Continental Refrigerator C97 Series Installation And Operating Manual

INSTALLER: PLEASE FAMILIARIZE YOURSELF WITH VENTING/DRAINING SECTIONS OF

THIS MANUAL BEFORE PROCEEDING WITH THE INSTALLATION. LEAVE THIS MANUAL WITH THE APPLIANCE FOR FUTURE REFERENCE.

CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

INSTALLATION AND

OPERATING MANUAL

CERTIFIED TO ANSI Z21.47b / CSA 2.3b-2008

C97 SERIES

TWO STAGE HIGH EFFICIENCY (CONDENSING) FORCED AIR GAS FURNACE

SAFETY INFORMATION

WARNING

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious inquiry, death or property damage.

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UM PG 59

Improper servicing could result in dangerous operation, serious injury, death or property damage.

- Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

- Before servicing, disconnect all electrical power to furnace.

- When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

- Verify proper operation after servicing.

Do not store or use gasoline or other ﬂ ammable

vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a neighbour’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

Patent Pending

MANUFACTURER RESERVES THE RIGHT TO DISCONTINUE, OR CHANGE AT ANY TIME, SPECIFICATIONS OR DESIGNS

WITHOUT NOTICE AND WITHOUT INCURRING OBLIGATIONS.

Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 0G8 Canada /

103 Miller Drive, Crittenden, Kentucky, USA, 41030

Phone (705)721-1212 • Fax (705)722-6031 • www.continentalheatingandcooling.com • ask@continentalheatingandcooling.com

$10.00

W415-1080 / A / 08.28.13

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TABLE OF CONTENTS

1.0 INTRODUCTION 3

2.0 SAFETY SYMBOLS AND WARNINGS 4

2.1 SAFETY RULES 5

2.2 CODES 6

3.0 FURNACE SIZING 9

4.0 LOCATION OF UNIT 10

4.1 GENERAL GUIDELINES 10

4.2 OTHER CONSIDERATIONS 10

4.3 INSTALLATION IN UPFLOW POSITION 11

4.4 AIR CONDITIONING 11

5.0 COMBUSTIBLE CLEARANCES 12

6.0 DUCTWORK 13

6.1 DUCTWORK STEPS 14

7.0 VENTING AND COMBUSTION PIPING 15

7.1 ACCEPTABLE MATERIALS IN CANADA 15

7.2 ACCEPTABLE MATERIALS IN UNITED STATES 15

8.0 NON-DIRECT VENT FURNACE INSTALLATIONS USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 16

8.1 DETERMINING COMBUSTION AIR 17

8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE 17

8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE 17

8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE 18

8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY 19

8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT 19

9.0 VENTING GUIDELINES 20

9.1 VENT TERMINATION 21

9.2 IN CANADA 22

9.3 IN UNITED STATES 22

9.4 FURNACE VENTING INSTALLATIONS 23

9.4.1 NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 23

9.4.2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO PIPE SYSTEM) 23

9.4.3 COMBUSTION AIR 23

10.0 TERMINATIONS 24

10.1 COMBUSTION AIR 24

10.2 EXHAUST 24

10.3 CONCENTRIC VENTING KIT 24

10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS 24

10.5 LOCATION 25

10.6 MULTIPLE VENTING 25

11.0 ROUTING OPTIONS 29

11.1 EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH MOUNTING 29

11.2 CONDENSATE DRAINS 30

11.3 PREPARATIONS FOR VENT AND DRAINING OPTION 30

11.4 DRAIN HOSE INSTALLATION 33

11.4.1 DRAIN PIPING 33

11.4.2 PRIMING CONDENSATE TRAP 34

11.5 ALTERNATE CONDENSATE DRAIN PIPING INSTALLATION USING PVC OR CPVC 34

11.6 CONDENSATE NEUTRALIZERS 35

12.0 GAS SUPPLY AND PIPING 36

12.1 GAS SUPPLY 36

12.2 GAS PIPING 36

12.3 GAS INLET PRESSURE 37

12.4 LEAK TESTING 37

12.5 PURGING GAS LINES 37

13.0 CONVERSIONS 38

13.1 HIGH ALTITUDE CONVERSION 38

13.2 NATURAL TO LP GAS CONVERSION 38

13.3 CONVERSION STEPS 38

13.4 CHECKING THE INLET GAS PRESSURE 38

13.5 SETTING THE MANIFOLD GAS PRESSURE 39

13.6 CHECKING FURNACE INPUT 40

14.0 ELECTRICAL SPECIFICATIONS 41

14.1 ELECTRICAL WIRING AND CONNECTIONS 41

14.2 FURNACE CONNECTION 42

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15.0 LOW VOLTAGE WIRING 43

15.1 SINGLE STAGE THERMOSTAT 43

15.2 TWO STAGE THERMOSTAT 43

15.3 THERMOSTAT LOCATION 43

16.0 OPTIONAL ACCESSORIES (FIELD SUPPLIED/INSTALLED) 44

16.1 ELECTRIC AIR CLEANER 44

16.2 POWER HUMIDIFIER 44

16.3 EMERGENCY HEAT MODE 44

17.0 INITIAL STARTUP PROCEDURES 45

17.1 TO START THE FURNACE 45

17.2 TO SHUT DOWN THE FURNACE 45

17.3 SEQUENCE OF OPERATION 46

17.4 PROGRAMMABLE THERMOSTAT (OPTION) 46

18.0 AIR FLOW 47

18.1 TEMPERATURE RISE CHECK 47

18.2 CALCULATING AIR FLOW 48

18.3 ADJUSTING BLOWER SPEEDS ON ECM 2.3 BLOWER MOTORS 48

18.4 DEHUMIDIFICATION - ECM 2.3 49

18.5 SETTING BLOWER “ON” AND “OFF” TIMINGS - ECM 2.3 MODELS ONLY 49

18.6 CONTINUOUS FAN OPERATION 49

19.0 MAINTENANCE AND TROUBLESHOOTING 50

19.1 AIR FILTER 50

19.2 LUBRICATION 50

19.3 TROUBLESHOOTING FLOWCHART 51

19.4 DIAGNOSTIC CODES FOR STATUS LED 52

19.5 FAULT CODE HISTORY 52

19.6 INTERNAL LIGHTING SYSTEM 52

19.7 UV LAMP REPLACEMENT (IF OPTIONAL UV PURIFICATION KIT INSTALLED) 53

20.0 WIRE DIAGRAM FOR TWO STAGE FURNACE WITH ECM 2.3 54

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21.0 WARRANTY 56

22.0 REPLACEMENT PARTS LIST 57

23.0 SERVICE HISTORY 58

NOTE: Changes, other than editorial, are denoted by a vertical line in the margin.

IMPORTANT: PLEASE READ THIS MANUAL CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICE TECHNICIAN.

ATTENTION: TO REMOVE OUTER STAINLESS STEEL DOOR, FIRMLY GRAB DOOR SIDES AND PULL OFF. TO REPLACE OUTER STAINLESS STEEL DOOR, ALIGN AND PUSH DOOR ON INTO PLACE.

1.0 INTRODUCTION

This high efﬁ cient gas ﬁ red two stage condensing furnace is an upﬂ ow warm air furnace suitable for residential and light commercial heating applications with inputs from 60,000 to 120,000 Btu/hr. This high efﬁ cient furnace series is CSA certiﬁ ed as a Category IV indirect or direct vent central forced air fur- nace. When installed as a direct vent furnace, all combustion air is supplied to the furnace burners through the air

intake system. (See Section 7, “Ventilation and Combustion Piping.”)

The furnace is shipped completely assembled except for the condensate drain trap assembly. Please inspect for damage when the furnace is unpacked.

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2.0 SAFETY SYMBOLS AND WARNINGS

Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following deﬁ ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

! !

DANGER

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL

RESULT IN DEATH OR SERIOUS INJURY.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD

RESULT IN DEATH OR SERIOUS INJURY.

CAUTION

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY

RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST

UNSAFE PRACTICES.

IMPORTANT:

READ THE FOLLOWING INSTRUCTIONS COMPLETELY BEFORE INSTALLING!

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.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

• 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, OR A CELLULAR PHONE FROM A LOCATION WELL AWAY FROM THE BUILDING. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.

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

• DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS SUPPLIER OR THE FIRE DEPARTMENT.

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE

CAN CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,

W415-1080 / A / 08.28.13

WHAT TO DO IF YOU SMELL GAS

SERVICE AGENCY OR THE GAS SUPPLIER.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE

PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF

THIS FURNACE. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING

INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE,

POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE

POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

2.1 SAFETY RULES

1. Use this furnace only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in dry indoor locations (protected from weather).

3. Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed in Section 7 of this

manual, “Ventilation and Combustion Piping.”

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only,

as speciﬁ ed in Section 7 of this manual, “Venting and Combustion Piping.”

5. Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution made speciﬁ cally

for the detection of leaks to check all connections as speciﬁ ed in Section 12 of this manual, “Gas Supply

and Piping.”

6. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system, which has an external static pressure within the allowable range, listed on the furnace rating plate, and as

speciﬁ ed in Sections 3, 6, and 18 of this manual, “Furnace Sizing,” “Ductwork,” and “Airﬂ ow.”

7. When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. (Furnace for heating the home located in the attached

garage, for example).

8. A gas-ﬁ red furnace for installation in a residential garage must be installed so that the burners and ignitor are no less than 18” (457 mm) above the ﬂ oor. The furnace must be located, or protected to avoid physical dam-

age by vehicles. (See safety warning).

9. This furnace may be used for heating of buildings or structures under construction provided that:

• The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed per these installation instructions.

• A room thermostat must control the furnace. The use of ﬁ xed jumpers that will provide continuous heating is not allowed.

• The return air duct must be provided and sealed to the furnace casing, and terminate outside the space containing the furnace.

• Return air temperature range between 55°F (13°C) and 80°F (27°C) must be maintained.

• Air ﬁ lters must be installed in the system and must be maintained during construction.

• Air ﬁ lters used to clean the circulating air during the construction process must be either replaced or thoroughly cleaned prior to occupancy.

• The input rate and temperature rise must be set per the furnace rating plate.

• One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction. This is to minimize the corrosive effects of adhesives, sealers and entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

• The furnace heat exchanger, components, duct system, and evaporator coils must be thoroughly cleaned following ﬁ nal construction clean-up.

• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be veriﬁ ed according to these installation instructions.

WARNING

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2.2 CODES

1. This furnace must be installed: a. In accordance with all local codes, by-laws and regulations by those authorities having jurisdiction. b. In Canada, this furnace must be installed in accordance with the current CAN/CGA -B149.1 and .2

Natural Gas and Propane, and the National Electric Code (NEC) NFPA 70.

c. In the United States, this furnace must be installed in accordance with the current ANSI Z223.1 (NFPA

54) National Fuel Gas Code.

2. Electrical connections must be made in accordance with: a. Any applicable local codes, by-laws and regulations. b. Canada: current edition of CAN/CSA C22.1 and C22.2, Canadian Electrical Code (Part 1 and 2). c. United States: current edition of ANSI/NFPA 70, National Electrical Code.

Codes and additional information may be obtained from:

Canadian Standards Association American Gas Association 5060 Spectrum Way 400 North Capitol Street, NW, Suite 450 Mississauga, Ontario, L4W 5N6 Washington DC, 20001 Phone: (416) 747-4000 Phone: (202) 824-7000 website: www.csa.ca website: www.aga.org

National Fire Protection Association 1 Batterymarch Park Quincy, MA, 02169-7471 Phone: (617) 770-3000 website: www.nfpa.org

WARNING

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME! THIS FURNACE IS NOT

APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE,

PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

THE FURNACE CONTAINS FOIL COVERED FIBERGLASS INSULATION. INHALATION OF

FIBERGLASS PARTICLES IS ASSOCIATED WITH RESPIRATORY DISEASE INCLUDING

CANCER.

NATURAL GAS AND PROPANE ARE NORMALLY ODORIZED BY THE FUEL SUPPLIER. IN

SOME CASES, THE ODORANT MAY NOT BE PERCEIVABLE. INSTALLATION OF UL AND

ULC RECOGNIZED FUEL GAS DETECTORS INSTALLED IN ACCORDANCE WITH THEIR

MANUFACTURER’S INSTRUCTIONS IS RECOMMENDED AS AN ADDITIONAL MARGIN OF

SAFETY.

THE EXHAUST GASES FROM THIS FURNACE CONTAIN CHEMICALS WHICH ON SOME OCCASIONS MAY INCLUDE CARBON MONOXIDE. CARBON MONOXIDE IS AN ODORLESS, TASTELESS, CLEAR COLORLESS GAS WHICH IS HIGHLY TOXIC. EVEN

LOW CONCENTRATIONS ARE SUSPECTED OF CAUSING BIRTH DEFECTS AND OTHER

REPRODUCTIVE HARM.

UL AND ULC RECOGNIZED CO DETECTORS ARE RECOMMENDED FOR ALL BUILDINGS

EQUIPPED WITH FOSSIL FUEL BURNING APPLIANCES. ALL CO DETECTORS SHOULD

BE INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS AND

APPLICABLE LOCAL BUILDING CODES.

FAILURE TO REPLACE WITH PROPER CONTROL COULD RESULT IN FIRE, EXPLOSION

REPLACE GAS VALVE ONLY WITH THE SAME MODEL NUMBER OR AS SPECIFIED BY THE

W415-1080 / A / 08.28.13

FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD!

OR CARBON MONOXIDE POISONING.

MANUFACTURER.

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE

INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN

18” (457 mm) ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE

VAPORS WHICH MAY BE PRESENT IN THE GARAGE.

THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY

VEHICLES.

FAILURE TO HEED THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING

IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

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FIGURE 1 - FURNACE DIMENSIONS AND CLEARANCE TO COMBUSTIBLES

0.625” (15.875 MM)

31.000” (787.4 MM)

19.625” (498.475 MM)

ALTERNATE VENT OUTLET

ALTERNATE AIR IN

SIDE CUTOUT

HIGH VOLTAGE IN

23.0” (584.200 MM)

LOW VOLTAGE IN

AIR INLET

0.625” (15.875 MM)

7.82” (198.628 MM)

STD. GAS SUPPLY

CONDENSATE DRAIN TRAP WITH 1/2” CPVC DISCHARGE LEFT & RIGHT SIDE

UPFLOW DRAIN HOLE

A B C

2” PVC VENT OUTLET

32.875”

(835.025 MM)

TABLE 1 - RANGE OF TEMPERATURE RISE

Furnace Models Temperature Rise

High Fire (HF) 35 - 65°F (20 - 36°C)

ALL

Low Fire (LF) 20 - 50°F (11 - 28°C)

H12.15.4

6.572”

(166.929 MM)

ALT. GAS LINE IN

ALT. AIR INLET

ALT. VENT OUTLET

ALT. UPFLOW DRAIN HOLE

ALT. HIGH

VOLTAGE IN ALT. LOW VOLTAGE IN

WITNESS MARKS FOR SIDE CUTOUTS

SIDE CUTOUT

TABLE B - MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

UPFLOW

TOP 0

PLENUM TOP 1/2ʺ (13mm)

FRONT 0*

BACK 0

SIDES 0

BOTTOM 0***

FLUE PIPE 0

ENCLOSURE CLOSET

*24ʺ (610mm) REQUIRED FOR SERVICE

*** CERTIFIED FOR CLOSET INSTALLATION ON COMBUSTIBLE FLOORING.

H12.11.4b

NOTES: S - Service clearance 24 inches (610mm) or more. C - Combustible oor (but not carpet or non-ceramic tile). All models approved for closet installation.

Top

W415-1080 / B / 08.28.13

Plenum 1/2" (13mm) on all sides

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FIGURE 2 - FURNACE COMPONENTS

*16

LEGEND

1. Combustion Air Intake Fitting 13. Two Speed Exhauster

2. Flame Roll-Out Switch (2) 14. Pressure Switch Assembly

3. Flame Sensor - located underneath 15. Front Manifold Cover Pressure Tap (3)

4. Two Stage Gas Valve *16. PFC “Choke Coil” (used on ¾ and 1 Hp units only)

5. Air High Temperature Limit - supply air 17. Door Switch and Junction Box

6. Vent and Drain (Assembly) Coupling 18. Blower Motor (not shown, located on right side of

7. Drain for Recovery Coil (3) blower)

8. Condensate Trap 19. Circulating Air Blower

9. Two Stage Integrated Furnace Control (IFC) 20. UV Light Ballast (Optional)

10. Transformer for 24 VAC / 40 VA 21. UV Light Bulb (Optional)

11. Burner Assembly 22. LED Trouble Light (2)

12. Hot Surface Igniter (HSI)(located underneath)

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3.0 FURNACE SIZING

The maximum hourly heat loss for each heated space shall be calculated in accordance with the procedures

described in the manuals of the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI), or by

any other method which is suitable for local conditions, provided the results obtained are in substantial agreement with, and not less than those obtained using the procedure described in their manuals.

In the United States, “Manual J - Load Calculation,” published by the Air Conditioning Contractors of America,

describes a suitable procedure for calculating the maximum hourly heat loss.

If the installation is a retroﬁ t application, do not rely on the capacity of the existing heating equipment as a method to size the new furnace. Many of the heat transfer multiples listed in earlier versions of load calculation manuals were much higher than those listed in more recent editions. It is possible that energy saving measures have been completed since the installation of the existing furnace. This might include additional insulation in the attic or walls, the application of sprayed foam insulation, the addition of storm windows and doors, weather-stripping, caulking, etc.

Many of the older furnaces were equipped with large belt drive blower systems, operating at low RPM’s. If replacing an existing furnace, be sure that the existing ductwork can handle the amount of airﬂ ow necessary for a reasonable temperature rise. Most older gas furnaces operated with a system temperature rise of 70 - 100°F (39 - 56°C). This furnace is designed to be operated with a system temperature rise (∆T) of High Fire 35 - 65°F (20 - 36°C), Low Fire 20 - 50°F (11 - 28°C). If the furnace selected has an identical output capacity as the original furnace, a substantial increase in system air ﬂ ow will be necessary. See Table 1 and the airﬂ ow characteristics in

Section 18 of this manual, “Airﬂ ow”.

Existing ductwork should be assessed for its air handling

TABLE 1 - RANGE OF TEMPERATURE RISE

Furnace Models Temperature Rise

High Fire (HF) 35 - 65°F (20 - 36°C)

ALL

Low Fire (LF) 20 - 50°F (11 - 28°C)

H12.15.4

capabilities.

The “Equal Friction Chart,” as published by ASHRAE and HRAI, is the basis for the various air duct calculators available through heating supply companies. Following the air velocity guide lines, according to the “Equal Friction Chart,” or a slide rule air duct calculator, a typical 6” (152 mm) round duct has a capacity of approxi-

mately 100 cfm.

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NOTE: The return air system is equally as important as the supply air system. An under-sized return air system will prevent sufﬁ cient quantities of air from reaching the supply air system and will consequently reduce the service life of the furnace and its components.

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4.0 LOCATION OF UNIT

4.1 GENERAL GUIDELINES

1. Select a location where the exhaust and combustion air piping can be routed between the furnace and their terminations with a minimum of lengths and ﬁ ttings. Be sure to check that the proposed termination

location will meet code requirements with respect to location and minimum clearances. (See venting sec-

tion for minimum and maximum limits.)

2. Select a location as near as possible to the existing or proposed duct system.

3. The furnace location must have provisions for condensate drainage. If a suitable drain is unavailable near the furnace, a condensate pump must be used. The condensate pump drain tubing must not terminate outdoors; similar to some air conditioning condensate installations. Be sure to select a condensate pump that has been approved for furnace condensate applications.

4. The furnace location must permit access for servicing and be within the clearance to combustibles guidelines as marked on the appliance rating plate.

5. The furnace must be installed on a level surface. It is recommended that the rear of the furnace be elevated 1/4” (6 mm) higher than the front to facilitate proper condensate drainage.

6. If the furnace is being installed so that the return air will enter through the bottom, the perimeter of the furnace must be properly supported.

7. In right venting conﬁ guration, furnace must drain on the left side.

4.2 OTHER CONSIDERATIONS

1. If the furnace is to be located in an area where the combustion air is laden with chemical compounds such as bromine, chlorine or ﬂ uorine, as may be found in swimming pool chemicals, laundry detergents, etc., use outdoor air for combustion. These compounds when exposed to ﬂ ame, form acids which attack the heat exchanger and other components.

Exposure to the following substances in the combustion air supply (but not limited to the following) will also require OUTDOOR AIR for combustion:

• Aerosols, particularly CFC based or propelled aerosols

• Air fresheners

• “Airplane Glue” and similar adhesives and cements

• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons

• Anti-static fabric softeners used in clothes dryers

• Carbon tetrachloride

• Chlorinated cleaners and waxes

• Chlorine and bromine based swimming pool chemicals

• De-icing salts or chemicals (rock salt, etc.)

• Dry cleaning ﬂ uids such as perchloroethylene

• Fumes from curing polyurethane and similar substances

• Halogen based refrigerants including R-12 and R-22

• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials

• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.

• Water softener salt and chemicals

2. If this furnace is to be installed in an area over a ﬁ nished ceiling or living area, install a ﬁ eld fabricated auxiliary drain pan under the furnace to protect that area from accidental condensate spills. The auxiliary pan should be large enough to collect accidentally spilled condensate from the air conditioning evaporator coil assembly if applicable.

3. If the furnace is installed in an area where freezing may occur, a garage, an attic, a crawl space or any unconditioned space, steps must be taken to protect the condensate trap and drain line from freezing. One possible measure could be to use a self-regulating 5 or 6 watt per foot heat tape covered with a jacket of insulation. Heat tapes are available in plumbing supply houses.

W415-1080 / A / 08.28.13

4.3 INSTALLATION IN UPFLOW POSITION

UPFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in accordance with instructions in the appropriate sections of this manual. NON-SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Figure 1, Table B. The furnace must be supported in such a way as to not allow twisting or sagging of the cabinet.

IMPORTANT:

• THE FURNACE MUST BE INSTALLED ON A LEVEL SURFACE. IT IS RECOMMENDED THAT THE REAR OF THE FURNACE BE ELEVATED 1/4” (6 mm) HIGHER THAN THE FRONT TO FACILITATE PROPER CONDENSATE DRAINAGE.

• IF THE FURNACE AND AIR CONDITIONER IS LOCATED ABOVE A FINISHED SPACE, INSTALL A DRAIN PAN UNDERNEATH THE UNIT.

NOTE THIS FURNACE IS CERTIFIED FOR UPFLOW INSTALLATION ONLY.

This furnace is approved for installation in attics, alcoves, utility rooms, closets and crawl spaces. If this furnace is to be installed in a utility room, be sure that it is located in such a way as to allow access for servicing or the removal of other appliances installed in the room (hot water heater, for example). It is not permissible to use a rear return on this appliance. Use only side and bottom returns.

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4.4 AIR CONDITIONING

This furnace may be used as part of an air conditioning system. The furnace wiring and control system is “air conditioning ready.” There are the following factors to consider:

• The air conditioning evaporator coil must be downstream of the heat exchanger. The cooled air passing over the warmer heat exchanger tubes can cause condensation inside the tubes, resulting in corrosion and premature failure.

• A parallel duct system can be installed to direct the air from the furnace through the evaporator coil only. Use dampers or other means to bypass the heat exchanger. If (summer/winter) dampers are used, they should be interlocked to prevent system operation unless the dampers are in the full open or full closed position.

NOTE

If installing a two stage air conditioning system, clip the JW38 jumper wire between Y (low cool) and Y2 (high cool) on the furnace control board.

Control defaults to Y2 (high cool) if JW38 jumper wire is NOT cut.

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5.0 COMBUSTIBLE CLEARANCES

Table B provides the certiﬁ ed clearances to combustibles and dimensional information. Also see the appliance rating plate afﬁ xed to the furnace for speciﬁ c model number, serial number and clearance to combustibles information.

IMPORTANT: THIS FURNACE REQUIRES A MINIMUM OF 24” (610 mm) OF FRONT CLEARANCE FOR SERVICE PURPOSES. FOR THIS PURPOSE, SERVICE CLEARANCE TAKES PRECEDENCE OVER CLEARANCE TO COMBUSTIBLES.

WARNING

THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. THIS

SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.

THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, OR OTHER

COMBUSTIBLE MATERIAL EXCEPT WOOD.

INSTALLATION ON COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL

COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS

AND LIQUIDS.

THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE

USED AS A CLOSET OR FOR ANY OTHER STORAGE PURPOSE.

! !

W415-1080 / A / 08.28.13

6.0 DUCTWORK

Proper airﬂ ow is required for the correct operation of this furnace. Insufﬁ cient airﬂ ow may cause erratic opera- tion, could cause the furnace to cycle on the high temperature limit, and may damage the heat exchanger. Excessive airﬂ ow may result in an excessively noisy duct system and may result in undesirable consequences such as creating uncomfortable drafts.

If air conditioning is to be used with the furnace, the duct system must be capable of delivering the correct amount of airﬂ ow for each system.

The ductwork should be sized and constructed in accordance with accepted industry standards. Duct sizing and construction information may be obtained from:

• A.C.C.A. (Air Conditioning Contractors of America)

• A.S.H.R.A.E. (American Society of Heating, Refrigeration and Air Conditioning Engineers

• H.R.A.I. (Heating, Refrigerating and Air Conditioning Institute (Canada)

• S.M.A.C.N.A. (Sheet Metal and Air Conditioning Contractors’ National Association (United States)

All of the above professional organizations have duct sizing manuals available. The total static pressure drop of the air distribution system (including ﬁ lters) should not exceed 1.0” w.c.

WARNING

DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SPACES THAT ARE

USED FOR RETURN AIR PURPOSES. DO NOT USE JOIST SPACES FOR RETURN AIR

PURPOSES IF THE JOIST SPACE ALREADY CONTAINS PLUMBING STACKS, CHIMNEY

COMPONENTS, ETC. UNLESS THE PORTION USED FOR RETURN AIR PURPOSES CAN

BE COMPLETELY ISOLATED FROM PORTIONS WITH OTHER USAGES.

IOM

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE

RETURN AIR OR SUPPLY AIR DUCTWORK.

ALL RETURN AIR DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO

THE FURNACE WITH SHEET METAL SCREWS. TAPE THE SHEET METAL SEAMS IN THE

VICINITY OF THE FURNACE WITH DUCT TAPE OR SIMILAR MATERIAL.

WHEN THE FURNACE IS MOUNTED ON A PLATFORM WITH RETURN AIR THROUGH THE

BOTTOM, IT MUST BE SEALED AIR TIGHT BETWEEN THE FURNACE AND THE RETURN

AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT

OF THE FURNACE WITHOUT SAGGING, OR GAPS AROUND THE BASE. IT MUST ALSO

BE SEALED BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO

THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING

CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR

DEATH.

W415-1080 / B / 08.28.13

IOM

6.1 DUCTWORK STEPS

1. Position the furnace to minimize ductwork length and ﬁ ttings.

2. Cut open a return air inlet. The choices are furnace bottom, either side, or any combination thereof (i.e., two sides or a side and the bottom).In all cases, cut the return air opening the full width of the return air markers on the side panel.

WARNING

DO NOT USE THE REAR PANEL AS A RETURN AIR INLET. THERE IS INSUFFICIENT

ROOM TO PERMIT ADEQUATE AIRFLOW.

DAMAGES, DEFECTS OR FAILURES CAUSED BY CONDITIONED AIR (RETURN AIR)

SUPPLIED TO THE FURNACE BEING GREATER THAN 20% FROM OUTDOORS (55°F/13°C

MIN. RETURN AIR TEMPERATURE).

SOME HEATING AIR FLOW VALUES MAY BE HIGHER THAN THOSE REQUIRED FOR

COOLING. BE SURE TO SIZE DUCT SYSTEM FOR HIGHEST POSSIBLE VALUES.

3. Connect the return air duct or ﬁ lter ﬁ tting to the furnace. The connection should be sealed air tight to prevent entraining combustion gases from an adjacent fuel burning appliance, or entraining combustion air for this furnace or adjacent fuel burning appliances.

4. Ensure that there is adequate space and accessibility for air ﬁ lter removal.

5. If an air conditioning evaporator coil is required, position it on the supply air side of the furnace. Ensure that no air can bypass the evaporator coil.

6. Connect the supply air plenum to the supply air outlet.

FLEXIBLE DUCT CONNECTORS are an effective device to prevent the telegraphing of mechanical noise from the furnace to other parts of the home via the ductwork. If using ﬂ exible connectors, ensure that the adjoining duct is independently supported.

NOTE: For upﬂ ow 5 ton airﬂ ow models where the airﬂ ow requirements exceed 1800 cfm, models will require air openings and ﬁ lters on: • both sides, OR

• one side and the bottom, OR

• just the bottom

W415-1080 / A / 08.28.13

7.0 VENTING AND COMBUSTION PIPING

IOM

WARNING

READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO

PROPERLY VENT OR SUPPLY COMBUSTION AIR TO THIS FURNACE CAN CAUSE CAR-

BON MONOXIDE POISONING, OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY

DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

7.1 ACCEPTABLE MATERIALS IN CANADA

Effective August 1, 2007, all vent piping materials and ﬁ ttings for ﬂ ue gas venting must be ULC S636 listed and identiﬁ ed as such on the material. The ﬁ rst 3ft. (900mm) of venting must be readily available for visual inspection. Speciﬁ ed primers and glues of the certiﬁ ed vent system must be from a single system manufacture, and not intermixed with other system manufacture’s vent system parts. The components of the certiﬁ ed vent system must not be interchanged with other vent systems, or unlisted pipe, and or ﬁ ttings. Follow the venting manufacturers instructions on installation, cutting, de-burring, cementing, curing and supporting of the venting system. This furnace must be vented with ULC S636 certiﬁ ed:

• PVC (Polyvinyl Chloride), OR

• PPE (Polypropylene) material with a minimum rating of 149°F (65º C) or more.

The combustion air piping does not have ﬂ ue gases traveling through it and may be installed with common ABS, PVC or CPVC piping or ﬁ ttings. This piping, ﬁ ttings, primer and cement will need to be installed as per the manufacturers instructions including cementing, cutting, curing and supporting the piping.

7.2 ACCEPTABLE MATERIALS IN UNITED STATES

For United States installations, the combustion air and vent piping and ﬁ ttings may be comprised of:

• Schedule 40 PVC, ASTM D1785 or CSA B137.3

• PVC-DWV, ASTM D2665 or CSA B181.2

• Schedule 40 CPVC, ASTM F441 or CSA B137.6

• PVC PRIMER AND SOLVENT CEMENT: ASTM D2564

• PPE ULC S636 Follow piping manufacturers instructions on proper installation of piping and ﬁ ttings including cutting, deburr- ing, priming, cementing, curing and supporting.

W415-1080 / B / 08.28.13

8.0 NON-DIRECT VENT FURNACE INSTALLATIONS

IOM

USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM)

The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside the structure.

WARNING

THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE

FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE BROUGHT TO

THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE PERSONAL INJURY, OR DEATH

FROM CARBON MONOXIDE POISONING.

Adequate provisions for combustion and ventilation air must be in accordance with CAN/CGA-B149 in Canada,

and ANSI Z223.1 - 1992, section 5.3, “Air for Combustion and Ventilation,” in the United States. Check with lo-

cal authorities for any additional building codes bylaws or regulations.

CAUTION

AIR FOR COMBUSTION AND VENTILATION PURPOSES MUST NOT ORIGINATE FROM A COR-

ROSIVE ATMOSPHERE. ANY FURNACE FAILURE CAUSED BY CORROSIVE ELEMENTS IS

EXCLUDED FROM WARRANTY COVERAGE.

The following types of installation sites (but not limited to the following) will REQUIRE OUTDOOR AIR for combustion because of chemical exposures:

• Commercial buildings

• Buildings with indoor swimming pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical storage areas

Exposure to the following substances in the combustion air supply (but not limited to the following) will also require OUTDOOR AIR for combustion:

• Aerosols, particularly CFC based or propelled aerosols

• Air fresheners

• “Airplane Glue” and similar adhesives and cements

• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons

• Anti-static fabric softeners used in clothes dryers

• Carbon tetrachloride

• Chlorinated cleaners and waxes

• Chlorine and bromine based swimming pool chemicals

• De-icing salts or chemicals (rock salt, etc.)

• Dry cleaning ﬂ uids such as perchloroethylene

• Fumes from curing polyurethane and similar substances

• Halogen based refrigerants including R-12 and R-22

• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials

• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.

• Water softener salt and chemicals Combustion air must be free of acid forming chemicals such as sulphur, ﬂ uorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish remov-

W415-1080 / A / 08.28.13

ers, refrigerants, and many other commercial and household products. When burned in a gas ﬂ ame, vapors from these products form acid compounds. Acid compounds increase the dew point temperature of the ﬂ ue products and are highly corrosive after they condense.

8.1 DETERMINING COMBUSTION AIR

8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE

Unconﬁ ned space does not necessarily mean that ventilation will not have to be introduced from the outdoors, particularly in airtight homes. The minimum requirement for unconﬁ ned space is a volume of 50 cubic feet (1.42 m³) for each 1000 Btu/hr for all fuel burning appliances located within the unconﬁ ned area.

If the amount of combustion and ventilation air is insufﬁ cient to properly operate the furnace and other fuel burning appliances within the unconﬁ ned area, it will be necessary to supply it from the outdoors based on the criteria used when calculating the air supply for a conﬁ ned space.

NOTE

If planning to use the inside air in an unconﬁ ned space, remember to test for proper furnace operation (as well as other fuel burning appliances located within the unconﬁ ned space) with respect to adequate combustion and ventilation air with ﬁ replace dampers open, clothes dryer running, bathroom exhaust fans on, kitchen range hood on, etc.

IOM

8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE

A conﬁ ned space, (any space smaller than the minimums discussed in Case 1), must have two air openings; one within 12” (305 mm) of the ceiling and the other within 12” (305 mm) of the ﬂ oor. The air openings must be sized based on whether the combustion and ventilation air is being taken from indoors or outdoors, the method outdoor air (if used) is introduced, and taking into account any other fuel burning appliances in the conﬁ ned space.

If sufﬁ cient indoor combustion and ventilation air is available for the furnace and all other fuel burning appliances, size each opening on the basis of one square inch (645 mm²) of free area per 1000 Btu/hr.

(Figure 4)

NOTE Be sure to consider all clothes dryers, bathroom fans, range hoods, etc., when making this calculation.

The minimum requirement for these openings is 100 square inches (645 mm²), even for the furnace models under 100,000 Btu/hr.

NOTE If using grills to cover the two openings, factor in the free area of the grill. Typically, a sidewall grill will have a free area approximately 50% of its nominal size. Consequently, if the required opening is 10 x 10 (254 mm x 254 mm), it will have to be doubled if using a sidewall grill with 50% free area.

FIGURE 4 - COMBUSTION/DILUTION AIR FROM

HEATED INSIDE SOURCES (CASE 2)

W415-1080 / B / 08.28.13

IOM

IMPORTANT:

IF AN EXHAUST FAN, FIREPLACE, CLOTHES DRYER OR ANY SIMILAR DEVICE IS PRESENT IN THE INDOOR AREA FROM WHICH THE COMBUSTION AND VENTILATION AIR WILL BE DRAWN, NEGATIVE PRESSURE COULD BE A PROBLEM IF NATURAL INFILTRATION FROM THE OUTDOORS DOES NOT MATCH THE RATE AT WHICH AIR IS EXHAUSTED.

8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE

In this circumstance, the free area of each of the two combustion and ventilation air openings is based on a minimum of 1 square inch (645 mm²) per 4000 Btu/hr. In this conﬁ guration, one opening can originate from the ﬂ oor drawing combustion and ventilation air from the ventilated crawl space.

The other opening may communicate freely with a ventilated the attic. If using the attic air, ensure that the opening is ducted from the ceiling high enough to be above the insulation. The attic must be adequately

vented with sofﬁ t vents or gable vents (Figure 5).

As an alternative to creating an opening in the ﬂ oor to draw air from a crawl space, a duct may be dropped from the attic terminating 12” (305 mm) above the ﬂ oor.

The following table shows minimum free areas and round pipe sizes when drawing combustion air vertically from the attic or crawl space for the furnace only. If other fuel burning appliances are present, their combustion air and ventilation air requirements must be added to those of the furnace.

FIGURE 5 - OUTSIDE AIR FOR COMBUSTION, ATTIC OR

CRAWL SPACE (CASE 3)

TABLE 2 - VERTICAL AIR SUPPLY (CASE 3)

Input Free Area

K/Btu/hr Ea. Opening

60 15 in.² (97 cm²) 5 in. (127 mm)

80 20 in.² (129 cm²)

100 25 in.² (161 cm²)

120 30 in.² (194 cm²) 7 in. (178 mm)

IMPORTANT:

Round Pipe Size

6 in. (152 mm)

H12.16.2

IF THE ATTIC HAS AN EXHAUST FAN (POWER VENT), IT MAY CREATE A NEGATIVE PRESSURE SUFFICIENTLY LARGE ENOUGH TO PREVENT THE ATTIC FROM BEING AN EFFECTIVE SOURCE OF COMBUSTION AND VENTILATION AIR. POWERED ATTIC FANS DO NOT CUSTOMARILY RUN DURING THE HEATING SEASON; HOWEVER, SOME ARE CONTROLLED BY A HUMIDISTAT AS WELL AS A THERMOSTAT, WHICH MAY ALLOW SOME OPERATION DURING THE HEATING SEASON. THE CHOICES ARE (A) USE THE DIRECT VENT OPTION; (B) OBTAIN OUTDOOR AIR FROM ELSEWHERE; OR (C) INTERLOCK THE ATTIC EXHAUST FAN WITH THE FURNACE SUCH THAT THE TWO CANNOT OPERATE SIMULTANEOUSLY.

W415-1080 / A / 08.28.13

8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY

Similar to Case 3, outdoor air for combustion and ventilation may be drawn through horizontal ducting. The free area for each opening is calculated on the basis of a minimum of 1 square inch (645 mm²) per 2000 Btu/hr input.

The following table shows minimum free areas and round pipe sizes when drawing combustion air horizontally from the outdoors for the furnace only. If other fuel burning appliances are present, their combustion air and ventilation air requirements must be added to those of the furnace.

TABLE 3 - HORIZONTAL AIR

SUPPLY (CASE 4)

IOM

Combustion Air Duct Terminates 12” (305mm) above oor.

Input

K/Btu/hr

100

120

Free Area

Ea. Opening

30 in

(194 cm2)

40 in

(258 cm2)

50 in

(323 cm2)

60 in

(387 cm2)

Round Pipe

Size

7 in

(178 mm)

8 in

(203 mm)

9 in

(229 mm)

H12.9.2

IMPORTANT:

THE OUTDOOR GRILLS MUST BE INSTALLED IN A LOCATION WHERE THEY WILL NOT BE OBSTRUCTED IN ANY MANNER.

IMPORTANT:

IF GRILLS ARE USED ON THE OUTSIDE WALL, THEY MUST BE SIZED PROPERLY. MOST SIDEWALL GRILLS HAVE ONLY 50% FREE AREA. IN THE CASE OF A UNIT WITH 100,000 BTU/HR INPUT, WHICH REQUIRES A PAIR OF 8” (203 mm) ROUND PIPES TO OBTAIN SUFFICIENT COMBUSTION AND VENTILATION AIR, THE DUCT COULD BE AN EQUIVALENT RECTANGULAR DUCT; 8” X 7” (203 mm X 178 mm) FOR EXAMPLE. BASED ON 50% FREE AREA FOR THE INLET GRILLS, THE ACTUAL GRILL SIZE WOULD HAVE TO BE 14” X 8” (356 mm X 203 mm) OR ITS EQUIVALENT. A TRANSITION MAY BE USED TO REDUCE TO THE SMALLER DUCT SIZE IF NECESSARY.

8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT

IMPORTANT: WHEN USING INDOOR AIR OR THE NON-DIRECT VENT CONFIGURATION, THE COMBUSTION AIR INLET TO THE FURNACE MUST BE PROTECTED FROM BLOCKAGE. USE A DOUBLE ELBOW ARRANGEMENT IF SUPPLYING COMBUSTION AIR THROUGH THE TOP, OR A DOWNWARD POINTING SINGLE ELBOW IF SUPPLYING COMBUSTION

AIR THROUGH THE SIDE. (FIGURE 7)

FIGURE 7 - NON-DIRECT

COMBUSTION AIR INLET

W415-1080 / B / 08.28.13

IOM

9.0 VENTING GUIDELINES

CAUTION

FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE

OPERATION, FREEZE-UP OF THE EXHAUST AIR PIPING.

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT THIS

FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE RESULTING

IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

NOTE

• Combustion air intake and exhaust termination should be inspected periodically to ensure they are clear of obstructions. i.e. vegetation, debris, snow, etc.

• Accumulation of snow around the combustion air intake and exhaust termination may have

negative effects on appliance operation and/or performance. Snow accumulation should be considered when locating combustion air intake and exhaust terminations.

ATTENTION: UPFLOW VENTING RIGHT, MUST DRAIN ON LEFT SIDE.

IMPORTANT:

• CLEAN AND DE-BURR ALL PIPE CUTS. THE SHAVINGS MUST NOT BE ALLOWED TO

BLOCK THE EXHAUST, COMBUSTION AIR INLET OR CONDENSATE DRAIN LINES.

• EVEN UNCUT FULL LENGTH SECTIONS PRODUCE SHAVINGS DURING ASSEMBLY THAT COULD BLOCK CONDENSES TO DRAINAGE.

• THE EXHAUST VENT MUST BE SUPPORTED APPROPRIATELY PRIOR TO IT BEING FITTED TO THE EXHAUSTER. UNDER NO CIRCUMSTANCES SHALL THE EXHAUSTER BEAR ANY WEIGHT OF THE VENTING SYSTEM.

• IF THE PIPE AND FITTINGS ARE TO BE OTHER THAN PVC, USE THE PROPER CLEANER, PRIMER AND CEMENT FOR THE DISSIMILAR MATERIALS.

• Venting may be vertical or horizontal.

• Minimum vent length - 15 total equivalent feet. (See Venting Table)

• Horizontal piping must slope back towards the furnace at a minimum rate of ¼” (6.4 mm) to the foot (305 mm), so that condensate drains towards the furnace.

• Horizontal runs must be supported at least every 3 feet (914 mm). Horizontal sections must not dip or sag.

• All vent runs through unconditioned space where freezing might occur should be insulated with 1” (25 mm) thick, medium density, foil-faced Fiberglass insulation. An equivalent “arm-a-ﬂ ex” or “rub-a-tex” may also be used as long as there is no heat tape applied to the vent pipe. For horizontal runs where water may collect, wrap the vent pipe with self regulating 3 or 5 watt heat tape. The heat tape must be CSA, UL, or ULC listed and installed per the manufacturer’s instructions. This includes travel through unconditioned attic space.

• DO NOT COMMON VENT WITH ANY OTHER APPLIANCE.

• If venting vertically, do not vent up a chimney serving another appliance or install in a chase with a metal or high temperature plastic pipe from another gas or fuel burning appliance unless the required clearances to combustibles can be maintained between the furnace venting system and other pipes.

All exhaust piping must be installed in accordance with CAN/CGA-B149.in Canada; the latest edition of National Fuel Gas Code, NFPA 54 / ANSI Z223.1 in the United States, as well as in accordance with local codes.

Size the combustion air and exhaust piping in accordance with Table 4. When calculating allowable vent

W415-1080 / A / 08.28.13

lengths, be sure to count all termination ﬁ ttings in addition to counting the concentric vent as a straight pipe.

Take the building orientation and the presence of other buildings or other nearby structures into consideration when planning the venting system location. Certain external structures could create

FIGURE 8 - STANDARD (STRAIGHT) HORIZONTAL

VENT DETAIL

*3"

(76mm)

MIN.

EXHAUST

air turbulence around the vent termination leading to downdrafts and similar venting problems. In windy and hill locations, roof venting may improve operations. Maximum venting length is based on 30 mph (48 km) winds, areas where higher gusts are dominant it is suggest to shorten the horizontal vent length.

The vent and combustion air intake shall be installed so that both are located in the same wind pressure zone.

WARNING

12"

(305mm)

MIN.

GRADE

*18" (457mm) MIN. FOR COLD CLIMATES (SUSTAINED 0°F (-18°C) FOR 24 OR MORE CONSECUTIVE HOURS

INTAKE

DO NOT CONNECT FURNACE TO A CHIMNEY OR FLUE SERVING OTHER APPLIANCES OR A

SOLID FUEL BURNING APPLIANCE.

IOM

9.1 VENT TERMINATION

Horizontal vents should pass through the exterior wall. Figure 8 shows a standard horizontal vent detail. Terminate the vent approximately 8” (203 mm) or more from the wall. Exterior vent pipe greater than 24” (610 mm) should be insulated with ½” (13 mm) insulation to prevent moisture from freezing within the pipe and accumulating. Size the exhaust pipe as speciﬁ ed in

Table 4 - Direct and Non-Direct Vent Lengths. This table lists the maximum

allowable length of pipe with respect to the number of 90° elbows used. For the purposes of this calculation, one 90° elbow is equivalent to two 45° elbows. Avoid locating the terminal in locations where dripping condensate may cause problems such as sidewalks, patios, above planters, near windows where exhaust gases may cause fogging, etc. Avoid locating the termination too close to shrubs and other vegetation. The condensate may stunt or kill them.

EQUIVALENTS

Short Radius Elbow = 7’ (2.13 m) Medium Radius Elbow = 2.5’ (.76 m) Long Radius Elbow = 5’ (1.52 m)

Vent lengths that require more than 6-90° elbows, add listed equivalents for every elbow up to the maximum allowable vent length.

TABLE 4 - DIRECT AND NON-DIRECT VENT LENGTHS

Maximum Allowable Length Of Exhaust Or Intake. Minimum Vent Length 15 ft. (4.6 m) or equivalent.

INPUT

K/Btu/hr

100

120 3 100* 95 90 85 80 75 70

NOTE * Maximum allowable vent (intake and exhaust) length.

When 1½” or 3” pipe is used, exit the cabinet with 2” pipe. Reduce or increase immediately after exiting the cabinet on both intake and exhaust.

PIPE SIZE

1½ 60* 55 50 45 40 35 30

2 75* 70 65 60 55 50 45

3 100* 95 90 85 80 75 70

2 50* 45 40 35 30 25 20

3 100* 95 90 85 80 75 70

2 50* 45 40 35 30 25 20

3 100* 95 90 85 80 75 70

NUMBER OF 90° ELBOWS

0123456

1. Count concentric vent

2. Use medium or long

3. One 90° elbow is

4. For direct vent, the

5. For non-direct vent,

H12.4.3

NOTES

ﬁ tting as straight pipe.

sweep elbows where possible.

equivalent to two 45° elbows.

listed lengths are allowed for each vent (intake and exhaust).

the listed lengths are allowed for exhaust. The intake should have a 1½” or 2” snorkel intake ﬁ tting. (Figure 7)

W415-1080 / B / 08.28.13

INTAKE

EXHAUST

GRADE

*3"

(76mm)

MIN.

12"

(305mm)

MIN.

12"

(305mm)

MIN.

*18" (457mm) MIN. FOR COLD CLIMATES (SUSTAINED 0°F (-18°C) FOR 24 OR MORE CONSECUTIVE HOURS

IOM

FIGURE 9 - PERISCOPED VENT DETAIL

CAUTION

FIGURE 10 - VERTICAL VENTING

ROOF TERMINATION EXHAUST

18" (457mm) MIN.

MOISTURE IN THE FLUE GASES CONDENSES AS IT LEAVES THE TERMINAL. THIS MOISTURE

CAN FREEZE ON EXTERIOR WALLS, ON SOFFITS, AND OTHER NEARBY OBJECTS. SOME

DISCOLORATION IS TO BE EXPECTED; HOWEVER, IMPROPER LOCATION OR INSTALLATION CAN

CAUSE STRUCTURAL OR EXTERIOR FINISH DAMAGE TO THE BUILDING.

Caulk all cracks, seams or joints within a 6 foot radius of the termination.

Do not terminate under a deck unless there is adequate clearance to prevent damage from the ﬂ ue gases. A termination may be located at the end of a patio deck. Piping running beneath the deck must be suitably insulated and suspended in a manner to prevent condensate from collecting and freezing.

Do not locate the terminal on the side of the building facing the prevailing winter winds.

9.2 IN CANADA

In addition to the general guidelines, in Canada, the vent exhaust shall not terminate:

• Directly above a paved sidewalk or paved driveway which is located between two single-family dwellings and serves both dwellings;

• Less than 7 feet (2.1 m) above a paved sidewalk or paved driveway located on public property;

• Within 6 feet (1.8 m) of a mechanical air supply inlet to any building;

• Above a meter/regulator assembly within 3 feet (.91 m) horizontally of the center line of the regulator;

• Within 6 feet (1.8 m) of any service regulator vent outlet;

• Less than 12” (305 mm) above grade level or anticipated snow level;

• Within 12” (305 mm) of any door, window, or non-mechanical air supply inlet to any building;

• Within 12” (305 mm) of the combustion air inlet of any other appliance;

• Underneath a veranda, porch or deck, unless (a) the veranda, porch or deck is fully open on a minimum of two sides beneath the ﬂ oor, and (b) the distance between the top of the vent termination and the underside of the veranda, porch or deck is greater than 12” (305 mm).

9.3 IN UNITED STATES

In addition to the general guidelines, in the United States, the vent exhaust shall be installed in accordance with the following:

• The clearance from the bottom of the terminal to grade shall be 12” (305 mm).

• The vent shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard.

• The vent terminal shall be installed 4 feet (1.2 m) below, 4 feet (1.2 m) horizontally from, or 1 foot (305 mm) above any door, window, sofﬁ t, under eave vent or gravity air inlet to the building.

• The vent terminal shall have a minimum horizontal clearance of 4 feet (1.2 m) from electric meters, gas meters, regulators and relief equipment.

W415-1080 / A / 08.28.13

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