Amana AMV9 User Manual

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AMV9/ACV9

TWO-STAGEVARIABLESPEED

GAS-FIREDWARM AIR FURNACE

INSTALLATIONINSTRUCTIONS

Installer: Affix all manuals adjacent to the unit.

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

These furnaces comply with requirements

 

 

 

 

embodied in the American National Standard

 

®

 

/ National Standard of Canada ANSI

 

 

 

 

Z21.47·CSA-2.3Gas Fired Central Furnaces.

C

 

US

 

 

 

 

 

 

 

 

 

 

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

*NOTE: Please contact your distributor or our website for the applicable product data book

referred to in this manual.

®is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved.

www.amana-hac.com

IO-253H

© 2004-2006Goodman Company, L.P.

07/06

Table of Contents

 

I. Component Identification ...............................................................................................................................................

5

II. Safety ..............................................................................................................................................................................

6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ...................................................................................................

6

III. Product Application ......................................................................................................................................................

6

IV. Location Requirements & Considerations..................................................................................................................

7

GENERAL .........................................................................................................................................................

7

CLEARANCES AND ACCESSIBILITY ...........................................................................................................................

8

FURNACE SUSPENSION ........................................................................................................................................

8

EXISTING FURNACE REMOVAL ..............................................................................................................................

8

THERMOSTAT LOCATION .......................................................................................................................................

9

V. Combustion & Ventilation Air Requirements ...............................................................................................................

9

VI. Installation Positions ...................................................................................................................................................

11

VII. Horizontal Applications & Considerations ................................................................................................................

11

GENERAL ........................................................................................................................................................

11

DRAIN TRAP AND LINES .....................................................................................................................................

11

LEVELING ........................................................................................................................................................

11

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS .....................................................................................

11

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............................................................................................

12

DRAIN PAN .....................................................................................................................................................

12

FREEZE PROTECTION ........................................................................................................................................

12

FURNACE SUSPENSION ......................................................................................................................................

12

VIII. Propane Gas /High Altitude Installations ...............................................................................................................

12

IX. Vent/Flue Pipe & Combustion Air Pipe .....................................................................................................................

12

GENERAL .......................................................................................................................................................

12

DUAL CERTIFICATION:NON-DIRECT/DIRECT VENT ...................................................................................................

12

MATERIALS AND JOINING METHODS .....................................................................................................................

13

PROPER VENT/FLUE AND COMBUSTION AIR PIPING PRACTICES .................................................................................

13

TERMINATION LOCATIONS ...................................................................................................................................

13

CANADIAN VENTING REQUIREMENTS .....................................................................................................................

13

STANDARD FURNACE CONNECTIONS .....................................................................................................................

14

ALTERNATE FURNACE CONNECTIONS .....................................................................................................................

14

NON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................................

16

DIRECT VENT (DUAL PIPE) PIPING ......................................................................................................................

17

VENT/INTAKETERMINATIONSFORINSTALLATION OFMULTIPLEDIRECTVENTFURNACES..................................................

18

CONCENTRIC VENT TERMINATION .........................................................................................................................

18

X. Condensate Drain Lines & Drain Trap ........................................................................................................................

18

GENERAL .......................................................................................................................................................

18

UPRIGHT INSTALLATIONS .....................................................................................................................................

19

HORIZONTAL INSTALLATIONS ................................................................................................................................

20

XI. Electrical Connections ................................................................................................................................................

21

WIRING HARNESS ............................................................................................................................................

21

115 VOLT LINE CONNECTIONS ............................................................................................................................

21

24 VOLT THERMOSTAT WIRING ............................................................................................................................

22

SINGLE-STAGE THERMOSTAT APPLICATION .............................................................................................................

22

24 VOLT DEHUMIDISTAT WIRING ..........................................................................................................................

22

FOSSIL FUEL APPLICATIONS ...............................................................................................................................

23

115 VOLTLINECONNECTION OFACCESSORIES(HUMIDIFIER ANDELECTRONICAIRCLEANER) .......................................

23

24 VOLT HUMIDIFIER ........................................................................................................................................

23

XII. Gas Supply and Piping ..............................................................................................................................................

23

GENERAL .......................................................................................................................................................

23

GAS PIPING CONNECTIONS ................................................................................................................................

24

PROPANE GAS TANKS AND PIPING ......................................................................................................................

25

XIII. Circulating Air & Filters ............................................................................................................................................

26

DUCTWORK - AIR FLOW .....................................................................................................................................

26

BOTTOM RETURN AIR OPENING [UPFLOW MODELS] ...............................................................................................

26

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK .......................................................

27

UPRIGHT INSTALLATIONS .....................................................................................................................................

27

HORIZONTAL INSTALLATIONS ................................................................................................................................

28

2

Table of Contents

 

XIV. Startup Procedure & Adjustment .............................................................................................................................

28

HEAT ANTICIPATOR SETTING ................................................................................................................................

28

DRAIN TRAP PRIMING .......................................................................................................................................

28

FURNACE OPERATION .........................................................................................................................................

28

GAS SUPPLY PRESSURE MEASUREMENT ..............................................................................................................

28

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ..................................................................................

29

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) .........................................................................................

29

TEMPERATURE RISE .........................................................................................................................................

30

CIRCULATOR BLOWER SPEEDS ...........................................................................................................................

30

BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................................

32

XV. Normal Sequence of Operation ................................................................................................................................

32

POWER UP .....................................................................................................................................................

32

HEATING MODE ...............................................................................................................................................

32

COOLING MODE ..............................................................................................................................................

32

FAN ONLY MODE .............................................................................................................................................

33

XVI. Operational Checks ..................................................................................................................................................

33

BURNER FLAME ...............................................................................................................................................

33

XVII. Safety Circuit Description .......................................................................................................................................

33

GENERAL .......................................................................................................................................................

33

INTEGRATED CONTROL MODULE ..........................................................................................................................

33

PRIMARY LIMIT ................................................................................................................................................

33

AUXILIARY LIMIT ...............................................................................................................................................

33

ROLLOUT LIMIT ................................................................................................................................................

33

PRESSURE SWITCHES ........................................................................................................................................

33

FLAME SENSOR ...............................................................................................................................................

33

XVIII. Troubleshooting ......................................................................................................................................................

33

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .................................................................................................

33

DIAGNOSTIC CHART ..........................................................................................................................................

34

RESETTING FROM LOCKOUT ...............................................................................................................................

34

XIX. Maintenance .............................................................................................................................................................

34

ANNUAL INSPECTION ..........................................................................................................................................

34

FILTERS ..........................................................................................................................................................

34

BURNERS .......................................................................................................................................................

34

INDUCED DRAFT AND CIRCULATOR BLOWERS .........................................................................................................

34

CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ......................................................................

35

FLAME SENSOR (QUALIFIED SERVICER ONLY) ......................................................................................................

35

FLUE PASSAGES (QUALIFIED SERVICER ONLY) .....................................................................................................

35

XX. Internal Filter Removal .............................................................................................................................................

35

XXI. Before Leaving an Installation ................................................................................................................................

35

XXII. Repair & Replacement Parts ..................................................................................................................................

35

 

APPENDIX

Troubleshooting Chart

...................................................................................................................................................... 37

Wiring Diagram ................................................................................................................................................................

39

3

WARNING

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE 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.

IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE.FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.

IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

CARBON MONOXIDE POISONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such as an automobile, space

heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of

the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any

mode.

CO can cause serious illness including permanent brain damage or death.

B10259--216

TOTHEOWNER

It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date.

Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference.

If additional information or operating instructions are required, contact the dealer where the purchase was made.

Homeowner Notice:

If the residence is left unattended for an extended period of time (i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances beyond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.

TOTHEINSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.

TRANSPORTATIONDAMAGE

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1.Make a notation on delivery receipt of any visible damage to shipment or container.

2.Notify carrier promptly and request an inspection.

3.With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4.File the claim with the following support documents within a nine month statute of limitations.

Original or certified copy of the Bill of Lading, or indemnity bond.

Original paid freight bill or indemnity in lieu thereof.

Original or certified copy of the invoice, showing trade and other discounts or reductions.

Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

Keep this literature in a safe place for future reference.

4

I. COMPONENT IDENTIFICATION

BLOWER COMPARTMENT BURNER COMPARTMENT

5

4

3

2

1

31 32

30

19

20

21

29

6

7

8

7

9

10

 

 

5

27

 

28

 

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

33

 

 

 

 

 

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13

12

26

25

 

 

 

 

 

 

 

*

*

 

 

 

 

 

 

 

 

 

 

 

*

*

*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*

 

 

 

 

 

 

 

 

 

 

 

 

29

 

*

*

*

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

15

24

 

 

 

 

 

3

 

 

 

 

 

 

17 18

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

23

 

 

 

 

 

16 15

 

 

 

 

 

19

 

 

 

 

 

 

 

 

 

 

32

 

 

 

 

 

 

 

 

 

 

18

 

 

 

 

 

 

 

 

 

 

20

21

 

 

 

 

 

30

17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

 

 

 

 

 

 

 

 

31

 

 

 

 

 

 

19

 

 

 

 

 

 

1219

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

W R

 

 

 

 

 

 

 

 

 

21

20

 

 

 

Intell-Ignition

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

23

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

26

 

13

 

 

 

 

 

2

22

 

28

27

 

25

 

 

9

7

8

7

6

4

1

 

 

 

 

 

 

 

 

BURNER COMPARTMENT BLOWER COMPARTMENT

 

Upflow/Horizontal

 

Counterflow/Horizontal

1

Two-StageGas Valve

22

Drain Trap

2

Gas Line Entrance (Alternate)

23

Blower Door Interlock Switch

3

Pressure Switch(es)

24

Inductor (Not All Models)

4

Gas Manifold

25

Two-StageIntegrated Control Module

5

Combustion Air Intake Connection

 

(with fuse and diagnostic LED)

6

Hot Surface Igniter

26

24 Volt Thermostat Connections

7

Rollout Limit

27

Transformer (40 VA)

8

Burners

28

ECM Variable Speed Circulator Blower

9

Flame Sensor

29

Auxiliary Limit

10

Flue Pipe Connection

30

Junction Box

11

Flue Pipe

31

Electrical Connection Inlets

12

Combustion Air Intake (Alternate)

32

Coil Front Cover

13

Primary Limit

33

Combustion Air Inlet Pipe

14Gas Line Entrance

15Flue Pipe Connection (Alternate)

16Rubber Elbow

17Two-SpeedInduced Draft Blower

18Electrical Connection Inlets (Alternate)

19Coil Front Cover Pressure Tap

20Coil Front Cover Drain Port

21Drain Line Penetrations

5

II. SAFETY

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL.FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THESTATE OFCALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER.

WARNING

HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION.IF THE BUILIDNG IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALLWATER-BEARINGPIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.

ELECTROSTATICDISCHARGE(ESD) PRECAUTIONS

NOTE: Discharge static electrictiy accumulated in the body before touching the unit. An electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed(ungrounded) furnaces.

1.Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2.Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

3.Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.).

If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

4.Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

III.PRODUCT APPLICATION

This furnace is primarily designed for residential home-heatingapplications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. This unit is NOT designed or certified for outdoor applications. The furnacemust be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door).

This furnace can be used in the following non-industrialcommercial applications:

Schools, Office buildings, Churches, Retail stores Nursing homes, Hotels/motels, Common or office areas

In such applications , the furnace must be installed with the following stipulations:

It must be installed per the installation instructions provided and per local and national codes.

It must be installed indoors in a building constructed on site.

It must be part of a ducted system and not used in a free air delivery application.

It must not be used as a “make-up”air unit.

It must be installed with two-pipesystems for combustion air, especially if VOC’s or other contaminants are present in the conditioned space.

All other warranty exclusions and restrictions apply This furnace is an ETL dual-certifiedappliance and is appropriate for use with natural or propane gas (NOTE: If using propane, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

Non-directvent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.

This furnace may be used as a construction site heater ONLY if the following conditions are met:

The vent system is permanently installed per these installation instructions.

A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.

Return air ducts are provided and sealed to the furnace.

A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.

Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced.

The input rate and temperature rise are set per the furnace rating plate.

100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used.

6

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions underSection V, Combustion and Ventilation Air Requirements, Section 5.3.3.

The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up.

All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met:

Gas furnaces must be installed by a licensed plumber or gas fitter.

A T-handlegas cock must be used.

If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.

To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.

WARNING

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute 1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CSA B149 Installation Codes can also be obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-LoadCalculations” published by the Air Conditioning Contractors of America.

IV. LOCATION REQUIREMENTS & CONSIDERATIONS

GENERAL

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V, Combustion and Ventilation Air Requirements.

Centrally locate the furnace with respect to the proposed or existing air distribution system.

Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termination can be accomplished within the guidelines given.NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.

Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to

Section X, Condensate Drain Lines and Trap for further details.

Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Section V, Combustion and Ventilation Air Requirements.

Set the furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2"larger than the base of the furnace. Refer to theSection VII, Horizontal Applications and Considerations for leveling of horizontal furnaces.

Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.

Exposure to contaminated combustion air will result in safety and performance-relatedproblems. Do not install the furnace where the combustion air is exposed to the following substances:

chlorinated waxes or cleaners chlorine-basedswimming pool chemicals water softening chemicals

deicing salts or chemicals carbon tetrachloride

7

halogen type refrigerants

cleaning solutions (such as perchloroethylene) printing inks

paint removers varnishes hydrochloric acid cements and glues

antistatic fabric softeners for clothes dryers and masonry acid washing materials

Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects thenon-direct vent furnace from airborne contaminants. To ensure that the enclosednon-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to theSection V, Combustion and Ventilation Air Requirements for details.

construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

FURNACESUSPENSION

If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

3/8" DIAMETER THREADED ROD (6 PLACES)

HOLD DOWN

NUTS

SUPPORT

NUTS

PROVIDE 8" MINMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL

ASSURE FURNACE IS LEVEL FROM

END TO END AND HAS A SLIGHT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE

If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace.

If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.

CLEARANCES ANDACCESSIBILITY

Installations must adhere to the clearances to combustible materials which this furnace has been design certified to. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used additional clearance must be provided to accommodate these connections. Refer to Section IX, Vent Flue Pipe and Combustion Air Pipe for details.NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

T O P

 

 

 

 

 

T O P

S IDE

SID E

 

S ID E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B O T TO M

 

 

B O T TO M

 

 

 

Upflow

 

C ou nte rflow

Horizon tal

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to Product Data Book applicable to your model* for minimum clearances to combustible surfaces. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical

2"X2"X1/8" ANGLE IRON

 

 

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE

TILT OUTWARD TO ALLOW FOR

 

DOOR AND CIRCULATOR BLOWER

 

TO BLOWER DECK TO ALLOW FOR

 

REMOVAL

 

CIRCULATOR BLOWER REMVOAL

 

 

 

Suspended Furnace

 

EXISTINGFURNACEREMOVAL

NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the American

National Standard/National Standard of Canada for Gas-FiredCentral Furnaces ANSIZ21.47b-2002,CSA-2.3b-2002Section 1.23.1.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a.Seal any unused openings in the venting system;

b.Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

c.In so far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

d.Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously;

e.Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;

f.After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

g.If improper venting is observed during any of the above tests, the common venting system must be corrected.

*NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual.

8

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes.

THERMOSTATLOCATION

The thermostat should be placed approximately five feet fom the floor on a vibration-free,inside wall in an area having good air circulation. Do not install the thermostat where it may be influenced by any of the following:

Drafts, or dead spots behind doors, in corners, or under cabinets.

Hot or cold air from registers.

Radiant heat from the sun.

Light fixtures or other appliances.

Radiant heat from a fireplace.

Concealed hot or cold water pipes, or chimneys.

Unconditioned areas behind the thermostat, such as an outside wall.

DRAFTS OR DEAD SPOTS

HOT

-BEHINDDOORS

COLD

-INCORNERS

-UNDERCABINETS

 

Thermostat Influences

Consult the instructions packaged with the thermostat for mounting instructions and further precautions.

V. COMBUSTION & VENTILATION AIR REQUIREMENTS

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

House depressurization can cause back drafting or improper combustion of gas-firedappliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide.

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/

ANSI Z223.1 (Section 5.3), or CSA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section

5.3.

5.3.1General:

(a)The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b)Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

(c)In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d)In addition to air needed for combustion, air shall be supplied for ventilation, including all air required for comfort and proper working conditions for personnel.

(e)While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.

(f)Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3- b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3Equipment Located in Confined Spaces:

(a)All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU

9

per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.

Chimney or Gas Vent

NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of

the total input rating of all equipment in the enclosure, but not less than 100 square inches.

Opening

Water

Furnace Heater

Opening

Equipment Located in Confined Spaces; All Air from Inside Building. See 5.3.3-a.

(b)All Air from Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1.When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the

total input rating of all equipment in the enclosure.

 

 

 

 

Outlet Air

 

 

 

 

 

 

 

 

 

 

 

 

 

Water

 

 

 

Heater

 

Furnace

Inlet Air

 

 

 

 

 

 

Alternate air inlet

Ventilation louvers for unheated crawl space

Equipment Located in Confined Spaces; All Air from Outdoors— Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic. See 5.3.3-b

2.When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the

total input rating of all equipment in the enclosure.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Outlet Air

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Water

 

 

 

 

 

 

 

 

 

 

 

 

 

Heater

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Furnace

Inlet air duct

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[ends 1 ft (300 mm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

above floor]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Equipment Located in Confined Spaces; All Air from Outdoors Through Ventilated Attic. See 5.3.3-b.

3.When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Outlet air duct

Water

Furnace Heater

NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input

rating of all equipment in theenclosure*.

Inlet air duct

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

Equipment Located in Confined Spaces; All Air from Outdoors. See 5.3.3-b.

4.When ducts are used, they shall be of the same cross-sectionalarea as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

NOTE: The single opening must have

a free area of not less than one Chimney or Gas Vent square inch per 3000 BTU of

the total input rating of all equip-

ment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Opening

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Alternate

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Water

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Opening

 

 

 

 

 

 

 

 

 

 

 

Heater

 

 

 

 

 

 

 

 

 

 

 

 

 

Location

 

 

 

 

 

 

Furnace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Equipment Located in Confined Spaces; All Air from Outdoors - Single Air Opening. See 5.3.3-b.

10