INSTALLATION INSTRUCTIONS FOR *CVC9/95 & *MVC95 - TWO-STAGE GAS FURNACE
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements em- |
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Gas Fired Central Furnaces. |
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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 Specification
Sheet referred to in this manual.
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5151 San Felipe Suite 500 |
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Houston, TX 77056 |
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IO-341E |
www.goodmanmfg.com • www.amana-hac.com |
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12/10 |
© 2009-2010 Goodman Manufacturing Company, L.P. |
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SHIPPING INSPECTION ........................................................................................................................... |
6 |
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ..................................................................................... |
6 |
TO THE INSTALLER .............................................................................................................................. |
6 |
IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY................................................................. |
6 |
PRODUCT DESCRIPTION ............................................................................................................................. |
7 |
FEATURES .......................................................................................................................................... |
7 |
PRODUCT APPLICATION ............................................................................................................................. |
7 |
LOCATION REQUIREMENTS & CONSIDERATIONS ........................................................................................... |
8 |
CLEARANCES AND ACCESSIBILITY ............................................................................................................ |
9 |
FURNACE SUSPENSION .......................................................................................................................... |
9 |
EXISTING FURNACE REMOVAL ................................................................................................................ |
9 |
THERMOSTAT LOCATION ...................................................................................................................... |
10 |
COMBUSTION & VENTILATION AIR REQUIREMENTS ....................................................................................... |
10 |
INSTALLATION POSITIONS .......................................................................................................................... |
10 |
HORIZONTAL APPLICATIONS & CONSIDERATIONS ........................................................................................... |
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 |
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS ............................................................................................. |
12 |
VENT/FLUE PIPE & COMBUSTION AIR PIPE ................................................................................................ |
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 ....................................................................................................... |
14 |
STANDARD FURNACE CONNECTIONS ....................................................................................................... |
14 |
ALTERNATE FURNACE CONNECTIONS ....................................................................................................... |
15 |
NON-DIRECT VENT (SINGLE PIPE) PIPING ............................................................................................... |
17 |
DIRECT VENT (DUAL PIPE) PIPING ........................................................................................................ |
18 |
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES ...................................... |
20 |
CONCENTRIC VENT TERMINATION ........................................................................................................... |
20 |
SIDE WALL VENT KIT ........................................................................................................................ |
20 |
CONDENSATE DRAIN LINES & DRAIN TRAP ................................................................................................. |
21 |
STANDARD RIGHT OR LEFT SIDE DRAIN HOSE CONNECTIONS ....................................................................... |
21 |
UPRIGHT INSTALLATIONS-TRAP ON RIGHT SIDE ........................................................................................ |
22 |
UPRIGHT INSTALLATIONS-TRAP ON LEFT SIDE .......................................................................................... |
24 |
HORIZONTAL INSTALLATIONS ................................................................................................................ |
25 |
ELECTRICAL CONNECTIONS ...................................................................................................................... |
27 |
WIRING HARNESS .............................................................................................................................. |
27 |
115 VOLT LINE CONNECTIONS ............................................................................................................. |
27 |
JUNCTION BOX RELOCATION ................................................................................................................ |
27 |
24 VOLT THERMOSTAT WIRING ............................................................................................................ |
28 |
SINGLE-STAGE HEATING THERMOSTAT APPLICATION .................................................................................. |
28 |
24 VOLT DEHUMIDISTAT WIRING ........................................................................................................... |
29 |
FOSSIL FUEL APPLICATIONS ................................................................................................................ |
29 |
2
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) ............................. |
29 |
24 VOLT HUMIDIFIER ......................................................................................................................... |
30 |
GAS SUPPLY AND PIPING ......................................................................................................................... |
30 |
HIGH ALTITUDE DERATE ...................................................................................................................... |
30 |
PROPANE GAS CONVERSION ................................................................................................................ |
30 |
GAS VALVE ..................................................................................................................................... |
31 |
GAS PIPING CONNECTIONS .................................................................................................................. |
31 |
PROPANE GAS TANKS AND PIPING ......................................................................................................... |
33 |
CIRCULATING AIR & FILTERS .................................................................................................................... |
34 |
DUCT WORK - AIR FLOW ..................................................................................................................... |
34 |
CHECKING DUCT STATIC ..................................................................................................................... |
34 |
BOTTOM RETURN AIR OPENING [UPFLOW MODELS] .................................................................................. |
35 |
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK ........................................... |
35 |
UPRIGHT INSTALLATIONS ..................................................................................................................... |
36 |
HORIZONTAL INSTALLATIONS ................................................................................................................ |
36 |
STARTUP PROCEDURE & ADJUSTMENT ....................................................................................................... |
36 |
HEAT ANTICIPATOR SETTING ................................................................................................................ |
37 |
DRAIN TRAP PRIMING ........................................................................................................................ |
37 |
FURNACE OPERATION ......................................................................................................................... |
37 |
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. |
37 |
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... |
38 |
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ............................................................................ |
39 |
TEMPERATURE RISE ........................................................................................................................... |
39 |
CIRCULATOR BLOWER SPEEDS ............................................................................................................. |
40 |
BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................... |
42 |
COMFORTNET™ SYSTEM ........................................................................................................................ |
42 |
OVERVIEW ....................................................................................................................................... |
42 |
AIRFLOW CONSIDERATIONS .................................................................................................................. |
42 |
FOSSIL FUEL APPLICATIONS ................................................................................................................ |
42 |
CTK01AA WIRING .......................................................................................................................... |
43 |
COMFORTNET SYSTEM ADVANCED FEATURES .......................................................................................... |
44 |
NETWORK TROUBLESHOOTING ................................................................................................................ |
46 |
SYSTEM TROUBLESHOOTING ................................................................................................................. |
47 |
NORMAL SEQUENCE OF OPERATION ........................................................................................................... |
47 |
POWER UP ...................................................................................................................................... |
47 |
HEATING MODE ................................................................................................................................. |
47 |
COOLING MODE ................................................................................................................................ |
48 |
FAN ONLY MODE .............................................................................................................................. |
48 |
OPERATIONAL CHECKS ............................................................................................................................ |
49 |
SAFETY CIRCUIT DESCRIPTION .................................................................................................................. |
49 |
INTEGRATED CONTROL MODULE ............................................................................................................. |
49 |
PRIMARY LIMIT ................................................................................................................................ |
49 |
AUXILIARY LIMIT ............................................................................................................................... |
49 |
ROLLOUT LIMIT ................................................................................................................................ |
49 |
PRESSURE SWITCHES ......................................................................................................................... |
49 |
3
FLAME SENSOR ................................................................................................................................ |
49 |
TROUBLESHOOTING ................................................................................................................................. |
49 |
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... |
49 |
DIAGNOSTIC CHART........................................................................................................................... |
49 |
RESETTING FROM LOCKOUT ................................................................................................................ |
50 |
MAINTENANCE ........................................................................................................................................ |
50 |
ANNUAL INSPECTION ........................................................................................................................... |
50 |
FILTERS .......................................................................................................................................... |
50 |
BURNERS ......................................................................................................................................... |
50 |
INDUCED DRAFT AND CIRCULATOR BLOWERS ............................................................................................ |
50 |
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) ........................................................... |
51 |
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... |
51 |
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ......................................................................................... |
51 |
BEFORE LEAVING AN INSTALLATION ............................................................................................................ |
51 |
REPAIR AND REPLACEMENT PARTS ............................................................................................................ |
51 |
DIP SWITCHES ........................................................................................................................................ |
52 |
TROUBLESHOOTING CHART ...................................................................................................................... |
53 |
STATUS CODES ...................................................................................................................................... |
58 |
*CVC9_AA, *MVC95_AA ................................................................................................................... |
59 |
*CVC9_AB, *MVC95_AB .................................................................................................................. |
60 |
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY
DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME
RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE
WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO
INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
4
SAFETY PRECAUTIONS
Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.
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, SERVICER AGENCY OR THE GAS SUPPLIER.
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
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
WARNING
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE,
ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILDING 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,
ALL WATER BEARING PIPES 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.
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.
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
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.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
5
PRODUCT DESCRIPTION & APPLICATION
SHIPPINGINSPECTION
All units are securely packed in shipping containers tested according to International Safe TransitAssociation specifications. The cartonmustbe checkeduponarrivalfor 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.Makeanotationondeliveryreceiptofanyvisibledamage to shipment or container.
2.Notify carrier promptly and request an inspection.
3.Withconcealeddamage,carriermustbenotifiedassoon as possible - preferably within five days.
4.Filetheclaimwiththefollowingsupportdocumentswithin 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 representativeatthetimedamageisreportedtocarrier.
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.
ELECTROSTATICDISCHARGE(ESD)PRECAUTIONS
NOTE: Discharge body’s static electricity before touching 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 furnaces 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 controlstotheircontainersbeforetouchinganyungrounded object.
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.
IMPORTANTNOTETOTHEOWNERREGARDINGPRODUCTWAR-
RANTY
Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty certificate carefully to determine what is and is not covered and keep the warranty certificate in a safe place. If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service (877-254-4729) to obtain a copy.
To receive the Lifetime Heat Exchanger Limited Warranty, good for as long as you own your home, and the 10-year Parts Limited Warranty, online registration must be completed within 60 days of installation. Online registration is not required in California or Quebec.
ToregisteryourGoodmanbrandunit,gotowww.goodmanmfg.com. Click on the word “Warranty” located on the left side of the home page. Next, click on the word “Product Registration” located on the left side of the Warranty page and complete the forms in the manner indicated on the Product Registration page.
To register your Amana brand unit, go to www.amana-hac.com. Click on the word “Warranty” located on the top right of the home page. Next, click on the word “Product Registration” located on the left side of the Warranty page and complete the forms in the manner indicated on the Product Registration page.
Product limited warranty certificates for models currently in production can be viewed at www.goodmanmfg or www.amanahac.com. If your model is not currently in production or does not appear on the website, please contact your installing contractor or contact customer service at (877-254-4729) to obtain a copy of your warranty certificate.
Each product overview page contains a Product Warranty link; by clicking on it you will be able to view the limited warranty coverage for that specific product.To view warranty registration information, click on the Product Warranty text on the left navigation panel on the home page of each website. The Online Product Registration pages are located in this same section.
6
PRODUCT DESCRIPTION & APPLICATION
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.
PRODUCT DESCRIPTION
FEATURES
This furnace is a part of the ComfortNet™ family of products. The CTK01 ComfortNet thermostat kit allows this furnace to be installedaspartofadigitallycommunicatingsystem.TheComfortNet system provides automatic airflow configuration, enhanced setup features, and enhanced diagnostics. It also reduces the number of thermostat wires to a maximum of four. It may be also installed as part of a “legacy” system using a standard 24 VAC thermostat.
This product may also be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conditioning unit. However, this reduces the benefits of the ComfortNet system as the enhancements will only apply to the furnace.
PRODUCTAPPLICATION
This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must 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-industrial commercial applications:
Schools,Officebuildings,Churches,Retailstores,
Nursinghomes,Hotels/motels,Commonorofficeareas
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-pipe systems 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-certified appliance and is appropriateforusewithnaturalorpropanegas(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-direct vent (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 all of 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 and can cause long term equipment damage.
•Return air ducts are provided and sealed to the furnace.
•A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.
•Airfiltersareinstalledinthesystemandmaintainedduring construction replaced as appropriate during construction, and upon completion of construction.
•Theinputrateandtemperaturerisearesetperthefurnace rating plate.
•100% outside air is provided for combustion air requirementsduringconstruction.Temporaryductingcan be used.
NOTE: Do not connect the temporary duct directly to the furnace.Theductmustbesizedforadequatecombustion and ventilation in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1 Installation Codes.
•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.
•AT-handle gas 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 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 (NFPA54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.
7
LOCATION REQUIREMENTS & CONSIDERATIONS
Acopy of the National Fuel Gas Code (NFPA54/ANSI Z223.1)
can be obtained from any of the following:
American National Standards Institute
1430Broadway
New York, NY 10018
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
CSA International
8501 East Pleasant Valley
Cleveland,OH44131
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 accor- dancewith“ASHRAEGuide”or“ManualJ-LoadCalculations”pub- lished by theAir Conditioning Contractors ofAmerica.
A copy of the CAN/CSA B149 Installation Codes can also be obtained from:
CSA International
178RexdaleBoulevard Etobicoke, Ontario, Canada M9W 1R3
LOCATION REQUIREMENTS &CONSIDERATIONS
Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements section when selecting a furnace location.
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT.
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
•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 Vent/Flue Pipe and CombustionAir Pipe -Termination Locations for appropriate termination locations and to determineifthepipingsystemfromfurnacetotermination 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
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
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 the 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-related problems. Do not install the furnace where the combustion air is exposed to the following substances:
permanent wave solutions chlorinated waxes or cleaners
chlorine-based swimming pool chemicals water softening chemicals
deicing salts or chemicals carbon tetrachloride halogen type refrigerants
cleaning solutions (such as perchloroethylene) printing inks
paintremovers 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 the non-direct vent furnace from airborne contaminants. To ensure that the enclosednon-directvent furnacehasanadequatesupply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements for details.
8
LOCATION REQUIREMENTS & CONSIDERATIONS
•If the furnace is used in connection with a cooling coil unit, install the furnace upstream or in parallel with the cooling coil 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, ensure the access doors are not on the “up/top” or “down/bottom” side of the furnace.
•Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.
•OnCounterflowInstallations,theairconditioningcoilmust bedownstreamonthesupply(positive)sideofthefurnace heat exchanger.
•Counterflow Installation over a noncombustible floor.
Beforesettingthefurnaceovertheplenumopening,ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout.
•Counterflow Installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory subbase (see Specification Sheet applicableforyourmodelfordetails.) Aspecialaccessory subbase must be used for upright counterflow unit installationsoveranycombustiblematerialincludingwood. Refertosubbaseinstructionsforinstallationdetails.Follow the instructions with the subbase for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.)
CLEARANCESANDACCESSIBILITY
Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearanceinformationforthisfurnaceisprovidedontheunit’sclearance 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. RefertoVent/FluePipeandCombustionAirPipefordetails. 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
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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 Specification Sheet 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 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 in the following diagram. The length of rod will depend on the application and the clearances necessary.
2"X2"X3/8" ANGLE IRON
(3 PLACES)
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 theAmerican
NationalStandard/NationalStandardofCanadaforGas-FiredCentral FurnacesANSI Z21.4, CSA-2.3 latest edition Section 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:
1. Seal any unused openings in the venting system;
9
COMBUSTION & VENTILATION AIR REQUIREMENTS
2.Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-05 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3.As 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.
4.Close fireplace dampers.
5.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.
6.Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously.
7.Test for spillage from draft hood appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
8.If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas CodeANSI Z223.1/NFPA 54 and/ or National Gas and Propane Installation Code CSA B149.1-05.
9.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.
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 B149.1-05 Installation Codes.
THERMOSTATLOCATION
The thermostat should be placed approximately five feet from 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.
Consult the instructions packaged with the thermostat for mounting instructions and further precautions.
COMBUSTION & VENTILATION AIR REQUIREMENTS
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
SUFFICIENT FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO 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-fired appliances, 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 or CAN/CSA B149 Installation Codes 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.
INSTALLATION POSITIONS
This furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan. For both upright or horizontal counterflow furnaces, return ductwork must be attached to the basepan (top end of the blower compartment). NOTE: Ductwork must never be attached to the back of the furnace. Contact your distributor for proper airflow requirements and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements.
10
HORIZONTAL APPLICATIONS & CONSIDERATIONS
HORIZONTAL APPLICATIONS & CONSIDERATIONS |
When using the horizontal alternate vent configuration, you must |
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use the RF000142 vent drain kit. See following illustration. |
Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and combustion air pipe connections, etc. The basic applicationofthisfurnaceasahorizontalfurnacediffersonlyslightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:
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FURNACE MUST BE LEVEL |
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ALTERNATE VENT/FLUE |
FROM END TO END |
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FURNACE MUST BE LEVEL |
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AND COMBUSTION AIR |
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INTAKE LOCATIONS |
OR SLIGHTLY TILTED FORWARD |
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“FIELD-SUPPLIED DRAIN |
VENT-DRAIN |
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HOSE” FROM VENT- |
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DRAIN CONNECTED TO |
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CONDENSATE DRAIN
LINE WITH “FIELD-
SUPPLIED CONNECTOR”
NOTE: MAKE SMALL
LOOP IN HOSE TO
SERVE AS “P-TRAP”
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4 3/4" MINIMUM |
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DRAIN TRAP |
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GAS LINE WITH |
CLEARANCE |
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DRIP LEG (3" MINIMUM) |
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DRAIN LINE WITH 1/4" PER FOOT |
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FURNACE MUST BE SUPPORTED |
36" MINIMUM SERVICE |
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AT BOTH ENDS AND MIDDLE |
CLEARANCE REQUIRED |
HorizontalFurnace
DRAINTRAPANDLINES
In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4 inches below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing.
LEVELING
Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil frontcover.
ALTERNATEVENT/FLUEANDCOMBUSTIONAIRCONNECTIONS
In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge and counterflow furnaces with right air discharge. This configuration allows the flue and combustion air piping to be run vertically through the side of the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connections may also be used in these positions. Refer to Vent/ Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue and combustion air connections.
AlternateVent/FlueLocation
RecommendedInstallationPositions
NOTE: Alternate “vertical” piping connections can not be used when an upflow furnace is installed with supply air discharging to the right, or when a counterflow furnace is installed with supply air discharging to the left. In either case, use the standard flue and combustion air piping connections.
11
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS
ALTERNATEELECTRICALANDGASLINECONNECTIONS
This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.
DRAINPAN
A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).
FREEZEPROTECTION
Refer to Horizontal Applications and Conditions - Drain Trap and Lines.
FURNACESUSPENSION
If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. Refer to Location Requirements and Considerations - Furnace Suspension for further details.
PROPANE GAS/HIGHALTITUDE INSTALLATIONS
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice and orifice change to compensate for the energy content difference between natural and propane gas.
High altitude installations may require both a pressure switch and an orifice/spring change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.
For installations above 7000 feet, please refer to your distributor for required kit(s).
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1LPM -05* supports White-Rodgers 2-stage valve only
2LPM -06* supports both Honeywell and White-Rodgers 2-stage valves
N OT E: In Canada, gas furnaces are only certified to 4500 feet.
Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.
VENT/FLUE PIPE & COMBUSTION AIR PIPE
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH. CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION.
WARNING
UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE FURNACE TO ASSURE IT IS PROPERLY SEALED. LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.
A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.
This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connectors” other than those shipped with this product.
It is the responsibility of the installer to follow the manufacturers’ recommendationsandto verifythatall vent/flue pipingandconnectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.
DUALCERTIFICATION:NON-DIRECT/DIRECTVENT
This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. Anon-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.
12
VENT/FLUE PIPE & COMBUSTION AIR PIPE
WARNING
TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.
Twoor three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solventcementmeetingASTMD2564specificationsmustbeused. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the pipe manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.
The use of Schedule 40 PVC Cellular Core (Foam Core) plastic pipe is also acceptable as a flue/vent and intake pipe material. PVC primer meetingASTM F656 and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meetingASTM D2665 andASTM D3311. Carefully follow the manufactures instructions for cutting, cleaning and solvent cementing of PVC.
MATERIALSANDJOININGMETHODS
As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cementforthePVCtoABStransitionjointmustmeetASTMD3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSAlisted. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/orABS.
All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/ 16” minimum from the plane of one opening to the centerline of the other opening for 2” diameter pipe, and 4 9/16” minimum for 3” pipe.
PROPERVENT/FLUEANDCOMBUSTIONAIRPIPINGPRACTICES
Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions.
Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.
Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing temperatures below 35°F for extended periods of time must be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.
TERMINATIONLOCATIONS
NOTE: Refer to Location Requirements and Considerations for combustion air contaminant restrictions.
The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on termination construction.
•All terminations (flue and/or intake) must be located at least12inchesabovegroundlevelortheanticipatedsnow level.
•Vent terminations (non-direct and direct vent) must terminate at least 3 feet above any forced air inlet located within 10 feet.
NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.
•The vent termination of anon-direct ventapplicationmust terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.
•The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).
•The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).
•Aventterminationshallnotterminateoverpublicwalkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.
•The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.
13
VENT/FLUE PIPE & COMBUSTION AIR PIPE
Non-Direct Vent
&
Direct Vent
Vent/Flue Terminations
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Direct Vent
Vent/Flue Termination
Vent Termination Clearances
NOTE: InCanada,theCanadianFuelGasCodetakesprecedence over the preceding termination restrictions.
CANADIANVENTINGREQUIREMENTS
In Canada, venting must conform to the requirements of the current CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, ULC-S636complianttwo-orthree-inchdiameterPVCorABSpipe, solvent cement, and fittings throughout. The certified piping should be clearly marked with the ULC Std “S636” on the pipe and fittings. Carefully follow the pipe manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/orABS.
The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.
STANDARDFURNACECONNECTIONS
It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported.
As shipped, attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or basepan (counterflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.
VENT/FLUEPIPE
Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (see “Standard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during ser-
vicing. CombustionAir and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc. If necessary, clearances may be increased by utilizing two 45 deg. Long-Sweep Elbows and creating an “S” joint to provide additional space at connection locations. This joint can be rotated on the fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is the equivalent of one 90 deg. elbow when considering elbow count.
V
E
N
T
45 DEGREE LONG-SWEEP ELBOWS
Increased Clearance Configuration
NOTE: Do not use other commercially available “no hub connectors” due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see Materials and Joining Methods).
NOTE: For non-direct vent installations, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage.
COMBUSTION AIR PIPE
DIRECTVENTINSTALLATIONS
On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber couplingandwormgearhoseclampsprovidedwiththeunit.Thecounterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. NOTE: Because of probable material conflicts, do not use other commercially available “no hub connectors”. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.
NON-DIRECTVENTINSTALLATIONS
A minimum of one 90° elbow should be installed on the combustion air intake “coupling” to guard against inadvertent blockage.
14
VENT/FLUE PIPE & COMBUSTION AIR PIPE
COMBUSTION |
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COMBUSTION |
VENT/FLUE |
VENT/FLUE |
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AIR PIPE |
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AIR PIPE |
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PIPE |
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90 PVC |
RUBBER |
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RUBBER |
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ELBOW |
COUPLING |
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ELBOW |
COUPLINGS |
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WITH WORM |
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(NON-DIRECT VENT) |
WITH WORM |
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GEAR CLAMPS |
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GEAR CLAMPS |
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OR |
OR |
UPFLOW |
COUNTERFLOW |
Standard Connections
ALTERNATEFURNACECONNECTIONS
If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil, or to upright counterflow installations requiring additional access to a filter or electronic air cleaner, or to horizontal installations desiring vent/flue (and combustion air intake) piping run vertically from the side of the cabinet.
NOTE: Standard and alternate locations can be combined (i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.
WARNING
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS.
ALTERNATEVENT/FLUELOCATION
The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps and the “Alternate Vent/Flue Location” figure.
NOTE: Counterflow instructions follow the upflow instructions.
1.Remove and save the four screws securing the vent/flue coupling to the furnace top panel.
Counterflow units.
Remove and save the four screws securing the vent/flue coupling to the furnace basepan. Also remove the three screws securing the furnace’s internal vent/flue piping to the blower deck.
2.Upflow andCounterflow units.
Loosen the worm gear hose clamps on the rubber elbow and detach it from both the induced draft blower and the vent/flue pipe.
3.Upflow andCounterflow units.
Remove the vent/flue pipe from the furnace.
4.Cut the vent/flue pipe 3.75 inches from the flanged end of the pipe (see “Vent/Flue Pipe Cuts” figure). The section of pipe attached to the coupling will reach through the side panel to the induced draft blower. Discard remaining pipe and elbows.
Counterflowunits.
Cut the vent/flue pipe 3.75 inches from the blower deck coupling (see “Vent/Flue Pipe Cuts” figure). Save vent/flue pipeattachedtoblowerdeckcouplingforuseinthealternate location. Discard remaining pipe and elbows.
FLANGE 
3.75"
CUT HERE 
Vent/FluePipeCuts
5.Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (top cover).
Counterflow units.
Remove plastic plug from alternate vent/flue location. Relocate and install plug in standard vent/flue location (basepan). Plug remaining hole in blower deck with plastic plug included in the drain kit bag.
6.Upflow andCounterflow units.
Insertcutsectionofvent/fluepipeandcouplingintoalternate vent/flue location. Using a rubber coupling and worm gear hose clamps from the drain kit bag, attach the vent/flue pipe and coupling to the induced draft blower. Secure the coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self drilling screws.
WARNING
THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD. WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,
EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES,
INCLUDING CARBON MONOXIDE
7.Upflow andCounterflow units.
For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe.
15
VENT/FLUE PIPE & COMBUSTION AIR PIPE
8.Upflow andCounterflow units.
For horizontal installations, externally secure the fieldsuppliedvent/fluepipedirectlytothevent/fluecouplingusing a PVC orABS coupling or elbow.
ALTERNATECOMBUSTIONAIRINTAKELOCATION
The alternate combustion air intake location consists of a large, unobstructed hole (alternate vent connection is aligned with the Induced Draft Blower). To use the alternate combustion air intake location, refer to the following steps, and the “Alternate CombustionAir Intake Location” figure.
1.Removeandsavethefourscrewssecuringthecombustion air intake coupling to the basepan. Remove an additional three screws securing the furnace’s internal combustion air intake pipe to the blower deck.
2.Remove the combustion air intake pipe from the furnace andcutthepipeatthebasepancoupling. Savethebasepan coupling and gasket from the blower deck coupling for use in the alternate location. Discard the remaining pipe.
3.Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake location (basepan). Plug the remaining hole in the blower deck with the plastic plug included in the drain kit bag.
4.With the gasket facing the cabinet side panel, and the flange’s flat spot facing forward, secure the combustion air intake coupling to the cabinet using the screws removed in step 1 or with field-supplied 3/8” #8 self -drilling screws.
CAUTION
BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS.
5.For non-direct vent installations installed horizontally, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. Noelbowisrequiredonthealternatecombustion air intake of upright installations, however, a minimum clearanceof2inchesisrequiredtoassureproperairsupply.
6.For direct vent installations, secure field-supplied combustion air intake pipe directly to the air intake coupling. NOTE: APVC coupling or elbow is required on counterflow units.
3 REMOVE PIPE
5 REMOVE
AND RELOCATE
2 DETACH RUBBER
ELBOW FROM ID BLOWER AND VENT/FLUE PIPE
5 |
ADDITIONAL PLUG |
FROM DRAIN KIT |
7 |
EXTERNALLY |
MOUNT |
RUBBER ELBOW |
6 |
SECURE TO |
ID BLOWER WITH |
RUBBER COUPLING |
AND HOSE |
CLAMPS |
3 REMOVE PIPE
1 REMOVE 3 SCREWS
5 REMOVE
AND RELOCATE
2 DETATCH RUBBER
ELBOW FROM ID BLOWER AND VENT/FLUE PIPE
6 SECURE TO
ID BLOWER WITH |
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16 |
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VENT/FLUE PIPE & COMBUSTION AIR PIPE
NON-DIRECTVENT(SINGLEPIPE)PIPING
Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Vent/Flue Pipe and Combustion Air - Standard Furnace Connections or Alternate Furnace Connections for specific details. Refer to the following Non-Direct Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for specific details on termination construction.
Although non-direct vent installations do not require a combustion air intake pipe, a minimum of one 90° elbow should be attached to the furnace’s combustion air intake if: an upright installation uses the standard intake location, or a horizontal installation uses the alternate air intake location. This elbow will guard against inadvertent blockage of the air intake.
VENT/FLUE PIPE LENGTHS AND DIAMETERS
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a nondirect vent installation. In addition to the vent/flue pipe, a single 90° elbow should be secured to the combustion air intake to prevent inadvertent blockage. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.
UPFLOW
Non-Direct Vent (Single Pipe)
Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2)
Unit |
Pipe |
(4) |
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Number of Elbows (3)(5) |
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Input |
(Inch) |
1 |
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2 |
3 |
4 |
5 |
6 |
7 |
8 |
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45,000 |
2 or 2 |
1/2 |
71 |
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68 |
65 |
62 |
59 |
56 |
53 |
50 |
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70,000 |
2 or 2 |
1/2 |
49 |
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43 |
40 |
37 |
34 |
31 |
28 |
3 |
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71 |
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68 |
65 |
62 |
59 |
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90,000 |
3 |
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65 |
62 |
59 |
56 |
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115,000 |
3 |
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43 |
40 |
37 |
34 |
31 |
28 |
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COUNTERFLOW |
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Maximum Allowable Length of Vent/Flue Pipe (ft) (1)(2) |
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Number of Elbows (3)(5) |
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Input |
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1 |
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3 |
4 |
5 |
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7 |
8 |
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70,000 |
2 or 2 |
1/2 |
61 |
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58 |
55 |
52 |
49 |
46 |
43 |
40 |
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3 |
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71 |
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68 |
65 |
62 |
59 |
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90,000 |
2 or 2 |
1/2 |
61 |
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55 |
52 |
49 |
46 |
43 |
40 |
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115,000 |
3 |
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68 |
65 |
62 |
59 |
56 |
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1)One 90° elbow should be secured to the combustion air intake connection.
2)Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee.
3)Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.
4)2-1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
5)Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.
VENT/FLUEPIPE TERMINATIONS
The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.
Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations for details concerning location restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe. A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.
17
VENT/FLUE PIPE & COMBUSTION AIR PIPE
In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.
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TEE (OPTIONAL) |
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12 " Min |
To Roof |
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12 " Min To Roof |
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Or Highest Anticipated |
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Level |
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Vertical Termination (Single Pipe)
90º MEDIUM RADIUS
ELBOWS
12" MIN. TO ROOF
OR HIGHEST ANTICIPATED
SNOW LEVEL
DIRECTVENT(DUALPIPE)PIPING
The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe. Installation of screens, while strongly recommended, is not required and will not affect performance of the unit.
Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Vent/Flue and Combustion Air Pipe - Termination Locations or Concentric Vent Termination for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Vent/Flue Pipe and Combustion Pipe - StandardFurnaceConnectionsorAlternateFurnaceConnections.
VENT/FLUE &COMBUSTION AIR PIPE LENGTHS &DIAMETERS
Alternate Vertical Termination (Single Pipe)
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MIN. |
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12" |
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12" TO GROUND OR |
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FROM |
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WALL |
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HorizontalTermination(SinglePipe)
12" MIN.
VENT/FLUE TEE or
90° ELBOW TURNED
DOWN
12" MIN. ABOVE HIGHEST ANTICIPATED
SNOW LEVEL
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a direct vent (dual pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & CombustionAir Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.
If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™whererequired.
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS
The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall.
HorizontalTermination(SinglePipe)
AboveHighestAnticipatedSnowLevel
18
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