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HEIL G8MVL - User Manual

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Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.12009©, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washing-
ton, DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.
Printed in U.S.A. 441 01 2121 01 Sept. 2010
INSTALLATION INSTRUCTIONS
80% TwoStage, Variable Speed
Category I, Gas Furnace
F8MVL & G8MVL
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals
The signal words DANGER, WARNING, CAUTION, and NOTE
are used to identify levels of hazard seriousness. The signal word
DANGER is only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION, and NOTE will
be used on product labels and throughout this manual and other
manual that may apply to the product.
The signal word WARNING is used throughout this manual in the
following manner:
The signal word CAUTION is used throughout this manual in the
following manner:
!
WARNING
DANGER Immediate hazards which will result in severe person-
al injury or death.
WARNING Hazards or unsafe practices which could result in
severe personal injury or death.
CAUTION Hazards or unsafe practices which may result in
minor personal injury or product or property damage.
NOTE Used to highlight suggestions which will result in en-
hanced installation, reliability, or operation.
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors and/or pictures
or product labels.
Safetyalert symbol
When you see this symbol on the unit and in instructions or manu-
als, be alert to the potential for personal injury.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 3........................................
INTRODUCTION 4..................................................
CODES AND STANDARDS 4.........................................
Safety 4..........................................................
General Installation 5...............................................
Combustion and Ventilation Air 5.....................................
Duct Systems 5...................................................
Acoustical Lining and Fibrous Glass Duct 5............................
Gas Piping and Gas Pipe Pressure Testing 5..........................
Electrical Connections 5............................................
Venting 5.........................................................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE 5....
LOCATION 5.......................................................
AIR FOR COMBUSTION AND VENTILATION 8..........................
INSTALLATION 10...................................................
Upflow Installation 10.............................................
Downflow Installation 11...........................................
Horizontal Installation 11...........................................
Filter Arrangement 13............................................
Air Ducts 13....................................................
Gas Piping 18...................................................
Electrical Connections 19.........................................
Venting 21......................................................
STARTUP, ADJUSTMENT, AND SAFETY CHECK 32....................
General 32.......................................................
StartUp Procedures 33............................................
Adjustments 33...................................................
Check Safety Controls 39...........................................
Checklist 40......................................................
SERVICE AND MAINTENANCE PROCEDURES 40....................
Introduction 40..................................................
Care and Maintenance 41.........................................
Sequence of Operation 47........................................
Wiring Diagram 50...............................................
Troubleshooting 51..............................................
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org .
!
WARNING
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning could
result in equipment malfunction, property damage,
personal injury and/or death.
Installation or repairs made by unqualified persons
could result in equipment malfunction, property
damage, personal injury and/or death.
The information contained in this manual is intended for
use by a qualified service technician familiar with safety
procedures and equipped with proper tools and test
instruments.
Installation must conform with local building codes and
with the Natural Fuel Gas Code (NFCG) NFPA
54/ANSI Z223.1, and National standards of Canada
CAN/CSAB149.1 and .2 Natural Gas and Propane
Installation Codes.
INSTALLER: Affix these instructions on or adjacent to the furnace.
CONSUMER: Retain these instructions for future reference.
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Summary

Safety Labeling and Signal Words

Signal Words in Manuals

Explains signal words like WARNING/CAUTION used in manuals.

Signal Words on Product Labels

Describes signal words used on product labels with colors/pictures.

Installation Safety Hazard Warnings

Personal Injury;Property Damage Hazard

Warns of hazards from improper installation or unqualified persons.

Safety Considerations

Fire, Explosion, Shock & CO Hazards

Severe hazards from improper installation/service causing injury or death.

Furnace Reliability Hazard

Warns of component damage from improper application or installation.

Cut Hazard Warning

Alerts to personal injury from sharp sheet metal edges.

Safety-Alert Symbol & Signal Words

Explains safety symbols and signal words like DANGER, WARNING, CAUTION.

Installation Clearances and Codes

Minimum Clearances to Combustible Construction

Specifies minimum clearances required for furnace installation near combustible materials.

Downflow Position Requirements

Details installation requirements for downflow configurations on combustible flooring.

Codes and Standards Compliance

Emphasizes compliance with national, local codes, and manufacturer instructions.

Installation Procedures and Requirements

General Installation Guidelines

Covers general installation practices and references to codes and standards.

Air for Combustion and Ventilation

Specifies requirements for providing adequate air for combustion and ventilation.

Duct Systems, Gas Piping, and Venting

Details duct systems, gas piping, electrical connections, and venting requirements.

Electrostatic Discharge Precautions

Provides procedures to prevent damage to electronic components from static discharge.

Furnace Installation Requirements

Outdoor Air for Combustion

Lists scenarios requiring outdoor air for combustion due to chemical exposure.

Garage Installation Safety

Specific safety requirements for installing furnaces in residential garages.

Cooling Equipment Proximity

Guidance on positioning the furnace relative to cooling equipment to prevent condensation.

Construction Use and Installation Prohibitions

Furnace Use During Construction Precautions

Conditions and requirements for using the furnace in buildings under construction.

Air for Combustion and Ventilation Requirements

Furnace Corrosion Hazard

Warns of furnace damage from air contaminants like halogen compounds.

Carbon Monoxide Poisoning Hazard

Warns of CO poisoning risk due to negative pressure from ventilation devices.

Outdoor Combustion Air Method

Details requirements for providing outdoor air for combustion and ventilation.

Combustion Air Calculation Methods

Carbon Monoxide Poisoning Hazard

Warns of CO poisoning risk due to negative pressure from ventilation devices.

Combustion Air Calculation Methods

Explains the Standard and Known Air Infiltration Rate methods for calculating combustion air.

Installation - Upflow and Leveling

Upflow Installation - Bottom Return Air

Instructions for removing the bottom closure panel for bottom return air.

Side Return Air Inlet

Notes on using the bottom closure panel for side return air.

Installing Leveling Legs

Guidance on installing optional leveling legs for furnace positioning.

Furnace Installation - Downflow and Horizontal

Downflow Installation Requirements

Details furnace installation requirements for downflow applications.

Furnace Mounting and Support

Covers methods for supporting the furnace via suspension or platform.

Roll-Out Protection

Describes the installation of flame roll-out protection.

Horizontal Installation Safety

Safety warnings and considerations for horizontal furnace installations.

Air Ducts and Filter Requirements

Filter Arrangement and Safety

Covers filter installation and safety warnings related to its operation.

General Air Duct Requirements

Outlines general requirements for designing and sizing duct systems.

Supply Air Duct Connections

Details how to connect supply air ducts to the furnace or coil casing.

Furnace Installation - Attic and Downflow

Typical Attic Installation

Illustrates typical installation procedures for furnaces in attics.

Downflow Furnace Duct Connection

Specifies how to connect supply-air ducts for downflow furnaces.

Gas Piping and Return Air Connections

Return Air Connection Guidelines

Specifies proper connection methods for return air ducts for different furnace orientations.

Gas Piping Installation Safety

Warns about hazards related to gas piping installation and testing.

Electrical Connections and Wiring

Electrical Shock and Fire Hazards

Warns of shock and fire risks from improper electrical connections and grounding.

Furnace Operation Hazard

Warns that improper grounding can lead to intermittent furnace operation.

115-V Wiring Requirements

Details voltage, frequency, phase, and code compliance for 115-V wiring.

Electrical Connections and J-Box

Electrical Wiring Safety

Warns against aluminum wire and emphasizes separate circuits and disconnects.

J-Box Relocation Procedures

Details the process for relocating the J-Box to a desired position.

Electrical Connection to J-Box

Provides steps for making electrical connections to the J-Box.

Wiring and Venting

Power Cord and BX Cable Installation

Covers installation procedures for power cords and BX cables in the J-Box.

24-V Wiring and Accessories

Details 24-V wiring and connections for accessories like EAC and humidifiers.

Venting Requirements

Outlines requirements for connecting the furnace to vent systems.

Venting Safety and Requirements

Carbon Monoxide Poisoning Hazard

Warns of CO poisoning hazard related to venting system issues.

General Venting Requirements

General safety codes and requirements for proper vent sizing and installation.

Type B Vent Connector Requirements

Specifies requirements for using Type B vent connectors with the furnace.

Chimney Inspection

Chimney Inspection Chart

Provides a flowchart for inspecting chimneys for suitability with the furnace.

Chimney and Appliance Requirements

Masonry Chimney Requirements

Details requirements for using masonry chimneys with the furnace.

Appliance Application Requirements

Discusses how appliance operation impacts venting system performance.

Condensation Prevention Precautions

Lists precautions to prevent condensation and corrosion in the furnace and vent system.

Venting and Safety Precautions

Burn Hazard from Hot Vent Pipe

Warns of burn hazard from hot vent pipe in downflow position.

Additional Venting Requirements

Specifies requirements for vent connectors and adapters.

Cut Hazard Warning

Alerts to personal injury from sharp sheet metal edges during maintenance.

Start-Up, Adjustment, and Safety Checks

Sidewall Venting Prohibition

States furnace is not approved for direct sidewall horizontal venting.

General Start-Up Procedures

General instructions for start-up, adjustment, and safety checks.

Fire Hazard Warning

Warns about bypassing limit switches and potential overheating.

Start-Up, Adjustments, and Setup Switches

Start-Up Procedures and Hazards

Details start-up steps and associated fire/explosion and electrical shock hazards.

Adjustment Precautions and Hazards

Warns about hazards from improper gas valve adjustment or orifice modification.

Furnace Setup Switch Functions

Explains the function of various setup switches (SW1) on the furnace control.

Service and Electrical Controls

Service Label and Status Codes

Explains the service label, LED codes, and status codes for diagnostics.

Component Test Procedure

Details the procedure for performing a component test sequence.

Electrical Hazards and Precautions

Warns about electrical hazards during service and general operation.

Gas Input Rate, Orifice, and Manifold Pressure Adjustments

Determining Correct Gas Input Rate

Guides on how to determine the correct gas input rate based on altitude and heat value.

Orifice and Manifold Pressure Adjustment

Details the process for adjusting orifice size and manifold pressure for proper gas input.

Low Fire Input Rate Adjustment

Provides steps to adjust the manifold pressure for low fire input rate.

High Fire Input Rate Adjustment

Provides steps to adjust the manifold pressure for high fire input rate.

Temperature Rise and Operation Checks

Setting Temperature Rise

Guides on how to set and measure the furnace's temperature rise.

Furnace Damage and Overheating Hazards

Warns of damage from incorrect temperature rise and overheating.

Fire Hazard Warning

Warns about gas leaks when reinstalling manifold pressure tap plug.

Airflow Settings for Cooling and Continuous Fan

Airflow for Single Stage Cooling

Details how to set airflow for single-stage cooling operations.

Airflow for Continuous Fan;Low Speed Cooling

Explains how to set airflow for continuous fan and low-speed cooling.

Safety Control Checks

Main Limit Switch Check

Procedure to check the function of the main limit switch.

Draft Safeguard Switch Check

Procedure to verify the draft safeguard switch is functioning correctly.

Service Safety Warnings and Electrical Controls

Fire, Injury, Death, or Property Damage Hazard

General warnings about performing maintenance on this equipment.

Environmental Hazard

Caution regarding proper disposal of components to prevent environmental pollution.

Electrical Shock, Fire, or Explosion Hazard

Warnings about electrical hazards during service and maintenance.

Electrical Operation Hazard

Warns that wiring errors can cause improper operation or failure.

Electrical Controls and Wiring

General guidance on servicing electrical controls and wiring.

Component Self-Test and Maintenance

Component Self-Test Procedure

Details the procedure for initiating and running the component self-test.

Care and Maintenance Warnings

Provides critical warnings regarding fire, explosion, shock, and CO hazards during maintenance.

Minimum Furnace Maintenance

Routine Maintenance Checks

Lists essential monthly and seasonal maintenance tasks for the furnace.

Filter and Blower Motor Maintenance

Cleaning or Replacing Air Filter

Provides information on filter sizes and how to clean/replace them.

Cut Hazard Warning

Alerts to personal injury from sharp sheet metal edges during maintenance.

Blower Motor and Wheel Maintenance

Details procedures for cleaning the blower motor and wheel.

Heat Exchanger Cleaning and Electrical Safety

Heat Exchanger Cleaning Procedure

Provides step-by-step instructions for cleaning the heat exchanger cells.

Electrical Shock Hazard Warning

Warns about electrical shock hazards when performing service.

Sequence of Operation and Modes

Furnace Control and Grounding

Emphasizes the importance of furnace control grounding for proper operation.

Two-Stage Heating Operation

Details the operation of the furnace in two-stage heating modes with different thermostats.

Cooling Mode Operation

Explains the furnace operation during single-speed and two-speed cooling cycles.

Dehumidify Mode Operation

Describes how the furnace operates when a dehumidify demand is present.

Furnace Operation Modes

Inducer Prepurge and Igniter Sequence

Details the inducer prepurge and igniter warm-up process during heating cycles.

Trial-for-Ignition Sequence

Explains the trial-for-ignition sequence, including flame proving and blower operation.

Furnace Operation Sequences

Blower Delay and Switching Modes

Describes blower delays and transitions between heating modes.

Cooling and Dehumidify Modes

Explains furnace operation during cooling and dehumidify cycles.

Advanced Operation and Troubleshooting

Continuous Blower and Heat Pump Modes

Details operation in continuous blower mode and with heat pumps.

Component Test and Wiring Diagram

Covers component test procedures and refers to the wiring diagram.

Troubleshooting Guide Introduction

Introduces the troubleshooting guide for diagnosing furnace problems.

Troubleshooting Guide

Initial Status Checks

Checks for power, door switch, fuses, and LED status.

Status Code and Thermostat Signal Checks

Guides on recalling status codes and checking thermostat signal response.

Troubleshooting Common Faults

Pressure Switch and Limit Circuit Faults

Addresses issues with pressure switches and limit circuits.

Flame Proving and Ignition Failures

Troubleshoots abnormal flame signals and ignition failures.

Blower and Model Selection Errors

Diagnoses blower motor faults and invalid model selection errors.

Advanced Troubleshooting and Electrical Checks

Lockout Faults and Polarity Issues

Addresses lockout conditions, gas heating lockouts, and polarity checks.

Blower Motor Fault Diagnosis

Guides on diagnosing blower motor faults using voltage checks.

Parts and Model Information

Parts Replacement Groups

Lists various groups of replacement parts for furnace components.

Model Number Identification Guide

Explains how to identify the furnace model number based on its configuration.

HEIL G8MVL Specifications

General IconGeneral
ModelG8MVL
Ignition TypeDirect Spark Ignition
Heating Capacity40, 000 to 120, 000 BTU/h
Fuel TypeNatural Gas or Propane
Warranty10-Year Parts Limited Warranty

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