ICP Furnaces/Heaters Manual L0602183

User Manual: ICP ICP Furnaces/Heaters Manual ICP Furnaces/Heaters Owner's Manual, ICP Furnaces/Heaters installation guides

Open the PDF directly: View PDF .
Page Count: 19

GUK Series

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel

should install, repair, or service heating equipment.

Untrained service personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must

be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags, and on

labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the current edition National Fuel Gas Code (NFGC) NFPA No.

54/ANSIZ223.1. In Canada, refer to the current edition of the National Standard Canada CAN/CGA-B149.1 - and .2-M91 Natural Gas and

Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during starf-up and ad-

justment procedures and service calls.

Recognize safety information. This is the safety-alert symbol_J...._,i . When you see this symbol on the furnace and in instructions or manu-

als, be alert to the potential for personal injury.

Understand the signal word DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER identifies

the most serious hazards will result in severe personal injury or death. WARNINGsignifiesahazardthatcouldresultinpersonalinjuryor

death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these

instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residenlial construction

practices. We require these instructions as a minimum for a safe installation.

Table of Contents

1, Safe Installation Requirements.............. 1

2. Installation .............................. 3

3. Combustion& Ventilation Air ............... 4

4. Vent and CombustionAir Piping ............. 7

5. GasSupplyand Piping ..................

6. Electrical Wiring .......................

7. Ductworkand Filter ....................

S. Checksand Adjustments ................

9, FurnaceMaintenance ...................

D_sign Cer_tled

_AG.A.

Manufactured By: lnter_Uity products Corporation (USA)

Lavergne, Tlq USA 37086

This furnace is not designed for use in mobile

homes, trailers or recreational vehicles. Such

use could result in property damage, bodily in-

jury and/or death.

LP1 1-18-96 441 011002 00

LP1 formerly 7212-114

1. Safe InstallationRequirements

Installation or repairs made by unqualified

persons can result in hazards to you and others.

Installation MUST conform with local codes or, in

the absence of local codes, with codes of the

country having jurisdiction.

The information contained in this manual is

intended for use by a qualified service technician

familiar with safety procedures and equipped

with the proper tools and test instruments.

Failure to carefully read and follow all instruc-

tions in this manual can result in furnace

malfunction, property damage, personal injury

and/or death.

NOTE: This furnace is design certified by the American Gas Association

and the Canadian Gas Association for installation in the United States and

Canada. Refer to the appropriate codes, along Figure I with this manual,

for proper installation.

•This furnace is NOT approved for installation in mobile

homes, trailers or recreation vehicles.

• Do NOT use this furnace as a construction heater.

• Use only the Type of gas approved for this furnace (see Rating

Plate on unit). Overtiring will result in failure of heat exchanger and

cause dangerous operation.

+ Do NOT use open flame to test for gas leak.

• Ensure adequate combustion and ventilation air is provided to the

furnace.

• Seal supply and return air ducts.

•The vent system MUST be checked to determine that it is the cor-

rect type and size.

• Install correct filter type and size.

•Unit MUST be installed so electrical components are protected

from direct contact with water.

NOTE: it is the personal responsibility and obligation of the customer to

contact a qualified installer to ensure that the installation is adequate and

conforms to governing codes and ordinances.

Carbon Monoxide Poisoning Hazard.

This furnace can NOT be common vented or

connected to any type B, BW or Lvent or vent

connector, nor to any portion of a factory-built or

masonry chimney. If this furnace is replacing a

previously common-vented furnace, it may be

necessary to resize the existing vent line and

chimney to prevent oversizing problems for the

other remaining appliance(s). See Venting and

Combustion Air Check in Gas Vent Installation

section. This furnace MUST be vented to the

outside.

Failure to properly vent this furnace or other

appliances can result in property damage,

personal injury and/or death.

1LLJ

START-UP CHECK SHEET

(Keep this page for future reference)

Dealer Name:

Address:

City, State(Province), Zip or Postal Code:

Business Card Here

Phone:

Owner Name:

Address:

City, State(Province), Zip or Postal Code:

Model Number:

Serial Number:

Natural: [_1 LP: [_1

Type of Gas:

Blower Motor H.P.:

Supply Voltage:

Limit Opens at...(°F) or(°C)

Limit Closes at...(°F) or(°C)

Which blower speed tap is used?

(Heating)_ (Cooling)

Temperature of Supply Air: (°F) or(°C)

Temperature of Return Air: (°F) or(°C)

Rise (Supply Temp - Return Temp): (°F) or(°C)

Filter Type and Size:

Fan 'q'ime ON" Setting:

Fan "Time OFF" Setting:

Manual Gas Shut-Off Upstream

of Furnace/Drip-Leg? YES

Drip-Leg Upstream of Gas Valve? YES _1

Condensate Drain Connected? YES _1

NO[_

NO_1

Blower Speed Checked? YES _J NO _1

All Electrical Connections Tight? YES [_1 NO _1

Gas Valve OK? YES [a NO _J

Measured Line Pressure When Firing Unit:

Calculated Firing Rate:(See ChecksandAdjustmentsSec-

tion).

Measured Manifold Pressure:

Thermostat OK? YES _1

Subbase Level? YES _1

Anticipator Set? YES [_

Breaker On? YES _-_

Date of Installation:

Date of Start-Up:

NO_.,i

Noel

NO _1 Set At?:

NO [3

Dealer Comments:

2. Installation

Locationand Clearances

1. Refer to Figure 1 for typicalinstallation and basic connecting parts

required. Supply and return air plenums and duct are also re-

quired.

2. If furnace is a replacement, it is usually best to install the furnace

where the old one was. Choose the location or evaluate the exist-

ing location based upon the minimum clearance and furnace di-

mensions (Figure 2).

CAUTION

Special precautions MUST be made if installing

furnace in an uninhabited home which may drop below

freezing. This can cause improper operation or

damage to equipment. If furnace environment has the

potential of freezing, the drain trap and blower must be

protected with antifreeze. During uninhabited time,

disconnect the rubber coupling on top of furnace and

pour 8 onces of sanitary type (RV) antifreeze into the

vent pipe to protect the blower and drain trap from

freeze damage.

Do NOT operate furnace in a contaminated

atmosphere containing chlorine, fluorine or any other

damaging chemicals. Refer to Combustion &

Ventilation Air section, Contaminated Combustion Air.

Installation Requirements

1. Install furnace level.

2. This furnace is NOT to be used for temporary heat of buildings or

structures under construction.

3. install furnace as centralized as practical with respect to the heat

distribution system.

4. Install the vent pipes as shod as practical. (See Vent and Com-

bustion Air Piping section).

5. Maintain clearance for fire safety and servicing. A front clearance

of 30" (762mm) is recommended for access to the burner, controls

and filter.

6. Use a raised base if the floor is damp or wet at times.

7. Residential garage installations require:

Burners and ignition sources installed at least 18" (457mm) above

the floor.

Located or physically protected from possible damage by a ve-

hicle.

Figure 1 Typical Installation

*8" (200mm) Min.

20' (6m) Max.

in same atmospheric zone

Inlet Pipe is

//Optional

Aluminum or

non-rusting

_t_, shield recom-

mended. (See

Vent Terminatior

_ Shielding for di

- mensions)_

Vent Pipes MUST be

supported Horizontally and

Vertically

Tee to prevent airlock

Tee for overflow _'_q=

/\ Coupling on ends

\of exhaust pipe.

/_ Total pipe & cou-

// piing outside

/structure = 8"

20" (6m) Max.

in same atmospheric zone

_ Increaseminimumfrom8" to 18" for coldclimates

/(substained temperatures below 0 °F).

25 20=70

Figure 2 Dimensions and Clearances

7/a(22)

Unit

Capacity

50,000

75,000

100,000

125,000

CABINET

Back

Drain

Connection

I_ H 1"

\C /

\/B"

\ 25-20_S5

ELECTRICALCONNECTIONS

TOP LEFTSIDE LOW VOLT

A B C D E D E F G

48 19-1/8 28-1/2 1-1/2 1-1/2 1-5/8 2-1/2 4-1/2 17-5/16

48 19-1/8 28-1/2 1-!/2 1-!/2 1-5/8 2-1/2 4-1/2 17 5/16

48 22 3/4 28-1/2 1-1/2 1-1/2 1J5/8 2-1/2 4-1/2 17-5/16

48 26-3/8 28-1/2 1-1/2 1-1/2 1-5/8 2 1/2 4-1/2 17-5/16

Cabinet Clearances

TOP BOT RH LH BACK FRNT FLUE

0_ 0_ 0_ 0_ 3_ 0_

SUPPLYAIR

16-1_ 17-5/8

16-1_ 17_/8

16-1_ 21-1_

16-1_ 24-7/8

RETURNAIR

BOTTOM SIDE

J K L M

29-1/8 14-3/4 22-1/2 14-1/2

23-1/8 14-3/4 22-1/2 14-1/2

29-1/8 18-3/4 22-1/2 14-1/2

23-1/8 23-1/2 22-1/2 14-1/2

Unit

Capacity

50,000

75,000

100,000

125,000

GASCONNECTIONS

RIGHT SIDE LEFT SIDE

N P N P R

36-1/2 23-7/8 36-1/2 26-1/16 19-7/8

36-1/2 23-7/8 36-1/2 26-1/16 10-7/8

36-1/2 29-7/8 35-1/2 26-1/16 10-7/8

36-1/2 23-7/8 36-1/2 26-1/16 10-7/8

DRAINCONNECTIONS

RIGHTSIDE LEFT SIDE

S S

2-3/4 6-112

2-3/4 6-1/2

SUPPLYAIR

T V

2-!1/16 4-13/16

2-11/16 4-13/16

2-11/1, 4-13/16

RETURNAIR

Bo'rroM

W Y Z

!2-7/8 2-11/16 2-1/8

12-7/8 2-11/16 2-1/8

14-11/16 2-11/16 1-7/8

18 2-11/16 1-7/16

48"= (1219) 26-1/2"= (724) 19-7/8"= (276) 29-1/8"= (587) 14-11/16"= (373) 22-1/2"= (572)

CONVERSION 36-1/2"= (902) 1-1/2"= (38) 4-1/2"= (114) 17-5/16"= (440) 21-1/4"= (540) 12-7/8"= (327) 2-11/16"= (68)

FROM INCHES 19-1/8"= (486} 26-1/16"= (662) 2-3/4"= (70) 6-1/2"= (165) 24-7/8"= (632) 18"= (457) 1-7/8"= (48)

TO 22-3/4"= (578) 1-5/8"= (41) 16-1/2"= (470) 17-5/8_= (448) 2-11/16"= (68) 14-3/4"= (375) 2-1/8"= (54)

METRIC (ram) 23-7/8"= (606) 2-1/2"= (64) 17-5/8_= (448) 6-1/2"= (165) 19-3/4"= (476) 14-1/2"= (368)

26-3/8"= (670) 4-13/16"= (122) 29-1/2"= (597) 1-7/16"= (37)

ALL DIMENSIONS IN INCHES (MM)

3. Combustion& VentilationAir

Venting and Combustion Air Check

Carbon monoxide Poisoning Hazard.

Use methods described here to provide com-

bustion and ventilation air.

Failure to provide adequate combustion and

ventilation air can result in personal injury and/

or death.

NOTE: This section of the manual applies to this furnace IF venting as a

non-direct vent (single pipe) appliance. The following information is

supplied to allow the installer to make adjustments to the setup of existing

appliances, IF NEEDED. These instructionsare presented to be used for

reference ONLY IF NEEDED, based on good trade practices, local codes,

and good judgment of the installer. Manufacturer does NOT take respon-

sibility for modifications made 1o existing equipment.

NOTE: If this installation removes an existing furnace from a venting sys-

tem serving one or more other appliances, and to make sure there is ade-

quate combustion air for all appliances, MAKE THE FOLLOWING

CHECK,

1. Seal any unused openings in the venting system. 4L.L]

Visually inspect the venting system for proper size and horizontal

pitch to ensure there is no blockage or restriction, leakage, corro-

sion or other deficiencies which could cause an unsafe condition.

Insofar as is practical, close all doors and windows and all doors

between the space in which the appliance(s) remaining 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. Turn on any exhaust fans, such as range hoods

and bathroom exhausts, so they will operate at maximum speed.

Do not operate a summer exhaust fan. Close fireplace dampers.

Follow the lighting instructions for each appliance being inspected.

Adjust thermostat so appliance(s) will operate continuously.

Allow 5 rain utes of main burner operation, then check for spillage at

the draft hood relief opening of each appliance. Use the flame of a

match or candle (Figure 3).

After it has been determined that each appliance vents properly,

return doors, windows, appliances etc. to their normal condition.

If improper venting is observed, the cause MUST be corrected us-

ing the appropriate tables in code books of country having judsdic-

tion.

NOTE: Ifflame polls towards draft hood, this indicates sufficient infiltration

air.

NOTE: Non direct vent appliances occupying same enclosed space as

furnace MUST have enough air for proper combustion and ventilation. All

duct or openings for supplying combustion and ventilation air must comply

with the gas and electrical codes of the country having jurisdiction.

When the installation is complete, check that all appliances have ade-

quate combustion air and are venting properly. See VentingAnd Combus-

tion Air Check in this manual.

Air Openingsand ConnectingDucts

Total input rating for all non direct vent gas appliances MUST be

considered when determining free area of openings.

Connect ducts or openings directly to outside.

When screens are used to cover openings, they MUST be no less

than 1/4" (6mm) mesh.

The minimum dimension of rectangular air ducts MUST NOT be

less than 3" (75mm).

When sizing grille or louver, use the free area of opening. If free

area is NOT stamped or marked on grill or louver, assume a 20%

free area for wood and 60% for metal.

Confined Space Installation

NOTE: A confined space is defined as an area with less than 50 cubic

feet( 1.4m 3) per 1,000 BTUH input rating for all gas appliances installed in

the area.

Requirements

1. Provide confined space with sufficient air for proper combustion

and ventilation of flue gases using horizontal or vertical ducts or

openings.

2. Figure 4 illustrate how to provide combustion and ventilation air. A

minimum of two permanent openings, one inlet and one outlet, are

required.

3. One opening MUST be within 12" (300mm) of the floor and the se-

cond opening within 12" (300mm) of the ceiling.

4. Size openings and ducts per Figure 3.

Figure 3 Vent Check

Vent Pipe "_! IJ/ Draft Hood

Match

5. Horizontal duct openings require 1" square (25sq. mm) of free

area per 2,000 BTUH of combined input for all gas appliances in

area (see Table 1).

6. Vedical duct openings or openings directly to outside require 1"

square (6.5mm 3) of free area per 4,000 BTUH for combined input

of all gas appliances in area (see Table 1).

Table1 Free Area

MinimumFreeAreaRequiredforEachOpening

BTUH

Input HorizontalDuct

Rating (2,000BTUH)

50,000 25 sq.in.(161cm2)

75,000 35.5 sq. in.(242cm2)

100,OOO 50 sq. In.(323cm2)

125,000 62.5 eq. In.(403cm2)

150,000 71 sq. in.(484cm2)

VerticalDuctor openings Round

to outside Duct

(4,000 BTUH) (4,000

BTUH)

12.5sq.in.(81 cm2) 4"

15.75sq.in.(121cm2) 5"

25 sq.in.(161cm2) 6"

31.25sq.in.(202crnz) 7"

37.5sq. in.(242cm2) 7"

EXAMPLE: Determining Free Area

Appliance 1 Appliance 2 Total Input

100,OOO+ 30,000 =(130,000 ÷4,DO0) =210 cm2

(32.5 Sq. In.) Vertical

Appliance 1 Appliance 2 Totallnput

100,000 + 3D,O00 = (130,000 +2,000) - 419 cm2

(65 Sq. In.) Horizontal

Figure 4 Outside Air (This is ONLY aguide. Subject to codes of country having jurisdiction.)

This installationNOTapprovedinCanada

_SGable Vent

Op:ion..n.t.ir,t,

I-] IN

MinimumOneinlet and One Outlet Air Supply is Required

Maybe in andCombination Shown

InletAir Opening Must be Within12"(30Omm}of floor

Outlet Air Opening Must be Within12"(300mm)of ceiling

(1) t SquareInch(6cm2)per 40006TUH

(2) 1 Square Inch (6cm2)per 2000 BTUH

Outlet

Air(t)

Fumace G_

ttaten m

Inlet

Air(1

Outlet

Air(2)

Inlet

Air(2)

Inlet I

Air(1)

GasVent GableVent

SoffitVent

inlet

UnconfinedSpaceInstallation

Carbon Monoxide Poisoning Hazard.

Most homes will require additional air.

An unconfined space or homes with tight

construction may not have adequate air infiltra-

tion for proper combustion and ventilation of flue

gases,

Failure to supply additional air by means of ven-

tilation grilles or ducts could result in personal in-

jury and/or death.

An unconfined space is defined as an area having a minimum volume of

50 cubic feet( 1.4m 3) per 1,000 Btu h total input rating for all gas appliances

in area. Refer to Table 2 for minimum area required.

Table 2 Unconfined Space

Minimum Area in Square Feet

BTUH Input Minimum Area in Square Feet

Rating

50,000 312(29m 2)

78,000 490(46m 2)

114,000 712(66m 2)

155,000 968(90m 2)

EXAMPLE: NOTE: Square feet is based on 8 foot ceilings.

28.000 BTUH X 50 Cubic Ft. = 1,400 =175 Sq. Ft.

1,000 8' Ceiling Height

NOTE: Refer to definitions in section titled Unusually Tight Construction. if

any one of the conditions apply, the space MUST be considered confined

space regardless of size.

1. Adjoining rooms can be considered part of an unconfined area if

there are openings without doors between rooms.

2. An attic or crawlspace may be considered an unconfined space

provided there are adequate ventilation openings directly to out-

doors. Openings MUST remain open and NOT have any means of

being closed off. Ventilation openings to outdoors MUST be at

least 1"square (25ram 2) of free area per 4,000 BTUH of total input

rating for all gas appliances in area.

3. Instafl air intake a minimum of f 2" (300ram) above maximum snow

level and clear of any obstruction. Duct or ventilation opening re-

quires one square inch of free area per 4,000 BTUH of total input

rating for all gas appliances in area,

4. Air inlet MUST be screened with not less than 1/4" (6mm) mesh

screen.

UnusuallyTight Construction

in unconfined spaces, infiltration may be adequate to provide air for com-

bustion, ventilation and dilution of flue gases. However, in buildings with

unusually tight construction, additional air MUST be provided using the

methods described in section titled Confined Space Installation:

Unusually tight construction is defined as: Construction with

1. Wails and ceilings exposed to the outside have a continuous,

sealed vapour barrier. Openings are gasketed or sealed and

2. Doors and openable windows are weather sthpped and

3. Other openings are caulked or sealed. These include joints around

window and door frames, between sole plates and floors, behNeen

wall-ceiling joints, between wall panels, at penetrations for plumb-

ing, electrical and gas lines, etc.

VentilationAir

Some provincial codes and local municipalities require ventilation or

make-up air be brought into the conditioned space as replacement

air, Whichever method is used, the mixed return air temperature across

the heat exchanger MUST not fall below 60 °F (15° c) or flue gases will con-

dense in the heat exchanger. This will shorten the life of the heat exchang-

er and possibly void your warranty.

L2J

4. VentandCombustionAirPiping

Carbon monoxide poisoning, fire and explosion

hazard.

Read and follow all instructions in this section.

Failure to properly vent this furnace can result in

property damage, personal injury and/or death.

Dual Certified Furnace

This fu rnace is certified as a category t¥ appliance and is dual certified as

a direct vent furnace using outside air for combustion or it can use air from

inside the structure for combustion. The INLET air pipe is optional. If com-

bustion air comes from inside the structure, adequate make up air MUST

be provided to compensate for oxygen burned. See Confined Space

installation in the Combustion and Ventilation Air chapter. If combus-

tion air is drawn from outside the structure, it MUST be taken from the

same atmospheric pressure zone as the vent pipe.

Contaminated Combustion Air

Installations in certain areas or types of structures will increase the expo-

sure to chemicals or Halogens which may harm the furnace.

The following areas or types of structures may contain or have exposure

to the substances listed below. The installation must be evaluated careful-

ly as it may be necessary to provide outside air for combustion.

Q Commercial buildings.

• Buildings with indoor pools.

• Furnaces installed in laundry rooms.

• Furnaces installed in hobby or craft rooms.

• Furnaces installed near chemical storage areas.

• Permanent wave solutions for hair.

• Chlorinated waxes and cleaners.

• Chlorine based swimming pool chemicals.

• Water softening chemicals.

• De-icing salts or chemicals.

• Carbon tetrachloride.

• Halogen type refrigerants.

• Cleaning solvents (such as perchloroethylene).

• Printing inks, paint removers, varnishes, etc..

• Hydrochloric acid.

• Sulfuric Acid.

• Solvent cements and glues.

• Antistatic fabric softeners for clothes dryers.

• Masonry acid washing materials.

Vent and Combustion Air Piping Guidelines

1. Determine the best routing and termination for the vent pipe and

air inlet pipe when used by referring to all of the instructions and

guidelines nth s Sect on.

2. Determine the size required for the vent pipe and air inlet pipe

(when used).

3. Loosely assemble all venting parts without adhesive (pipe joint

cement) for correct fit before final assembly.

Use of vertical piping is preferred because there will be some mois-

ture in the flue gases that may condense as it leaves the vent pipe

(See Special Instruction For Horizontal Vents).

The vent MUST exit the furnace at the top left side.

The vertical vent pipe MUST be supported so that no weight is al-

lowed to rest on the combustion blower.

7. Exhaust vent piping diameter MUST NOT be reduced.

8. All exhaust vent piping from the furnace to termination MUST slope

upwards, away from furnace, a minimum of 1/4" per foot of run

(6mm per 300mm).

9. Use DWV type long radius elbows whenever possible, as they pro-

vide for the minimum slope on horizontal runs and they provide

less resistance in the vent system. If DWV elbows cannot be used,

use two, 45 ° elbows when possible. On horizontal runs the elbows

can be slightly misaligned to provide the correct slope.

10. All horizontal pipe runs MUST be supported at least every five feet

with metal pipe strapping. NO sags or dips are permitted.

11. All vertical pipe runs MUST be supported every six feet where ac-

cessible.

12. The maximum pipe length is 40' (12m) total in the inlet or outlet

side of the system. Up to five, 90 ° elbows can be used on the inlet

orthe outlet. If more than five elbows ar_erequired, reduce the

length of both the inlet and exhaust pipes 5 (1.5m) for each addi-

tional elbow used, (See Vent Tables).

13. The minimum pipe run length is 2' (.6m).

14. The piping can be run in the same chase or ad acent to supply or

vent pipe for water supply or waste plumbing. It can also be run in

the same chase with a vent from another 90+ furnace.

NOTE: In NO case can the piping be run in a chase where temper-

atures can exceed 140 ° F. or where radiated heat from adjacent

surfaces would exceed 140 ° E

15. If installing as a direct-vent appliance, the vent outlet MUST be

installed to terminate in the same atmospheric pressure zone as

the combustion air inlet,

16. The vent system can be installed in an existing unused chimney

provided that:

• Both the exhaust vent and air intake run the length of the chimney.

• No other gas fired appliance or fireplace (solid fuel) is vented into

the chimney.

•The top of the chimney MUST be sealed flush or crowned up to

seal against rain or melting snow so ONLY the piping protrudes.

•The termination clearances shown in Figure 10 are maintained.

PipingInsulation Guidelines

NOTE: In general, chimneys on an outside wall and attics are exposed to

cold conditions which can cause the vent pipe to sweat from condensa-

tion. This can lead to moisture damage to living spaces. It is highly recom-

mended that piping inthese cases be insulated to insure proper protection

from condensation damage.

Use 1/2" (50mm) wall, closed cell, neoprene insulation or equivalent. If

Fiberglas ar equivalent insulation is used it must have a vapor barrier. Use

R values of 7 up to 10, R-11 if exposure exceeds 10'. if Fiberglas insula-

tion is used, exterior to the structure, the pipe MUST be boxed in and

sealed against moisture.

1. Insulate pipe when the exhaust vent passes through an uncondi-

tioned space or raceway.

2. g situations require pipe to be run on the exterior wall to reach a

suitable termination point, it MUST be properly insulated.

3. If it is necessary to insulate piping when an inactive chimney is

used as a chase, the top of the chimney MUST be sealed flush or

crowned up to seal against rain or melting snow so ONLY the pip-

ing protrudes,

4. When the vent or combustion air pipe height above the roof ex-

ceeds 30" (760ram), or if an exterior vertical rise ris used on a hori-

zontal vent to get above snow levels, the exterior portion MUST be

insulated.

5. When combustion air inlet piping is installed above a suspended

ceiling, the pipe MUST be insulated with moisture resistant insula-

tion such as Armaflex or other equivalent type of insulation.

6. Insulate combustion air inlet piping when run in warm, humid

spaces such as basements,

SizingCombustionAir andVent Pipe

1.. Single Pipe Installation-If installing as a non-direct vent ap-

pliance, (single outlet pipe and no inlet pipe) refer to Table 3. The

table shows the maximum number of elbows allowed with any giv-

en pipe diameter and length of run.

2.. Double Pipe Installation-If installing as a direct-vent appliance,

consult Table 4 to select the proper diameter exhaust and com-

bustion air piping. Exhaust and combustion air piping is sized for

each furnace Btuh size based on total lineal vent length (on inlet or

outlet side), and number of 90 ° elbows required.

3.. Use of Elbows-Two 45 ° elbows can be substituted for one 90 ° el-

bow. The elbow or elbows used for vent termination outside the

structure ARE counted, including elbows needed to bring termina-

tion above expected snow levels. When the vent system length

used is borderline with the next size combination category, al-

ways use the next larger size.

EXAMPLE: Refer to, 75,000 Btuh Furnace, Table 4.

• A vent system uses 25' of Inlet pipe and 24' of Outlet pipe. Use the

maximum length found in your system, so 25" is the length to use in

these tables. The 25-30 column should be used.

• There are 4 elbows on the Outlet and 2elbows on the Inlet. Use the

4 elbows row because that is the maximum number of elbows on any

one side (Inlet or Exhaust).

• In this example, combinations C or F are allowed. Using the leg-

end at the bottom of the table, combination Cis 3" Inlet with a 21/2" Ex-

haust. Combination F is a3" Inlet with a 3" Exhaust. Either combination

is allowed together, but they can NOT be mixed. In other words, part of

aCcombination can NOT be used with part of an F combination just

because they are listed together in the same block.

Table 3 Pipe Diameter Table

Single Piping ONLY

50,000 & 75,000 Btuh Furnaces

Max No. Of Feet of Pipe*

Elbowsin

OnsSide_ 0-9 110-14 115-19 120-24 120-29 130-. 135-40

UP TO 5 All combinations use "A" a 2" Exhaust

100,000 Btuh Furnace

Max No.Of Feet of Pipe*

Elbows in

OneSide_ 0-9 10-14 15-19 20-24 25-29 30-34 35-40

1 A A A A A A B,C

2 A A A A A B,C B,C

3 A A A A B,C B,C B,C

4 A A A B,C B,C B,C B,C

5 A A B,C B,C B,C B,C B,C

125,000 Btuh Furnace

Max No. Of Feet of Pipe*

Elbows in

OneSide_ 0-9 10-14 15-19 20-24 25-29 30-34 35-40

1 A A B,C B,C B,C B,C C

2 A B,C B,C B,C B,C C C

3 B,C B,C B,C B,C C C C

4 B,C B,C B,C C C C C

5 B,C B,C C C C C C

Possible combination legend:

A = 2" Exhaust

B = 21/2 "Exhaust

C = 3" Exhaust

Elbows are DWV Long Radius Type for 2" and 3" vents.

Schedule 40 (sharp radius) for ,_12/2"

3-Signifies the maximum number of elbows, including the termina-

tion elbow(s), on any one part of the system. Example: 4 elbows on

the exhaust and 5 elbows on the inlet would use the chart showing 5

elbows, because 5 is the maximum number on any one side.

If more than five elbows are required, reduce the length of both the

inlet and exhaust pipes 5' (1.5m) for each additional elbow used.

*Feet of pipe is whichever pipe run is the longest, either inlet orout-

let side.

Table 4 Pipe Diameter Table

Dual Piping ONLY

50,000 Btuh Furnaces

MaxNo. Of Feet of Pipe*

Elbowsin

OneSide_ 0-9 110-14 115-19 120-24 125-29 130-34 135-40

UP TO 5 All combinations use "A" a 2" Exhaust and 2" Air

Inlet Pipe

75,000 Btuh Furnace

MaxNo. Of Feet of Pipe*

Elbowsin

OneSide _0-9 10-14 15-19 20-24 25-29 30-34 35-40

1 A A A A D,B E,B E,B

2 A A A D,B E,B E,B C,F

3 A A D,B E,B E,B C,F C,F

4 A D,B E,B E,B C,F C,F C,F

5 D,B E,B E,B C,F C,F C,F C,F

100,000 Btuh Furnace

MaxNo. Of Feet of Pipe*

Elbowsin

OneSide_ 0-9 10-14 15-19 20-24 25-29 30-34 35-40

1 A A A D,B E,B E,B C,F

2 A A D,B E,B E,F C,F C,F

3 A D,B E,B E,F C,F C,F C,F

4 D,B E,B E,F C,F C,F C,F C,F

5 D,B E,F C,F C,F C,F C,F C,F

125,000 Btuh Furnace

MaxNo.Of Feet of Pipe*

Elbowsin

OneSide_ 0-9 110-14 115-19 120-24 120-29 130-34 135-40

UP TO 5 All combinations use "F" a 3" Exhaust and 3" Air

Inlet Pipe

Possible combination legend:

A = 2" Inlet with a 2" Exhaust

a = 3- Inlet with a 2" Exhaust

C = 3" Inlet with a 2112"Exhaust

D = 21/2" Inlet with a 2" Exhaust

E = 21/2"Inlet with a 21/2"Exhaust

F = 3" Inlet with a 3" Exhaust

Elbows are DWV Long Radius Type for 2" and 3" vents.

Schedule 40 (sharp radius) for _12/2"

Vent TerminationClearances

Carbon monoxide poisoning, fire and explosion

hazard.

Inlet and outlet pipes may NOT be vented

directly above each other.

Failure to properly vent this furnace can result in

property damage, personal injury and/or death.

1. Determine termination locations based on clearances specified in

following steps and as shown in Figure 5, Figure 8, Figure 9 and

Figure 10.

2. The vent termination must be located at least 12" (300ram) above

ground or normally expected snow accumulation levels.

Do NOT terminate over public walkways, Avoid areas where con-

densate may cause problems such as above planters, patios, or

adjacent to windows where steam may cause fogging.

The vent termination shall be located at least 4" (1220mm) horizon-

taUy from any electric meter, gas meter, regulator, and any relief

equipment. These distances apply ONLY to U,S. installations.

The vent termination is to be located at least 3' (914mm) above

any forced air inlet located within 10' (3m) ; and at least 10" (3m)

from a combustion air intake of another appliance, except another

direct vent furnace intake.

In Canada, the Canadian Fuel Gas Code takes precedence over

the preceding termination instructions.

A condensa e pump MUST have an auxiliary safety switch to pre-

vent operation of furnace and resulting overlow of condensate in

the event of pump failure. The safety switch MUST be wired

through the R circuit ONLY (low voltage) to provide operation in ei-

ther heating or cooling modes.

Install an overflow line if routing to floor drain or sump pump. See

Figure I for example of proper routing and installation of overflow

line.

If the condensate drain has the potential for freezing, heat tape

must be used on the drain trap and condensate drain.

Connecting Furnace and Piping

Vent Termination Clearances

Figure 5 (United States Only)

See text for Canadian Requirements

OtherThan

Direct Vent

Other Than

Direct Vent

Terr_nal

50,C_0 Btuh

0flees

Carbon monoxide poisoning hazard.

Cement or mechanically seal all joints, fittings,

etc. to prevent leakage of flue gases.

Failure to properly seal vent piping can result in

personal injury and/or death.

1. Preassemble the exhaust end combustion air piping from the fur-

nace to the vent termination. Do NOT cement any joints together

until the preassembly process is complete.

Vent Pipe Connection

1, nsta the section ABS vent pipe supplied to the combustion

blowerusingthe flexible coupling and clamps provded. Remove

the three screws holding the vent collar to the top panel. Remove

the vent collar. Remove the two screws in the chase tube. Squeeze

the chase tube together and slide the chase tube through the top

panel. The blower snout is now accessible for installing the ABS

pipe. See Figure 6and Figure 7, Reassemble in reverse order.

Condensate Drain Trap and Neutralizer

This furnace removes both sensible and latent heat from the combustion

flue gases. Removal of latent heat results in condensation of flue gas (wa-

ter vapor). This condensed water vapor drains from the secondary heat

exchanger, through a built-in drain trap transition, and out of the unit. Con-

densate line can exit from the right side, left side, or rear of the cabinet.

NOTE: The 90 ° compression fitting elbow (provided), requires the drain

line to be 1/2" (13mm) CPVC* ( 5/8" OD). 5/8" (16mm) I.D. vinyl tubing may

be used outside the furnace cabinet to connect to the drain line. Internal

trap assembly provides the required 4"water column, so no additional trap

is required.

* Make sure the 1/2" CPVC is 5/8" OD as there is also a schedule 40

available that will not work.

Figure 6 Proper Sealing Procedure for

Combustion Blower

_ABS Pipe

Rubber Coupling

Clamps_,,_

Blower_,

25-21-86

Do NOT put a loop in the drain piping. This would cause an extra

water column pressure in addition to the pressure inside the built-

in drain trap.

Drains must terminate at an inside drain to prevent freezing of con-

densate and possible property damage.

2. nstal the rema ningflexiblecouplingandciamps (supplied) onthe

end of the ABS vent pipe from the combustion blower. Ths w be

used to connect to the rest of the vent system. See Figure 7.

Consideration MUST be given to type of filter being installed.

125,000 Btuh furnace require 2-16"x25"x1" filters(one on each

side of furnace). This configuration does NOT allow the conden-

sate drain line to be run out the side of furnace. If line MUST be run

out the side, an optional standoff filter rack with one 20"x25"xl"

filter is needed, Install optional filter rack on side of furnace oppo-

site the side where condensate drain line will exit.

4. A condensate or sump pump MUST be used if local codes require,

or if no inside floor drain is available. If pump is approved for use

with acidic condensate, a neutralizer cartridge is not needed. If us-

ing a neutralizer cartridge, it MUST be installed in the drain line in a

horizontal position ONLY.

Air Inlet Pipe Connection

NOTE Ar net Collar is sized for 3" PVC pipe. If 2" 50ram) or 21/2

64ram combus on air piping is used, a 3" (75ram) to 2" 50mm) or 3

(75mm to 21/2 (64mm reducer fi ing is required.The reducing section

can be before the 90 ° elbow in a horizontal section.

1. nstaU pipe section or pipe/reducer fitting as required) to the inlet

collar using RTV sealant ONLY to provide for future serviceab ty.

NOTE: On single pipe installation, using combustion air from inside the

structure, it is recommended that a screen be placed inside the Combus-

tion Air Inlet. A 3" plastic screen is provided for this purpose, It will prevent

small objects from falling into the combustion chamber. Use RTV sealant

ONLY to provide for future serviceability.

Figure 7 Vent Trap and Furnace Connections

coupling and clamps _._)

Flexible

(supplied) are installed

side the cabinet. Air Intake Pipe

"(Direct-Vent Installation only)

Place a 3" Plastic Screen (Op-

inside the Air Inlet Collar

when Combustion Air comes

from inside the structure.

ABS pipe (supplied) MUST be

installed between

tion blower and coupling.

RTV sealant used to join com-

bustion blower and ABS pipe

and Air inlet Pipe to Combus-

tion Air Inlet. See Figure 6.

Condensate compression

fitting can be turned to exit out the

left side, right side, or rear of cabi-

net. If piping is exiting out the

right side of cabinet, it is neces-

sary to use an elbow to run pipe in

front of electronic module. Cabi-

net entrance hole is offset enough

to allow adequate clearance.

Joining Pipe andFittings

Fire hazard.

Provide adequate ventilation and do NOT

assemble near heat source or open flame. Do NOT

smoke while using solvent cements and avoid

contact with skin or eyes.

Observe all cautions and warnings printed on

material containers to prevent possible personal

injury and/or death.

NOTE: All PVC, CPVC, ABS, and Cellular Core pipe fittings, solvent ce-

ment, primers and procedures MUST conform to American National Stan-

dard Institute and American Society for Testing and Materials

(ANSVASTM) standards. Schedule 40 is the ONLY approved wall thick-

ness.

•Pipe and Fittings- ASTM D1785, D2466, D2661, D2665, F-891

• PVC Primer and Solvent Cement - ASTM D2564

• Procedure for Cementing Joints - Ref ASTM D2855

NOTE: In order to create a seal that allows future removal of pipe, RTV

sealant MUST be used on both the inlet and the exhaust pipes where they

join to the furnace. PVC, CPVC, ABS, and Cellular Core pipe and cement

may be used on all other joints.

NOTE: Stir the solvent cement frequently while using. Use a natural bristle

brush or the dauber supplied with the cement. The proper brush size is

one inch.

2.. After checking pipe and socket for proper fit, wipe socket and pipe

with cleaner-primer. Apply a liberal coat of primer to inside surface

of socket and outside of pipe. Do NOT allow primer to dry before

applying cement.

3.. Apply a thin coat of cement evenly in the socket. Quickly apply a

heavy coat of cement to the pipe end and insert pipe into fittings

with a slight twisting movement until it bottoms out.

NOTE: Cement MUST be fluid while inserting pipe. If NOT, recoat pipe.

4.. Hold the pipe in the fitting for 30 seconds to prevent the tapered

socket from pushing the pipe out of the fitting,

5.. Wipe all excess cement from the joint with a rag. Allow 15 minutes

before handling. Cure time varies according to fit, temperature and

humidity.

ConnectingVentPipesandTermination

NOTE: Combustion air intake and vent MUST terminate in the same at-

mospheric pressure zone. If installation is in a cold climate (substained

temperatures below 0° F), increase the minimum distance between vent

pipe and air intake from 8" to 18".

CAUTION

Maintain a minimum of 36" (lm) between combustion

air inlet and clothes dryer vent. Terminate the combus-

tion air intake as far as possible from any air condition-

er, heat pump, swimming pool, swimming pool

pumping, chorlinator or filtration unit.

CAUTION

Do NOT use solvent cement that has become curdled,

lumpy or thickened and do NOT thin. Observe precau-

tions printed on containers. For applications below

32 °F., use only low temperature type solvent cement.

1.. Cut pipe end square, remove ragged edges and burrs. Chamfer

end of pipe, then clean fitting, socket and pipe joint of all dirt,

grease, or moisture.

Carbon monoxide poisoning, fire and explosion

hazard.

Inlet and outlet pipes may NOT be vented

directly above each other.

Failure to properly vent this furnace can result in

property damage, personal injury and/or death.

L2J

t. Install all couplings, nipples and elbows using proper procedures

for Joining Pipe and Fittings and maintain spacing between vent

and combustion air piping as indicated in Figure 8 through Figure

10.

Vertical Termination

1. NO TAG shows the proper installation and clearances for vertical

vent termination. The vertical roof termination should be sealed

with a plumbing roof boot or equivalent flashing. The inlet of the in-

take pipe and end of the exhaust vent must be terminated no less

than 12" (300ram) above the roof or snow accumulation level, and

12" (300mm) away from avertical wall or other protrusion.

2. If the vent system is installed in an existing chimney make sure

clearances shown in Figure 10 are maintained. Horizontal section

before the termination elbow can be extended on the inlet air to

provide necessary clearance.

Horizontal Termination

1. If installingasadirect-vent appliance cuttwoholes.21/2 " (67mm)

for 2" (50mm) pipe, 3"(75mm) for 2 /2" (67rnrn) pipe, or 31/2"

(90ram) for 3" (75mm) pipe. Do NOT make the holes oversized, or

it will be necessary to add a sheet metal or plywood plate on the

outside with the correct size hole in it. If venting as a single pipe

appliance, cut only one hole.

2. Check hole sizes by making sure it is smaller than the couplings or

elbows that will be installed on the outside. The couplings or el-

bows MUST prevent the pipe from being pushed back through the

wall.

3. Extend vent pipe and combustion air pipe through the wall 3/4" to

f"(19 to 25mm) and seal area between pipe and wall.

4. Install the couplings, nipple and termination elbows as shown and

maintain spacing between vent and combustion air piping as indi-

cated in Figure 8 through Figure 10.

Using Exterior Risers

1. Install elbows and pipe to form riser as shown in Figure 9.

2. Secure vent pipe to wall with galvanized strap or other rust resis-

tant material to restrain pipe from moving.

3. Insulate pipe with Armaflex or equivalent moisture resistant closed

cell foam insulation or Fiberglass insulation if boxed in and sealed

against moisture.

OptionalVent Screens

To prevent unwanted pests or foreign material from entering terminated

ptpes, plastic vent screens are available in 2" and 3" sizes (check parts

list). Use of these screens is recommended except in cold climate areas

where ice is likely to form on them. Glue the screen inside the termination

elbow using pipe cement. Screens should be inspected monthly for block-

age and cleaned yearly prior to startup.

Sidewall Termination 12" or More

Figure 8 Above Snow Level or Grade Level

8"* F)

MIN

Inlet is ]

optional

Vent TerminationShielding

Under certain wind conditions some building materials may be affected by

flue products expelled in close proximity to unprotected surfaces. Sealing

or shielding of the exposed surfaces with a corrosion resistant material

(such as aluminum sheeting) may be required to prevent staining or dete-

rioration. The protective material should be attached and sealed (if neces-

sary) to the building before attaching the vent terminal.

A metal shield is recommended 18" x 18" (457mm x 457mm) min. or 18"

(457mm) rain. diameter around the vent termination at the exterior wal! to

protect the house exterior materials from flue product or condensation

(freezing) damage.

Sidewall Termination with Exterior

Figure 9 Risers to Get Above Snow Level or

Grade Level

8" ** lS" Minimum for cold climates

MIN (substained below (Y F)

Inlet is ]

optional

GRADE LEVEL

NOW LL=VEL 25-00-04 F

Figure 10 Rooftop Termination

Inlet is

optional

or snow accumulation level

t_ I f

B = 8 Min., 20' Maximum, except In areas with extreme

cold temperatures (substained below O°F), then 18" Min.

5. GasSupplyandPiping

Fire and explosion hazard.

1. Supply pressure can be checked using the !/8"(3.2mm) NPT port

on the supply side of the gas valve.

Natural Gas

Models designated for Natural Gas are to be used

with Natural Gas Only, unless properly converted

to use with LP gas.

NOTE; The rating plate is stamped with the model number, gas type and

gas input rating. In addition, models manufactured for sale in Canada

have orifice size information stamped on the rating plate.

Alternate BTUHInput Ratings(USAOnly)

The input rating of these fu maces can be changed from the standard input

rating to the alternate input rating shown in Table 5, by changing the main

burner orifices. Changing of burner orifices MUST be done by a qualified

service technican. See section on changing orifices.

Table 5

STUH

Standard

Rating

50,000

75,000

100,000

125,000

Alternate Input Ratings, USA ONLY.

BTUH

Alternate

Rating

40,000

60,000

80,000

100,000

Natural LP

Gas Gas

Orifice Orifice

#44 #55

#44 #56

#44 #55

SupplyPressure

Fire hazard.

2. Gas input to burners MUST NOT exceed the rated input shown on

rating plate.

3. Do NOT allow minimum gas supply pressure to vary downward.

Doing so will decrease input to furnace. Refer to Table 6for normal

gas supply and manifold pressures.

Table 6

Gas

Type

Natural

Gas Pressures Below 2000 Ft.

Supply Pressure Manifold

Recommended Max. Min. Pressure

7inches 14 inches 4.5 inches 3.5 inches

11 inches 14 inches 11 inches 10 inches

Important Notes

With Propane gas, the rated input is obtained when the

BTU content is 2,500 BTU per cubic toot and manifold

pressure set at 10 inches W.C.

If Propane gas has a different BTU content, orifices MUST be

changed by licensed Propane installer.

Measured input can NOT exceed rated input.

Combustion Air Box Cover MUST be removed when adjust-

ing manifold pressure.

Any major change in gas flow requires changing burner ori-

fice size.

GeneralDeratingRules

Do NOT set input rating above that shown on

rating plate.

Failure to properly set input pressure can result in

property damage, personal injury and/or death.

1. For operation with natural gas at altitudes 2,000' and above, orifice

change and/or manifold pressure adjustment may be required to

suit gas supplied. Check with gas supplier. If orifice sizing is need-

ed, it should be based on reducing the input rating by 4 percent for

each 1,000" above sea level. See Table 7 and Figure 11 for re-

quired pressure change and/or orifice change for high altitudes.

Table 7

Heat Value

Btu/Cu.Ft.

8OO

85O

9OO

95O

1000

1050

1100

Orifice Size

0-1999

3.5

3.2

2.9

#42

2000-2999

3.5

3.3

3.0

2.7

2.5

#42

3000-3999

3.5

3.4

3.1

2.8

2.5

2.3

#42

High Altitude Pressure Chart

2000-8000 ft. (Natural Gas)

Elevation Above Sea Level

4000-4999

3.5

3.1

2.8

2.5

2.3

#45

5000-5999 6000_999

3.5 3.2

3.2 2.9

2.8 2.5

2.5 2.3

2.9

#45 #45

7000-7999

2.9

2.6

2.3

#45

Shaded box requires orifice change.

No Shading indicates factory installed orifice and manifold pressure change only.

2. For operation with LP gas, gas orifices MUST be changed and

manifold pressure MUST be maintained as per Table 6. Orifice

sizes for 0-2000" above sea level are #54. 2000-7000" above sea

level, use #55. 7000-8000" above sea level, use #56 orifices.

Orifices can be ordered through your distributor.

Manifold GasPressureAdjustment

NOTE: Gas supply pressure MUST be within minimum and maximum vaF

ues listed on rating plate. Pressures are usually set by gas suppliers.

Make adjustment to manifold pressure with burners operating and com-

bustion air box cover removed.

1. Remove combustion air box cover.

2. Connect U-Tube manometer to the tapped opening on the outlet

side of gas valve. Use manometer with a0-min.12" water column

range.

3. Turn gas ON, fire the furnace and remove adjustment screw cover

on gas valve.

4, Turn counterclockwise to decrease pressure and clockwise to in-

crease.

5. Set pressure to value shown inTable 6. Refer to Important Notes

in Table 6. Pressure is also listed on furnace rating plate.

6. When pressure is set, replace adjustment screw cover on gas

valve.

7. Replace combustion air box cover.

NOTE: Adjustment screw cover MUST be replaced on gas valve BE-

FORE reading manifold pressure and operating furnace.

HighAltitude Air PressureSwitch

Altitudes over 4,000' require a different air pressure switch than the one

installed at the factory. Check parts list for pressure switch and consult

your distributor for part number and availability. In Canada, provincial

codes may govern installation of switch. Check with gove rning authorities.

ChangingOrificesfor HighAltitude

Electrical shock, fire or explosion hazard.

Turn OFF electric power (at disconnect) and gas

supply (at manual valve in gas line) when

installing orifices. Installation of orifices requires

a qualified service technician.

Failure to properly install orifices can result in

property damage, personal injury and/or death.

NOTE: Main burner orifices can be changed for high altitudes.

1. Disconnect gas line from gas valve.

2. Remove combustion box front cover and manifold from furnace.

3. Remove the orifices from the manifold and replace them with prop-

erly sized orifices.

4. Tighten orifices so there is 11/16"(27mm) from the faces of the ori-

rices to the back side of the manifold, Figure 11.

Figure 11 Changing Orifices

Measure 11116,, (27mm) from

face of orifice to the back side

of the manifold.

5. Reinstall manifold and combustion air box cover. Ensure burners

do NOT bind on new orifices.

Natural Gas Input Rating Check

NOTE: The gas meter can be used to measure input to furnace. Rating is

based on a natural gas BTU content of 1,000 BTU's per cubic meter.

Check with gas supplier for actual BTU content.

1. Make sure combustion air box cover is in place and closed before

performing the following steps.

2. Turn OFF gas supply to all appliances and start furnace.

3. Time how many seconds it takes the smallest dial on the gas meter

to make one complete revolution. Refer to Example.

Example

NaturalGas | No.of Seconds Time PerCubic BTUPer

BTUContent tPerHour Footin Seconds Hour1,000 3,600 48 75,000

1,000 x 3,600 +48 = 75,000 BTUH

NOTE: If meter uses a 2 cubic foot dial, divide results (seconds) by two.

4. Relight all appliances and ensure all pilots are operating.

GasPipingRequirements

1. Properly size gas pipe to handle combined appliance load or run

gas pipe directly from gas meter or LP gas regulator. Refer to

NFGC and ANSI Z223.1 for proper gas pipe size.

2. Install correct pipe size for run length and furnace rating.

3. Measure pipe length from gas meter or LP second stage regulator.

Connections

NOTE: Refer to Figure 12 for the general layout at the furnace. The rules

listed apply to natural and LP gas pipe installations.

Figure 12 _Typical Gas Piping

Drip Leg and Union. Union*

should be outside the cabinet.

Manual shut-off valve MUST be

upstream of dripleg, union,

and furnace.

Use elbows to connect valve to

piping when using left side gas

pipe

a _

LP Low Pressure Switch

(Optional Some Models)

*Union may be installed inside the cabinet

when necessary because of clearances.

Use black iron or steel pipe and fittings or other pipe approved by

local code.

Use ground joint unions and install a drip leg no less than 3" long to

trap dirt and moisture before it can enter gas valve.

Final Check

1. The furnace and its individual shut-off valve must be disconnected

from the gas supply piping system during any pressure testing of

that system at test pressures in excess of 1/2" PSIG (3.5 kPa).

Use two pipe wrenches when making connections to prevent gas

valve from turning.

Install a manual shut-off valve external to fumace casing and tight-

en all joints securely.

The furnace must be isolated from the gas supply piping system by

closing its individual manual shut-off valve during any pressure

testing of the gas supply piping system at test pressures equal to or

less than 1/2" PSIG (3.5 kPa).

2. Test all pipes for leaks.

Additional LP ConnectionRequirements

1. Have a [icensed LP gas dealer make all connections at storage

tank and check all connections from tank to furnace.

2. If copper tubing is used, it MUST comply with limitation set in Na-

tional Fuel Gas Code or CGA codes.

Gas pressure MUST NOT exceed 1/2" PSIG to gas valve. Check-

ing gas piping above 1/2" PSIG requires the furnace and manual

shut-off valve to be disconnected during testing.

Apply soap suds (or a liquid detergent) to each joint. Bubbles form-

ing indicate a leak.

Correct even the smallest leak at once.

3. Two-stage regulation of LP gas is recommended. 6. If odfices were changed, make sure they are checked for leakage•

6. Electrical Wiring

Electrical shock hazard.

Grounding

Turn OFF electric power at fuse box or service

panel before making any electrical connections

and ensure a proper ground connection is made

before connecting line voltage.

Failure to do so can result in property damage,

personal injury and/or death.

NOTE: The furnace MUST be electrically wired and grounded in accor-

dance with local codes or, in the absence of IocaJ codes, with the electrical

codes of the country having jurisdiction. Electronic controls and furnace

will NOT operate unless properly grounded. A ground lug wire is provided

for ground connection. Use an approved copper connector from furnace

to service panel or properly driven ground rod.

Polarizing

NOTE: To insure safe, reliable operation, unit MUST be polarized. Proper

polarity is shown in Figure 13. The white wire is neutral and the black wire

is hot.

Labeling

CAUTION

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dan-

gerous operation. Verify proper operation after servic-

ing.

Power Supply

The furnace MUST be electrically wired and grounded in accordance with

local codes, or in the absence of local codes, the applicable national

codes.

Field wiring connections must be made inside the furnace connection box.

A suitable strain relief should be used at the point the wires exit the furnace

casing.

Copper conductors must be used. Line voltage wires should be sized for

the input amps stated on the rating plate. Furnace should be connected to

its own separate circuit.

Figure 13 _Electrical Connections

115V.60 Hz.

Iul

G _;

-- CONNECTION

GROUNDBOX

LOW VOLTAGE

TERMINAL BOARD

t I

25-20-86

Thermostat

NOTE: Thermostat location has an important effect on the operation of the

unit. Follow instructions included with thermostat for correct mounting and

wiring.

Heat Anticipator

Set thermostat heat anticipator in accordance with thermostat

instructions and actual measured value. To measure heat anticipa-

tor, do the following:

1. Wrap 10 loops of single strand, insulated thermostat wire around

the prongs of an amp meter. Set the scale on the amp meter to

measure no more than 10 amps.

Connect the uninsulated ends of this wire jumper across terminals

Rand Won the subbase. (Multi-stage thermostats use RH and W)

Do NOT attach thermostat to subbase.

Fire the thermostat for about one minute. Read the amp meter. Di-

vide the amp reading by 10 and set anticipator to this number.

Remove wires from subbase and attach thermostat to subbase.

Optional Equipment

NOTE: All wiring (except thermostat) from furnace to optional equipment

MUST conform to the temperature limitations of local codes or, in the ab-

sence of local codes, with the electrical codes of the country having juris-

diction. See Appendix. Install wiring in accordance with manufacturer's

instructions.

Humidifier/ElectronicAirCleaner

The furnace is pre-wired for humidifier and/or electronic air cleaner con-

nection.

CAUTION

Do NOT exceed 115VI1.0 amp maximum current load for both the

EAC terminal and the HUM terminal combined.

1. For connection of a humidifier, connect the spade terminal wires of

the humidifier to the HUM and HUM Neutral.

2. For connection of an electronic air cleaner, connect the spade termi-

nal wires of the humidifier to the EAC and EAC Neutral.

NOTE: The humidifier will be powered when the combustion blower is em

ergized. The electronic air cleaner will be powered anyti me the thermostat

calls.

NOTE: The furnace electronic fan control will change fan speeds auto-

matically as heat and cool are selected at the thermostat.

Fan Control

The fan control can be set to turn ON at 15, 30, 45, 60 seconds after the

burners light, It can be adjusted to turn OFF at 60, 90, 120, and 180 se-

conds. Refer to "Furnace Wiring Diagram" for desired setting.

NOTE: It is recommended to achieve maximum efficiency that the fan

control be set to turn on at 30 seconds after the burners light.

Operate the furnace and ensure that the blower turns ON and OFF at the

appropriate time to provide the desired comfort level.

Figure 14 Fan Timer Connections

"HUM"and "EAC"

TERMINALS DIP

SWITCHES10-11-55

7. DuctworkandFilter

Carbon monoxide poisoning hazard.

Do NOT draw return air from inside a closet or util-

ity room, Return air duct MUST be sealed to fur-

nace casing.

Failure to properly seal duct can result in personal

injury and/or death,

Instailation

NOTE: Design and install air distribution system to comply with Air Condi-

tioning Contractors of America manuals and/or NFPA pamphlets 90A and

90B or other approved methods that conform to local codes and good

trade practices.

1. When furnace supply ducts carry air outside furnace area, seal re-

turn air ducl to furnace casing and terminate duct outside furnace

space.

install air conditioning cooling coil (evaporator) on outlet side of fur-

nace.

For fu maces installed without acooling coil it is recommended that

the outlet duct be provided with a removable access panel. This

panel should be accessible when the furnace is installed so the

exterior of the heat exchanger can be viewed for inspections.The

access panel MUST be sealed to prevent leaks.

If separate evaporator and blower units are used, install good seal-

ing dampers for air flow control Chilled air going through the fur-

nace could cause condensation and shorten the furnace life.

NOTE: Dampers (field supplied) can be either automatic or manual.

Manually operated dampers MUST be equipped with a means to prevent

furnace or air conditioning operation unless damper is in the full heat or

cool position.

Carbon monoxide poisoning hazard.

Cool air passing over heat exchanger can

cause condensate to form resulting in heat ex-

changer failure.

This could result in personal injury and/or

death.

Connections

NOTE: Return air can enter through either side, both sides, or the bottom.

Return air _ enter through rear of the furnace. When the furnace is

located in an area near or adjacent to the living area, the system should be

carefully designed with returns to minimize noise transmission through

the return grille. Any blower moving a high volume of air will produce audi-

ble noise which could be objectionable to when the unit is located very

close to living areas. It is advisable to route the return air ducts under the

floor or through the attic.

1. For side connections using a 16" x 25" internal filter, cut out the

embossed area shown in Figure t5. This will provide a 141/2" x

221/2 " approximate opening.

Figure 15 Side Return Air Cutout

A = 141/2" Height Of cutout for 16" x 2,5"Filter

B = 221/2" Width of Cutout for 16" x 25" Filter j

//,

Embossed Are_ i

on Side of Fur- .,/_ _,,

l//Furnace

Bottom

NOTE: A 125,000 8tuh furnace requires two side returns or a bottom re-

turn for 5 tons cooling. If two side returns are used it does NOT allow the

condensate drain line to be run out the side of furnace, if line MUST be run

out the side, an optional standoff filter rack with one 20x25x 1 filter is need-

ed. Install optional filter rack on side of furnace opposite the side where

condensate drain line will exit.

2, Bottom returns can be made by removing the knockout panel in the

furnace base. Do NOT remove knock-out except for a bottom re-

turn. A 20" x 25" filter can be used for a bottom return for a 100,000

8tub furnace, A 25" x 25" filter is required for 125,000 Btuh fur-

Races.

3. An optional 20" x 25" duct standoff (NAHA001TK) is available to be

used in lieu of one filter on each side of furnace.

4. Installation of locking-type dampers are recommended in all

branches, or in individual ducts to balance system's air flow.

5. Non-combustible, flexible duct connectors are recommended for

return and supply connections to furnace.

6. If air return grille is located close to the fan inlet, install at least one,

90 degree air turn between fan and inlet grille to reduce noise.

NOTE: To further reduce noise, install acoustical air turning vanes and/or

line the inside of duct with acoustical material.

Sizing

Existing or new ductwork MUST be sized to handle the correct amount of

airflow for either heating only or heating and air conditioning.

Insulation

1. Insulate ductwork installed in attics or other areas exposed to out-

side temperatures with a minimum of 2" insulation and vapor barri-

er.

2. Insulate ductworkin indoor unconditioned areas with a minimum of

1" insulation with indoor type vapor barrier.

Filters

Use either filter type:

• Washable, high velocity filters are based on a maximum air flow

rating of 600 FPM.

•Disposable, lowvelocityfiltersarebesedonamaximumairflow

of 300 FPM when used with filter grille.

NOTE: Disposable, low velocity filters may be replaced with washabJe,

high velocity filter providing they meet the minimum size areas. Washable,

high velocity filters can be replaced ONLY with same type and size.

Figure 16 Side Mounted Filter Rack

i •

I •

Filter Installation

When installing or removing a bottom mounted filter, slide the two side

filter clips to the back of the furnace BEFORE installing or removing. This

will allow the filter to clear the front raised edge of the furnace. Insert filter

into side clips first and push filter back until it is fully engaged into back clip.

When filter is in pl ace, slide clips back into place midway on filter as shown

in Figure 17.

Figure 17 _J Bottom Mounted Filter Rack

AW3192

Slide filter clips towards back before removing

Refer to Figure 18 through Figure 19 for guidelines to install filters. Fur-

naces which require larger filter media and have fimited clearances on one

side of furnace, require astandoff filter rack, see Fig ure 18, available from

your distributor.

CAUTION

If filters are only suitable for heating application, ad-

vise homeowner that filter size may need to be in-

creased if air conditioning is added.

Addition Of Air Conditioning

When a refrigeration coU is used in conjunction with this unit, it must be

installed on the discharge side of the unit to avoid condensation on the

heat exchanger• The coil installation instructions must be consulted for

proper coil location and installation procedures. With a parallel flow ar-

rangement, dampers must be installed to prevent chilled air from entering

the furnace. If manually operated dampers are used, they must be

equipped with a means to prevent operation of either unit unless the

damper is in full heat or full cool position.

A 3" (75mm) clearance is required on the right side of the furnace in order

to run the condensate drain line. Copper, iron or plastic tubing may be

used for the condensate drain line.

Figure 18 Standoff Filter Rack

Using Optional _ F

Standoff Filter I_ J _'_

Rack I _ _ _ __

_25-21-45a

Figure 19 Filters Installed on Two Sides

Using Two _ "__'_

Filter Racks _ _

8. ChecksandAdjustments

Startup Main BurnerFlameCheck

NOTE: Refer to Start-up procedures in the user's information manual•

CAUTION

If any sparks, odors or unusual noises occur, immediately

shut OFF power to furnace. Check for wiring errors or ob-

struction to blower.

Allow the furnace to run approximately 10 minutes then inspect the main

burner and pilot flames. See Figure 20.

Check for the following (Figure 20):

•Stable and blue flames. Dust may cause orange tipsor wisps of

yellow, but flames MUST NOT have solid, yellow tips.

•Flames extendin9 directly from burner into heat exchanqer,

•Flames do NOT touch sides of heat exchanger ChangingBlowerSpeed

If any problems with main burner flames are noted, it may be necessary to

adjust gas pressures, or check for drafts.

Figure 20 Main Burner

10-10-78

TemperatureRiseCheck

The blower speed MUST be set to give the correct air temperature rise

through the furnace as marked on the rating plate. Temperature rise is the

difference between supply and return air temperatures.

To check temperature rise, use the following procedure:

1. Place thermometers in supply and return air registers as close to

furnace as possible, avoiding direct radiant heat from heat ex-

changers.

2. Operate furnace continuously for 15 minutes with all registers and

duct dampers open.

The blower is factory set for heating and cooling. If it is necessary to

change speeds, refer to steps below.

1. Refer to Furnace Wiring Diagram for location of the heating and

cooling speed taps located on the electronic fan control as well as

location of unused blower motor speed leads. Use the chart (Table

8 ) to determine the blower motor speed settings.

Table 8

Wire Color

Black

Orange*

Blue

Red

Blower Speed Chart

Motor Speed

High

Med-High

Medium

Low

*Meal-High speed may not be provided on all models.

Change the heat or cool blower motor speed by removing the mo-

tor lead from the "Heat" or "Cool" terminal and replace it with the

desired motor speed lead from the "Park" location. Connect the

wire previously removed from the "Heat" or "Coor' terminal to the

vacated "Park" terminal.

If the same speed must be used for both heating and cooling, re-

move the undesired motor speed lead from the "Heat" or "Cool"

terminal and connect that lead to the open terminal at "Park" loca-

tion. Attach a jumper between the"Heat" and"Cool" terminals and

the remaining motor speed lead.

Take reading and compare with range specified on rating plate.

If the correct amount of temperature rise is NOT obtained, it may

be necessary to change blower speed. A higher blower speed will

lower the temperature rise. A lower blower speed will increase the

temperature rise.

A terminal is provided on the electronic fan control located in the circulat-

ing blower compartment for operation of the continuous fan option. This

connection is intended for the low speed motor tap, and has a lower con-

tact rating (8 amps) than the heat and cool taps. When the low speed

blower lead isconnected to this terminal, this will provide low speed blow-

er operation whenever the other two speeds (Heat or Cool) are not ener-

gized.

9. FurnaceMaintenance

CAUTION

It is recommended that the furnace be inspected and

serviced on an annual basis (before the heating sea-

son) by a qualified service technician.

See "User's Information Manual"

ICP Furnaces/Heaters Manual L0602183

Navigation menu

Versions of this User Manual:

Views

Navigation