etc.) can cause excessive burner operating noise and misdirection of burner flames. This could result in flume impingement on burners and heat exchanger surfaces, leading to potential failures. c. Adjust gas manifold pressure (1.) Move SW -2 to the ON position to lock out the adaptive algorithm. (See Fig. 13 and 14.) Jumper R to W/W 1 and W2 to call for high stage. (2.) Remove gas control regulator adjustment seal caps. (See Fig. 17.) (3.) Turn high -fire adjusting screw (5/64 -in. hex alien wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate. When adjust- ing input rate, DO NOT set manifold pressure less than 3.2 -in. we or more than 3.8 -in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices. (4.) Remove R -to -W2 jumper to place furnace in low - stage operation for low -stage adjustment. (5.) Tum low -stage adjusting screw (5 /64 -in. hex alien wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate. When adjust- ing input rate, DO NOT set manifold pressure less than 1.3 -in wc or more than 1.7 -in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices. 0 'A31i t0l•CBZRC 2 a 1 iii =_aij dril e qq" L-1 �LI310 ri 5 2 5 i I t 17'.7.R. L:1 1114 gam d / F i 1101 (3NVdo1:1d V SW) 1VNl1VN) WVHOVIO OIlVI HOS ° VV a a , , J'1 1 0 v 5 s 1-g Wg g L20 I g z g g �1� L• 2 •9 .9 9= ug f•Wd .RI np N •• T:2• Is 9. .0 3A tlg wit g ggeu Rl l 3711 2 17— O m -4 Fig. 16— Wiring Diagram TABLE 11— MODELS 333BAV AND 333JAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT RATE (Tabulated Data Based on Altitude Up to 2000 ft and 20,000 Btuh High Heat/13,000 Btuh Low Heat Per Burner) GAS HEAT VALUE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72 Orf No. Heat High/Low Orf No. Heat High/Low Orf No. Heat HIgh /Low Orf No. Heat HIgh /Low Orf No. Heat High/Low Orf No. Heat High/Low Orf No. Heat High/Low Orf No. Heat High/Low 860 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.5 41 42 3.2/1.4 3.6/1.5 41 42 3.3/1.4 3.7/1.5 41 42 3.4/1.4 3.8/1.6 875 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 41 42 3.2/1.3 3.5/1.5 41 42 3.3/1.4 3.6/1.5 890 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 41 42 3.2/1.3 3.5/1.5 905 43 44 3.3/1.3 3.7/1.5 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 920 43 44 3.2/1.3 3.7/1.5 43 44 3.3/1.4 3.8/1.6 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 43 3.8/1.5 42 3.2/1.3 42 3.3/1.3 935 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 43 3.5/1.5 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.3 950 44 3.5/1.5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 43 3.4/1.5 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6 965 44 3.4/1.4 44 3.5/1,5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 43 3.4/1.5 43 3.5/1.5 43 3.6/1.5 980 44 3.3/1.4 44 3.4/1.4 44 3,5/1.5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 43 3.4/1.5 43 3,5/1.5 995 44 45 3.2/1.3 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 43 3.4/1.4 1010 45 3.7/1.6 44 45 3.2/1.3 3.8/1.6 44 3,3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 43 44 3.3/1.4 3.8/1.6 1025 45 46 3.6/1.5 3.8/1.6 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 43 44 3.2/1.4 3.7/1.6 1040 45 46 3.5/1.5 3.7/1.6 45 46 3.6/1.5 3.8/1.6 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1,5 44 3.6/1.5 1055 45 46 3.4/1.4 3.6/1.5 45 46 3.5/1.5 3.7/1.6 45 46 3.6/1.5 3.8/1.6 45 3.8/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 1070 45 46 3.3/1.4 3.5/1.5 45 46 3.4/1.4 3.6/1.5 45 46 3.5/1.5 3.7/1.6 45 46 3.7/1.5 3.8/1.6 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4 1085 45 46 47 3.2/1.4 3.4/1.4 3.8/1.6 45 46 3.3/1.4 3,5/1.5 45 46 3.4/1.5 3.6/1.5 45 46 3.6/1.5 3.7/1.6 45 3.7/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 1100 46 47 3.3/1.4 3.7/1.6 45 46 3.2/1.4 3.4/1.4 45 46 3.4/1.4 3.5/1.5 45 46 3.5/1.5 3.6/1.5 45 46 3.6/1.5 3.8/1.6 45 3.7/1.6 45 3.8/1.6 44 3.2/1.4 NOTE: If orifices are changed, both high- and low -stage input rates must be readjusted, with manifold pressures within ranges specified in items (3.) and (5.). NOTE: If orifice appears damaged or it is suspected to have been redrilled, check the orifice size with a numbered drill bit of the correct size. Never use a redrilled orifice. A burr-free and squarely aligned orifice is essential for proper flame characteristics. (6.) Remove jumper on R -W/W 1 after low -stage adjust- ments. (7.) When correct input is obtained, replace regulator seal caps. Main burner flame should be clear blue, almost transparent. (See Fig. 18.) 2. Set air temperature rises. Place SW -2 in ON position. Jumper R to W/W I and W2 to check high -stage temperature rise. To check low -stage temperature rise, remove jumper to W2. Determine air temperature rises for both high and low stages. Do not exceed temperature rise ranges specified on unit rating plate for high and low stages. a. Place duct thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not see heat exchangers so that radiant heat will not affect thermometer readings. This is particularly important with straight run ducts. —18— b. When thermometer readings stabilize, subtract rctum -air temperature from supply -air temperature to determine temperature rise. NOTE: If the temperature rise is outside this range, first check: (1.) Gas input for low- and high -stage operation. (2.) Derate for altitude if applicable. (3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.70 -in. wc. c. Adjust air temperature rise by adjusting airflow. Move the RED jumper wire on the airflow selector control to MID, HI, or M -HI for mid -point of the air temperature rise range, high end of the rise range, or in- between, respectively. The single RED jumper selection is used for both high- and low -stage rises. Power need not be reset after making this selection. CAUTION: Recheck the temperature rise. It must be within the limits specified on the unit rating plate. Recommended operation is at midpoint of rise range or above. TABLE 12—GAS RATE (CU FT /HR) SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL 1 cu It 2 cu ft 5 cu It 1 cu It 2 cu it 5 cu ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 100 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 88 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 -.1 - ■I A U10 m0 200 36 100 200 500 92 39 196 37 97 195 486 84 38 192 38 95 189 474 96 38 188 39 92 185 462 98 37 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 84 161 47 76 153 383 116 31 62 155 48 49 75 73 150 147 375 367 120 30 60 150 INLET PRESSURE TAP MANUAL LOW -STAGE ON /OFF i ADJUSTMENT ALLEN SCREW (UNDER CAP) MANIFOLD PRESSURE TAP A93376 Fig. 17— Redundant Automatic Gas Control Valve 3. Set thermostat heat anticipator. a. When using a non - electronic thermostat, the thermostat heat anticipation must be set to match the amp draw of the electrical components in the R -W/W l circuit. Accu- rate amp draw readings can be obtained at the wires normally connected to thermostat subbase terminals R and W/W 1. Fig. 19 illustrates an easy method of obtain- ing the actual amp draw. The amp reading should be taken after the blower motor has started and the furnace is operating in low stage. To operate the furnace in low stage, first move SW -2 to ON position, THEN connect the ammeter wires as shown in Fig. 19. The thermostat HIGH -STAGE ADJUSTMENT ALLEN SCREW (UNDER CAP) —19— BURNER MANIFOLD Fig. 18— Burner Flame anticipator should NOT be in this circuit while measur- ing the current. If the thermostat has no subbase, the thermostat MUST be disconnected from the R and W/W 1 wires during the current measurement. Return SW -2 to final desired location after completing the reading. See the thermostat manufacturer's instructions for adjusting the heat anticipator and for varying the heating cycle length. b. When using an electronic thermostat, set the cycle rate for 3 cycles per hr, if possible. THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED A89020 HOOK- AROUND VOLT /AMMETER 10 TURNS FROM UNIT 24 -VOLT TERMINAL BLOCK EXAMPLE: 5.0 AMPS ON AMMETER n 0.5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS A80201 Fig. 19—Amp Draw Check With Ammeter F. Check Safety Controls The flame sensor, gas valve, and pressure switches were all checked in the Start-up section as part of normal operation. I. Check primary limit control. This control shuts off the combustion control system and energizes the circulating -air blower motor if the furnace overheats. The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes. As soon as the limit has shut off the burners, the return -air opening should be unblocked. By using this method to check the limit control, it can be established that the limit is functioning properly and will operate, if there is u motor failure. 2. Check draft safeguard switch. The purpose of this control is to cause safe shutdown of the furnace during certain blocked vent conditions. a. Disconnect power to furnace and remove vent connector from furnace flue collar. Be sure to allow time for vent connector pipe to cool down before removing. b. Restore power to furnace and set room thermostat above room temperature. c. After normal start-up, allow furnace to operate for 2 minutes, then block flue outlet 100 percent. Furnace should cycle off within 2 minutes. d. Remove blockage and reconnect vent connector to furnace flue collar. e. Wait 5 minutes and then reset draft safeguard switch. 3. Check flow - sensing pressure switches. This control proves operation of draft- inducer blower. a. Turn off 115 -v power to furnace. b. Remove gas control door and disconnect inducer motor leads from wire harness. c. Turn on 1 15 -v power to furnace. d. Close thermostat switch as if making normal furnace start. If the hot surface ignitor does not glow within several minutes and control flashes code 32, then the flow- sensing switches are functioning properly. e. Turn off 115 -v power to furnace. f. Reconnect inducer motor wires, replace gas control door, and turn on 115 -v power. G. Checklist 1. Put away tools and instruments, and clean up debris. 2. Check SW -1 through SW -4 after completing installation to ensure desired settings for thermostat type (SW -1 and SW -2) and blower -off delay (SW -3 and SW -4). Refer to Tables 6 and 7. 3. Verify manual reset switches have continuity. 4. Ensure blower and gas control access doors are properly installed. 5. Cycle -test furnace with room thermostat. 6. Check operation of accessories per manufacturer's instruc- tions. 7. Review User's Manual with owner. 8. Leave literature packet near furnace. SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book. Classroom Service Training plus "hands -on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1- 800-962 -9212 [ ] Packaged Service Training [ ] Classroom Service Training 0 1996 BDP Co. • P.O. Box 70 • Indianapolis, IN 46206 Printed In U.S.A. —20-- 333b602 Catalog No. BDP43333.303 Sent by: STONE DREW ASHE & JONES 12067630842; 03/12/99 12:17PM;JetFax #87; Page 2 Supplemental Instructions for Gas Water Heaters Installed in Potable / Space Heating Applications The Installation Instructions in this Use & Care Manual should be followed in addition to the following Supplemental Instructions for this special application. �i� Spring Loaded Check VaNM In Heating Unit Hot Water Supply Une and Coto Water Return Ina. (Not supplied with Wafer Healer). NOTE: This valve to incsrporaletl in some Heating Units. Refer to Installation Instructions supplied with specific Heating Unit to determine it it is required In your appcatierr, Isolation Valve in Hot Water Supply line to Heating Unit (Not supplied with Water Heater) See Diagrams below for proper pipe applications for Vertical or Horizontal Supply Lines Mixing or Tempering Valve REFER TO WARN(N S RELOW Air Vert Domestic Hol Wa ter Suppiy Incoming Cold Waler Supply NOTE • local Codes or Plumbing Authority require- ments may vary from the instructions or diagrams pro- vided on this sheet, and take precedent over these in- structions. Refer to Local Codes, Plumbing Authority and Use i Care Manual supplied with water heater be- fore starting any Installation work, • Isolation Valve m Cold Water Rerun ins Iron Heatng Une INa supaied with Water Heater) Gas Linetc Waler Heater (Raler to Instatlauon Section oI this manual) Gas Water Heater. Refer to Insraratton Sea on in tins manual Icr details regarding its proper and safo nstallatfon. 1 b P valve discharge line (Reler to installation Section of this manual) Afir Grain Valve (Not suppled win Waler Heeler) Cold Water Return Une bon Hoeing Unit Hot Waler Supply Lme into Healing Unit tt Heaung Unit Figure 1. • Typical Piping Diagram tor Combination Potable / Space Heating Installation. 1 Hol War Supply lo House I I Hot Water to Hearing Un l.. L. J Tee ;ring must oe installed as snow. This 'mutes Mat any air in me water lines will be purged through the domestic wafer faucets ono showers. tFrom HOT cutlet on water heater VERTICAL HOT WATER SUPPLY LINES Hot Water Suppy from HOT cutlet to House on water healer Hot Water _. to Heating Unit Tee Fitting must be instatiod as shown. This n ores that any air in the water fines will be purged through the oomesuc water faucets and showers HORIZONTAL HOT WATER SUPPLY LINES IA WARNING When this System requires waterfor space heating at elevated temperatures (above 125° F), a mixing or tempering valve must be installed in the hot water supply line to the house In order to reduce the SCALD HAZARD potential . rA WARNING It this water heater is installed in an application intended to supply domestic hot water needs and hot water for space heating purposes, 00 NOT connect the heater to an existing Heating Unit or components of a heating system that have previously been used with a non potable water sys- tem. Toxic chemicals such as those used for boiler treatment may be present and will contami- nate the potable water supply causing possible health risks. A WARNING If this water heater is installed in an application intended to supply domestic hot water needs and hot water for space heating purposes, NEVER introduce toxic chemicals, such as those used for boiler treatment, into this system, A CAUTION Any piping or components used in the installation of this water heater In a combination potable and space heating application MUST be suitable for use with potable water. 14 Seat by: STONE DREW ASHE & JONES 12067630842; c • 03/12/99 12:18PM;JetFax #87; Page 3/15 Trouble Shooting Guide NATURE OF TROUBLE POSSIBLE CAUSE SERVICE Unable to light pilot 1. Gas knob dial not correctly positioned 2. Pilot orifice clogged 3. Pilot tube pinched or clogged. 4. Air in gas line Fallow lighting instructions " Clean or replace " Clean, repair or replace " Purge alr from gas line Pilot does not stay lit when red button is released 1. Loose Thermocouple 2. Thermocouple breakdown 3, Safety magnet breakdown 4. Thermostat's single use gas shut -off device has opened " Tighten connection at thermostat " Replace " Replace thermostat " Replace Thermostat Not enough hot water Water too hot or not hot enough Ye!low (lame Sooting 1. Heater undersized 2. Low gas pressure Reduce rate of hot water usage " Check gas supply pressure and manifold pressure 1. Thermostat setting loo high or low 2. Thermostat out of calibration 3, High water temperature followed by pilot outage 1. Scale on top of bumer 2. Combustion air Inlets or llueway restricted 3. Not enough combustion or ventilation air supplied to the room Change setting as required " Replace "• Thermostat out of calibration, replace Shut off heater and remove scale Remove lint or debris and inspect air Inlet opening for restriction Refer to Sec. E In Introduction section of this manual Rumbling noise 1, Scale or sediment in lank Clean tank • See Maintenance, Sec, IF r CAUTION " For your safety, DO NOT attempt repair of thermostat, burners or gas piping. Refer repairs to qualified service personnel. NOTES Model No. Serial No. 13 Date of Installation Installed By: Sent by: STONE OREW ASHE & JONES Thermostat and Burner Parts List 12067630842; 03/12/99 12:18PM;1aax #87; Page 4/15 M� The Parts List below includes the most commonly required components, NOTE: All orders for repair parts must include the following information: 1. Part number(s) (If not illustrated, indicate) 2. Description of par(s) 3. Model number and name of water heater. 4. Sena/ number of water heater. 5. Number of specific pans desired. 6. Specify type of gas, Address parts orders to your distributor or dearer. 3/3A 1A • When ordering this part, the model, type of gas, and serial number must be included. LQ CAUTION, For your safety, 00 NOT attempt repair of gas piping, thermostat, burners, vent connectors or other safety devices. Refer repairs to qualified service personnel. 12 Gallonage Ref, No. Part Description 30 40 50 20 -S (Lowboy) 30.S (Lowboy) 40 -S (Lowboy) 1 1A 2 2A 3 3A 4 S 5A 6 7 Thermostat, Natural Gas Thermostat, LP Gas Burner Supply Tube, Natural Gas Burner Supply Tube,L.P. Gas Burner, Natural Gas Burner, L.P. Gas Pilot Supply Tube Pilot Burner, Natural Gas Pilot Burner, L.P. Gas Thermocouple Orifice, Main Burner AP8555' AP8456' AP8964' AP 10499' AS294588 AS36335 AP11245• AP8980B AP8980C AP6379' AP7492' AP8555' AP8456' AP•8964 -' AP10499' AS29458B AS36335 AP1 1245' AP8980B AP8980C AP6379' AP7492• AP8555' AP8456' AP•8964 -' AP10499' AS294588 AS36335 AP11245' AP89808 AP8980C AP6379' AP7492' • When ordering this part, the model, type of gas, and serial number must be included. LQ CAUTION, For your safety, 00 NOT attempt repair of gas piping, thermostat, burners, vent connectors or other safety devices. Refer repairs to qualified service personnel. 12 Sent by: STONE DREW ASHE & JONES f t • 12067630842; 03/12/99 12:19PM;JetFaix #87; Page 5/15 Operation Figure 6. — Main 9urner and Pilot Flame Pattern A CAUTION For your safety, cleaning of main burner should be performed ONLY by qualified service personnel, as it involves disconnection of gas piping and leak testing. 0. For adequate combustion (proper burner operation) and ventilation, make certain the flow of air to the water heater is not obstructed. E. At least once a year, lift and release the lever handle on the temperature pressure relief valve. located near the top of the water heater, to make certain the valve operates freely and allow several gallons to flusn through discharge line, Make certain the discharged water Is directed to an open drain. DANGER Before manually operating the relief valve, make certain no one will be exposed to the danger of coming in contact with the hot water released by this valve. The water may be hot enough to create a SCALD hazard. The water released should be directed to a suitable drain to prevent Injury or damage. NOTE: If the temperature and pressure relief valve on the water heater discharges periodically, this may be due to thermal expansion In a "Closed" water system. Contact the water supplier or your plumbing contractor on how to correct this. 00 NOT plug the relief valve outlet. F. A water heaters tank can act as a settling basin for solids suspended in the water. It is, therefore, not uncommon for hard water deposits to accumulate in the bottom of the tank. Deposits should not be allowed to accumulate as this can affect the service life of the water heater. It is suggested that a few quarts of water be drained from the water heater's tank every month. II sufficient hard water deposits accumulate, a rumbling or pounding sound can occur, There is no danger involved and the efficiency of the water heater is not seriously affected, but the noise can be annoying. Your plumbing contractor should be contacted to clean the lank of these deposits. G. Rapid closing of faucets or solenoid valves in automatic water using appliances can cause a pounding "water hammer" sound, "Water hammer'' can be described as a banging noise heard in a water pipe following an abrupt alteration 01 the flow with resulting pressure surges. Strategically located risers in the water pipe system can be used to minimize the problem. Also water hammer arresting devices are usually available from your plumber or local plumbing supply store. 2. ANODE ROD INSPECTION—The anode rod should be removed from the water heater's tank annually for inspection and replaced when more Than 6" of core wire is exposed at either end of the rod. Refer to Fig. 4 for anode rod location. Make certain cold water supply is turned off before removing anode rod, How to Obtain Service Assistance t . Should you have any questions about your new water heater. or if It requires adjustment, repair, or routine maintenance, it is suggested that you first contact your Installer, plumbing contractor or previously agreed upon service agency. In the even? that the firm has moved, or is unavailable, refer to the telephone directory commercial listings or local unity for qualified service assistance. 2. Should your problem not be solved to your complete satisfaction, you should then contact the Manufacturers Regional Service Manager at the office closest to your location as listed below or the National Service Department at 1.800.432.8373. When contacting the manufacturer, the following information should be made available: 1. Model and serial numbers of the water heater as shown on the rating plate attached to the jacket of the heater. 2. Address where water heater is located and can be seen. 3. Name and address of installer and any service agency who performed service on the water heater. 4. Date of anginal installation and dales any service work was performed. 5. Details of the problem as you can best describe them, 6. List of people, with dates, who have been contacted regarding your problem. 2600 Gunter Park Drive 5887 Gienridge Road, Suite 400 6800 South Belt Circle Drive 1180. 1131h St. 11 Harts lane • Suite C 14300 Alondra Blvd. Montgomery, AL 36109 Atlanta, GA 30328 Bedford Park, IL 60638 Grand Prairie, TX 75050 East BrunswacK, NJ 08818 La Mirada, CA 90638 (334) 279.8930 1404) 256.6586 (708) 5944100 (214) 680-3223 (908) 238.3636 (714) 523 -7029 11 Sent by: STONE DREW ASHE & JONES 12067630942; Operation HIGH ALTITUDE— Ratings of gas appliances are based on sea level operation and need not be changed lor installations at elevations up to 2000 feet, For installations above 2000 Met, reduce input rating by 4 percent for each 1000 feel above sea level. 4. SAFETY CONTROLS— The thermostat is constructed with a built In safety shutoff device designed to shut off the gas supply to the burner in the event the pilot flame is extinguished for any reason, The thermostat is also equipped with single use gas shutoff device that will shut off the gas supply to the burner, if the water in the water heater exceeds normal operating temperatures. Refer to the Troubleshooting Section of this manual, or contact your dealer for service. 5. EMERGENCY SHUTDOWN— ^41, WARNING Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. if water heater has been subjected to (ire, flood, or physical damage turn all the manual gas control (shut•ofi) valve, and do not operate the water heater again until it has bean checked by qualified personnel. NOTE: Replace any part of the gas control system which has been under water. 6. CONDENSATION— Condensation can Ion on the lank when it Is first filled with cold water. The condensation might also occur with a heavy water draw and very cold inlet water. Drops of water fatting on the bumer can produce a sizzling or pinging sound, and water may also be seen beneath the water heater. This condition is not unusual, and will disappear alter the water in the water heater becomes heated. If, however, the condition is continuous, examine the piping and fittings for possible leaks. 7. VACATION AND LONG TIME SHUTDOWN— If the wafer heater Is to remain idle for an extended period of lime, the gas should be turned off to conserve energy. The water heater and piping shou!d be drained if they might be subjected to freezing temperatures. 03/12/99 12:19PM;Je.FaX #87; Page 6/15 NOTE: Refer to Hydrogen Gas Caution, in Safety Precautions Section on page 9. After a very long shut-down period, the water heater's operation and controls should be checked by qualified service personnel. Make certain the water heater is filled before again placing it in operation. 8. DRAINING WATER HEATER- 41, CAUTION Shut oft gas at thermostat gas cock or supply line manual shut-off valve before draining water from the water heater. In order to drain water, turn off cold water supply, then it is necessary to open a hot water faucet or lift the handle on the relief valve to admit air to the tank. Attach a garden hose to the drain valve on the water heater and direct the stream of water to a drain where it will do no damage. A DANGER The water drained from the tank may be hot enough to present a SCALD HAZARD and should be directed la a suitable drain to prevent injury or damage. 9. ANODE— This water heater is equipped with an anode rod designed to prolong the lite of the glass lined lank. Refer 10 Fig. 4 far location. The anode rod is slowly consumed catholically, thereby eliminating or minimizing corrosion of the glass Tined tank. Water sometimes contains a high sulfate and/or mineral content and together with the cathodic protection process can produce a hydrogen sulfide or rotten egg odor in the heated water. Chlonnatton of the water supply should minimize the problem. NOTE: Do not remove the anode-rod from the water heater's tank, except for inspection andlor replacement, as permanent removal will shorten the life of the glass lined lank and eflect the water heater warranty. Maintenance P'operly maintained, your water healer will provide years of dependable trouble free service. It is suggested that a regular routine maintenance program be established and followed by the user, It is further recommended that a periodic Inspection of the thermostat, burner, relief valve, internal Ilueway and venting system should be made by service personnel qualified in gas appliance repair. 1. ROUTINE PREVENTATIVE MAINTENANCE A. The water heater's internal flue must be inspected annually to be certain it is clean by removing the draft hood and flue baffle. (Refer to Fig. 1.) When reinstalling the flue baffle make certain it is hung securely by its hanger at the top of the flue way. Remove any scale that may have fallen on the burner or floor shield. Reinstdil the draft hood. inspect gas venting system to make certain vent connector from draft hood to chimney is property positioned and securely attached and 10 Inspect chimney, Replace any corroded through vent connector and remove any obstruction in vent connector or chimney. B. Visusally inspect the burner annually while tiring and pilot burner flame with main burner oft. (Refer to Figure 6 lor normal flame panern.) If any unusual burner operation is noted, the water heater should be shut off until qualified service assistance can be obtained. For cleaning, remove the burner from the water heater, A vacuum cleaner can be used on the burner and floor shield inside the water heater. The burner can also be cleaned by scrubbing with mild detergent c. The arca neat the water neater must be kept free of flammable Itgt;ids such as gasoline or paint thinners, adhesives and other combustible materials. 1 c Sent by: STONE DREW ASHE & JONES E 12067630842; 03/12/99 12 ;20PM;JetFex .#87; Page 7/15 Operation SAFETY PRECAUTIONS E. Do not allow combustible materials such as newspaper, rags or mops to accumulate near water heater. A. Do turn off manual gas shut-off valve if water heater has been subjected to over healing, fire, flood, physical damage or if gas supply fails to shut off. H. Do Not turn on water heater unless it is filled with water. C. Do Not turn on water heater if cold water supply shut-off valve is closed. D. Do Not store or use gasoline or other flammable vapors and liquids, such as adhesives or paint thinner, in vicinity of !his or any other appliance. If such flammables must be used, open doors and windows for ventilation, and all gas burning appliances in vicinity should be shut off, including their pilot lights, to avoid vapors Igniting, NOTE: Flammable vapors may be drawn by air currents from surrounding areas to the water heater. F. 11 there is any difficulty in understanding or following the OPERATION or MAINTENANCE instructions, it is recommended that a qualified person or serviceman perform the work. A CAUTION Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE!! To dissipate such gas and to reduce risk of Injury, it Is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hat water system. It hydrogen is present, there will probably be unusual sound such as air escaping through the pipe as the water begins to flow. Do not smoke or use an open flame near the faucet at the time it is open. 2 WATER TEMPERATURE SETTING— The temperature of the water in the healer can be regulated by setting the temperature dial on front of the thermostat. (Refer to Fig, 5.) To comply with safety regulations the thermostat was set at its lowest setting before water heater was shipped from the factory. A sening of 120 °F., or lower If local codes require, Is recommended as a starting point. Fed Bullon Gas Cock Knoo 130'F ( Approx. 1401 (Approx.) 150'F. (Approx.) 160`F ( Approx.) 1204F. (Approx.) 110'F. ( Approx.) 100'F. (Approx.) 90'F. (Approx.) 80'F. ( Approx.) 70'F. ( Approx.) 60'F. (Approx.) Figure 5 -- Thermostatic Gas Valve. The wide reference mark near "Warm" on rim of temperature dial, represents an approximate water temperature of 120 °F. The long wide reference mark. to the left, represents an approximate water temperature of 130 °F. Each reference mark above or below these points indicates an approximate change of 10'F. Safety and energy conservation are factors :o be considered when selecting the water temperature setting of water heater's thermostat. The lower the setting the greater the safety and savings in energy and operating cost, 9 TIME / TEMPERATURE RELATIONSHIPS IN SCALDS Temperature Time to Produce Serious Burn 120' F. More than 5 minutes 125' F. 11/210 2 minutes 130° F. About 30 seco. .ids 135° F. About 10 Seconds 140° F Less than 5 seconds 145° F. Less than 3 seconds 150° F. About 1112 seconds 165' F. About 1 second Table oxwu sy of Shiners Bum Inshture Q DANGER There is a Hot Water SCALD Potential if the thermostat is set too high. NOTE: Households with small children or Invalids may require a 120'F. or lower thermostat setting to prevent contact with "HOT" water. Maximum water temperatures occur just after burner has shut off. To find hot water temperature being delivered, tum on a hot water faucet and place a thermometer in the hot water stream and read the thermometer. Mixing valves for reducing point of ag water temperature by mixing hot and cold water in branch water lines are available. Contact a licensed plumper or the local plumbingauihority for further information. 3. ADJUSTMENTS— There are no user adjustments (other than water temperature selection) required on this wafer heater. The thermostatic valve is equipped for total regulation of the main burner and pilot gas pressures. The burner does not require adjustment. Sent by: STONE OREW ASHE & JONES Operation 12067630842; 03/12/99 12:21PM;JetFax #87; Page 8/15 Before operating this water heater, be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in unsafe operation of the water heater resulting in property damage, bodily injury, or death. Should you have any problems reading or following the instructions in this manual, STOP, and get help from a qualified person. 1. LIGHTING PROCEDURE • Lighting procedures are outlined on the label pictured below. This label Is also located on the water heater near the thermostat. FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these Instructions exactly. 8, BEFORE PUTTING THIS APPLIANCE INTO SERVICE — Smell all around the appliance area for gas. Be sure to smell net to the floor because some gas is heavier than alr and will settle on the floor. WHAT TO 00 IF YOU SMELL GAS: ► Do not try to light the appliance, • Do not touch any electrical switch; do not use any phone in your building. ► Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the lire de- partment. C. Use only your hand to turn the gas control knob. Never use tools, If the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in fire or explosion. D. Do not use this appliance it any part has been under water. immediately call a qualified service technician to Inspect the appliance and to replace any part of the control system and any gas valve that has been under water. OPERATING INSTRUCTIONS 1. STOP! READ THE SAFETY INFORMATION ABOVE ON THIS LABEL. 2. TURN GAS COCK KNOB CLOCKWISE TO 1 'OFF' POSITION. RED BUTTON GAS COCK .ri KNOB - j 7 r INDEX 1/L,1(� TEMPERATURE DIAL 3. TURN TEMPERATURE DIAL COUNTER CLOCK- >( WISE TO LOWEST SETTING 4. WAIT FIVE (5) MINUTES TO CLEAR OUT ANY GAS. IF YOU SMELL GAS, STOPI FOLLOW "B" IN THE SAFE- TY INFORMATION ABOVE ON THIS LABEL. IF YOU DON'T SMELL GAS, GO TO THE NEXT STEP, 5, REMOVE BOTH THE INNER 000R AND OUTER DOOR FROM THE WATER HEATER. 6. FOLLOW THE METAL TUBES FROM GAS CONTROL THRU DOOR OPENINGS. THE PILOT PILOT IS LOCATED ON THE THERMOCOUPLE HORIZONTAL LEG BURNER OF THE LARGER TUBE (OR BURN- Ali ER). tit 7. TURN THE GAS COCK KNOB COUNTER CLOCKWISE TO 'PILOT' POSITION. 8. PUSH DOWN ON THE 'RED BUTTON' UNTIL IT COMES TO REST ON THE TOP OF CONTROL. IT MUST CLEAR THE NOTCH PROVIDED IN THE 'GAS COCK KNOB ". HOLD 'RED BUTTON' DOWN AND LIGHT THE PILOT WITH A MATCH. CONTINUE TO HOLD THE'RED BUTTON" IN FOR ABOUT ONE (1) MINUTE AFTER THE PILOT IS LIT . RE- LEASE BUTTON AND IT WILL POP BACK UP. PILOT SHOULD REMAIN LIT. IF IT GOES OUT, REPEAT STEPS 2 THROUGH 8. • IF THE BUTTON DOES NOT POP BACK UP WHEN RE- LEASED, STOP ANO IMMEDIATELY CALL YOUR SER• VICE TECHNICIAN OR GAS SUPPLIER. • IF THE PILOT WILL NOT STAY LIT AFTER SEVERAL TRIES, TURN THE "GAS COCK KNOB' TO 'OFF' AND • CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLI- ER, 9. REPLACE INNER AND OUTER DOORS. 10. TURN 'GAS COCK KNOB' COUNTER CLOCKWISE TO t� '0N'. 11. TURN THE TEMPERATURE DIAL TO THE DESIRED SET- TING, TO TURN OFF GAS TO APPLIANCE I. TURN TEMPERATURE DIAL COUNTER CLOCKWISE j TO LOWEST SETTING, 2. TURN GAS COCK KNOB CLOCKWISE 1 TO "OFF POSITION. 8 Sent by: STONE DREW ASHE & JONES c 12067630842; Installation Horizontal vent connectors must be pitched upward to the chimney at least Y,' per foot of length. Single wall vent connectors must be at east 6" from adjacent unprotected combustible surfaces. Joint of vent connectors should be securely fastened by sheet metal screws or other approved method. A DANGER Failure to install the draft hood and properly vent the water heater to the outdoors as outlined above can result in unsafe operation of the water heater causing bodily injury, explosion, fire or death. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, NEVER operate this water heater unless it is property vented and has an adequate air supply for proper operation. Be sure to inspect the vent system for proper installation at Initial startup; and at least annually thereafter. Refer to Maintenance section of this manual for more information regarding vent system inspections. TA WARNING The manufacturer's warranty does not cover any damage or defect caused by installation, attachment or use of any type of energy saving or other. unapproved devices (other than those authorized by the manufacturer) into, onto or in conjunction with the water heater. The use of unauthorized energy saving devices may shorten the life of the water heater and may endanger life and property. The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices. 'Howl codes require external application of insulation blanket kits, the instructions included with the kit must be carefully followed. 03/12/99 12:22PM;1ltE»Y #e7; Page 9/15 A CAUTION Application of any external insulation to this water heater will require careful attention to the following: • Do not apply insulation to top of water heater, as this will interfere with the safe operation of the draft hood. • Do not cover burner access panel, thermostat/gas valve or pressure and temperature relief value. • Do not cover operating instructions or warning labels attached to the water heater nor attempt to relocate them on the exterior of the insulation blanket. • Do not apply insulation to bottom or the 2" space between the bottom pan of the water heater and the floor, as this area must be unobstructed so as not to restrict combustion air flow to the burner. • Do inspect the insulation blanket frequently to make certain it has not sagged and is restricting the combustion air to the bottom of the water heater, as this could result in an unsafe operating condition. Installation Check List A Water Heater Location O Close to area of vent. O Indoors and protected from freezing temperatures O Proper clearance from combustible surfaces observed and water heater not installed on carpeted floor. O Sufficient fresh air supply for proper operation of water heater O Air supply tree of corrosive elements and flammable vapors. • Provisions made to protect area from water damage. O Sufficient room to service heater. B. Water Supply O Water heater completely filled with water. 0 Water heater and piping air vented. O Water connections tight and tree of leaks C. Gas Supply 0 Gas line equipped wlln shut•ort valve, union and sediment trap. 7 U Approved pipe joint compound used. C Soap and water solution used to cneck all connections and fittings for possible gas leak, 0 Gas Company inspected installation (if required). D. Relief Valve O Temperature and Pressure Relief Valve properly Installed and discharge line run to open drain O Discharge line protected from freezing. E. Venting O Flue baffle properly hung in top of heater's flue. 0 Draft hood properly installed O Vent connector(s) pitched upward to chimney (W per foot of length minimum) . O Vent connector(s) securely fastened together with screws. • Single wall vent connector(s) at least 6" from combustible material. Sent by: STONE DREW ASHE & JONES 12067630842; 03/12/99 12:22PM;JetFax #87; Page 10/15 Installation Vent Connector to Chimney Union Heat Trap 1 % f 6' Min. r Hot Wea` � N Outlet to Fixtures /r -- Pilch up ' per 'col Draft Hood Anode Temperature & Pressure Rebel Valve Manual Gas Snut.Ott To Gas Supply Union Shut -0h Valve Sediment Trap Cap ' Heat Trap 6' Min. To Cold Rebel Valvo Water Discharge Supply Line to suitable open drain Groom Joint Union Thermostatic Gas Valve Jacket Door Grain valve Auxiliary Caton Pan Air Gap ` v, 6. Figure 4. — Typical Installation 3. RELIEF VALVE —A new combination pressure and temperature relief value, mmptying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI 221.22, must De installed in the opening provided on the water heater, at the time of installation. (Refer to Fig. 4.) No valve of any type should be installed between the relief valve and the tank. Local codes shall govern the Installation of relief valves. The pressure rating of the relief valve must not exceed 150 PSI, the maximum working press re of the water heater as marked on the rating plate The BTUH rating of the relief valve must equal or exceed the BTUH input of the water heater as marked on its rating plate. Connect the outlet of the relief valve to a suitable open drain. Piping used should be of a type approved for hal water distrbution. The discharge line must be no smaller Than the outlet of the valve and must pitch downward tram the valve to allow complete drainage (by gravity) of the relief valve and discharge line. The end of the discharge line should not be threaded or concealed and should be protected from freezing. No valve of any type, restriction or reducer coupling should be installed in the discharge line. 4. To FILL WATER HEATER —Make certain drain valve Is closed. Open shut -off valve in cold water supply line. Open each hot water faucet slowly to allow air to vent from the water heater and piping. A steady flow of water from the hot water laucegs) indicates a full water heater. 6 A WARNING Tank MUST be lull of water before water heater Is turned an. The water heater's warranty does not cover damage or failure resulting from operation with an empty or partially empty tank (dry fired). 5. GAS SUPPLY —The branch gas supply line to the water beater should be dean '4 " black steel pipe or other approved gas piping material. A ground joint union or ANSI design certified semi -rigid or flexible gas appliance connector should be installed in gas line close to the water heater, and a manual gas shut-off valve should be installed in the gas Tine prior to the union. The manual gas shut-off valve should be at least 5 feet above the floor and readily accessible for fuming on or off. A sediment trap should be installed at bottom of the gas line. (Refer to Fig. 4) Compound used an threaded joints al the gas piping must be al the type resistant to the action of liquefied petroleum gas. Use compound sparingly on male threads only. Do not use excessive farce (over 31.5 Ft. Lbs.) in tightening the pipe joint at the thermostat inlet, particularly If teflon pipe compound Is used, as the valve body may be damaged. The inlet gas pressure to the water heater must nol exceed 10.5' w.c. for Natural gas, and 13" w.c. far L.P. gas. For purposes of input adjustment, the minimum inlet gas pressure (with main bumer on) is shown on the water heater rating plate. If high or tow gas pressures are present, contact your gas aipplier for correction. LA WARNING 1 Do not attempt to convert this water heater for use with a different type of gas other than the type shown on the rating plate. Such conversion c could result in hazardous operating condltiana. 6. LEAK TESTING —The water heater and its gas connections must be leak tested at normal operating pressures before it is placed In operation. Turn on the manual gas shut-off valve near the water neater (Refer to Fig.4). Use a soapy water solution to test tor leaks at ail connections and fittings. Bubbles indicate a gas leak that must be corrected. The factory connections to the thermostat should also be leak tested after the water heater is placed in operation. A WARNING Never use open flame to test for gas leaks, as bodily injury, property damage or death could result. PRESSURE TESTING THE GAS SUPPLY SYSTEM — The water heater and its manual gas shut-off valve must be disconnected from the gas supply piping system during any high pressure testing of that system at pressures in excess of k psi (14" W.C.). The water heater must be isolated from the gas piping system by dosing the manual gas shut-off valve (Refer to Flg. 4), during any pressure testing of the gas supply piping at pressures equal to or less than % psi (14" W.C). 7. VENTING —This water heater must be Installed with the factory supplied draft Mod in place. (Refer 10 Fig. 4.) Vent connectors must be attached to the draft hood outlet to connect the water heater to the gas vent or chirmey. The vent connectors must be the same size (diameter) as the draft hood outlet or larger, never smaller. For proper venting in certain installations a larger vent connector size may be needed, Consult Vent Tables in Appendix "G" of the latest version of the National Fuel Gas Code (ANSI booklet 2223,1 or NFPA booklet 54). Sent by: STONE DREW ASHE & JONES 12067630842; L Introduction all directions. If the water heater is installed in an alcove or closet, the entire floor must be covered by the panel. A minimum of 24 inches clearance from the front and top should be available for adequate inspection and servicing. CA WARNING "Combustible construction" refers to adjacent walls and ceilings, and should not be confused with combustible or flammable products and materials. Combustible and/or flammable products and materials should never be stored In the vicinity of this or any gas appliance. A CAUTION The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent to it or to lower floors of the structure, When such areas cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the water heater. The pan MUST NOT restrict combustion air flow to bottom of water heater. .L .- a A — oyRMler ol %oar hWro*Oka 2" 'n B — MauA1I0 1•Y' To corn ararn, IMO MAO O. a(lia:I <' '0 Ina ontned lot ploy* alai# . Figure 3. — Auxiliary Catch Pan NOTE: Auxiliary catch pan installation MUST conform to local codes. Catch Pan Kits are available in 16 ", 19 ", 22', 24 ", and 26'G' diameters from the distnbutor or store where the water heater was purchased E. COMBUSTION & VENTILATION AIR — Proper operation of the water heater requires air for combustion and ventilation, If the water heater is instaled in an unconfined space within a building of conventional frame, masonry or metal construction, infiltration air is normally adequate for proper combustion and ventilation. However, if the space is confined, 03/12/99 12:23PM;JltFnx #87; Page 11 /15 provisions for this air must be made. A confined space is one having a volume of less than 50 cubic feet per 1000 BTUH of the aggregate input of all appliances within that space. The air must be supplied through Iwo pemnane it openings of equal area, one of which is to be located within 12 inches above the floor and the other is to be located within 12 inches below the ceiling. The minimum net free area of each opening must be not less than one square inch per 1000 BTUH of the total input rating of all the appliances in the enclosure (but not less than 100 square Inches), if each opening communicates with other unconfined areas inside the building. Buildings of unusually tight construction shall have the combustion and ventilation air supplied from outdoors or a freely ventilated attic or crawl space. If air is supplied from outdoors, directly or through verticai ducts, there must be two openings located as specified above and each must have a minimum net free area of not less than one square inch per 4000 BTUH of the total input rating of all the appliances in the enclosure. 11 horizontal ducts are used to communicate with the outdoors, however, each opening must have a minimum net free area of not less than one square inch per 2000 BTUH of the total input rating of all the appliances in the enclosu,e, 11 ducts are used, the minimum dimension of rectangular air ducts shall be not less than 3 inches. NOTE: If the openings are to be covered with a protective screen or grill, the net free area of the covering material must be used in determining the size of the openings, as stated above. Protective screening for the openings MUST NOT be smaller than 1/4 inch mesh to prevent clogging by lint or other debris Provisions for combustion and ventilation air must comply with referenced codes and standards. See Local Installation Regulations Section. F. CORROSIVE ATMOSPHERES —The water neater should not be installed near an air supply containing halogenated hydrocarbons. For example,the air in beauty shops, drycleaning establishments, photo processing labs, and storage areas for liquid and powdered bleaches or swimpool chemicals often contain such hydrocarbons. The air there maybe safe to breathe, but when it passes through a gas flame, corrosive elements are released that will shonen the life of any gas burning appliance. Propellants from common spray cans or gas leaks from refrigeration equipment are highly corrosive after passing through a flame. The limited warranty is voided when failure of water neater is due to a corrosive atmosphere, (Reference is made to the limited warranty for complete terms and conditions.) Installation 1. INSPECT SHIPMENT— Inspect water heater for possible shipping damage. Check the marking of the rating plate of the water heater to be certain the type of gas being furnished corresponds to that for wnich the water heater is equipped. 2. WATER SUPPLY CONNECTIONS— Refer to Fig, 4 for suggested typical installation. The installation of unions or flexible copper connectors is recommended on the HOT and COLO water lines, so that the water heater may be easily disconnected for servicing if necessary. The HOT and COLD water connections are dearly marked. Install a shut -off valve in the cold water line near water heater. Deterrnine it there is a check valve In the cold water supply line. It may have been installed as a separate component or it may be pars of a pressure reducing valve, water meter or water softener. A check value located in the cold water inlet line can cause a ''closed" 5 water system, A closed system prevents the water, as It is being healed, from expanding back into the cold water supply line. Pressure can ouild up wihin the heater causing the relief valve to operate during a healing cycle This excessive operation can cause premature failure of the relief valve and possibly the healer itself. Replacing the relief valve will not correct the problem. A method of preventing pressure buildup is to install an expansion lank in the cold water supply line between the heater and the check valve, Contact your installing contractor, water supplier, local plumbing inspector or plumbing supply house for assistance. IMPORTANTU Do not apply heat to the cold water supply fitting, If sweat connections are used, sweat tubing to adapter before fitting adapter to cold water inlet of heater, Any heat applied 10 the cold water inlet will permanently damage the dip tube. Sent by: STONE DREW ASHE & JONES 12067630842; 03/12/99 12:24PM;JetFax #87; Page 12/15 COMPONENTS OF YOUR WATER HEATER — So that you may better understand the operation of your new water heater, the following section illustrates the basic components of a typical water heater. 22, Ave, 20121 / 11 I/ o Fig. 1. -- Basic Gas Water Heater 1e A WARNING Fig. 2. — Thermostat and Burner Introduction Read and Review this entire Manual with special emphasis on the Venting Section (Pages 6.1) and Operation Section (Pages 8.10) prior to any installation work The location chosen for the water heater must take into consideration the following: LOCAL INSTALLATION REGULATIONS This water heater must be installed in accordance with these instructions, local codes, utility company requirements, and/or in the absence of local codes. the latest edition of the American National Standard I National Fuel Gas Code. A copy can be purchased from either American Gas Association, 1515 Wilson Blvd, Arlington, VA 22209 as booklet /223.1 or National Fire Prevention Assmiation, Batterymarch Park, Quincy, MA 02269 as booklet NFPA No.54. LOCATION A. A gas fired water heater should not be installed in a space where liquids which give off tlammabfe vapors are to be used or stored, Such liquids include gasoline. LP gas (butane and propane), paint or adhesives and their thinners, solvents or removers. Because of natural air movement in a room or other enclosed space, flammable vapor can be carned some distance from where their liquids are being used or stored. The open flame cf the water heater's plot Tight or main burner can ignite these vapors causing an explosion or fire which may result in severe bums or aoatn to chose in range, as well as property damage. For these reasons installation of a gas fired water heater in a garage Is not desirable. 4 1. Thermostatic Gas Valve 2. Gas Cock Knob 3. Red Button 4. Thermostat Temperature Dial 5. Main Burner 6. Pilot Burner 7. Thermocouple 8. Main Bumer Orifice 9. Glasslined Tank 10. Insulation 11, Jacket 12. Jacket Door 13. Inner Door 14. Floor Shield 15. Drain Valve 16. Internal Flueway 17. Flue Baffle 18. Dip Tube (Cold Water Inlet) 19. Anode 20, Relief Valve Opening (On Top) 21. Water Connections (On Top) 22. Draft Hood A WARNING 11 a location in a garage is the only alternative, the gas water heater should be installed so that the on (tame of the pilot and main burner are no less than 18 inches above the garage floor, unless specifically exempted from this by local code, rule, regulation or custom. Raising the gas fired water heater will reduce but not eliminate the possibility of lighting the vapor of any flammable liquids which may be improperly stored or accidentally spilled. The water heater must be located or protected so it is not subject to physical damage, for example, by moving vehicles, area flooding etc, Stand Kits to raise the water heater the required 18" above the floor are available from the distributor or store where the wafer heater was purchased. Request 'Stand Kil, Part Number AS29061'. The water heater should be installed as close as practical to the gas vent or chimney. Long hot water lines should be insulated to conserve water and energy. The water heater and water lines should be protected from exposure to freezing temperatures. DO NOT install the water heater in bathrooms, bedrooms, any occupied rooms normally kept closed, or in outdoor unprotected areas. Minimum clearance from combustible construction is 1 inch sides and rear, 1 inch from front of control; 12 inches top, If clearances stated an Instruction/Warning label, located on front of heater, differ from the aforementioned clearances, Install heater according to the clearances stated on the Instruction/Warning label. The water heater may be installed on combustible Itoors, but not directly on carpeting. If the water heater must be installed on carpeting, place a metal or wood panel beneath water heater, extending beyond its full width and depth at least 3 inches in B. C. Sept by STONE OREW ASHE & JONES c L. turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer. 12067630842; 03/12/99 12:24PM;jltFax #87; Page 13/15 A General Safety Precautions WATER TEMPERATURE ADJUSTMENT • Safety and energy conservation are factors to be considered when selecting the water temperature setting of water heater's thermostat. Water temperatures above 125 °F, can cause severe bums or death from scalding. Be sure to read and follow the warnings outlined on the label pictured below, NOTE: Households with small children, disabled, or elderly persons may require a 120 °F. or lower thermostat setting to prevent contact with "HOT" water. Water temperature over 125 °F can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. See instruction manual before setting temperature at water heater. Feel water before bathing or showering. Temperature limiting valves are available, see manual. Maximum water temperatures occur just after burner has shut off. To find hot water temperature being delivered, 3 The following chart may be used as a guide in determining the proper water temperature for your home. TIME / TEMPERATURE RELATIONSHIPS IN SCALDS Temperalure Time to Produce Serous Bum 120° F. More than 5 minutes t25° F. 11/210 2 minutes 130° F. About 30 seconds 135° F About 10 Seconds 140° F Less than 5 seconds _ 145° F. Less than 3 seconds 150° F. About 1112 seconds 155° F. About 1 second Tide carroty of SMners eLIm trawls The temperature of the water in the heater can be' regulated by setting the temperature dial on front of the thermostat. To comply with safety regulations the thermostat was set at its lowest setting before water heater was shipped from the factory. The illustration below details the approximate water temperature for each mark on the Thermostat Temperature Dial. "Danger Range" j "Safety Range" 130 °F. ( Approx) 140'F. (Approx .) 150'F. IApp ox.) 160'F. (Approx ) 120'F. (Approx.] 110'F, (Approx.) 100'F. (Approx.) 90°F. (Approx .) 80 °F (Approx.) 70 °F. (Approx,) 60°F. ( Approx.) A DANGER There is a Hot Water SCALD Potential if the thermostat is set too high. Mixing valves for reducing point of gek water temperature by mixing hot and cold water in branch water lines are available. Contact a licensees plumbersr tjtg local piumbingauthooity for fuller infoC ation. Sejtt by: STONE DREW ASHE & JONES 12067630842; 03/12/99 12:Z5PM;JetEaL - #87; Page 14/15 A General Safety Precautions Be sure to read and understand the entire Use & Care Manual before attempting to install or operate this water heater. Pay particular attention to the following General Safety Precautions. Failure to follow these warnings could result in a lire or explosion, causing property damage, bod- ily injury or death . Should you have any problems understanding the instructions in this manual, STOP, and get help from a qualified installer or service technician or the gas supplier. © WARNING I Gasoline, as well as other flammable materials and liquids (adhesives, solvents, etc.), and the vapors they produce, are extremely dangerous. DO NOT handle, use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater. Be sure to read and follow the warning label pictured below and other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in property damage, bodily injury, or death. © DANGER Failure to install the draft hood and properly vent the water heater to the outdoors as outlined in the Venting Section of this manual can result in unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, never operate this water heater unless it is properly vented and has an adequate air supply for proper operation, Be sure to inspect the vent system for proper installation at initial start -up; and at least annually thereafter. Refer to Maintenance section of this manual for more information regarding vent system inspections. Q Vapors from flammable liquids will explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater. Keep flammable products: 1. far away from heater, 2. in approved containers, 3. tightly closed and a. out of children's reach. Water heater has a main burner and pilot flame. The pilot flame: 1. Is on all the Gme and 1. will Ignite flammable vapors. Vapors: 1 cannot be seen, 2. are heavier then air, 3. go a long way on the floor and 4. can be carried from other rooms to the pilot flame by air currents. Installation: Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames are at least 18" above the floor. This will reduce, but not eliminate, the risk of vapors being ignited by the main burner or pilot (lame, Road and follow water heater warnings and 1naouctions. If owners manual is missing, contact me retailer or manufacturer. 2 © DANGER LIQUEFIED PETROLEUM MODELS -- Propane, or LP gas, must be used with great caution. • It is heavier than air and will collect first in lower areas making it hard to detect at nose level. • Make sure to look and smell for LP leaks before attempting to light appliance. Use a soapy solution to check all gas fittings and connections. Bubbling at a connection indicates a leak that must be corrected. When smelling to detect an LP leak, be sure to sniff near the floor too. • Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer's recommendations andlor local laws, rules, regulations or customs. • It is recommended that more than one method be used to detect leaks in LP applications. IF LP GAS IS PRESENT OR SUSPECTED: • DO NOT attempt to find the cause yourself; • 00 NOT try to light any appliance; • DO NOT touch any electrical switch; • DO NOT use any phone in your building. • Leave the house immediately and make sure your family and pets leave also. • Leave the doors open for ventilation and contact the gas supplier, a qualified service agency or the fire department. • Keep the area clear until the service call has been made, the leak is corrected, and a qualified agency has determined the area to be safe. A WARNING Both LP and natural gas have an odorant added to help detection. Some people may not physically be able to smell or recognize this odorant. If unsure or unfamiliar about the smell associated with LP or natural gas, ask the gas supplier. Other conditions, such as "Odorant Fade ", which causes the odorant to "fade ", or diminish in intensity can also hide or camouflage a gas leak. Q DANGER Water heaters utilizing Liquefied Petroleum gas (LP) are different from natural gas models. A natural gas heater will not function safely on LP gas and vice versa. No attempt should ever be made to convert a heater from natural gas to LP gas. To avoid possible equipment damage, personal injury or tire: DO NOT connect this water heater to a fuel type not in accordance with unit data plate. Propane for propane units. Natural gas tor natural gas units. These units are not certified for any other type fuel. A WARNING] LP appliances should not be installed below -grade (for example, in a basement) if such installation is prohibited by federal, state andlor local laws, rules, regulations or customs. 4 Sept by: STONE DREW ASHE & JONES 12067630842; 03/12/99 12:26PM;JetFax #87; Page 15/15 Residential Gas Water Heater C USE&CAREMANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR The purpose of this manual is twofold: for the installing contractor, to provide requirements and recommenda- tions for the proper installation and adjustment of the water heater, and for the owner - operator, to explain the features, operation, safety precautions, maintenance and trouble shooting of the water heater. This manual also in- cludes a parts list. It is imperative that all persons who are expected to in- stall, operate or adjust this water heater read the in- structions carefully so that they may understand how to do so, Any questions regarding the operation, maintenance, ser- vice or warranty of this water heater should be directed to the entity from whom it was purchased. If additional in- formation is required, refer to the section on How to Ob- tain Service Assistance. Do Not Destroy this Manual. Please read care- fully and keep in a safe place for Future Refer- ence. Recognize this symbol as an Indication of Important Safety Information! AWARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. ,A FOR YOUR SAFETY! — Do not store or use gasoline or other flammable vapors or liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. — WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. • Do not return to your home until authorized by the gas supplier or fire department. • Improper installation, adjustment, alteration, service or maintenance can cause injury, property damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier. Printed in USA AP8a99•e (7195) 1 1 Frvr4-Coosd Cop'. PLAN REVIEW/ROUTING ACTIVITY NUMBER: M99 -0060 DATE: 3 -19 -99 PROJECT NAME: THOMAS BRUMMEL Original. Plan Submittal Response to Incomplete Letter Revision # : After .Permit Is Issued Response to Correction Letter # DEPARTMENTS: Build' it 'vision y P b is Wolk-Pif Fire Prevention ® Planning Division n /74- St uctural ❑ Permit Coordinator DETERMINATION OF COMPLETENESS: (Tues, Thurs) Complete Incomplete [] Comments: DUE DATE: 3 -23 -99 Not Applicable ❑ TUES /THURS ROUTING: Please Route No further Review Required Routed by Staff El (if routed by staff, make copy to master file and enter into Sierra) n REVIEWERS INITIALS: DATE: APPROVALS OR CORRECTIONS: (ten days) DUE DATE: 4 -20 -99 Approved ❑ Approved with Conditions Not Approved (attach comments) 0 REVIEWERS INITIALS: DATE: CORRECTION DETERMINATION: DUE DATE: Approved ❑ Approved with Conditions Not Approved (attach comments) El REVIEWERS INITIALS: DATE: \PR•ROUTE.DOC 6/98 1162!.11:11.4)110 18,471 DEPARTMENT OF LABOR AND INDUSTRIES REGISTERED AS PROVIDED BY LAW AS CONST CONT GENERAL REGIST. # EXP. DATE CCO1 • WASHIES07403 06/24/1999 EFFECTIVE DATE 09/23/1993 WASHINGTON ENERGY SERVICES CO ONE UNION SQ 9TH FL PO BOX 91060 SEATTLE WA 98111 -9160 State of Washington County of King I certify that this is a true and correct copy of the original document presented to me by Anne Schmidt of Washington Energy Services on Thursday, November 19, 1998. DL.t.u.h And Di.play Certificate REGISTERED AS PROVIDED BY LAW AS CONST CONT GENERAL REGIST. # EXP. DATE CCO1 WASHIES07403 06/24/1999 EFFECTIVE DATE 09/23/1993 WASHINGTON ENERGY SERVICES CO ONE UNION SQ 9TH FL PO BOX 91060 SEATTLE WA 98111 -9160 Sisnatur• Issued by DEPARTMENT OF LABOR .AND INDLSTR(ES Please Remove And Sian Identification Card Before Placing In Billfold Notary Public in and for the State of Washington My Commission Expires 09/09/99