Kelvinator KG7S(C,L) User manual

GAS FURNACES

SINGLE STAGE, TWO-STAGE, & MODULATING FURNACES

USER’S MANUAL

NON-CONDENSING GAS FURNACES

CONDENSING GAS FURNACES

80+ AFUE 92.1% AFUE 95% - 97% AFUE

*SA Upﬂow / Horizontal

Furnaces

*SC Upﬂow / Horizontal

Furnaces

*SD, *TC, *MQ Upﬂow /

Horizontal Furnaces

*SK Downﬂow

Furnaces

*SL Downﬂow

Furnaces

*SM & *TL Downﬂow

Furnaces

WARNING

FIRE OR EXPLOSION HAZARD

•Failuretofollowsafetywarningsexactlycould

resultinseriousinjuryorpropertydamage.

•Installationandservicemustbeperformedby

aqualiedinstaller,serviceagencyorthegas

supplier.

•Donotstoreorusegasolineorotherammable

vaporsandliquidsinthevicinityofthisorany

otherappliance.

WHAT TO DO IF YOU SMELL GAS

•Donottrytolightanyappliance.

•Donottouchanyelectricalswitch;donotuse

anyphoneinyourbuilding.

•Leavethebuildingimmediately.

•Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers

instructions.

•Ifyoucannotreachyourgassupplier,callthe

redepartment.

DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

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TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION ................................................................................... 4

GAS SUPPLY & PIPING .................................................................................................................................... 4

VENTING SYSTEM ............................................................................................................................................ 4

CLEARANCES TO COMBUSTIBLES ................................................................................................................ 5

SOURCES OF CORROSION ............................................................................................................................. 5

FILTER ............................................................................................................................................................... 5

FLOOD DAMAGE ............................................................................................................................................... 5

IMPORTANT SAFETY INFORMATION ................................................................................... 5

ABOUT THE FURNACE .......................................................................................................... 6

INTRODUCTION ................................................................................................................................................ 6

CATEGORY I (NON-CONDENSING) FURNACES .........................................................................................6

CATEGORY IV (CONDENSING) FURNACES ................................................................................................6

FILTER ............................................................................................................................................................... 6

THERMOSTAT ................................................................................................................................................... 6

FURNACE LOCATION ....................................................................................................................................... 6

COMPONENT LOCATIONS FOR NON-CONDENSING TYPE FURNACES .................................................... 7

COMPONENT LOCATIONS FOR CONDENSING TYPE FURNACES ............................................................. 8

STARTUP & SHUTDOWN ....................................................................................................... 10

STARTING THE FURNACE ............................................................................................................................... 10

SHUTTING DOWN THE FURNACE .................................................................................................................. 10

TROUBLESHOOTING ............................................................................................................. 10

MAINTENANCE & INSPECTION ............................................................................................ 11

FURNACE & AIR DUCTS .................................................................................................................................. 11

VENTING SYSTEM ............................................................................................................................................ 11

BLOWER & FILTER ........................................................................................................................................... 11

BURNER OPERATION ...................................................................................................................................... 11

NEW CONSTRUCTION ..................................................................................................................................... 11

IMPORTANT NOTE

Ifthegassupplyfailstoshutofforifoverheating

occurs,shutoffthegasvalvetothefurnacebefore

shuttingofftheelectricalsupply!

WARNING:

The furnace was shipped from the factory

equippedtooperateonnaturalgas.Conversion

to LP/propane gas must be performed by a

licensed HVAC technician using a factory

suppliedconversionkit.Failuretousetheproper

conversionkitcancausere,explosion,property

damage,carbonmonoxidepoisoning,personal

injury,ordeath.

WARNING:

All gas piping and shutoff valves must be

installed in compliance with local codes and

utilityregulationsbylicensedinstallers.DONOT

attempttomodify,ortapintoexistinggaslines

yourself.Fireorexplosionmayresultcausing

propertydamage,personalinjuryorlossoflife.

Failuretofollowthesafetywarningsexactlycould

resultinseriousinjury,deathorpropertydamage.

VENTINGSYSTEM

WARNING:

Itisimperativetomaintainproperoperationofthe

ventingsystem,includingthemasonrychimney

(ifapplicable).Insufcientventingcouldcreate

theproductionofexcessiveamountsofCarbon

Monoxide(CO)-acolorless,odorlessgasthatis

producedduringincompletecombustionofany

fuel.Itcancausedeathwithoutwarning.Carbon

monoxidepoisoningcancauseu-likesymptoms

andalsodizziness,fatigue,headaches,nausea,

andirregularbreathing.

If you suspect that you are experiencing CO

poisoning,getfreshairimmediately.Leavethe

homeandcallforassistancefromaneighbor’s

home.

 

      



        







      



WARNING

   

CAUTION





WARNING:

The safety information listed below must be

followed during the installation, service, and

operationofthisfurnace.Failuretofollowsafety

recommendations could result in possible

damage to the equipment, serious personal

injury,ordeath.

WARNING:

PROPOSITION 65 WARNING: This product

contains chemicals known to the state of

Californiatocausecancer,birthdefectsorother

reproductiveharm.

WARNING:

Thisfurnaceisnotapprovedforinstallationin

mobilehomes.Installingthisfurnaceinamobile

homecouldcausere,propertydamage,and/or

personalinjury.

GAS SUPPLY & PIPING

WHAT TO DO IF YOU SMELL GAS

•Donottrytolightanyappliance.

•Donot touch anyelectrical switch; donot

useanyphoneinyourbuilding.

•Leavethebuildingimmediately.

•Immediately call your gas supplier from a

neighborsphone.Followthegassuppliers

instructions.

•Ifyoucannotreachyourgassupplier,call

theredepartment.

Installation and service mustbe performedbya

qualiedinstaller,serviceagencyorthegassupplier.

Thisfurnacedoesnothaveapilot.



DO NOT

IMPORTANT SAFETY INFORMATION

CAUTION:

This furnace requires unrestricted airow for

combustion and ventilation. For proper and

safeoperation,itisextremelyimportantthatthe

furnacereceivesanunobstructedowofclean,

freshairtoproperlyburnthefuelgas.Ifthisow

ofairisrestricted,thepartiallyburnedcombustion

gasesmaycreatedangerousamountsofcarbon

monoxidethatcancausepersonalinjuryordeath.

 









           















        



      

    

       

       





CLEARANCES TO COMBUSTIBLES

WARNING:

Donotplacecombustiblematerialsonoragainst

thefurnacecabinetorwithin6inchesofthevent

pipe.Furnaceareamustbekeptclearandfree

of combustible materials, gasoline and other

ammablevaporsandliquids.Areorexplosion

mayresultcausingpropertydamage,personal

injuryorlossoflife.Failuretofollowthesafety

warningsexactlycouldresultinseriousinjury,

deathorpropertydamage.







   





SOURCES OF CORROSION









Donotstorethesechemicalsnearthefurnace:

 

 

 

 

 

 

 

 

 

 

 

 

 

FILTER

WARNING:

Neveroperatethefurnacewithoutalterinplace.

Accumulatingdust in the return air can build

uponinternalcomponents,resultinginlossof

efciency,equipmentdamage,andpossiblere.







FLOOD DAMAGE

WARNING:

Donotusethisfurnaceifanyparthasbeenunder

water. A ood damaged furnace is extremely

dangerous.Attemptstousethefurnacecanresult

inreorexplosion.Aqualiedserviceagency

shouldbecontactedtoinspectthefurnaceand

toreplaceallgascontrols,controlsystemparts,

electricalpartsthathavebeenwetorthefurnace

ifdeemednecessary.

IMPORTANT SAFETY INFORMATION

INTRODUCTION



       



       





      









       

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.



















Therearenouserserviceableparts.Allrepairs

mustbeperformedbyalicensedHVACtechnician.

CategoryI(Non-Condensing)Furnaces











CategoryIV(Condensing)Furnaces





  







      











 





 





Ifcondensatefreezesinthelines,thiswill

causethecondensatedrainswitchtoshutdown

thefurnace.OnlyalicensedHVACtechniciancan

resetthisswitch.

FILTER

WARNING:

Neveroperatethefurnacewithoutalterinplace.

Accumulatingdust in the return air canbuild

uponinternalcomponents,resultinginlossof

efciency,equipmentdamage,andpossiblere.

 Air lter(s) are notsupplied with the furnace as

shippedfromthefactory.







 







        

      





 

Donotoperatethe

furnacewithoutalldoorsandcoversinplace.

THERMOSTAT







          





         



NOTE:



        

      



        





FURNACE LOCATION











ABOUT THE FURNACE

COMPONENT LOCATIONS FOR NON-CONDENSING TYPE FURNACES

SingleStageModels

2-StageModels

Blower

Door

Switch

Burner

Assembly

Flame Sensor

Gas

Manifold

Gas Valve

Igniter

Inducer

Assembly

Pressure

Switch

Roll-Out

Switch

Transformer

Blower

Assembly

Furnace

Control

Board

Main Air

Limit Switch

Combustion Tube

Gas

Manifold

Gas Valve

Inducer

Assembly

Pressure

Switch

Transformer

Blower Assembly

(behind blower panel)

Burner

Assembly

Flame

Sensor

Roll-Out

Switch

Igniter

Main Air

Limit Switch

Blower

Door Switch

(behind blower panel)

*SA 80+

Upﬂow / Horizontal Gas Furnace

*SK 80+

Downﬂow Gas Furnace

Furnace

Control

Board

1 2 3

5 6 7

Motor Choke

(C & D cabinets only)

Motor Control

Board

Motor

Control Box

Blower

Door

Switch

Burner

Assembly

Flame Sensor

Gas Manifold

Gas Valve

Igniter

Inducer

Assembly

Pressure

Switch

Roll-Out Switch

Transformer

Blower

Assembly

Furnace

Control Board

Main Air

Limit Switch

1 2 3

5 6 7

Furnace

Control

Board

Combustion Tube

Gas Manifold

Gas Valve

Inducer

Assembly

Pressure

Switches

Transformer

Burner

Assembly

Flame

Sensor

Roll-Out

Switch

Igniter

Main Air

Limit Switch

Blower

Door Switch

(behind blower panel)

Motor Choke

(C & D cabinets only)

Motor

Control

Board

Blower Assembly

(behind blower panel)

*TA 80+

Upﬂow / Horizontal Gas Furnace

*TK 80+

Downﬂow Gas Furnace

COMPONENT LOCATIONS FOR CONDENSING TYPE FURNACES

SingleStageModels

Blower

Assembly

Blower Door

Switch

Burner

Assembly

Furnace

Control

Board

Finish

Flange

Flame

Sensor

Gas

Manifold

Gas

Valve

Igniter

Inducer

Assembly

Main Air

Limit Switch

Inducer

Pressure Switch

Condensate

Pressure Switch

(‘B’, ‘C’, & ‘D’ cabinets only)

Roll-Out

Switch

Transformer

Inducer

Limit Switch

Finish

Flange

Blower Door

Switch

(behind blower panel)

Burner

Assembly

Flame

Sensor

Gas Manifold

Gas Valve

Igniter

Inducer

Assembly

Inducer

Pressure

Switch

Vent Limit

Switch

Furnace

Control

Board

Main Air

Limit Switch

Transformer

Roll-Out

Switch

*SC 92.1%

Upﬂow / Horizontal Gas Furnace

*SL 92.1%

Downﬂow Gas Furnace

Blower Assembly

(behind blower panel)

Burner

Assembly

Finish

Flange

Flame

Sensor

Igniter

Roll-Out

Switch

Gas Valve

Furnace

Control Board

Condensate

Pressure

Switch

Transformer

Blower

Assembly

Blower

Door Switch

Inducer

Assembly

Inducer Pressure

Switch

Inducer

Limit Switch

Main Air

Limit Switch

Burner

Assembly

Flame

Sensor

Roll-Out

Switch

Finish

Flange

Blower Door Switch

(behind blower panel)

Gas

Manifold

Gas Valve

Igniter

Inducer

Assembly

Inducer

Limit Switch

Furnace

Control

Board

Pressure

Switch

Transformer

Blower Assembly

(behind blower panel)

*SD 95.0%

Upﬂow / Horizontal Gas Furnace

*SM 95.0%

Downﬂow Gas Furnace

Gas

Manifold



Two-StageModels

AIR FLOW

1 2 3

5 6 7

Burner

Assembly

Finish

Flange

Igniter

Roll-Out

Switch

Gas Valve

Furnace

Control Board

Condensate

Pressure

Switches

Transformer

Motor

Control

Board

Blower

Assembly

Motor Choke

(C & D cabinets only)

Blower Door

Switch

Inducer

Assembly

Inducer

Pressure

Switches

Motor

Control Box

Inducer

Limit Switch

Main Air

Limit Switch

Burner

Assembly

Flame

Sensor

Roll-Out

Switch

Finish

Flange

Blower Assembly

(behind blower panel)

Blower

Door Switch

(behind blower panel)

Motor Choke

(C & D cabinets only)

Gas

Manifold

Gas Valve

Igniter

Inducer

Assembly

Inducer Limit

Switch

Main Air

Limit Switch

Furnace

Control

Board

Motor

Control

Board

Pressure

Switches

Transformer

FLOWAIR

*TC 95.1%

Upﬂow / Horizontal Gas Furnace

*TL 95.1% +

Downﬂow Gas Furnace

Flame

Sensor

Gas

Manifold

Burner

Assembly

Finish

Flange

Roll-Out

Switch

Transformer

Motor

Control

Board

Blower

Assembly

Flame

Sensor

Motor Choke

(C & D cabinets only)

Motor

Control

Box

Blower Door

Switch

Inducer

Assembly

Pressure

Switches

Inducer

Limit Switch

Furnace

Control Board

Igniter

Gas Valve

Gas

Manifold

Main Air

Limit Switch

*MQ 97.1%

Upﬂow / Horizontal Gas Furnace

STARTING THE FURNACE

 

 

 

 

 

 

 



 



 

 

 

 

 



 

SHUTTING DOWN THE FURNACE





OFF THE GAS VALVE TO THE FURNACE BEFORE

TURNING OFF THE ELECTRICAL SERVICE.

NOTE:















 

 

 

 

 

 

Ifthefurnacefailstooperatecheckthefollowing:

 

 

 



 

 

        



Figure1.GasValves

SINGLE STAGE VALVE

MODULATING VALVE

TWO - STAGE VALVE

STARTUP & SHUTDOWN

TROUBLESHOOTING

MAINTENANCE ITEMS

FREQUENCY OF MAINTENANCE

BEGINNING OF EACH

HEATING SEASON

END OF EACH

HEATING SEASON

MONTHLY



X X X



X X X



X X X



X X



X X



X X



X X











Table1.MaintenanceTable

FURNACE & AIR DUCTS

 





 















VENTINGSYSTEM

     

     





 



 



       



 

        





 



BLOWER & FILTER

        







        

       





 



BURNER OPERATION









NEW CONSTRUCTION









 





 



 







MAINTENANCE & INSPECTION

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REMARQUE IMPORTANTE :

Sil’alimentationengaznesecoupepasous’ilyasurchauffe,

fermerlerobinetdegazverslegénérateurd’airchaudavant

decouperl’alimentationélectrique.

AVERTISSEMENT:

Legénérateurd’airchaudestexpédiédel’usineéquipé

pourfonctionneraugaznaturel.Laconversionaugaz

propane(GPL)doitêtreréaliséeparuntechnicienen

CVCagrééavecunetroussedeconversionfournie

à l’usine. L’utilisation de la mauvaise trousse de

conversionpeutcauserunincendie,uneexplosion,

des dommages matériels, un empoisonnement au

monoxydedecarbone,desblessuresoulamort.

AVERTISSEMENT:

Toutelatuyauteriedegazettouslesrobinetsd’arrêt

doiventêtreinstallésconformémentaucodeslocaux

etàlaréglementationdesservicespublicspardes

installateursagréés.NEPAS tenterd’apporter des

modicationsoud’ajouterunrobinetauxconduites

degazparvous-même.Unincendieouuneexplosion

pourraitsurveniretcauserdesdommagesmatériels,

desblessuresoudespertesdevie.Lenon-respect

desavertissementsdesécuritépourraitentraînerdes

blessuresgraves,lamortoudesdommagesmatériels.

SYSTÈMEDEVENTILATION

AVERTISSEMENT:

Ilestessentieldemaintenirlebonfonctionnementdu

systèmedeventilation,ycomprisdelacheminéede

maçonnerie(s’ilyalieu).Uneventilationinsufsante

risque d’entraîner une production excessive de

monoxydedecarbone(CO),ungazincoloreetinodore

produitpendantlacombustionincomplètede tout

carburant.Ilpeutcauserlamortsanssigneavant-

coureur.L’empoisonnementaumonoxydedecarbone

peutcauserdessymptômessemblablesàceuxdela

grippe,ainsiquedesvertiges,lafatigue,desmauxde

tête,lanauséeetunerespirationirrégulière.

Si vous croyez avoir subi un empoisonnement au

monoxydedecarbone(CO),allezrespirerdel’airfrais

immédiatement. Sortir de la maison et téléphoner

pourobtenirdel’aidedepuislamaisond’unvoisin.

       

      













       



AVERTISSEMENT





MISE EN GARDE    





AVERTISSEMENT:

Lesrenseignementsdesécuritéindiquésci-dessous

doivent être respectés pendant l’installation,

l’entretien et le fonctionnement de ce générateur

d’airchaud.Lenon-respectdesrecommandationsde

sécuritépeutcauserdesdommagesàl’équipement

oudesblessuresgraves,voiremortelles.

AVERTISSEMENT:

AVERTISSEMENTRELATIFÀLAPROPOSITION65:

Ceproduitcontientdesproduitschimiquesreconnus

dansl’ÉtatdelaCaliforniecommepouvantcauserle

cancer,desmalformationscongénitalesoud’autres

problèmesdusystèmereproductif.

AVERTISSEMENT:

Cegénérateurd’airchaudn’estpashomologuépour

uneinstallationdansunemaisonmobile.L’installation

decegénérateurd’airchauddansunemaisonmobile

risquedecauserunincendie,desdommagesmatériels

oudesblessures.

ALIMENTATION EN GAZ ET TUYAUTERIE

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Nepastenterd’allumerquelqueappareilquece

soit.

• Ne toucher à aucun interrupteur électrique;

n’utiliseraucuntéléphonedanslebâtiment.

• Évacuerl’immeubleimmédiatement.

• Appelerimmédiatementlefournisseurdegazen

employantletéléphoned’unvoisin.Respecterles

instructionsdufournisseurdegaz.

• S’il n’est possibledejoindrelefournisseur de

gaz,appelerleservicedesincendies.

L’installation et l’entretien doivent être effectués par

uninstallateurqualié,unorganismedeserviceoule

fournisseurdegaz.

Cetappareiln’estpasdotéd’uneveilleused’allumage.



NE PAS

RENSEIGNEMENTS IMPORTANTS SUR LA SÉCURITÉ

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708967B

708967B

¶

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







Kelvinator KG7S(C,L) User manual

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