Goodman GM9S80 Guide
Service and Troubleshooting
Copyright © 2021 Goodman Manufacturing Company, L.P.
RS6621008
July 2021
TABLE OF CONTENTS
IMPORTANT INFORMATION............................................ 2
PRODUCT IDENTIFICATION ........................................... 4
SYSTEM OPERATION...................................................... 5
SCHEDULED MAINTENANCE ....................................... 25
SERVICING..................................................................... 29
CHECKING VOLTAGE .............................................. 30
CHECKING WIRING .................................................. 30
CHECKING THERMOSTAT, WIRING ....................... 30
CHECKING TRANSFORMER AND CONTROL
CIRCUIT...................................................................... 31
CHECKING AIR CIRCULATOR BLOWER MOTOR 31
CHECKING DUCT STATIC........................................ 32
CHECKING TEMPERATURE RISE .......................... 32
CHECKING PRIMARY LIMIT CONTROL................. 33
CHECKING AUXILIARY LIMIT CONTROL............... 33
CHECKING FLAME ROLLOUT CONTROL ............. 34
INDUCED DRAFT BLOWER MOTOR ...................... 35
CHECKING GAS VALVE (REDUNDANT) ................ 35
CHECKING MAIN BURNERS ................................... 35
CHECKING ORIFICES .............................................. 35
CHECKING GAS PRESSURE .................................. 36
CHECKING HOT SURFACE IGNITER ..................... 38
CHECKING FOR FLASHBACK................................. 38
CHECKING PRESSURE SWITCH............................ 38
HIGH ALTITUDE APPLICATION ............................... 39
CHECKING FOR DELAYED IGNITION.................... 39
CHECKING INTEGRATED IGNITION CONTROL
BOARDS ..................................................................... 40
CHECKING FLAME SENSOR................................... 40
AIRFLOW TABLES........................................................ 42
1 STAGE STATUS CODES ........................................... 50
1 STAGE TROUBLESHOOTING CODES.................... 52
WIRING DIAGRAMS....................................................... 54
Pride and workmanship go into every product to provide
our customers with quality products. It is possible, however,
that during its lifetime a product may require service.
technician who is familiar with the safety procedures
required in the repair and who is equipped with the proper
tools, parts, testing instruments and the appropriate service
manual.
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-
IMPORTANT INFORMATION
2
Pride and workmanship go into every product to provide our
customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products
is familiar with the safety procedures required in the repair
and who is equipped with the proper tools, parts, testing in-
struments and the appropriate service manual.
OUTSIDE THE U.S., call 1-713-861-2500.
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
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-
IMPORTANT INFORMATION
3
B10259-216
CO can cause serious illness including permanent brain
damage or death.
Advertencia especial para la instalación de calentadores ó manejadoras
de aire en áreas cerradas como estacionamientos ó cuartos de servicio.
B10259-216
El monóxido de carbono puede causar enfermedades severas
como daño cerebral permanente ó muerte.
Las emisiones de monóxido de carbono pueden circular a través
del aparato cuando se opera en cualquier modo.
B10259-216
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE
Cette ventilation est nécessaire pour éviter le danger d'intoxication
au CO pouvant survenir si un appareil produisant du monoxyde
de carbone continue de fonctionner au sein de la zone confinée.
•
•
•
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PRODUCT IDENTIFICATION
4
Please use these numbers when requesting service or parts information.
A M 9 C 8 0 0 6 0 3 B N A A
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Brand Minor Revision
G - Goodman®
Brand A - Initial Release
V - GMC® Brand B - 1st Revision
A- AMANA® Brand
Configuration
M - Upflow/Horizontal Major Revision
C - Downflow/Horizontal A - Initial Release
B - 1st Revision
Nox
Motor
9 - Nine Speed ECM
Cabinet Width
A - 14"
Gas Valve B - 17.5"
C - 2 Stage C - 21"
S - 1 STAGE D - 24.5"
Maximum CFM
3 - 1200 CFM
AFUE 4 - 1600 CFM
80 - 80% AFUE 92 - 92% AFUE 5 - 2000 CFM
96 - 96% AFUE 97 - 97% AFUE
MBTU/h
030 - 30,000 BTU/h 080 - 80,000 BTU/h
040 - 40,000 BTU/h 100 - 100,000 BTU/h
060 - 60,000 BTU/h 120 - 120,000 BTU/h
N = > 40 NG/J NOx
X = < 40 NG/J NOx
U = < 14NG/J NOx
®
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
SYSTEM OPERATION
5
1. 115 VAC power applied to furnace.
2. Integrated ignition control module performs internal
checks.
3. Integrated ignition control module LED will light.
4. Integrated ignition control monitors safety circuits
continuously.
5. Furnace awaits call from thermostat.
1. R and W thermostat contacts close, initiating a call
for heat.
2. Integrated control module performs safety circuit
checks.
3. The induced draft blower is energized causing pres-
sure switch contacts to close. Induced draft blower
remains energized for pre-purge period.
4. Ignitor warm up begins after pre-purge is completed.
5. Gas valve opens at end of ignitor warm up period, de-
6.
within seven (4) seconds after the gas valve is ener-
is present.
7. Circulator blower is energized on heat speed following
8. Furnace runs, integrated control module monitors
safety circuits continously.
9. R and W thermostat contacts open, allowing the gas
10. -
teen (15) - second post purge.
11. Circulator blower is de-energized following a selectable
12.
-
tomize the comfort level.
The normal operational sequence in cooling mode is as
follows:
1. R and Y thermostat contacts close, initiating a call for
cool.
2. Integrated control module performs safety circuit
checks.
3. Outdoor fan and compressor are energized.
4. Circulator blower is energized on cool speed following
5. Furnace circulator blower and outdoor cooling unit
run, integrated control module monitors safety circuits
continuously.
6. R and Y thermostat contacts open, completing the call
for cool.
7. Outdoor fan and compressor are de-energized.
8. -
9.
The normal operational sequence in fan only mode is as
follows:
1. R and G thermostat contacts close, initiating a call for
fan.
2. Integrated control module performs safety circuit
checks.
3. Circulator blower is energized on heat speed.
4. Circulator blower runs, integrated control module
monitors safety circuits continuously.
5. R and G thermostat contacts open, completing the call
for fan.
6. Circulator blower is de-energized.
7.
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-
The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be re-
Refer to the wiring diagram for wire routings. If any of the
original wire as supplied with the furnace must be replaced,
it must be replaced with wiring material having a tempera-
ture rating of at least 105° C. Any replacement wiring must
be copper conductor.
Before proceeding with electrical connections, ensure that
the supply voltage, frequency, and phase correspond to
furnace must be N.E.C. Class 1, and must comply with all
SYSTEM OPERATION
6
applicable codes. The furnace must be electrically grounded
in accordance with local codes or, in their absence, with the
latest edition of The National Electric Code, ANSI NFPA 70
and/or The Canadian Electric Code CSA C22.1. An electri-
cal disconnect must be provided at the furnace location.
connections.
Connect hot, neutral, and ground wires as shown in the wir-
ing diagram located on the unit’s blower door. Metal conduit
is not considered a substitute for an actual ground wire to
connections. Line voltage connections can be made through
either the right or left side panel.
located inside the burner compartment. To make electrical
connections through the opposite side of the furnace, the
-
er compartment prior to making electrical connections.
Wire routing must not interfere with circulator blower
-
Electronic
Turn OFF power to the furnace before installing any acces-
-
structions for locating, mounting, grounding, and controlling
these accessories.
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the wiring must
conform to all local codes, and have a minimum temperature
rating of 105°C. All line voltage wire splices must be made
Wiring routing must not interfere with
maintenance. Low voltage connections can be made
through either the right or left side panel. Thermostat wiring
entrance holes are located in the blower compartment. The
This furnace is equipped with a 40 VA transformer to facili-
tate use with most cooling equipment. Consult the wiring di-
agram, located on the blower compartment door, for further
details of 115 Volt and 24 Volt wiring.
Y
C
Y
C
G
R
W
Y2
Y/Y1
C
G
R
W
ROOM THERMOSTAT
INTEGRATED FURNACE
CONTROL MODULE
REMOTE COOLING UNIT
(SINGLE STAGE)
Thermostat - Single-Stage Heating with Single-Stage Cooling
Y1
C
Y1C
G
R
W
Y2
Y/Y1
C
G
R
W
ROOM THERMOSTAT
INTEGRATED FURNACE
CONTROL MODULE
REMOTE COOLING UNIT
(TWO STAGE)
Y2
Y2
Thermostat - Single-Stage Heating with Two-Stage Cooling
This furnace can be used in conjunction with a heat pump
in a fossil fuel application. A fossil fuel application refers to
a combined gas furnace and heat pump installation which
uses an outdoor temperature sensor to determine the most
A heat pump thermostat is required to properly use a sin-
gle-stage furnace in conjunction with a heat pump. Refer to
the fossil fuel kit installation instructions for additional ther-
mostat requirements.
Strictly follow the wiring guidelines in the fossil fuel kit instal-
lation instructions. All furnace connections must be made
to the furnace two-stage integrated control module and the
SYSTEM OPERATION
7
Two furnaces of the same model may be twinned. The in-
located beside the low voltage thermostat connection strip.
Twinning allows simultaneous operation of two furnaces and
forces the indoor blower motors of each furnace to operate
synchronously into a common duct system. Using the twin-
must be set the same on both furnaces.
Each furnace must be connected to it’s own 115
VAC power supply. The L1 connection to each furnace must
be in phase (connected to circuit breakers on the same 115
VAC service panel phase leg). To verify that the furnaces
are in phase, check from L1 to L1 on each furnace with a
voltmeter. If the furnaces are in phase, the voltage between
both furnaces will be ZERO.
ROOM THERMOSTAT
Y2
Y/Y1
C
G
R
W
Y2
Y/Y1
C
G
R
W
Y2
Y/Y1
C
G
R
W
TWIN
TWIN
COND UNIT
CONTACTOR
COND UNIT
CONTACTOR
FURNACE 1
FURNACE 2
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an op-
Humidifier
Electronic Air Cleaner
Turn OFF power to the furnace before installing any acces-
-
structions for locating, mounting, grounding, and controlling
these accessories. Accessory wiring connections are to be
conform to applicable codes. Connections should be made
as shown.
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the wiring must
conform to all local codes, and have a minimum temperature
rating of 105°C. All line voltage wire splices must be made
H) is energized with 115 volts whenever the induced draft
blower is energized. The integrated control module electron-
ic air cleaner terminal (EAC H) is energized with 115 volts
whenever the circulator blower is energized. This terminal
transformer. The remaining primary transformer wire would
be connected to the Line N on the control board.
-
115 VAC EAC
115 VAC HUM
W R G C Y
The furnace integrated control module is equipped with
a low voltage terminal for providing power to an optional
energized any time the draft inducer is powered. See con-
nection diagram below.
This is a 24 volt circuit only, the common connec-
tion must be on C terminal of the low voltage terminal strip
(where thermostat wires are connected). Wiring for this cir-
cuit must NOT be connected to the line N location where line
voltage neutral wires are connected.
SYSTEM OPERATION
8
24 VOLT HUM. &
HUMIDISTAT
W R G C Y
24V HUM Terminal is
energized when pressure
switch is closed
1.
furnace.
2.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
This furnace is equipped with an ignition device
which automatically lights the burner. Do not try to light the
burner by hand.
5. Move the furnace gas valve manual control to the OFF
position.
6.
air.
7.
the safety instructions in the Safety Considerations on
minutes, move the furnace gas valve manual control
to the ON position.
8. Replace the burner compartment door.
9.
furnace.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room
temperature.
12. After the burners are lit, set the thermostat to desired
temperature.
• On a call for heat, the thermostat contacts close & the
control board receives 24 VAC on the W terminal.
• The control board microcomputer runs its self-check
routine.
•
on Pin 8 of the 12 Pin connector).
•
(0 VAC on Pin 5).
• The control module performs a gas valve circuitry
check to verify gas valve relay state and presence of
voltage at the valve.
• The system will energize the Induced draft blower.
• The pre-purge period begins once the pressure switch
is detected closed (24 VAC on Pin 5).
• After the completion of pre-purge, the control will
energize the igniter.
• After completion of the ignitor warm-up period:
• The gas valve is energized.
•
• After 30 seconds the indoor blower is energized on
heating speed.
•
• The gas valve is de-energized.
• The inducer remains energized for the post purge
period (15 seconds).
•
(90 seconds by default, adjustable from 30 – 180
seconds).
To change the main blower speed in HEATING mode, follow
the following steps:
1.
single stage HEATING). Press center button and LED
Blower speed number).
2. The control shall rotate available speed number ev-
ery time Left/Right switches are pressed. Table be-
low shows the available speeds for Low & High heat
mode.
3. When the center switch is pressed, the current dis-
played speed shall be selected, and control shall
Always refer to the Heating Chart to choose
from available heating speeds
THERMOSTAT CALL AVAILABLE SPEEDS
W/W1
F01
F03
F04
F02 (DEFAULT)
To change the main blower speed in circulation mode, follow
the following steps:
1.
Press the center switch and LED will display the select-
from 1 to 9). F01 is the default speed for circulation.
2. The control will rotate available speed number every
time left/right switches are pressed. All 9 speeds are
available for circulation.
SYSTEM OPERATION
9
3. When the center switch is pressed, the current dis-
played speed will be selected, and control will imme-
diately apply that speed setting.
THERMOSTAT
CALL
AVAILABLE
SPEEDS
G
F01
F02
F03
(DEFAULT)
F04
F05
F06
F07
F08
F09
On a call for low stage cooling, the Y/Y1 or Y/Y1 and G ther-
mostat contacts close signaling the furnace control board
with 24 VAC on Y/Y1 or Y/Y1 and G terminals.
• The 7-Segment will display the cool mode:1 A C
• The compressor and condenser fan are energized.
• The circulator fan is energized at low cool speed after
a cool on delay. The electronic air cleaner will also be
energized.
•
begins.
•
circulator and air cleaner relay are de-energized.
On a call for 2nd stage cooling, the Y2 or Y2 and G thermo-
stat contacts close signaling the furnace control board with
24 VAC on Y2 or Y2 and G terminals.
• The 7-Segment will display the cool mode: 2 A C
• The compressor and condenser fan are energized.
• The circulator fan is energized at cool speed after a
cool on delay. The electronic air cleaner will also be
energized.
•
begins.
•
circulator and air cleaner relay are de-energized
To change the main blower speed in COOLING mode, fol-
low the following steps:
1.
COOLING). Press the center switch and LED will dis-
speed number from 1 to 9).
2. The control will rotate available speed number every
time left/right switches are pressed. All 9 speeds are
available for both Single and Two Stage cooling.
3. When the center switch is pressed, the current dis-
played speed will be selected, and control will apply
THERMOSTATCALLAVAILABLESPEEDS
Y/Y1
F01
F02
F03
F04(DEFAULT)
F05
F06
F07
F08
F09
THERMOSTATCALLAVAILABLESPEEDS
Y2
F01
F02
F03
F04
F05(DEFAULT)
F06
F07
F08
F09
1. Set the thermostat to the lowest setting. The inte-
2. Remove the burner compartment door and move the
furnace gas valve manual control to the OFF position.
3.
furnace.
4. Replace the burner compartment door.
SYSTEM OPERATION
10
Please adhere to the following warnings and cautions
when installing, adjusting, altering, servicing, or operating
the furnace.
-
-
-
Discharge body’s static electricity before touching
-
cal components.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
age. By putting the furnace, the control, and the person at
the same electrostatic potential, these steps will help avoid
-
charge. This procedure is applicable to both installed and
uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to
the control prior to discharging your body’s electro-
static charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wir-
ing following the discharge process in Step 2. Use
caution not to recharge your body with static electrici-
ungrounded objects, etc.). If you come in contact with
an ungrounded object, repeat Step 2 before touching
control or wires.
4. Discharge any static electricity from your body to
ground before removing a new control from its con-
tainer. Follow Steps 1 through 3 if installing the control
on a furnace. Return any old or new controls to their
containers before touching any ungrounded object.
This product is designed for use as a residential home gas
furnace. It is not
home, trailer, or recreational vehicle applications.
This furnace can be used in the following non-industrial
commercial applications:
In such applications, the furnace
must be installed with the installation instructions.
Goodman & Amana®-
ances and are appropriate for use with natural or propane
gas. (If using propane gas, a propane conversion kit
is required).
-
To ensure proper installation, operation and servicing, thor-
oughly read the installation and service manuals for specif-
ics pertaining to the installation, servicing and application of
this product.
To ensure proper furnace operation, install, operate, main-
tain and service the furnace in accordance with the instal-
lation, operation and service instructions, all local building
codes and ordinances. In their absence, follow the latest edi-
tion of the National Fuel Gas Code (NFPA 54/ANSI Z223.1),
and/or CAN/CGA B149 Installation Codes, local plumbing or
waste water codes, and other applicable codes.
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heat-
ed. The total heat loss should be calculated by an approved
-
tractors of America.
SYSTEM OPERATION
11
Follow the instructions listed below when selecting a fur-
nace location. Refer also to the guidelines provided in the
Combustion and Ventilation Air Requirements section in this
manual or the installation instructions for details.
• Centrally locate the furnace with respect to the
• Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
• If the furnace is installed in an application where the
typical operating sound level of a furnace is deemed
objectionable, an optional sound reduction kit is
available. Consult your local distributor for more details.
• Provide provisions for venting combustion products
outdoors through a proper venting system. Special
and combustion air intake pipe when applicable.
• All installations must be vented in
accordance with National Fuel Gas Code, NFPA 54/
ANSI Z223.1 - lateset edition. In Canada the furnaces
must be vented in accordance with the National
Standard of Canada, CAN/CGA B149.
•
directly on carpeting, or any other combustible material.
The only combustible material allowed is wood.
• A special accessory subbase must be used for upright
material (including wood). Refer to subbase instructions
for installation details. ( A subbase will not be
required if an air conditioning coil is located beneath
the furnace between the supply air opening and the
•
in safety and performance-related problems. Do not
to the following substances:
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
• non-direct vent furnace if it is installed near
an area frequently contaminated by any of the above
substances. This protects the non-direct vent furnace
from airborne contaminants. To ensure that the enclosed
non-direct vent furnace has an adequate supply of
combustion air, vent from a nearby uncontaminated
room or from outdoors. Refer to the Combustion and
Ventilation Air Requirements section in this manual or
the installation instructions for details.
• If the furnace is used in connection with a cooling
unit, install the furnace upstream or in parallel with
will result if the cooling unit coil is placed ahead of the
furnace.
• If the furnace is installed in a residential garage, position
the furnace so that the burners and ignition source are
located not less than 18 inches (457 mm) above the
vehicles.
• If the furnace is installed horizontally, the furnace
Installations must adhere to the clearances to combustible
The minimum clearance information for this furnace is pro-
vided on the unit’s clearance label. These clearances must
minimum clearances to combustible materials. Clearances
must also accommodate an installation’s gas, electrical, and
drain trap and drain line connections. In addition to
the required clearances to combustible materials, a mini-
mum of 24 inches service clearance must be available in
front of the unit.
room) must have two ventilation openings with a total min-
imum free area of 0.25 square inches per 1,000 BTU/hr of
furnace input rating. One of the ventilation openings must be
within 12 inches of the top; the other opening must be within
construction, the clearance between the door and door frame
is usually adequate to satisfy this ventilation requirement.
-
a concrete pad. Never install the furnace on the ground or
on the application and the clearances necessary.
SYSTEM OPERATION
12
PROVIDE 8" MINIMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET TO
ALOW FOR CIRCULATOR BLOWER REMOVAL.
ALTERNATE
GAS PIPING
ASSURE FURNACE IS LEVEL FROM
END TO END. ON 90% FURNACES
MAKE SURE THE UNIT HAS A
SLIGHT FORWARD TILT WITH THE
FRONT OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE
FURNACE.
CONDENSATE
DRAIN
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR
BLOWER REMOVAL
POSITION AS CLOSE AS
POSSIBLE TO BLOWER DECK TO
ALLOW FOR CIRCULATOR
BLOWER REMOVAL.
2"x2"x1/8" ANGLE IRON
(3 PLACES)
GAS PIPING
SUPPORT
NUTS
HOLD DOWN
NUTS
3/8" DIAMETER
THREADED ROD
(6 PLACES)
system serving other appliances, the venting system may be
too large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the
-
The following steps shall be followed with each appliance
connected to the venting system placed in operation, while
any other appliances connected to the venting system are
not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and
horizontal pitch, as required by the National
Fuel Gas Code, ANSI Z223.1 or the CSA B149
Installation Codes and these instructions. De-
termine that there is no blockage or restriction,
could cause an unsafe condition.
c. In so far as practical, close all building doors
and windows and all doors between the space
in which the appliance(s) connected to the
venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the venting system.
d. Follow the lighting instructions. Place the appli-
ance being inspected in operation. Adjust ther-
mostat so appliance shall operate continuously;
e. Test for draft hood equipped spillage at the draft
hood relief opening after 5 minutes of main
candle.
f. After it has been determined that each appli-
ance connected to the venting system properly
vents when tested as outlined above, return
-
ers and any other gas burning appliance to their
previous conditions of use;
g. If improper venting is observed during any of
the above tests, the common venting system
must be corrected.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or
CSA B149 Installation Codes.
If resizing is required on any portion of the venting system,
-
tion of the National Fuel Gas Code ANSI Z223.1 and/or
CSA B149 Installation Codes.
A high quality single stage thermostat with a common termi-
nal is recommended.
In an area having good air circulation, locate the thermostat
-
bration-free inside wall. Do not install the thermostat or dehu-
• Drafts, or dead spots behind doors, in corners, or under
cabinets.
• Hot or cold air from registers.
• Radiant heat from the sun.
•
•
• Concealed hot or cold water pipes, or chimneys.
• Unconditioned areas behind the thermostat and
dehumidistat, such as an outside wall.
Consult the instructions packaged with the thermostat and de-
humidistat for mounting instructions and further precautions.
-
Improved construction and additional insulation in build-
escape around doors and windows. These changes have
helped in reducing heating/cooling costs but have created
a problem supplying combustion and ventilation air for gas
etc.) increase the problem by starving appliances for air.
SYSTEM OPERATION
13
If this furnace is to be installed in the same space with other
gas appliances, such as a water heater, ensure there is an
adequate supply of combustion and ventilation air for the oth-
er appliances. Refer to the latest edition of the National Fuel
Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA
B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applica-
ble provisions of the local building codes for determining the
combustion air requirements for the appliances.
Most homes will require outside air be supplied to the fur-
nace area by means of ventilation grilles or ducts connecting
directly to the outdoors or spaces open to the outdoors such
as attics or crawl spaces.
The following information on air for combustion and ventila-
tion is reproduced from the
gases for appliances installed in buildings shall be obtained
by application of one of the methods covered in 9.3.2 through
9.3.6. Where the requirements of 9.3.2 are not met, outdoor
air shall be introduced in accordance with methods covered
in 9.3.3 through 9.3.6.
Exception No. 1: This provision shall not apply to direct vent
appliances.
Appliances of other than natural draft design and
other than Category 1 vented appliances shall be provided
with combustion, ventilation, and dilution air in accordance
with the appliance manufacturer’s instructions.
Appliances shall be located so as not to interfere with
proper circulation of combustion, ventilation, and dilution air.
Where used, a draft hood or a barometric draft regu-
lator shall be installed in the same room or enclosure as the
between the hood or regulator and the combustion air supply.
-
haust fans, kitchen ventilation systems, clothes dryers, and
of a space to provide combustion air requirements.
The required volume of in-
door air shall be determined in accordance with the method
is known to be less than 0.40 ACH, the method in 9.3.2.2
shall be used. The total required volume shall be the sum
of the required volume calculated for all appliances locat-
ed within the space. Rooms communicating directly with the
space in which the appliances are installed through open-
ings not furnished with doors, and through combustion air
openings sized and located in accordance with 9.3.2.3, are
considered a part of the required volume.
The minimum required volume
shall be 50 ft 3per 1,000/Btu/hour (4.8m3/kW).
Where the air
volume shall be determined as follows:
(1) For appliances other than fan-assisted, calculate using
the following equation:
Required Volume other > 21 ft3I
other
ACH 1000 Btu/hr
(2) For fan-assisted appliances, calculate using the following
equation:
Required Volume fan > 15 ft3I
fan
ACH 1000 Btu/hr
where:
I other = all appliances other than fan-assisted input in Btu
per hour
I fan = fan-assisted appliances input in Btu per hour
ACH = air change per hour (percent of volume of space
-
er than 0.60 ACH shall not be used in the equations in
9.3.2.2(1) and 9.3.2.2(2).
Openings
used to connect indoor spaces shall be sized and located in
accordance with the following:
(1)*Combining spaces on the same story. Each opening shall
have a minimum free area of 1 in.2/1000Btu/hr (2200
mm2/kW) of the total input rating of all appliances in the
space but not less than 100 in.2(0.60m2). One opening
shall commence within 12 in. (300 mm) of the top, and
one opening shall commence within 12 in. (300 mm) of
the bottom, of the enclosure [see Figure A.9.3.2.3(1)].
The minimum dimension of air openings shall be not less
than 3 in. (80 mm).
Furnace
Water
Heater
Opening
Chimney or Gas Vent
Opening
SYSTEM OPERATION
14
(2) Combining spaces in dierent stories. The volumes of
-
municating spaces where such spaces are connected
minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW)
of total input rating of all appliances.
Outdoor combustion air shall
be provided through opening(s) to the outdoors in accordance
with the methods in 9.3.3.1 or 9.3.3.2. The minimum dimen-
sion of air openings shall not be less than 3 in. (80 mm).
Two permanent
openings, one commencing within 12 in. (300 mm) of the top
and one commencing within 12 in. (300 mm) of the bottom, of
the enclosure shall be provided. The openings shall commu-
nicate directly, or by ducts, with the outdoors or spaces that
freely communicate with the outdoors, as follows:
(1)*Where directly communicating with the outdoors or
where communicating to the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 in.2/4000 Btu/hr (550 min2/kW) of total input rating of all
appliances in the enclosure. [See Figure A.9.3.3.1(1)(a)
and Figure A.9.3.3.1(1)(b).]
Furnace
Water
Heater
Outlet Air
Chimney or Gas Vent
the
Inlet Air
Ventilation louvers for
unheated crawl space
Alternate
air inlet
Ventilation louvers
(each end of attic)
Furnace
Water
Heater
Outlet Air
Chimney or Gas Vent
the
Inlet air duct
[ends 1 ft (300 mm)
above floor]
Ventilation louvers
(each end of attic)
(2)*Where communicating with the outdoors through horizon-
tal ducts, each opening shall have a minimum free area
of 1 in.2/2000 Btu/hr (1100 min2/kW) of total input rating of
all appliances in the enclosure. [See Figure A.9.3.3.1(2).]
Furnace
Water
Heater
Chimney or Gas Vent
less than one
ent in the
Outlet air duct
Inlet air duct
One perma-
nent openings, commencing within 12 in. (300 mm) of the
top of the enclosure, shall be provided. The appliance shall
have clearances of at least 1 in. (25 mm) from the sides and
back and 6 in. (150 mm) from the front of the appliance.
The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct
to the outdoors or spaces that freely communicate with the
outdoors (see Figure A.9.3.3.2) and shall have a minimum
free area of the following:
(1) 1 in.2/3000 Btu/hr (700 mm2per kW) of the total input
rating of all appliances located in the enclosure, and
(2) Not less than the sum of the areas of all vent connectors
in the space.
Furnace
Water
Heater
Opening
Chimney or Gas Vent
Alternate
Opening
Location
The use of a combination of indoor and outdoor combustion
air shall be in accordance with (1) through (3) (see example
calculation in Annex J]:
(1) Indoor Openings: Where used, openings connecting the
interior spaces shall comply with 9.3.2.3.
(2) Outdoor Opening(s) Location. Outdoor opening(s) shall
be located in accordance with 9.3.3.
SYSTEM OPERATION
15
(3) Outdoor Opening(s) Size. The outdoor opening(s) size
shall be calculated in accordance with the following:
(a) The ratio of the interior spaces shall be the available
volume of all communicating spaces divided by the
required volume.
(b) The outdoor size reduction factor shall be 1 minus
the ratio of interior spaces.
(c) The minimum size of outdoor opening(s) shall be the
full size of outdoor opening(s) calculated in accor-
dance with 9.3.3, multiplied by the reduction factor.
The minimum dimension of air openings shall not be
less than 3 in. (80 mm).
Engineered combustion air
installations shall provide an adequate supply of combus-
tion, ventilation, and dilution air and shall be approved by the
authority having jurisdiction.
Where all com-
bustion air is provided by a mechanical air supply system,
the combustion air shall be supplied form outdoors at the
minimum rate of 0.35 ft3/min per 1000 Btu/hr (0.034 m3/min
per kW) for all appliances located within the space.
Each of the appliances served shall be interlocked
to the mechanical air supply system to prevent main burner
operation where the mechanical air supply system is not in
operation.
Where combustion air is provided by the building’s
mechanical ventilation system, the system shall provide
ventilation air.
The required size of openings
for combustion, ventilation, and dilution air shall be based
on the net free area of each opening. Where the free area
through a design of louver or grille or screen is known, it shall
be used in calculating the size opening required to provide
and free area are not known, it shall be assumed that wood
louvers will have 25 percent free area, and metal louvers and
grilles will have 75 percent free area. Nonmotorized louvers
Screens shall not be
smaller than 1/4 in. mesh.
Motorized louvers shall be inter-
locked with the appliance so they are proven in the full open
position prior to main burner ignition and during main burner
operation. Means shall be provided to prevent the main burn-
er form igniting should the louver fail to open during burner
startup and to shut down the main burner if the louvers close
during burner operation.
Combustion air ducts shall
comply with 9.3.8.1 through 9.3.8.8.
Ducts shall be constructed of galvanized steel or a
material having equivalent corrosion resistance, strength,
and rigidity.
Exception: Within dwellings units, unobstructed stud and joist
spaces shall not be prohibited from conveying combustion air,
provided that not more than one reblock is removed.
Ducts shall terminate in an unobstructed space, al-
lowing free movement of combustion air to the appliances.
Ducts shall serve a single space.
Ducts shall not serve both upper and lower combus-
tion air openings where both such openings are used. The
separation between ducts servicing upper and lower com-
bustion air openings shall be maintained to the source of
combustion air.
Ducts shall not be screened where terminating in an
attic space.
Horizontal upper combustion air ducts shall not slope
downward toward the source of combustion air.
The remaining space surrounding a chimney liner,
gas vent, special gas vent, or plastic piping installed within a
masonry, metal, or factory built chimney shall not be used to
supply combustion air.
Exception: Direct vent appliances designed for installation in
a solid fuel-burning replace where installed in accordance
with the manufacture’s installation instructions.
-
terior of the building shall have the lowest side of the com-
bustion air intake openings located at least 12 in. (300 mm)
vertically from the adjoining grade level.
-
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted
Sin-
gle-Stage and Two-Stage gas furnaces with induced draft
-
changer allowing in some instances common venting with
natural draft appliances (i.e. water heaters).
All installations must be vented in accordance with National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In
Canada, the furnaces must be vented in accordance with
the National Standard of Canada, CAN/CGA B149.1 and
CAN/CGA B149.2 - latest editions and amendments.
SYSTEM OPERATION
16
The vertical height of the Category I venting system
must be at least as great as the horizontal length of the
venting system.
-
When an existing furnace is removed from a venting sys-
tem serving other appliances, the venting system may be
too large to properly vent the remaining attached applianc-
es. For complete details refer to Exisiting Furnace Removal
section of this manual.
When resizing any portion of the common venting system,
of the National Fuel Gas Code NFPA 54/ANSI Z223.1.
Upow or Horizontal units are shipped with the induced
blower can be rotated 90 degrees for Category I venting.
-
Vent the furnace in accordance with the National Fuel Gas
Code NFPA 54/ANSI Z223.1 - latest edition. In Canada,
vent the furnace in accordance with the National Standard
of Canada, CAN/CGA B149.1 and CAN/CGA B149.2 - lat-
est editions and amendments.
Refer to Electrical Connections section of this manual for
instructions.
-
-
-
-
Wash
Crown
Clay Tile Size Generally
1/2" to 1" Air Space
Second Floor
First Floor
Attic Floor
Roof Line
Throat
Damper
Breech
Clean Out
Fan Assisted
Forced Air
Furnace
Natural Draft
Water Heater
Water Heater
Vent Connector
Basement Floor
F.A.F. Vent
Connector
This checklist serves as a summary of the items to be
checked before venting an 80% furnace into a masonry
-
viceman use this checklist to perform a yearly inspection of
the furnace venting system.
This checklist is only a summary. For detailed information
on each of the procedures mentioned, see the paragraph
referenced with each item.
-
report represents the best information on this subject which
is currently available.
SYSTEM OPERATION
17
Proper Chimney
Termination?
(Check 1)
Line, terminate with
listed vent cap
No
Yes
Chimney channel
free of solid and
liquid fuel
appliances?
(Check 2)
Change venting
arrangements
No
Yes
Crown in good
condition
(Check 3)
Rebuild crown
and/or Reline
Yes
No
Yes
No
No
Reline
Reline
Cleanout free of
debris?
(Check 4)
Liner in good
condition?
(Check 5)
Yes
Yes
No Reline
Dilution air
available?
(Check 6)
Complete the
installation.
(Check 7)
feet higher than any portion of a building within a horizontal
distance of 10 feet. In addition, the chimney must terminate
at least 3 feet above any forced air inlet located within 10
If the chimney does not meet these termination require-
ments, but all other requirements in the checklist can be
2' Min. 2' Min. 3' Min.
10' or Less
Wall or
Parapet
Chimney
Ridge
2' Min.
10' or Less
3' Min.
Chimney
Wall or
Parapet
Chimney
: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
More than 10'
3' Min.
Ridge
3' Min.
Chimney
2' Min.
More than 10'
10'
Height above any
roof surface within
10 feet horizontally.
-
furnaces, and incinerators. Liquid fuel appliances include oil
-
ances which burn propane (sometimes referred to as LP (liq-
crown. If any of the following trouble signs are present, the
condition of the crown is not satisfactory:
a. Crown leaning
b. Bricks missing
c. Mortar missing
SYSTEM OPERATION
18
d. Tile liner cracked
e. No tile liner
f. Salt staining at mortar joints. (White stains, and
mortar becomes sandy and/or erodes.)
It may be necessary to
A cleanout (dropleg) must be present such that the upper
edge of the cleanout cover is at least 12 inches below the
lower edge of the lowest chimney inlet opening.
A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be re-
found:
• Fuel oil residue
• Bricks
• Mortar or sand
• Pieces of the tile liner
• Rusted pieces of the metallic liner reline the chimney
If a metal liner is present, it must be checked. It cannot be
and in good condition.
the inside of the elbow or tee at the base of the liner. A small
amount of soot may be considered acceptable, provided
the installer vacuums it away. If rusted pieces of the liner
have collected here, the metal liner must be removed and
-
driver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be
Remember that all appliances must be vented inside the lin-
er. Venting one appliance inside the liner and another appli-
ance outside the liner is not acceptable.
vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably
be helpful here.
is spiraled in the chimney and in good condition, it should be
The surfaces of the liner must be physically sound. If gaps
or holes are present, the metal liner must be removed and
appliances to be installed. Use the GAMA tables and rules.
If a metal liner is not present, a clay tile liner must be pres-
-
nector to inspect the clay tile liner. If any of the following
problems are present:
• Tile sections misaligned
• Tile sections missing
• Gaps between tile sections
• Signs of condensate drainage at the cleanout or vent
connectors
• Mortar protruding from between tile sections
• Use of sewer pipe or drainage pipe rather than an
this from the cleanout. The liner must be at least as large
as the minimum size established by the tables in National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and
in the National Standard of Canada, CAN/CGA B149.1 and
CAN/CGA B149.2 - latest editions and amendments. If the
liner is too small or too large, then the chimney must be
a source of dilution air is required.
Dilution air cannot be obtained through:
• Induced draft appliances
• Natural draft appliances with vent dampers
draft hood of a natural draft appliance only if the appliance’s
vent connector does not include a vent damper.
If dilution air will not be available, the chimney must be re-
SYSTEM OPERATION
19
If Checks 1 through 6 have been satisfactory, and the liner is
an acceptable size as determined by the tables in National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and
in the National Standard of Canada, CAN/CGA B149.1 and
CAN/CGA B149.2 - latest editions and amendments, then
the clay tile liner can probably be used as a vent for the gas
appliances. However, the installer must keep in mind the
following factors which may render the tile liner unsuitable
for use as a vent:
•
• Long vent connectors
• Masonry chimneys with no air gap between the liner
detect.)
•
Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CGA B149.1 and
CAN/CGA B149.2 - latest editions and amendments
assume interior chimneys.)
If in the judgment of the local gas utility, installer, and/or local
codes, one or more of the above factors is likely to present a
Any cap or roof assembly used with a liner must be ap-
proved by the liner manufacturer for such use. The liner and
cap/roof assembly must then terminate above the roof in ac-
cordance with the manufacturer’s instructions.
possible with a liner than would be required with a masonry
If the masonry chimney has more than one channel, it may
be possible to vent the gas appliances into one channel and
vent the solid or liquid fuel appliance(s) into another chan-
nel(s). Do not vent an 80% furnace inside of a metal liner
with other appliances vented outside the liner.
Alternatively, the homeowner may agree to discontinue use
-
ing must then be permanently sealed.
-
fuel oil residue.
If none of the above options are practical, the 80% furnace
may need to be vented vertically with B vent.
Under some conditions a 90%+ furnace could be installed
rather than an 80%. The 90% furnace can be vented hori-
zontally or vertically through PVC pipe.
repair it in accordance with nationally recognized building
codes or standards. One such standard which may be refer-
enced is the Standard for Chimneys, Fireplaces, Vents, and
Solid Fuel Burning Appliances, ANSI/NFPA 211.
be used.
If B vent is to be used, it must be supported adequately.
prevent the B vent from coming into direct contact with the
tile liner or chimney walls. Direct contact would result in
higher heat loss, with an increased possibility of poor vent-
ing system performance.
It is not acceptable to vent one appliance inside the B vent
B vent and the chimney walls must be covered at the top of
The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s in-
A B vent installed as described in this section is considered
to be an enclosed vent system, and the sizing tables in Na-
tional Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CGA B149.1
and CAN/CGA B149.2 - latest editions and amendments
may be used.
materials:
• For most residential applications, an aluminum liner
should be acceptable.
• If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine
compounds include indoor swimming pools and
chlorine bleaches, paint strippers, adhesives, paints,
and solvents used during construction and remodeling.
Various commercial and industrial processes may also
• Heavier gauge 300 and 400 series stainless steel liners
were developed for use with oil or solid fuel appliances.
SYSTEM OPERATION
20
National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CGA B149.1
and CAN/CGA B149.2 - latest editions and amendments.
To install the liner, read and follow the liner manufacturer’s
liner as recommended by the liner manufacturer.
sleeve designed to be added to the liner before it is installed
in the chimney. (Poured insulation, either vermiculite or
other materials, is no longer recommended.) Insulation will
• It is required by the liner manufacturer’s instructions.
• The previous liner was properly sized and installed,
• It is required by your local building codes.
-
ditional liner insulation, the installer may wish to consider it if:
• The local climate is very cold.
• The chimney is very tall.
• The vent connectors used are very long or have a large
number of elbows.
•
without insulation are likely to have condensation
problems.
Insulation must be selected and installed in accordance with
the liner manufacturer’s instructions.
Finally, cap the chimney and terminate the liner in accor-
dance with the liner manufacturer’s instructions.
Horizontal applications, in particular, may dictate many of
Furnaces have provisions allowing for electrical and gas line
connections through either side panel. In horizontal applica-
-
-
ural gas at standard altitude. Propane gas installations re-
-
High altitude installations may require both a pressure
-
sary to compensate for the natural reduction in the density
of both the gas fuel and the combustion air at higher altitude.
Refer to the Accessories Charts in this manual or prod-
manufacturer’s kits for propane gas and/or high altitude in-
stallations. The indicated kits must be used to insure safe
and proper furnace operation. All conversions must be per-
The furnace rating plate includes the approved furnace gas
input rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any con-
version kits required for alternate fuels and/or high altitude.
Inlet gas supply pressures must be maintained within the
-
-
ances operating. The minimum gas supply pressure must
Natural Gas Minimum: 4.5" w.c.
Propane Gas Minimum: 11.0" w.c.
When this furnace is installed at high altitude, the appropri-
due to the natural reduction in the density of both the gas
fuel and combustion air as altitude increases. The kit will
This manual suits for next models
5
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