Coleman 035-16329-002 User manual

OWNER'S MANUAL
SEALED COMBUSTION
DOWNFLOW
GAS FURNACE
WARNING
FOR YOUR SAFETY -Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury or loss of life. Installation and service must be
performed by a qualified installer, service agency or the gas supplier. Do not
store or use gasoline or other flammable vapors and liquids in the vicinity of this
or any other appliance.
Never attempt to modify this furnace. Fire, explosion, or asphyxiation may
result. If malfunction occurs, obtain the assistance of a qualified service agent.
If not installed, operated, and maintained in accordance with the manufacturer's
instructions, this product could expose you to substances in fuel or from fuel
combustion which are known to the State of California to cause cancer, birth
defects or other reproductive harm. Also, operation, installation and servicing of
this product could expose you to airborne particles of glasswool fibers known to
the State of California to cause cancer through inhalation.
Use of furnace or air conditioning components that are not included in the Inter-
tek Testing Services (ETL) certification of this appliance may create a hazard,
will invalidate the certification, and will in many states make installation illegal.
UL listed air conditioning components are specified on the furnace label.
I CAUTION'
Before placing furnace in service, itmust be checked to make sure it is equipped
for the type of gas being used. Failure to observe this caution may result in
unsafe operation, explosion, and/or fire or asphyxiation. Use of other compo-
nents not tested in combination with this furnace may make the equipment in
violation of State Codes, may create a hazard, and may ruin the equipment.
035-16329-002 Rev. B (0304)

035-16329-002 Rev. B (0304)
ConBratuL_tion_...
On your purchase of one of the most versatile furnaces available in the industry today. This compact, energy-efficient furnace
has been precision designed, manufactured of high-quality materials and has passed many rigorous inspections and tests to
ensure many years of satisfactory service. This booklet is meant to increase your understanding of your unit, tell you how to
operate it e_ciently and how to obtain the greatest measure of comfort at the lowest operating expense. Please read this book-
let thoroughly. We appreciate your interest in our product and your decision to purchase our furnace. Enjoy your comfort.
INTRODUCTION
WARRANTY AND
RESPONSIBILITIES
It is the sole responsibilityof the
home owner to make certain that
the gas furnace has been correctly
set up and converted to the proper
fuel (Propane or Natural gas) and
adjustedto operate properly.
The manufacturerwarrants the fur-
nace to be free from defects in
material or workmanship for the
stated time in the warranty agree-
ment (see warranty certificate
packedwith the furnace).
However, the manufacturerwill not
be responsiblefor any repair costs
to correct problems due to
improper set-up, improper installa-
tion, furnaceadjustments,improper
operating procedure by the user,
etc.
Some specific examples of service
calls which cannot be included in
warrantypayments are:
1. Convertingthe furnace to use
another type of gas.
2. Correctingfaulty duct work in
the home.
3. Correcting wiring problems in
the electricalcircuit tothe fur-
nace.
4. Resetting circuitbreakers or
otherswitches.
5. Adjusting the burner air shut-
ter or service calls madeto cor-
rectproblemscaused by
improper air adjustment.
6. Correctingproblemscaused by
impropergas supplypressure
to the furnace.
7. Instructionaltraining on how to
light and operate furnace.
8. Furnace problemscaused by
installationof air conditioner,
heat pump, or otherair quality
device which isnot approved.
9. Problemscaused by improper
installationofthe furnace flue
assembly (roofjack).
10. Adding a roofjack extension
because of unusualwind con-
ditionsor snowconditions.
11. Adjusting or calibrating the
thermostat.
12. Problems caused by construc-
tiondebds whichhas fallen into
the flue or combustion air
openings.
13. Replacement of fuses.
14. Problems caused by odfice
plugged or restricted by spider
webs.
You should establish a firm under-
standing of these responsibilities
with your manufactured housing
dealer, service company or gas
supplier sothere will be no misun-
derstandingat a later time.
GAS SUPPLY
The gas supply to your home will
either be Natural Gas or Propane
gas. Your furnace will be factory
equipped to operate on onlyone of
these two differentgases.
Asmall metal tag secured to the
fumace next to the gas valve will
specify the type of gas your fur-
nace is equippedto use.
If the gas is different from that
specified on the metal tag, the fur-
nace can be converted byfollowing
the instructions on the furnace
safety label inside lower front
panel. Parts for conversion are
containedin the small bag attached
to the gas valve. Be sure the
proper size odficeisused, as spec-
ifiedon the furnace name plate.
IA CAUTIONj
The furnace must be
converted by a qualified
technician. Improper
conversion can cause
unsafe operation, explo-
sion, and/or fire or
asphyxiation.
Natural Gas Operation
The fumece isdesignedfor7"W.C.
inletpressure. Pressure is reduced
to 3 1/2" W.C. by the pressure reg-
ulatorin the gas valve.
Propane Gas Operation
Inlet pressure to the gas valve
must be 11" W.C. When properly
converted to Propane gas, the
pressureis regulatedat 10" W.C.
SAFETY INFORMATION
For your safety read before light-
ing.
1. The firstlightingofthe furnace
after any home setup must be
performedby a qualified ser-
vicetechnician.
2.
3.
If this appliancehas a pilotthat
must be lit by hand, follow
these instructionsexactly.
BEFORE LIGHTING smell all
aroundthe furnace for gas. Be
sure to smellnext tothe floor
because some gas is heavier
than air and willsettle on the
floor.
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035-16329-002 Rev. B (0304)
WHAT TO DO IF YOU SMELL
GAS:
DOnot tryto lightany appli-
ance.
Do not touch any electric
switch and do not use any
phone in your building.
Immediately call your gas sup-
plier from a neighbor's phone.
Follow the gas supplier's
instructions. If you cannot
reach your gas supplier, call
the fire department.
4. Use only your hand to move
the gas control lever or switch.
Never use tools. If the lever or
switch will not move by hand,
don't try to repair it. Call a qual-
ifiedservice technician. Force
or attempted repair may result
in a fire or explosion.
5. Do not use this furnace if any
part has been under water.
Immediately call a qualified
service technician to inspect
the furnace and to replace any
part of the controlsystem and
any gas controlwhich has
been underwater.
INSTRUCTIONS FOR
STANDING PILOT
MODELS
LIGHTING INSTRUCTIONS
1. STOP! Read the Safety Infor-
mation.
2. Set the thermostat to the low-
est setting.
3. Turn off all electrical powerto
the appliance.
4. Remove the furnace doors.
5. Push in the gas controllever
slightlyand move rightto
"OFF". DO NOT FORCE.
6. Wait ten (10) minutes to clear
out any gas. Then smell for
gas, including near the floor. If
you smell gas, STOP! Follow
Step 3 in the Safety Informa-
tion above. If you don't smell
gas, go to the next step.
7. Open hinged observation door,
the pilot is found at the end of
the pilot shield on the left side
of the burner.
8. Slightly depress the gas control
lever and move itto the left to
the "ON" position and release;
then move it to the "PILOT"
position.
9. Move the control lever to "SET"
and hold. Immediately light the
pilot with a match (use match
holder provided). Continue to
hold the control lever for about
one (1) minute after the pilot is
lit. Release the lever and it will
spring back to the =PILOT"
position. Pilot should remain lit.
If it goes out, repeat steps 5
through 9 above.
If the lever does not spdng
back when released, stop and
immediately call your service
technician or gas supplier.
If the pilot will not stay lit after
several tdes, move the gas
control lever to =OFF"and call
your service technician or gas
supplier.
10. Move the gas control lever to
"ON".
11. Replace the furnace doors.
12. Turn on all electric power to the
furnace. Set the thermostat to
"HEAT" and/or the desired tem-
perature setting. Set the ON-
OFF-FAN switch to =ON".
In the event of any flashback or
explosion, immediately shut off
the furnace and call your service
technician.
To Turn off Gas to Appliance
1. Set thethermostat tothe low-
est setting.
2. Turn offall electdcpowerto the
appliance ifservice isto be
performed.
3. Remove the furnace doors.
4. Move gas control switch to
=OFF"position. DO NOT
FORCE.
5. Replace the furnace doors.
GAS CONTROL LEVER
PRESSURE
REGULATING
DEVICE
FIGURE I:STANDING PILOT
GAS VALVE
SEQUENCE OF
OPERATION
1. On a call for heat, the thermo-
statcontactsclose, supplying
24 VAC to the gas valve.
2. When the gas valve is ener-
gized it initially opens at a
reduced flow and opens fully
after approximately 30 sec-
onds.
3. About 1-2 minutes after the
burner lights, the furnace air
circulation blower will come on.
4. When the cell for heat is satis-
fied the thermostatcontacts
open, the gas valve shutsoff
gas flow.
5. After the burnershutsoff,the
air circulationblowerwillcon-
tinue to run for 2-4 minutes,
until the furnace has cooled.
Unitary Products Group 3

035-16329-002 Rev. B (0304)
THE FURNACE CONTROLS
AND THEIR FUNCTION
1. =ON-OFF-FAN" switchturns
electrical power to the furnace
on and off. The switch must be
set in the "ON" position for the
furnace to operate. To run the
blower continuously without
heating, set the switch to
"FAN".
2. Limit Control - This furnace is
protected by two (2) high tem-
perature limit switches. The
lower limit switch is an auto-
matic reset type.
IMPORTANT - The upper limit 1.
switch near left side of blower is a
manual reset type limit switch. If 2.
burner does not function, turn sys-
tem switch to =OFF"and push reset 3.
button in center of limit switch.
4.
3. Gas Valve - The gas valve is
100% shut-offtype and willfail
safe iffor some reasonthe gas
isturned offor the pilotgoes
out. It isalso ofthe step-open
type whichmeans theyopento
a lowfire positionand affer a
few seconds step-opento high
fire.
4.
warm weather and heat from
the pilot. This isnormal opera-
tionas long as there ispower
to thefurnace and the ON-
OFF-FAN switch isat the "ON"
position.IF blower operationis
not desired,the ON-OFF-FAN
switchmay be set in the"OFF"
positionto cutthe electrical
powerto the furnace.
INSTRUCTIONS FOR
AUTOMATIC IGNITION
MODELS
LIGHTING INSTRUCTIONS
5.
6.
Fan Switch -This fanswitch is 7.
a temperature sensingdevice
that turnson the blower when
sufficientheat has builtup
withinthe furnace, It alsoturns
the bloweroffwhen thefurnace
has cooled down sufficiently
after burnershut-off. Inwarm 8,
weather,there isa possibilityof
the blower comingon periodi- 9,
celly or operatingcontinuously
due toaheat buildupwithinthe 10.
furnace bya combinationof
STOP! Read the safety infor-
mation
Set the thermostatto the low-
est setting,or =OFF'.
Turn off all electdc power to the
furnace.
This appliance does not have a
pilot. It is equipped with an igni-
tion device which automatically
lights the burner. Do not try to
light the burner by hand.
Remove upper door panel.
Move gas valve control switch
to =OFF".See Figure 2.
Wait five (5) minutes to clear
out any gas. Then smell for
gas, including near the floor. If
you smell gas, STOP! Follow
Step 3, in the Safety Informa-
tion above. If you don't smell
gas, go to the next step.
Move gas control switch to
"ON".
Replace upper door panel.
Turn on allelectricpowertothe
furnace.
11. Set thermostat to desired set-
ting.
GAS CONTROL PRESSURE
SWITCH REGULATING
DEVICE
FIGURE 2:AUTO IGNITION GAS
VALVE
SEQUENCE OF
OPERATION
This fumace is equipped with an
electronic control system which
automatically supervises burner
and fan operation. Agreen indica-
tor light displays dudng normal
operation. This indicator light also
informsthe home owner when cer-
tain basic services are needed. In
response to a cell for heat by the
room thermostat, the burner is
lighted by a hot glowing ignitor at
the beginning of each operation
cycle. The burner will continue to
operate untilthe thermostat is sat-
isfiedat whichtime all burnerflame
isextinguished.Duringthe offcycle
no gas isconsumed. Withthe room
thermostatset below roomtemper-
ature, and with the electdcel power
and gas supply to the fumace on,
the normal sequence of operation
is as follows:
1. When the roomtemperature
falls belowthe settingofthe
roomthermostat,the thermo-
stat energizes thefurnace con-
trolboard.
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035-16329-002 Rev. B(0304)
2. When the furnace control
board isactivated, the combus-
tionair blower isturned on.
3. As the combustion air blower
increases in speed, the con-
tactsofthe pressure switchwill
close and completethe electd-
cal circuittothe ignitioncircuit.
4. Duringthe next40 to 50 sec-
onds, the combustionair
blowerwill bringfresh air into
the heat exchanger and the
ignitorwillbeginto glow. Atthe
end of this pedod,the gas
valve wi!l openand the burner
will light.
5. After the burner lights, a sepa-
rate sensor acts as a flame
probe to check for the pres-
ence offlame. As long as flame
is present, the system will
monitor it and hold the gas
valve open.
6. Ifthe burner fails to light within
6-8 seconds after the gasvalve
opens, the gas valve willclose
and the ignitor will be turned
off. After a short pause, the
systemwill recycle and try
again for ignition. If the burner
fails to light atler three tdes, the
ignition system will lock out.
The system will remain in lock-
out mode for aperiod of one
hour, then the furnace will try
for ignition again.
7. The lapsed time from the
moment the roomthermostat
closesto when the burner
lightsmay be 45-60 seconds.
This delay is caused by:
a. The timerequired for the
ignitorto heat up and
b. The time requiredfor fresh
air to be brought intothe
heat exchanger.
8. Approximately 60-90 seconds
after the burnerlights,furnace
air circulationblower willrun.
9. When roomthermostat issetis-
fled, the circuittothe furnace
control board isopened. The
circuittothe combustionair
blowerand the gas valve is
opened and the burnerisextin-
guished.Then the furnace con-
trolboard willkeep the
circulatingblower running for a
fixed pedod oftime to allow
additionalheat to be drawn
from the heat exchanger.
DIAGNOSTIC LIGHT
If furnace does not maintain home
temperature as set, check the light
indicator, visible through a small
window in the dght side of the fur-
Racecontrolbox.
The electronic furnace control is
equipped with a diagnostic light
which flashes when there is a ser-
viceproblem.The diagnosticcodes
are;
Steady on: Normal operation.
ONE flash: Ignition failure.
TWO flashes: Pressure switch
failedclosed.
THREE flashes: Pressure switch
failedopen.
FOUR flashes: Limitswitchopen.
FIVE flashes: Gas valve energized
with no call for heat
SIX flashes or
rapid flash: Reversed poladty
If a problem is indicated, contact
your authorized service person.
THE FURNACE CONTROLS
AND THEIR FUNCTION
1. System Switch - This system
switchturns=ON"or "OFF"the
120 volt electdcalcircuitthat
powersthe furnace controls
and the blower motor.The sys-
tem switch mustbe turned
"ON" for the furnace to oper-
ate. Turn the switchto "OFF"
when cleaningthe blower,etc.
2. Limit Control - This furnace is
protected bytwo (2) hightam-
perature limitswitches.The
lowerlimitswitch isan auto-
maticreset type.
3. Gas Valve - The gas valvefor
the gas furnaces are a 100%
shut-offtype and willfail safe if
for somereason the gas is
turned off.
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035-16329-002 Rev. B (0304)
GENERAL
INFORMATION FOR
ALL MODELS
GAS SHUTOFF
Should overheating
occur, or the gas supply
fail to shut off, shut off
the manual gas valve to
the furnace and allow
blower to run until fur-
nace cools down and
blower shuts off before
shuttingoff the electrical
supply
The furnace gas valve is equipped
with a manual gas shutoff.To turn
off gas to the furnace, move the
lever on the gas valve to the =OFF"
position.
The furnace installation shouldalso
have a manual shutoffvalve in the
gas pipingto the furnace, similarto
what is shown in Figure 3. To turn
off the gas to the furnace, use a
wrench and turn the knob or lever
so that it is pointing 90 degrees
fromthe gas pipe, as shownin Fig-
ure3.
OFF ON
OFF ON
FIGURE 3:MANUAL GAS
SHUTOFF VALVE
Set the room thermostat at the
desired room temperature. Great-
est comfortwill be achieved when
the setting is not changed fre-
quently.
For energy conservation and econ-
omy it is recommended that the
thermostat be set at 68 ° for heating
and 80° for cooling.
For Heating with Air Condition-
ing Applications -Set heat/cool
switch to =HEAT" position and set
fan switchto"AUTO" position.
OBSERVING BURNER
OPERATION
1. Observe bumer tomake sure it
ignites. Observe colorofflame.
On natural gas the flamewill
burnbluewith appreciablyyel-
low tips.On Propane gas a yel-
low flame may be expected. If
flame is notthe propercolor
cell a qualifiedservicemanfor
service.
2. Letfurnace heat untilblower
cycleson.
3. Turn thermostatdown.
4. Observe burnerto make sure it
shutsoff.
5. Letthe furnace cooland
blowercycle off.
If any abnormalities are observed
when checking for correct opera-
tion, such as burnerfailingto ignite
or to turnoff, sootyflame, etc., cell
your nearest authorized service
technicianas shown in the Service
Center List included in the home
owner envelope.
IF FURNACE FAILS TO
OPERATE PROPERLY
1. Check settingof thermostat-
and positionofheat/cool switch
ifair conditioning is installed. If
a set-backtype thermostatis
employed besure that thether-
mostatis inthe correctoperat-
ingmode.
2, Check to see thatelectrical
power is"ON".
3. Check to see that the lever or
switchon the gas control valve
is in the full "ON" position.
4. Make sure filters are clean,
return grilles are not
obstructed, and supply regis-
ters are open.
5. Be sure thatfurnace flue piping
isopen and unobstructed.
If the cause for the failure to
operate is not obvious, do not
attempt to service the furnace
yourself. Call a qualified service
agency or your gas supplier.
PERIODIClNSPECTION
AND MAINTENANCE BY
HOMEOWNER
It is recommended that the home-
owner or user make an inspection
of the furnace at least every 90
days, or more often if desired. It is
also recommended that a qualified
service agency inspectthe furnace
before each operating season the
furnace is used, both heating and
air conditioning, and at any time
that there is an indication of mal-
function. The owner/user should
not attempt to disassemble the fur-
nace unlessexperienced and qual-
ifiedto do so.
CAUTION
FOR SAFETY- Turn off
electrical power to fur-
nace before performing
service such as clean-
ing filters.
Filters
It is very important that filters in
your furnace or air conditioning
system be replaced frequently.
Clean filtersnot onlyprovideadded
comfortand a more healthfulenvi-
ronment,but also allowthe system
to operate more efficiently.Check
filtersevery two or three weeks.
6 Unitary Products Group

035-16329_02 Rev. B (0304)
Motor Lubrication
The circulating air blower motor
and combustionair blower are per-
manently lubricated and do not
require periodic lubrication.
Heat Exchanger Cleaning
Under normal conditions, the heat
exchanger should not require peri-
odic cleaning. However, should
cleaning of the interiorof the heat
exchanger become necessary,
access to the interior of the heat
exchanger may be gained by
removing the burner. Do not
attemptto disassemble any part of
the heat exchanger for cleaning.
Do not use any chemicalfor clean-
ing the heat exchanger. Such use
may cause a fire or explosion or
may result in corrosion of the
heat exchanger.
IMPORTANT -This furnace
must be serviced only by qualified
individuals specially trained in ser-
vicing of this type of equipment.
Installation and service personnel
are requiredto be licensedin some
areas. Personsnot qualifiedshould
not attemptto service this furnace.
Return Air
On some closet installations, the
return air opening to the furnace
may be on the floor,and/or on the
door and/or on the side wall of the
closet.The upper grilleon the front
of the furnace admits return air to
the blower. Return air must be pro-
vided backto the circulatingblower
in order toprovide air distribution.
IMPORTANT -Do not obstruct
these openings includingthe grille
on the fumace. To do so willcause
the furnace to activatethe high limit
and shut down or it may cause
asphyxiation.
While you are away
Your furnace is equipped with a
safety devicewhichwill shut offthe
supply of gas to the burner in case
of malfunction. For this reason it is
never practical to assume that the
furnace will operate unattended for
along period of time, especially if
there is a possibilityof damage to
your property because of freezing.
So, if you plan to be away from
home, arrange for someone to
checkyour houseevery day.
SEASONAL SERVICE
INFORMATION
During extreme cold weather, ice
.may form on the fumace roof jack
crown. Small amounts of ice form-
ing on the roof jack will present no
problem to proper furnace opera-
tion. However, excessive ice for-
mation could restrict the
combustion air supply to the burner
causing inefficient burner opera-
tion.
When the temperature isvery cold,
near zero or below, it is recom-
mended that the roof jack be
inspected every day or more fre-
quently if required. If ice has
started to collect on the roof jack
crown, itshouldbe carefullybroken
off.
Your Service Technician
Your furnace's best friend is your
qualified service technician. If the
unit gives any indication of
improper operation, call your ser-
vice technician. If the service tech-
nician is allowed to perform the
normal routine care of your fur-
nace, he can many times detect
potential difficulties and make cor-
rections before trouble develops.
Preventative maintenance of this
type will allow you to operate the
unit with a minimum of cencem,
and at the same time will pay for
itselfin added years of comfort.
When You Call For Service
Assistance
Very oftentime can be saved if you
will give the service agency the
MODEL and SERIAL NUMBER of
your furnace. This will enable him
to determine the specific compo-
nents used, and perhaps to better
identify the possible problem and
be better prepared ifa service call
is required.
To Contact Your Serviceman
(fill in)
COMPANY:
ADDRESS:
TELPHONE:
All appliances need maintenance
by serviceman at the beginning of
each heating season. Call your
nearest authorized service techni-
cianto:
1. Replace filters. Clean all lint
and dust from aroundfurnace.
2. Remove fan and clean all dust
and lintfrom unitwith stiffbris-
tle brush.
3. Inspectcombustionchamber,
the transition intothe blower
compartment,flue collar,and
reofjack.
4. Check the gas valveand line
connectionsfor leaks.
5. Make any adjustmentsneces-
sary for goodoperation.
NOTE: The coilpanel providesa
good removableaccess for
inspectinginsidethe fur-
nace casing. Smoke or
reflected lightinside the
casing indicatesthe pres-
ence of leaks inthe heat
exchanger.
Unitary Products Group 7

IMPORTANT
Ir As an owner of a new furnace you need to know the following information:
Ifyour home is locatedat an elevation above 2,000 feet, the burnerorificein yourfurnace will need to be der-
ated. Please contact the nearest authodzed Service Center to have this procedure performed properly.
Your dealer or gas company may have already applied the proper deration for your unit. If so, they should be
able to advise you as such. Ifnot, you need to have the deration made to insure continued use of your furnace.
Not having the unit derated properly will eventually render the furnace inoperable.
Deration of the odfice for furnaces installed in homes at elevations above 2,000 feet is not covered by the war-
ranty. Thisprocedure isconsidered a partof the installationprocess and is required to make the furnace operate
properly.
These furnaces are shipped fi'om the factory with a natural gas orifice. Ifyou will be operating this furnace on LP
(liquid propane gas), it will also be necessary to have the furnace converted. The correct LP orifice is supplied
with the furnace to allow operation at elevations below 2,000 feet. If the furnace will be operating on LP gas at
elevations above 2,000 feet, the orifice supplied will be too large to allowproper operation. You should contact
your LP supplier for assistance in getting the derated orifice installed.
We hope you follow these instructions and enjoy many years of trouble free service. If you have any questions,
please feel flee to contact the technical assistance hot line at 1-800-231-4822.
Subject to change without notice. Printed inU.S.A. 035-16329-002 Rev. B (0304)
Copyright ©by York International Corp. 2004. All rights reserved. Supersedes: 035-16329-002 Rev, A(401)
Unitary P.O. Wichita
Products Box KS
Group 19014 67204-9014