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Heat Controller GMUH User Manual

Heat Controller GMUH
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92-24161-65-02
SUPERSEDES 92-24161-65-01
INSTALLATION INSTRUCTIONS
FOR INDUCED DRAFT GAS FURNACES
GMUH UPFLOW/HORIZONTAL SERIES
GMDA DOWNFLOW SERIES
HEAT CONTROLLER
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer’s
recommendations and/or local laws, rules, regulations, or customs.
Upflow/Horizontal Models Downflow Models
Model Number Input (Btu) Tons Model Number Input (Btu) Tons
GMUH50-E3A 50,000 3 GMDA50-E3A 50,000 3
GMUH75-E3A 75,000 3 GMDA75-E4A 75,000 4
GMUH75-E4A 75,000 4 GMDA75-E3A 75,000 3
GMUH100-E3A 100,000 3 GMDA100-E3A 100,000 3
GMUH100-E4A 100,000 4 GMDA100-E5A 100,000 5
GMUH100-E5A 100,000 5 GMDA125-E5A 125,000 5
GMUH125-E5A 125,000 5 GMDA150-E5A 150,000 5
GMUH150-E5A 150,000 5
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Heat Controller GMUH Specifications

General IconGeneral
BrandHeat Controller
ModelGMUH
CategoryFurnace
LanguageEnglish

Summary

Safety Information and Warnings

General Safety Precautions

Essential safety precautions for installation and operation, preventing hazards like fire, explosion, and injury.

Installation Checklist Items

Gas Supply Checks

Verifies proper pipe size, gas leaks, and pressure for gas supply.

Electrical Checks

Verifies thermostat, voltage, grounding, and other electrical connections.

Venting Checks

Verifies vent pipe, material, clearance, and negative pressure.

Combustion Air Checks

Verifies proper source and opening size for combustion air.

Furnace Installation Checks

Verifies clearances, air temperature rise, static pressure, and ducting.

Comprehensive Safety Warnings

Fire and Explosion Prevention

Warnings about following instructions to prevent fire, explosion, and property damage.

Qualified Personnel and Proper Installation

Emphasizes installation by qualified personnel to avoid hazards.

Gas Handling and Leak Detection

Procedures for smelling gas and detecting leaks safely.

Combustion and Ventilation Air

Importance of adequate air for combustion and ventilation.

Equipment Mismatch and Improper Installation

Manufacturer is not responsible for mismatched or improperly installed equipment.

Gas Leak Testing

Advises using only approved methods for testing gas leaks, not open flames.

Ducting for Circulated Air

Requirements for ducting air to areas outside the furnace space.

Specific Installation Location Safety

Residential Garage Installation

Requirements for installing furnaces in residential garages to prevent ignition of vapors.

Duct Leakage and Pollutant Migration

Warnings about duct leaks drawing pollutants into living spaces.

Mobile Home Installation Prohibition

Explicitly prohibits installation in mobile homes due to fire risk.

Combustible Floor Installation

Restrictions on installing upflow/horizontal units on combustible flooring without bases.

Combustible Material Clearance

Strict clearance requirements around the furnace and vent pipe.

Ventilation and Combustion Air Safety

Return Air Duct Integrity

Ensures return air ducts are sealed to prevent combustion gas circulation.

Blower Door and Compartment Covers

Emphasizes operating the furnace only with the blower door in place.

Adequate Combustion Air Supply

Stresses the need for sufficient fresh air for proper combustion and ventilation.

Vent Pipe and Heat Exchanger Leaks

Warning about toxic fumes from leaks causing carbon monoxide poisoning.

Electrical and Gas Safety Precautions

Chimney Venting Restrictions

Prohibits connecting to chimneys used for solid fuel appliances.

Gas Line Purging and Leak Checks

Warnings against purging gas lines and using flames for leak checks.

Electrical Power Disconnection

Mandates disconnecting power before electrical connections for safety.

Cabinet Grounding

Requirement for permanent cabinet grounding via a provided screw.

General Information and Efficiency

Furnace Design and Certification

Details CSA certification for natural and propane gases, Category I type.

Installation Codes and Standards

Emphasizes installation per National Fuel Gas Code and local codes.

Annual Fuel Utilization Efficiency (AFUE)

Explains AFUE as a measure of heat energy efficiency and its consumer benefits.

Indoor Air Quality and Duct Systems

Discusses how duct system balance and sealing improve efficiency and IAQ.

Site Selection and Installation Requirements

Mobile Home Installation Prohibition

Reiterates that the furnace is not approved for mobile home installation.

Return Air Source Restrictions

Prohibits taking return air from specific areas like bathrooms or garages.

Return Air Duct Sealing

Emphasizes sealing return air ducts to prevent combustion gas circulation.

Upflow/Horizontal Model Clearances

Clearance Table for Upflow/Horizontal Models

Provides specific clearance dimensions to combustible materials for various models.

Downflow Model Clearances

Clearance Table for Downflow Models

Details required clearances to combustible materials for downflow models.

Clearance and Accessibility Requirements

Service Clearance

Recommends at least 24 inches of service clearance in front of furnaces.

Combustible Material Restrictions

Prohibits installing upflow/horizontal units on combustible materials.

Downflow Unit Floor Installation

Requirements for downflow units on non-combustible or combustible floors.

Ducting Requirements

Discusses proper duct sizing for airflow and avoiding damage.

Unit Installation Configurations

Upflow Unit Installation

Instructions for connecting return and supply air plenums for upflow units.

Base Plate for Side Air Return

Requirement for a base plate with side air returns to prevent combustion gas circulation.

Downflow Unit Installation

Instructions for connecting supply and return air plenums for downflow units.

Horizontal Unit Installation

Instructions for mounting and connecting ductwork for horizontal units.

Combustion and Ventilation Air Requirements

Furnace Air Requirements

Stresses the need for sufficient fresh air for proper combustion and ventilation.

Atmospheric Pollutants and Combustion Air

Lists substances in air that may require outdoor air for combustion.

Combustion Air in Confined Spaces

Unconfined Space Air Requirements

Details air volume requirements for unconfined spaces based on BTUH input.

Confined Space Air Requirements

Details air opening requirements for confined spaces based on BTUH input.

Outdoor Air for Combustion (Confined)

Air intake requirements when using outdoor air for combustion in confined spaces.

Combustion Air Intake Configurations

Upflow/Horizontal Combustion Air

Details fittings and openings for upflow/horizontal models using PVC pipe.

Method 1: Two Permanent Openings

Describes requirements for two permanent openings for combustion air.

Method 2: Single Permanent Opening

Describes requirements for a single permanent opening for combustion air.

Attic Air and Combustion Air Fittings

Attic Combustion Air Pull

Instructions for optional attic air pull with fittings and pipe limitations.

Venting System Requirements

General Venting Information

General requirements for venting in accordance with codes and instructions.

Devices Attached to Flue/Vent

Warning against using untested devices for reducing heat loss up the chimney.

Draft Inducer Vent Pipe Attachment

Warning about pre-drilling holes for vent pipe attachment to prevent inducer damage.

Furnace Category Information

Identifies the furnace as Category I type, explaining its operation.

Important Application Notes for Venting

Notes on inspecting existing vent systems and using proper vent pipe.

Vertical Venting with B-1 Pipe

B-1 Vent Installation Requirements

Details installation requirements for Type "B-1" vents, including support and spacing.

Vertical Vent System Termination

Requirements for terminating gas vents above the roof surface.

Chimney Venting Restrictions

Prohibits connecting to chimneys used for solid fuel appliances.

Venting System Options and Retrofit

Power Vent Systems

Acceptable methods for horizontal venting using power venters.

Existing Vent System Inspection

Importance of inspecting existing vent systems before furnace replacement.

Retrofit Venting Procedures

Steps for inspecting and testing existing vent systems for safe operation.

Gas Supply and Piping Installation

Furnace Gas Supply Warning

Warning about using only natural gas or proper LP conversion kits.

Gas Piping Installation Codes

Mandates installation according to local, state, and utility codes.

Gas Supply Line and Valve Requirements

Instructions for running separate supply lines and installing shut-off valves.

Gas Pipe Connection Tightening

Advises using a back-up wrench and not overtightening connections.

High Gas Line Supply Pressure

Ensures the gas control valve is not subjected to high supply pressures.

Gas Pressure and LP Conversion

Maximum and Minimum Gas Pressures

Specifies maximum and minimum gas supply and manifold pressures for natural and LP gas.

High Altitude Input Rate Adjustment

Notes need for input rate adjustment and orifice recalculation at high altitudes.

LP Gas Conversion Instructions

Details conversion to LP gas using specific kits and qualified technicians.

Setting Gas Pressure and Pipe Sizing

Gas Pressure Measurement Procedure

Step-by-step guide for measuring gas pressure using a manometer.

Natural Gas Pipe Capacity Table

Table showing capacity of natural gas pipes based on size, length, and pressure drop.

LP Gas Pipe Capacity Table

Table showing capacity of LP gas pipes based on size, length, and pressure drop.

Furnace Input Adjustment and Checking

Checking Furnace Input Rate

Procedure to measure and determine the furnace's input rate.

Meter Time and Input Rate Table

Table to determine input rate based on meter time and gas heating value.

Electrical Wiring and Thermostat Installation

Power Disconnection and Grounding

Mandates turning off power and completing ground connections before wiring.

Cabinet Grounding

Requirement for permanent cabinet grounding via a provided screw.

Thermostat Compatibility

Discusses thermostat compatibility and the use of isolation relays.

Control Circuit Wire Sizing

Table for selecting appropriate wire size for 24-volt control circuits.

Optional Accessories and Furnace Twinning

Furnace Twinning Requirements

Important notes on twinning furnaces with identical control boards and using twinning kits.

Twinning Installation Limitations

Limitations on returns, capacity, phase, and thermostat usage for twinning.

High Altitude Installation Adjustments

Altitude Installation Compliance

Mandates compliance with local codes or NFGC at altitudes above 2000 ft.

Altitude De-Rate for Natural Gas

Explains 4% de-rate per thousand feet for 80+ models using natural gas.

Natural Gas Orifice Drill Size Chart

Chart for selecting natural gas orifice sizes based on altitude and heat value.

LP Gas Orifice Selection Chart

Chart for selecting LP gas orifices based on altitude.

Orifice Sizing and Canadian Altitude Derate

Canadian High-Altitude Derate Method

Describes an alternate derate method for Canadian installations using manifold pressure.

Natural Gas Derate Table

Table for Canadian high-altitude derate of natural gas using orifice size and manifold pressure.

LP Gas Derate Table

Table for Canadian high-altitude derate of LP gas using orifice size and manifold pressure.

Supplemental Orifice Size Chart

Natural Gas Orifice Selection Chart

Quick reference chart for natural gas orifice selection based on altitude and heat value.

High Altitude Orifice Calculation Method

Instructions on how to calculate high altitude orifice requirements.

Start-Up Procedure and Safety

Pre-Start Safety Checks

Crucial safety checks before attempting to start the furnace.

Direct Spark Ignition Sequence

Detailed sequence of operation for the direct spark ignition system.

Lockout and Reset Procedures

Describes the lockout modes and how to reset the system.

Blower Speed and Timing Adjustments

Blower Speed Adjustment Warning

Warning about disconnecting power before changing blower speed.

Heating Speed Reduction Caution

Caution against reducing heating speeds that could cause overheating.

Temperature Rise Check After Speed Change

Importance of checking air temperature rise after speed adjustments.

Airflow and Temperature Rise

Duct System Sizing Importance

Emphasizes the importance of properly sized duct systems for furnace operation.

Low Air Flow and Overheating

Explains how low airflow can cause heat exchanger failure due to overheating.

Temperature Rise Measurement Procedure

Steps to measure temperature rise in supply and return air ducts.

Airflow Adjustment Recommendations

Actions to take if temperature rise is too high or too low.

Blower Performance Data

Upflow/Horizontal Model Performance

Tables showing CFM output for upflow/horizontal models at various static pressures.

Downflow Model Performance

Tables showing CFM output for downflow models at various static pressures.

Safety Features and Controls

Limit Control Function

Explains the high limit control's role in preventing overheating.

Causes of Limit Switch Opening

Lists common reasons for a limit switch to open, often related to low airflow.

Roll-Out Safety Switches

Describes the function of roll-out switches and their reset procedure.

Pressure Switch Function

Explains the pressure switch's role in monitoring the vent system.

Causes of Pressure Switch Failure

Lists reasons why the pressure switch might not close properly.

Maintenance and Filter Requirements

Disconnect Power for Maintenance

Warning to disconnect main electrical power before performing maintenance.

Filter Application and Placement

Importance of proper filter placement and its effect on system components.

Filter Location Recommendations

Recommends a single filter location in the return air duct system.

Filter Cleaning and Replacement

Advises keeping air filters clean and how to maintain them.

Dust Entrainment and Soot Damage

Discusses potential dust issues and soot damage from filters or lack thereof.

Filter Installation Details

Upflow Filter Retaining Rod (Side Return)

Details for installing filter retaining rods for side return upflow units.

Downflow Filter Installation

Illustration of filter installation for downflow units.

System Operation and Annual Inspection

Customer Advice for Efficient Operation

Tips for customers to ensure efficient operation and maintenance.

Combustible Material Clearance Warning

Reinforces keeping combustible materials away from the furnace.

Annual Furnace Inspection Recommendation

Recommends annual inspection of flue passageways, vent system, and burners.

Troubleshooting Reference

Directs users to a troubleshooting flowchart for problem diagnosis.

Wiring Diagram Reference

Directs users to the wiring diagram for furnace and power sources.

Troubleshooting Guide

Integrated Furnace Control (IFC) Troubleshooting

Flowchart for diagnosing issues with the integrated furnace control.

Key to Abbreviations and LED Codes

Explains abbreviations and LED codes used in the troubleshooting flowchart.

Electrical Wiring Diagrams

Component Code Identification

Lists and defines various electrical component codes used in the diagrams.

Wiring Information and Standards

Notes on factory wiring, field installed options, and wiring standards.

Upflow/Downflow/Horizontal Wiring

Detailed electrical wiring diagram for furnace configurations.

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