Fedders FV95A108, FV95A054, FV95A072, FV95A090 User Manual

Installation, Operation and Maintenance

CATEGORY I NATURAL GAS AND LP GAS HIGH EFFICIENCY TWO STAGE VARIABLE SPEED WARM AIR FURNACE

MODEL 77

For future reference write down the model, serial number, and date of purchase. Use these numbers in any correspondence or service calls concerning your furnace.

Model

Serial Number

Date of Purchase

Keep these instructions for future reference.

Please read the operating instructions and safety precautions carefully and thoroughly before installing and operating your furnace. Keep this manual in a safe place for future reference.

FV95A054 FV95A072 <

FV95A090<

FV95A108

USER’S INSTRUCTION GUIDE LOCATED AFTER PAGE 43 OF THIS INSTALLATION, OPERATION AND MAINTENANCE MANUAL

23-23-0508N-003

Table of Contents

INTRODUCTION ....................................................................... 1

AFETY ..................................................................................... 1

afety Rules ................................................................... 1

ODES....................................................................................... 3

FURNACE SIZING ..................................................................... 4

AIR CONDITIONING INSPECTION/ACCESS PANEL

LOCATION OF UNIT ................................................................. 5

General ......................................................................... 5

Other Considerations:................................................... 5

CLEARANCES ........................................................................... 6

UNIT DIMENSIONS ................................................................... 6

DUCTWORK ............................................................................. 7

Guide: ........................................................................... 7

Ductwork Steps: ........................................................... 7

INSTALLATION POSITIONS....................................................... 8

Inducer Blower Rotation ............................................. 9

Inducer Rotation Steps ............................................... 9

Non-Suspended Installation ......................................... 9

Suspended Installation ................................................. 9

Upflow Installation ...................................................... 10

Downflow Installation ................................................ 11

Horizontal Installation ................................................ 12

AIR FOR COMBUSTION .......................................................... 13

Case 1: Furnace Located In An

Case 2: Furnace Located In A

Case 3: Furnace Located In A Confined Space,

Case 4: Furnace Located In A Confined Space,

FURNACE VENTING ................................................................ 14

Direct Venting Pipe Connection.................................. 14

Combustion Air Inlet Piping........................................ 14

Air Filters....................................................................... 15

Exhaust Vent Piping...................................................... 15

Guidelines...................................................................... 16

Joining Pipe And Fittings.............................................. 16

Direct Vent Piping Termination................................... 17

Calculating Piping Length............................................ 18

Termination of Combustion Air and Ventilation

Pipe Using A Concentric Venting Kit.......................... 19

Horizontal Termination of Combustion Air and

Exhaust Vent................................................................. 20

Vertical Termination of Combustion Air and

Exhaust Vent................................................................. 21

Non Direct Vent Furnace Installations......................... 22

CONDENSATE DRAINS............................................................. 25

Drain Hose Installation.................................................. 25

Condensate Drain Installation....................................... 27

................................................................. 4

................................................... 4

Unconfined Space .......................................... 13

Confined Space .............................................. 13

Outdoor Air From Attic Or Crawl Space ...... 13

Outdoor Air Ducted Horizontally.................. 13

GAS SUPPLY ............................................................................. 28

Gas Piping ..................................................................... 28

Leak Testing ................................................................. 28

High Altitude ................................................................ 29

CONVERSIONS ......................................................................... 29

Natural to L.P. Gas ....................................................... 29

. to Natural Gas ........................................................ 29

L.P

Conversion Steps .......................................................... 29

HIGH ALTITUDE & AIRFLOW SPECIFICATION TABLES ........... 30

ELECTRICAL SPECIFICATIONS................................................... 32

Furnace Connection ..................................................... 32

Low Voltage Wiring ..................................................... 32

Thermostat ................................................................... 33

Thermostat Location..................................................... 33

Thermostat Heat Anticipator Setting ......................... 33

START UP PROCEDURES ......................................................... 34

To Start The Furnace: ................................................... 34

To Shut Down The Furnace:......................................... 34

Sequence of Operation ............................................... 34

Sequence of Operation if the Furnace

Does Not Light or Detect Flame ................................. 34

Setting The Manifold Gas Pressure ............................. 34

Checking Furnace Input ............................................... 34

Circulating Air Blower and

Temperature Rise Check............................................... 35

AIR FLOW ................................................................................. 35

Calculating Airflow....................................................... 35

Adjusting Dip Switches................................................. 36

ADJUSTING BLOWER SPEEDS ................................................. 37

Cooling Mode ............................................................... 37

Heating Mode ............................................................... 37

How To Remove The Blower ....................................... 37

How To Install The Blower........................................... 37

MAINTENANCE ....................................................................... 38

Air Filter......................................................................... 38

Lubrication ................................................................... 38

Vent Connector............................................................. 38

Operating Tips ............................................................. 38

ANNUAL INSPECTION/SERVICE ............................................... 38

Heat Exchanger............................................................. 38

Burners ......................................................................... 38

Induced Blower ............................................................. 38

Circulating Fan ............................................................. 38

Electrical ....................................................................... 39

Furnace Operation ....................................................... 39

FIELD SUPPLIED AND INSTALLED

OPTIONAL ACCESSORIES......................................................... 39

Electronic Air Cleaner................................................... 39

Humidifier/ Electronic Air Cleaners ............................. 39

TROUBLESHOOTING ............................................................... 39

WIRING DIAGRAM .................................................................. 43

INTRODUCTION

This 95% efficient gas fired furnace series is CGA / AGA

esign certified as a Category I (condensing with positive

d vent pressure) non-direct or direct vent central forced air furnace. It is an upflow, downflow, horizontal left and right furnace suitable for residential and light commercial heating applications from 54,000 to 108,000 BTU/Hr. When installed as a direct vent furnace, all combustion air is supplied directly to the furnace burners through a special air intake system. (See Section “Ventilation and Combustion Air.”)

ll models may be fired by natural gas or field convertible to

A LP gas (propane). The furnace is shipped completely assembled except for the drain trap assembly and the venting. Please inspect for damage when the furnace is unpacked.

SAFETY

Throughout the manual, symbols and words are used to draw attention to potentially hazardous conditions.

DANGER

THIS INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING

THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

CAUTION

THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.

. 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, as specified in the Furnace Sizing section on page 4, the Ductwork section on page 7, and

he Airflow section on page 35 of these instructions.

7. When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space

ontaining the furnace, the return air shall also be

c 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

arage, for example).

8. A gas fired furnace for installation in a residential garage must be installed so that the burners and ignitor are no less than 18 inches above the floor. The furnace must be located, or protected to avoid physical damage by vehicles.

THIS FURNACE IS NOT TO BE USED FOR TEMPORARY HEATING FOR BUILDINGS UNDER CONSTRUCTION.

DANGER

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.

WARNING

THE FURNACE CONTAINS FOIL COVERED FIBERGLASS INSULATION. INHALATION OF FIBERGLASS PARTICLES IS ASSOCIATED WITH RESPIRATORY DISEASE INCLUDING CANCER.

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 specified in the Determining Combustion Air section on page 13 of these instructions.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the Furnace Venting section on page 14 of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Supply section on page 28 of these instructions.

WARNING

THE FUEL SUPPLIER NORMALLY ODORIZES NATURAL GAS AND PROPANE. IN SOME CASES, THE ODORANT MAY NOT BE PERCEIVABLE. INSTALLATION OF UL AND CUL RECOGNIZED FUEL GAS DETECTORS INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS IS RECOMMENDED AS AN ADDITIONAL MARGIN OF SAFETY.

DANGER

FIRE OR EXPLOSION HAZARD

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT

, A FIRE OR EXPLOSION MA

FOLLOWED EXACTL RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

CAUTION

MAKE SURE TO REMOVE FOAM BLOWER HOUSING SHIPPING SUPPORTS BEFORE OPERATING FURNACE.

SHIPPING SUPPORTS ARE LOCATED ON THE BOTTOM RIGHT AND BOTTOM LEFT SIDES OF BLOWER HOUSING.

DANGER

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

•

EIGHBOR’S PHONE, OR A CELLULAR PHONE FROM A

N 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 ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS SUPPLIER OR THE FIRE DEPARTMENT

IMPROPER INSTALLATION, OPERATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL FOR PROPER INSTALLATION, OPERATION,

VICE, AND MAINTENANCE INSTRUCTIONS.

SER

A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER MUST PERFORM INSTALLATION AND SERVICE.

DO NOT DESTROY THIS MANUAL

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

DANGER

HEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL

W GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE

RESENT IN THE GARAGE.

P 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.

WARNING

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.

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.

WARNING

THE EXHAUST GASES FROM THIS FURNACE CONTAIN CHEMICALS, WHICH ON SOME OCCASIONS MAY INCLUDE CARBON MONOXIDE (CO). CARBON MONOXIDE IS AN ODORLESS, TASTELESS, CLEAR COLORLESS GAS, WHICH IS HIGHL CONCENTRA DEFECTS AND OTHER REPRODUCTIVE HARM.

UL AND CUL RECOGNIZED CO DETECTORS ARE RECOMMENDED FOR ALL BUILDINGS EQUIPPED WITH FOSSIL FUEL BURNING APPLIANCES. ALL CO DETECTORS SHOULD BE INST MANUFACTURER’S INSTRUCTIONS AND APPLICABLE LOCAL BUILDING CODES.

TIONS ARE SUSPECTED OF CAUSING BIR

ALLED IN ACCORDANCE WITH THEIR

Y TOXIC. EVEN LOW

CODES:

This furnace must be installed:

In accordance with all local codes, bylaws and

• regulations by those authorities having jurisdiction

• In the United States, this furnace must be installed in

ccordance with the current ANSI Z223.1 (NFPA 54)

a National Fuel Gas Code

• In Canada, this furnace must be installed in

ccordance with the current CAN/CGA -B149

a Installation Code for Fuel Burning Appliances

Electrical connections must be made in accordance with:

• Any applicable local codes, bylaws and regulations

• Canada: current edition of CAN/CSA C22.1, Canadian Electrical Code (Part 1)

• United States: current edition of ANSI/NFPA 70, National Electrical Code

Codes and additional information may be obtained from:

• American Gas Association 1515 Wilson Boulevard Arlington, VA, 22209 703-841-8400

•

National Fire Protection Association

1 Batterymarch Park Quincy, MA, 02269-9101 617-770-3000

•

Canadian Gas Association

Suite 1, 243 Consumers Road North York, ON, M2J 5E3 416-498-1994

INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF MASSACHUSETTS FOR DIRECT VENT APPLIANCES.

FOR ALL SIDE WALL HORIZONTALLY VENTED GAS FUELED EQUIPMENT INSTALLED IN EVERY DWELLING, BUILDING OR STRUCTURE USED IN WHOLE OR IN PAR PURPOSES, INCLUDING THOSE OWNED OR OPERATED BY THE COMMONWEALTH AND WHERE THE SIDE WALL EXHAUST VENT TERMINATION IS LESS THAN SEVEN (7) FEET ABOVE FINISHED GRADE IN THE AREA OF THE VENTING, INCLUDING BUT NOT LIMITED TO DECKS AND PORCHES, THE FOLLOWING REQUIREMENTS SHALL BE SA

INSTALLA

1. At the time of installation of the side wall horizontal

vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector

TION OF CARBON MONOXIDE DETECTORS:

T FOR RESIDENTIAL

TISFIED:

with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented

gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector

ith alarm and battery backup may be installed on

he next adjacent floor level.

b. In the event that the requirements of this subdivi-

sion can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as required in accor-

dance with the above revisions shall comply with NFPA 720 and be ANS/UL 2034 listed and IAS certified.

3. SIGNAGE: A metal or plastic identification plate shall be perma-

nently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION: The state or local gas inspector of the side wall hori-

zontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.0(2)(a)1 through 4.

5. PRODUCT-APPROVED VENT/AIR-INTAKE: A product-approved vent terminal must be used and, if

applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions.

6. INST

ALLATION INSTRUCTIONS:

A copy of all installation instructions for all product approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

FURNACE SIZING

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

n Manual J titled, "Load Calculation" published by the Air

i Conditioning Contractors of America, 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

heir manual.

t In Canada, the maximum hourly heat loss for each heated

space shall be calculated in accordance with the procedures

escribed in the manuals of the Heating, Refrigeration and

d 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.

If the installation is a retrofit application, do not rely on the capacity of the existing heating equipment as a method to size the new fur 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 RPMs. If replacing an existing furnace, be sure that the existing ductwork can handle the amount of airflow necessary for a reasonable temperature rise. Most older gas furnaces operated with a system temperature rise of 70 - 100°F. This series furnace has been designed for operation with a system temperature rise (

∆T) of 35 - 65°F. If the furnace selected has an identical output capacity as the original furnace, a substantial increase in system airflow will be required.

nace. Many of the heat transfer multiples

Existing ductwork should be assessed for its air handling capabilities. For residential applications, the recommended air velocity of a supply air trunk duct is 700 feet per minute (fpm), and should not exceed 900 fpm. The recommended air velocity of a supply air branch run is 600 fpm, and should not exceed 900 fpm. These values are slightly lower for

lexible ducting. The recommended air velocity of a return

ir trunk duct is 600 fpm, and should not exceed 700 fpm.

a The recommended and maximum air velocity of a return air branch is 600 fpm.

The equal friction chart, as published by ASHRAE and HRAI, is the basis for the various air duct calculators available through heating supply companies.

IMPORTANT

The return air system is equally as important as the supply air system. An undersized return air system will prevent sufficient quantities of air from reaching the supply air system, properly sized or otherwise, and will consequently reduce the service life of the furnace and its components.

AIR CONDITIONING

This furnace may be used as part of an air conditioning system. The furnace wiring and control system are “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 warm ambient air inside the 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.

INSPECTION / ACCESS PANEL

If an air conditioning coil is not to be used in the supply air plenum, it is recommended that the outlet duct be provided with a removable access panel, which is accessible when installed so the heat exchanger may be viewed for possible openings using light assistance or a probe that can be inserted for sampling the air stream. The access cover must be fabricated in such a manner as to prevent leaks.

LOCATION of UNIT

General

1. The furnace is not weatherized. Select a dry indoor location.

2. Select a location where the exhaust and combustion air

iping can be routed between the furnace and their

p terminations with a minimum of lengths and fittings. Be sure to check that the proposed termination location will meet code requirements with respect to location and minimum clearances. (See venting section for

inimum and maximum limits.)

. Select a location as near as possible to the existing or

proposed duct system.

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 should be installed on a firm base when installed in the upflow position. This is typically a concrete floor if installing the furnace in a basement.

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. When installed in the horizontal position, the furnace may be supported from the bottom, or suspended.

8. When installed in the down flow position on a combustible floor, subbase kit #30476 is required (contact manufacturer for availability).

9. 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.

10. The furnace must be installed level, or tilted slightly down in the front, to allow for the proper drainage of condensate. The furnace may shut down during operation if the condensate does not drain freely away from the furnace.

11. 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.

Other Considerations:

1. This furnace is not to be used for temporary heating of buildings or structures under construction.

2. If this furnace is to be used with air conditioning and is

o be installed in an area over a finished ceiling or

t living area, install a field 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

he air conditioning evaporator coil assembly if

t applicable. Follow local codes.

3. These furnaces are approved for installation in attics, alcoves, utility rooms, closets and crawlspaces. 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 any other appliance, (hot water heater, for example).

4. If the furnace is to be installed in a residential garage, the burners must be a minimum of 18 inches (460 mm) above the floor

5. If the furnace is to be installed in a commercial (repair) garage, the burners must be a minimum of 4.5 feet (1375 mm) above the floor.

6. The furnace must be protected from physical damage by metal barriers or other acceptable means.

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

A partial list of these contaminants includes:

• Aerosols, particularly CFC based aerosols

• Air fresheners

• “Airplane” glue and similar cements

• Ammonia, as is commonly found in permanent wave solutions used in women’

• Anti-static fabric softeners used in clothes dryers

• Carbon tetrachloride

• Chlorinated cleaners and waxes

• Chlorine and bromine based swimming pool chemicals and treatments

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

• Dry cleaning solutions such as perchloroethylene

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

• Hydrochloric acid, muriatic acid, or other acid based masonry washing compounds

• Polyurethane and similar derivatives fumes

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

• Water softener salts and chemicals

s hair dressing salons

DIMENSIONS (Inches)

MODEL INPUT

WIDTH DEPTH HEIGHT SUPPLY

ABCFx G

RETURN

SIDE BOTTOM

D x E J x K L H

54,000

72,000

90,000

108,000

54,000

72,000

90,000

108,000

17.5

20.5

24.5

14 x 22 16 x 19 3/4 2

14 x 22 19 x 19 3/4

14 x 22 23 x 19 3/4

VENT

16.5 x 19

19.5 x 19

24 x 19

CLEARANCES

0" 0" 0"

LOOKING AT UNIT AS INSTALLED

Table 2 provides the certified clearances to combustibles.

IMPORTANT

This furnace requires a minimum of 24-inches of front clearance for service purposes. For this purpose, service

learance takes precedence over clearance to

c combustibles.

TABLE 2: CLEARANCES TO COMBUSTIBLES

TOP PLENUM

TOP/BOTTOM PLENUM SIDES UNIT FRONT

UNIT BACK UNIT SIDES UNIT BASE UNIT FLUE PIPE

ENCLOSURE

* 24" REQUIRED FOR SERVICE ** SUPPLY AIR END / RETURN AIR END *** CERTIFIED FOR CLOSET INSTALLATION ON COMBUSTIBLE FLOORING **** CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY WHEN INSTALLED

ON SPECIAL BASE PART #30476

UPFLOW

CLOSET

COUNTERFLOW

1" 1"

0.5"

0" *

0" 0"

0" ***

0.5" 0.5"

0" *

0" ****

CLOSET

See the appliance rating plate affixed to the furnace for specific model number, serial number and clearance to combustibles information.

HORIZONTAL

2.5"

0" *

1" **

CLOSET

ALL DIMENSIONS IN INCHES

IGURE 2: DIMENSIONS

TABLE 3: DIMENSIONS

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET.

PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

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 THA FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSE.

UPFLOW FURNACES ARE DESIGN CER INSTALLATION ON COMBUSTIBLE FLOORS. THIS SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.

THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, VINYL TILE, OR OTHER COMBUSTIBLE MATERIAL EXCEPT WOOD. INSTALLATION ON COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPER

DANGER

TY DAMAGE, PERSONAL INJUR

T THE

TIFIED FOR

Y OR DEA

TH.

DUCTWORK

Proper airflow is required for the correct operation of this furnace. Insufficient airflow may cause erratic operation,

ould cause the furnace to cycle on the high temperature

c limit, and may damage the heat exchanger. Excessive airflow may result in an excessively noisy duct system and may result in undesirable consequences such as creating uncomfortable drafts and causing drapes or curtains to

low around.

b If air conditioning is to be used with the furnace, the duct

system must be capable of delivering the correct amount of

irflow for each system.

a 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 should not exceed 0.5 inches water column.

Guide:

Filter free area (in2) = 144 x (CFM / desired velocity (fpm))

IMPORTANT

Some high efficiency filters have a greater than normal resistance to airflow. This can adversely affect furnace operation. Pressure check the static differential from before the filter to the supply.

NOTE

When calculating an air filter size use the free air not the advertised size.

NOTE

UNITS FOR 4 AND 5 TON CF AIR CONDITIONING MUST HAVE DUAL RETURN AIR INLETS FOR OPTIMAL AIRFLOW AND AIR FIL STATED BY THE FILTER MANUFACTURER, FOR EFFECTIVE AIR FILTRATION, ASSUME A MAXIMUM VELOCITY OF 300 FPM FOR DISPOSABLE TYPE FIL OR 600 FPM FOR PERMANENT TYPE FILTERS.

TION. IF NOT SPECIFICALLY

TRA

TERS,

WARNING

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY AIR DUCTWORK TO OR FROM ANY

THER HEAT-PRODUCING DEVICE SUCH AS A FIREPLACE

O INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, LOSS OF LIFE, OR PROPERTY

AMAGE.

Ductwork Steps:

1. Position the furnace to minimize ductwork length and fittings.

2. Cut open a return air inlet. The choices are: a) either side b) furnace bottom c) any combination, i.e. two sides or a side and the

bottom.

In all cases, cut the inlet air opening the full width of

NOTE

When two return air inlets are used, both must be equipped with filters.

CAUTION

DO NOT USE THE REAR PANEL AS A RETURN AIR INLET. THERE IS INSUFFICIENT AREA TO PERMIT ADEQUATE AIRFLOW.

3. Install the filter rack(s) (field supplied).

4. Connect the return air duct or fitting to the furnace. The connection should be as air tight as possible to prevent entraining combustion gases from an adjacent fuel burning appliance, or entraining combustion air for this furnace .

5. Ensure that there is adequate space and accessibility for the air filter

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

7. 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 flexible connectors, ensure that the adjoining duct is independently supported.

Adequate provisions for combustion and ventilation air must be in accordance with ANSI Z223.1 (NFP

5.3 "Air for Combustion and Ventilation" in the United

States, and CAN/CGA B149 in Canada. Check with local authorities for any additional building codes, bylaws or regulations.

A 54), section

INSTALLATION POSITIONS

he furnace can be installed in any of four positions:

• Upflow

• Downflow

• Horizontal left

• Horizontal right

aintain clearances to combustibles as outlined in Table 2.

M Support the furnace cabinet to prevent twisting or sagging.

General Considerations

When choosing an installation position the installer must consider the following connections:

• Combustion air intake

• Exhaust vent

• Gas pipe

• Electrical wiring

• Condensate drain trap

Also consider the air conditioning connections, a/c drain, access to filter(s) and access to furnace and a/c for repair.

The blower compartment should be completely isolated from the burner compartment. In tight rooms with other combustion devices, the blower compartment must be completely isolated from the room. The combustion compartment must also be completely isolated from the room (unless non-direct vent). Sometimes the knockout tool will punch too deep and open holes. Use caulking on the inside of the cabinet to seal any holes. Insure that the combustion door gasket is in good condition.

IMPORTANT

Always secure or support the exhaust vent and combustion air inlet piping to the floor joists or rafters to avoid sagging and possible fatigue of venting materials. This ensures proper drainage and preventing spilling of the products of combustion into the building.

IMPORTANT

If the pipe and fittings are to be other than PVC, use the proper cleaner, primer and cement for the dissimilar materials.

IMPORTANT

Drains and traps of furnaces installed in spaces subjected to freezing temperature must also be protected against freezing.

IMPORTANT

lean and de-burr all pipe cuts. The shavings must not

C be allowed to block the exhaust, combustion air inlet

r condensate drain lines.

Combustion Air Inlet Connection

The combustion air inlet fitting is a 2” PVC Socket to Pipe Thread adapter. Chose the intake location and open the appropriate knock out. Install the adapter to the exterior

anel using the gasket on the outside of the panel and the

p locknut on the inside of the panel.

IMPORTANT

If the pipe is increased in size with a reducer it must be on a vertical section of the pipe to facilitate draining the vent. Reducing the size of pipe to exit the house (as shown on page 19, Figures 4 and 6), the reducer can be on the horizontal.

WARNING

THERE MUST NOT BE ANY OPENINGS BETWEEN THE BLOWER DIVISION PANEL AND THE COMBUSTION COMPARTMENT. THE BLOWER COMPARTMENT IS UNDER GREATER SUCTION THEN THE COMBUSTION COMPARTMENT AND CAN PULL COMBUSTION AIR FROM THE BURNERS AND CAUSE INCOMPLETE COMBUSTION AND ERRATIC FURNACE OPERATION.

IMPORTANT

Keep pressure switch hose above heat exchanger drain and exhaust port.

Exhaust V

The exhaust vent must be clamped to the exterior panel(s) with the clamp provided. Place the gasket between the clamp and the side panel. Tighten clamp and fasten in place using the three screws provided.

The clamp should secure the vent pipe to prevent internal damage if the vent pipe is tampered with.

THE VENT MUST BE CLAMPED TO THE FURNACE PANEL USING THE GASKET AND CLAMP PROVIDED. THE INTAKE MUST USE THE THREADED PVC CONNECTOR WITH THE GASKET AND LOCK NUT.

ent Connection

ARNING

Instructions for Re-orienting Air Inducer

FIGURE A : RIGHT INDUCER POSITION

FIGURE B : LEFT INDUCER POSITION

SUGGESTED METHOD FOR SUSPENDING HORIZONTAL FURNACE

ALLOW ENOUGH ANGLE IRON OVERHANG TO PERMIT OPENING THE BLOWER DOOR

3/8 INCH THREADED ROD 2 INCH ANGLE IRON JAM NUTS LOCK WASHER FLAT WASHER

SUPPLY AIR PLENUM

RETURN AIR PLENUM

SUSPENDED INSTALLATION

This furnace comes assembled ready for left side or vertical venting. Rotate the inducer 180 degrees to exit the right hand side.

1. Disconnect inducer wire connections.

2. Remove pressure switch hoses.

3. Remove pressure switches.

4. Remove 4 inducer screws

5. Remove inducer.

6. Reverse the bands on the rubber drain coupling so the screws are accessible if necessary. (Do not reverse the drain coupling.) Confirm that directional arrows on drain coupling point away from inducer.

7. Remove the appropriate knock out.

8. Reinstall the inducer in the correct orientation with 4 screws removed in step 1.

9. Reinstall the pressure switches so that the switches and hose is above the heat exchanger drain.

10. Complete the external venting as installation requires.

11. Rotate the drain coupling so the drain holes are angled downward and tighten coupling bands.

12. Tighten the vent clamp and secure in place using the screws provided.

INSTALLATION POSITIONS

Non-Suspended Installation

Maintain clearances to combustibles as outlined in Table 2

on page 6. The furnace must be supported in such a way as to not allow twisting or sagging of the cabinet.

Horizontal Suspended Installation

The furnace may be suspended in either the horizontal right or left position by field fabricated a cradle of angle iron and threaded rod. Secure the furnace with 2 inch minimum slotted angle or equivalent, as shown in figure below. The furnace must be supported in such a way as not to allow twisting or sagging of the cabinet. Position the supports so as not to interfere with accessing the burner and blower compartments.

Upflow Installation

The combustion air and exhaust vent may exit through the top, left or right side of the cabinet when viewed in the upflow position. The inducer is installed so that the exhaust vent may exit the top and left sides without requiring rotation.

f exhaust vent exits the top panel, use the two street

I elbows to route the vent. One elbow secured to the inducer drain connector, will angle toward the front of cabinet with the second nested inside directed towards the top panel. (The 108,000 BTUH will require an extension between the inducer and the first elbow that is not provided.)

If exhaust vent exits the left-side panel the pipe can be routed straight outside the cabinet.

exists the right-side panel the inducer requires rotation.

The exhaust vent pipe exiting the cabinet in any installation should be long enough to install the vent clamp on the outside of the cabinet.

If exhaust vent

COMBUSTION AIR

EXHAUST VENT

CONDENSATE DRAIN

Downflow Installation

When the furnace is installed in the downflow position the combustion air and exhaust vent may exit through the left or right side of the cabinet (when viewed in the upflow position.). The inducer is installed so that the left side exits require no rotation.

If exhaust vent exits the left-side panel the pipe can be routed straight outside the cabinet.

If exhaust vent exists the right-side panel the inducer requires rotation.

The pipe exiting the cabinet in any installation should be long enough to install the vent clamp on the outside of the cabinet.

WARNING

WHEN INSTALLED IN THE DOWNFLOW POSITION ON A COMBUSTIBLE FLOOR, SUBBASE KIT #30476 IS REQUIRED. FAILURE TO INSTALL SUBBASE KIT COULD RESULT IN FIRE, DEATH OR SERIOUS INJURY.

The opening in the floor must provide adequate clearances to the combustible material.

A half-inch of clearance will be required between the plenum and the combustible material. If installed on a non-combustible material, zero clearance is required.

In the downflow installation, this furnace can only vent through the left or right side of the furnace.

The condensate drain trap can be mounted on the right or left side.

COMBUSTION AIR

EXHAUST VENT

CONDENSATE DRAIN

SUBBASE KIT - REQUIRED WHEN

INSTALLED IN THE DOWNFLOW POSITION ON A COMBUSTIBLE FLOOR

Horizontal Left Installation

In the horizontal left installation the combustion air and exhaust vent may exit through the top or left side of the cabinet (when viewed in the upflow position). It is not permissible to vent downwards. The inducer is installed so that the top and left side exits require no rotation.

f exhaust vent exits the top panel, use the two street

If exhaust vent exits the left-side panel the pipe can be routed straight outside the cabinet.

The pipe exiting the cabinet in any installation should be long enough to install the vent clamp on the outside of the cabinet.

Horizontal Right Installation

In the horizontal right installation the combustion air and exhaust vent may exit through the top or right side of the cabinet (when viewed in the upflow position). In the horizontal right installation, it is not permissible to vent downwards.

he right side exit is used.

If exiting the top panel, use the two street elbows to route the vent. One elbow secured to the inducer drain connector, will angle toward the front of cabinet with the second nested inside directed towards the top panel. (The 108,000 BTUH will require an extension between the inducer and the first elbow that is not provided.)

If exiting the right-side the pipe can be routed straight outside the cabinet after the inducer has been rotated.

The pipe exiting the cabinet in any installation should be long enough to install the vent clamp on the outside of the cabinet.

The inducer will require rotation if

NOTE

It is not permissible to use a rear of the furnace as a return.

IMPORTANT

The furnace must be installed level or sloping towards the front to facilitate proper drainage.

NOTE

It is not permissible to use a rear of the furnace as a return.

IMPORTANT

The furnace must be installed level or sloping towards the front to facilitate proper drainage.

COMBUSTION AIR

EXHAUST VENT

CONDENSA

TE DRAIN

CASE 1: FURNACE LOCATED IN AN UNCONFINED SPACE

nconfined space does not necessarily mean that combus-

U tion and ventilation will not have to be introduced from the outdoors, particularly in airtight homes. Refer to the appropriate installation code requirements regarding the minimum combustion air required for all fuel burning appliances located within the unconfined area.

f the amount of combustion and ventilation air is insuffi-

ient to properly operate the furnace and other fuel burn-

c ing appliances within the unconfined area, it will be necessary to supply it from the outdoors based on the criteria used when calculating the air supply for a confined space.

NOTE

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

CASE 2: FURNACE LOCATED IN A CONFINED SPACE

A confined space, (any space smaller than the minimums discussed in CASE 1), must have two air openings one within 12 inches of the ceiling and the other within 12 inches of the floor. 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 confined space.

If sufficient indoor combustion and ventilation air is available for the furnace and all other fuel burning appliances, even when clothes dryers, bathroom fans, range hoods, etc. are running, size each opening according to the appropriate installation codes.

NOTE

If using grilles to cover the two openings, factor in the free area of the grille. Typically, a grille will have a free area approximately 50% of its nominal size. Consequently, if the required opening is 10 inches x 10 inches , it will have to be doubled if using a sidewall grille with 50% free area.

IMPORTANT

CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUT-

DOOR AIR FROM ATTIC OR CRAWL SPACE

In this circumstance, refer to the appropriate installation code for the free area of the combustion and ventilation air openings. If other fuel burning appli-

nces are present, their combustion air and ventilation

ir requirements must be added to those of the fur-

ace. If the attic has an exhaust fan (power vent), it

n 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.

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.

Consult the appropriate installation code for the free area for openings. If other fuel burning appliances are present, their combustion air and ventilation air requirements must be added to those of the furnace.

IMPORTANT

The outdoor grilles must be installed in a location where they will not be obstructed in any manner.

If grilles are used on the outside wall, they must be sized properly. Most sidewall grilles have only 50% free area, so the grill size opening must be twice the size of the free air opening requirement.

WARNING

DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SP POSES. 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 COMPLETEL WITH OTHER USAGES.

ACES THA

T ARE USED FOR RETURN AIR PUR

Y ISOLATED FROM PORTIONS

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.

FIGURE 1

FURNACE VENTING

Direct Venting Pipe Connections

(USING OUTDOOR COMBUSTION AIR)

The direct vent configuration is the preferred installation method. The primary advantages are:

• Dedicated combustion air and vent piping eliminates the need to use already heated air for combustion purposes

• The probability of corrosive contaminants being present in the combustion air is greatly reduced

• The direct vent configuration is unaffected by any other appliances, exhaust fans, or other devices that tend to create negative pressure conditions while operating

• No vents for combustion and ventilation air are required in confined spaces

DANGER

READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT OR SUPPLY COMBUSTION AIR TO THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING, OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

DANGER

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 THA OUTSIDE AIR BE BROUGHT TO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE PERSONAL INJURY OR DEATH FROM CARBON MONOXIDE POISONING.

Combustion Air Inlet Piping

This furnace is certified as a Category I Type FSP Non-

Direct and Direct Vent Furnace. When installed as a direct

vent furnace, all combustion air is supplied from the outdoors via the plastic piping system. All components are field supplied except for the adapter used to connect the piping to the furnace.

DANGER

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

r craft rooms, furnaces installed near chemical storage

o areas.

The combustion air piping, like the exhaust piping, must be

ir tight throughout the system. The adapter joining the

ombustion air to the furnace is supplied with a gasket to

aintain the seal.

IMPORTANT

The supplied adapter is made of PVC. If planning to use ABS pipe, use an all-purpose cleaner and ABS to PVC transition cement. If planning to use CPVC pipe, use an all-purpose cleaner, a clear or purple primer and all-purpose cement approved for the purpose. Additional information about cleaners, primers, solvents and cements may be obtained from their manufacturers.

CAUTION

Combustion air must be free of acid forming chemicals such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants, and many other commercial and household products.

When burned in a gas flame, vapors from these products form acid compounds. Acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense.

Any furnace failure caused by corrosive elements is excluded from warranty coverage.

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

• Antistatic fabric softeners used in clothes dryers Carbon tetrachloride

• Chlorinated cleaners and waxes

•

• Chlorine and bromine based swimming pool chemicals

• Deicing salts or chemicals, e.g. rock salt, etc.

• Dry cleaning fluids 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

•

TABLE F RECOMMENDED AIR FILTER AREA (SQUARE INCHES), FOR DISPOSABLE AND PERMANENT TYPE FILTERS

COOL (TONS)

AIR FLOW (SCFM)

AREA (INCH2)

1.5

2.5

3.5

650

810

1000

1150

1350

1550

1750

312

389

480

552

648

744

840

156

194

240

276

324

372

420

919

1226

1532

1839

441

588

735

883

221

294

368

441

HEAT INPUT

(BTU/HR)

54,000

72,000

90,000

108,000

Air Filters

IAQ types of air filters may cause higher static, higher temperature rise and erratic furnace operation and, with an ECM drive, can cause blower over speed more noise. Also

he consumer may at some time want to add UV treatment,

nd electrostatic air cleaners or HEPA filters. Thus the return

a duct should be sized larger than traditionally and also more clearance space allow around the return duct for future

quipment.

e Angling the air filter is one method of installing a larger

area air filter. Table below shows the recommended air filter sizes. By examining the table one can see that many existing installations have undersized air filters, resulting in poorer air quality.

RECOMMENDED AIR FILTER AREA (SQUARE INCHES), FOR DISPOSABLE AND PERMANENT TYPE FILTERS

DISPOSABLE PERMANENT

Exhaust Vent Piping

WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE RETURN AIR OR SUPPLY AIR

UCTWORK.

D ALL RETURN AIR DUCTWORK MUST BE ADEQUATELY

SEALED AND SECURED TO THE FURNACE WITH SHEET

ETAL SCREWS. TAPE THE SHEET METAL SEAMS IN THE

M 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, CRACKS OR GAPS AROUND THE BASE, PROVIDING A SEAL 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.

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.

Definitions

"Vent" and "Chimney" refer to open passageways that convey vent gases from the furnace, or its vent connector, to the outside. Vents and chimneys usually run vertically or nearly vertically. When they serve only one gas appliance, they are called "dedicated" vents or chimneys. When they serve multiple gas appliances, they are called "common" vents or chimneys.

"Vent Connector" refers to a pipe or duct that connects the furnace to a vent or chimney. Vent connectors usually run from the furnace’s vent collar to the vent or chimney. Vent connectors may have vertical and horizontal runs.

"Venting System" refers to a continuous open passageway from the vent collar to the outside. Venting systems usually have a vent connector(s) and a vent or chimney systems commonly serve a single furnace, or a single furnace and a hot water heater venting systems are less common.

"Fan Assisted Combustion System" refers to an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. This series furnace uses a draft inducer to draw combustion products through the heat exchanger and is considered to have a fan assisted combustion system. Category I furnaces with fan assisted combustion systems must not be vented into single wall metal vents.

. Other multiple appliance

. V

enting

CAUTION

FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE OPERATION, FREEZE-UP OF THE VENTILATION AIR PIPING, OR SOOTING OF THE FURNACE.

Guidelines

• Venting may be vertical or horizontal. Minimum vent length - 25 total equivalent feet.

• (See page 18, Table 4 - Venting Table)

• Horizontal piping must slope back towards the furnace at a minimum rate of 1/4” to the foot, so that condensate drains towards the furnace.

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

• All vent runs through unconditioned space where freezing might occur should be insulated with 1” thick, medium density, foil-faced Fiberglass insulation. An equivalent “arm-aflex” 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.

• 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 PVC pipe 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.

• 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 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 winds, areas where higher gusts are dominant it is suggest to shorten the horizontal vent length, increase the diameter of the vent, or vent vertically.

The exhaust vent and combustion air intake shall be

• installed so that both are located in the same wind pressure zone.

JOINING PIPE AND FITTINGS

Acceptable Materials for Combustion Air and Exhaust Vent Pipe

The furnace products of combustion include both flue gases and condensate. All venting and drain materials are

lastic.

p The combustion air and vent piping and fittings may be

comprised of:

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

• PVC-DWV, ASTM D2665 or CSA B181.2

• ABS-DWV, ASTM D2661 or CSA B181.1

• Schedule 40 CPVC, ASTM F441 or CSA B137.6 In Canada, construct all combustion-air and vent pipes for

this unit of CSA or ULC S636 listed schedule-40 PVC, PVCDWV or ABS-DWV pipe and pipe cement. SDR pipe is not approved in Canada. In addition, the first three feet of the exhaust must be accessible for visual inspection.

Procedure for Cementing Joints (ASTM D2855):

It is preferable to use a single type of plastic throughout the venting and combustion air piping; however, if dissimilar piping or fitting materials are used, they must be joined with an appropriate transition cement. Dissimilar pipe segments may be joined together by mechanical means (i.e., 2” rubber coupling).

DANGER

SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE NEAR HEAT SOURCE OR OPEN FLAME. DO NOT SMOKE. AVOID SKIN OR EYE CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURE TO FOLLOW THESE GUIDELINES MAY RESULT IN FIRE, EXPLOSION OR ASPHYXIATION CAUSING PERSONAL INJURY OR LOSS OF LIFE.

WARNING

All pipe, fittings, solvent cement, primers and procedures must conform to American National Standards Institute and American Society for Testing Materials (ANSI / ASTM) standards.

PIPE AND FITTINGS: ASTM D1785, D2466 and D2564 PVC PRIMER AND SOLVENT CEMENT: ASTM D2564 ABS PIPE AND FITTINGS: Use ABS Primer and Solvent

Cement D2235 CPVC SOL

VENT CEMENT

: F493

IMPORTANT

For proper installation, DO NOT thin or use solvent cement that has become curdled, lumpy or thickened.

PROCEDURE:

This guide is intended specifically for PVC pipe; however, the general procedure applies to all plastic piping systems.

MATERIALS: PVC Cleaner / Primer and PVC Solvent Cement.

IMPORTANT

After cutting pipe, remove all ragged edges and burrs. This will reduce restriction (pressure drop) throughout the venting and combustion air system.

Direct Vent Piping Termination

CAUTION

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 installa-

ion can cause structural or exterior finish damage to

he building. Caulk all cracks, seams or joints within a 6

t foot radius of the termination.

1. Cut the pipe end square. Chamfer edge of pipe. Clean

the fitting socket and pipe joint area of all dirt, grease and moisture.

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

socket and pipe with cleaner / primer. Apply a liberal coat of primer to inside surface of socket and outside surface of pipe. DO NOT ALLOW THE PRIMER TO DRY BEFORE APPLYING THE CEMENT.

NOTE

If alignment is critical, make an alignment mark with a

lead pencil on the outside of the socket to the portion of pipe beyond the joint. This will allow proper alignment as the joint is processed.

Apply a thin coat of solvent cement to the inside surface of the fitting socket. Quickly apply a heavy coat of solvent cement to the pipe end and insert it into the socket with a slight twisting motion until it bottoms out. If alignment is critical, match up the pencil marks made prior to this step.

NOTE

Cement must be fluid; if not, re-coat.

4. Hold the pipe in the fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting. Failure to do this may result in a weak or leaky joint.

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time varies according to fit, temperature and humidity.

NOTE

Stir the solvent cement frequently while using. Use a natural bristle brush or the dauber supplied with the container. If a dauber was not supplied, a 1 inch brush is ideal.

Observe shelf precautions printed on containers. Minimize the exposure of the container’s contents to air. For applications below 32°F (0°C), use only low temperature-type solvent cement.

CAUTION

Improper location or installation can result in structural damage to the building, damage to the exterior finish of the building, or may allow recirculation or freezing of the flue gases onto or into the combustion air intake. Moisture in the flue gases condenses as it leaves the terminals. This moisture can freeze on exterior walls, soffits, and other nearby objects. Some discoloration is to be expected.

General Guidelines

The external portion of the piping in all cases is to consist of 2” pipe. If 3” pipe is used between the furnace and terminal, transition to 2” within 18” or less of the exterior wall.

When 3” pipe is used, exit the cabinet with 2” pipe. Reduce or increase immediately after exiting the cabinet in a vertical run making provisions to secure the vent bracket between cabinet and fitting.

Avoid locating the terminals where the flue gas could become stagnant and allow recirculation into the combustion air intake.

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.

void locating the termination too close to shrubs and

A other vegetation. The condensate may stunt or kill them.

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 flue 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.

Avoid locating the terminal in locations where dripping condensate may cause problems such as side walks, 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.

The vent terminal should be located no fewer than 6 feet from an inside corner formed by two exterior walls. A 10 foot distance is recommended.

PIPE SIZE

NUMBER OF 90° ELBOWS

MAXIMUM ALLOWABLE

STRAIGHT LENGTH OF EXHAUST OR INTAKE

0123456

MODEL

054

072

090

108

15065140601305512050110451004090

140601305512050110451004090

150

Recommended clearance for overhangs is a minimum of 1 foot vertically for each foot horizontally up to 6 feet.

As a protection against freezing, do not expose a 3 x 2 reducing coupling to outdoor ambient temperatures.

Any adjacent painted surfaces should be in good condition; no cracks, peeling paint, etc. If wooden surfaces that may be periodically exposed to flue gases are present, consider treating with a sealer.

Calculating Piping Length

When calculating allowable vent lengths, be sure to count all termination fittings in addition to counting the concentric vent as a straight pipe. The ventilation pipe extending through the roof must extend 18” above the highest point where it extends through the roof, surface and above any obstruction within an 18” horizontal distance. The ventilation pipe must extend a minimum of 12” above the anticipated snow level.

Exterior vent pipe greater than 24” should be insulated with 1/2” insulation to prevent moisture from freezing within the pipe and accumulating.

Size the ventilation pipe as specified 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.

WARNING

DO NOT CONNECT FURNACE TO A CHIMNEY OR FLUE SERVING OTHER APPLIANCES OR A SOLID FUEL BURNING APPLIANCE.

TABLE 4:

VENT LENGTHS- DIRECT/NON-DIRECT VENT LENGTHS

• Count concentric vent fitting as straight pipe. Use medium or long sweep elbows where possible.

• One 90

•

• For direct vent, the above is the length allowed for each vent (intake and exhaust)

• For non-direct vent, the above is length allowed for exhaust. The intake should have a two inch upside down “U” intake installed on the cabinet intake fitting.

elbow is equivalent to two 45

elbows.

TERMINATION OF COMBUSTION AIR AND VENTILATION PIPE USING A CONCENTRIC VENTING KIT

oncentric venting terminal kits may be used for this series

urnace. They provide a means of obtaining combustion air

nd exhausting products of combustion utilizing a single

a penetration through the exterior wall. This can be useful when there is limited wall space available. Kits are available in 2” and 3” sizes. Read the instructions supplied with the kit for additional installation instructions and details.

he concentric venting terminal has the combustion air intake

uilt into the assembly. If using the concentric vent terminal,

here must be a minimum of 12” clearance to grade or antici-

t pated snow level. There are no means available to raise the terminal externally. If planning to use this terminal kit, see Figures 5 and 6.

The concentric vent termination kits may also be used in the vertical position.

Figure 3

VENT

COMBUSTION AIR

AIN 12” CLEARANCE

MAINT (18” FOR CANADA) ABOVE HIGHEST ANTICIP

TED SNOW LEVEL.

MAINTAIN 12” CLEARANCE (18” FOR CANADA) ABOVE HIGHEST

Figure 4

STRAP (FIELD SUPPLIED)

1” MAXIMUM

ELBOW (FIELD SUPPLIED)

Figure 5

Figure 6

ANTICIPATED SNOW LEVEL. MAXIMUM 24” ABOVE ROOF.

HORIZONTAL TERMINATION OF COMBUSTION AIR

TOP VIEW

INTERIOR

EXTERIOR

AND EXHAUST VENT

orizontal Combustion Air Termination

The combustion air termination is a 2” medium or long sweep 90° elbow pointing downward to prevent rain from readily entering the combustion air intake piping. An intake screening is optional; however, unless there is a compelling reason to use one, the screen may actually

ncourage the formation of rime ice, which could cause

he intake to become blocked in certain weather

onditions.

Horizontal Exhaust Vent Termination

Horizontal vents should pass through the exterior wall. Figure 8 shows a standard horizontal vent detail. Terminate the vent approximately 8” or more from the wall. If it is not possible to obtain proper clearance to grade or anticipated snow level by a straight out configuration, the termination may be raised by the use of a pair of 90° elbows.

The exhaust termination is normally a 2” 45° elbow or a medium or long sweep 90° elbow pointing within 45° of the downward position, away from the combustion air intake terminal.

If the required clearance to grade or anticipated snow level cannot be obtained with the “straight through” c 2 gases may be expelled horizontally. Use the same size pipe as the interior run and count the fittings and length as part of the total vent length.

If winter prevailing wind conditions are variable and likely to occasionally blow flue gases back in on the combustion air intake, the exhaust termination may be raised 18-24” above the combustion air intake terminal to take advantage of the natural buoyancy of the flue gases to help prevent re-circulation of the exhaust. (Figure 9)

If the required clearance to grade or anticipated snow level cannot be obtained with the “straight through” configuration, the combustion air intake pipe may be “periscoped” up to 24” to gain extra height (Figure 9)

onfiguration, the exhaust pipe may be “periscoped” up to

4” to gain extra height. (Figure 9) In this case, the flue

NOTE

Length of pipe and elbows count toward maximum

allowable vent length as shown in Table 4.

Figure 7

EXHAUST VENT

COMBUSTION AIR

8”

12”

2”

12” CLEARANCE ABOVE GRADE OR

Figure 9

ANTICIPATED SNOW LEVEL

Figure 8

12”- 18”

GRADE OR ANTICIPATED SNOW LEVEL

18” MAX

OUTSIDE WALL

TOP VIEW

INTERIOR

EXTERIOR

VERTICAL TERMINATION OF

TOP VIEW

INTERIOR

EXTERIOR

COMBUSTION AIR

AND EXHAUST VENT

Vertical Combustion Air Termination

he combustion air termination is a pair of 2” medium or

ong sweep 90° elbows pointing downward to prevent rain

l from entering the combustion air intake piping.

If 3” piping is used, it should be reduced to 2” within 18” of the point where the pipe penetrates the roof. The termination inlet must be positioned within 3” of the companion exhaust piping.

The combustion air inlet must be located a minimum of 12” above the anticipated snow level, and 12” below the exhaust outlet.

ertical Exhaust Vent Termination

The exhaust vent may terminate in a vertical venting configuration through the roof.

No termination fitting is required if venting vertically through a roof. The end of the exhaust pipe must be 12” higher than the entrance of the combustion air intake terminal.

The exhaust pipe extending through the roof must extend a minimum of 18” above any obstruction within an 18” horizontal distance.

MULTIPLE VENTING

IMPORTANT

When installing multiple furnaces in close proximity, each requires dedicated combustion air and exhaust venting.

WARNING

COMMON VENTING IS PROHIBITED

If two of these furnaces are to be installed in close proximity, the combustion air intake and exhaust terminations may be installed as shown in Figures 10.

If more than two furnaces are being installed in close proximity, each additional combustion air intake and exhaust termination set must be installed a minimum of 4 feet apart. This is an exception to the 10 foot requirement mentioned in the “Location” section on the previous page. If using the concentric venting kits, two terminals may be centered 12 inches apart.

Figure 10

COMBUSTION AIR

EXHAUST

8”

12”

2”

12” CLEARANCE

HIGHEST ANTICIPATED SNOW LEVEL.

ABOVE GRADE OR

COMBUSTION AIR

EXHAUST

8”

12”

2”

12” CLEARANCE

HIGHEST ANTICIPATED SNOW LEVEL.

8”

ABOVE GRADE OR

NON-DIRECT VENT FURNACE INSTALLATIONS (USING INDOOR COMBUSTION AIR)

The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside the structure. Non-direct vent installations require only an exhaust vent pipe.

on-direct venting may be desirable when:

• Using outdoor combustion air is not practical

• The furnace is in a garage or attic

• Provisions are not made for routing of combustion air

• The outdoor environment may contain contaminants undesirable for combustion

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.

DANGER

SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE NEAR HEAT SOURCE OR OPEN FLAME. DO NOT SMOKE. AVOID SKIN OR EYE CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURE TO FOLLOW THESE GUIDELINES MAY RESULT IN FIRE, EXPLOSION OR AS-PHYXIATION CAUSING PERSONAL INJURY OR LOSS OF LIFE.

Connecting a Non-Direct Vent to the Furnace

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.

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 RESUL SONAL INJURY OR LOSS OF LIFE.

TING IN PROPERTY DAMAGE, PER-

IMPORTANT

f the furnace is to be installed in the vicinity of other

I fuel burning appliances, adequate combustion air must be available for the non-direct vent appliances. See Section 10 of this manual, “Determining Combustion Air.”

IN THE U.S.A.

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

• The clearance from the bottom of the terminal to grade shall be 12” or increased to maintain 12” above the anticipated accumulated snow level.

• 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 below, 4 feet horizontally from, or 1 foot above any door, window, soffit, under eave vent or gravity air inlet to the building.

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

• Locate the vent terminal 3 feet above any forced air inlet located within 10 feet. Any fresh air or make-up air inlet, such as for a dryer or furnace area is considered a forced air inlet. The vent terminal should be located no fewer than 6 feet from an inside corner formed by two exterior walls; a 10 foot distance is recommended.

Recommended clearance from overhangs is a minimum of 1 foot vertically for each foot horizontally up to 6 feet.

IN CANADA

In addition to the general guidelines, in Canada, the nondirect 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 above a paved sidewalk or paved driveway located on public property;

• Within 6 feet of a mechanical air supply inlet to any building;

•

Above a meter/regulator assembly within 3 feet horizontally of the centerline of the regulator;

• Within 6 feet of any service regulator vent outlet;

• Less than 12” above grade level or anticipated snow level;

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

Within 12” 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 floor, and (b) the distance between the top of the vent termination and the underside of the veranda, porch or deck is greater than 12”.

A vent shall not terminate directly above a sidewalk or paveble Cell Footnoted driveway that is located between two single

Other Then Direct Vent Terminal Clearances

A = Clearance above grade, veranda, 12 in (30 cm) 12 in (30 cm)

porch, deck, or balcony

B = Clearance to window or door that 6 in (15 cm) for appliances 10,000 4 ft (121 cm) below or to side of

may be opened Btuh (3 kW), 12 in (30 cm) for opening; 1 ft (30 cm) above opening

C = Clearance to permanently closed * *

window

D = Vertical clearance to ventilated soffit * *

located above the terminal within a horizontal distance of 2 ft(61 cm ) from the center line of the terminal

E = Clearance to unventilated soffit * *

F = Clearance to outside corner * * G = Clearance to inside corner * * H = Clearance to each side of center 3 ft (91 cm) within a height 15 ft *

line extended above ( 458 cm) above the meter / regulator meter/regulator assembly assembly

I = Clearance to service regulator 3 ft (91 cm) *

vent outlet

J = Clearance to nonmechanical air 6 in (15 cm

supply inlet to building or t he (3 kW),12 in (30 cm) for appliances > opening; 1 ft (30 cm) above combustion air inlet to any other 10,000 Btuh (3 kW) and 100,000 Btuh opening appliance (30 kW), 36 in (91 cm) for appliances

K = Clearance to a mechanical air supply 6 ft (183 cm) 3 ft (91 cm) above if within 10 ft

inlet (305 cm) horizontally

L = Clearance above paved sidewalk or 7 ft (213 cm) ** 7 ft (213 cm)

paved driveway located on public property

M = Clearance under veranda, porch 12 in (30 cm) *** *

deck. or balcony

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B1 49.1, the following statement shall be included:

appliances > 10,000 Btuh (3 kW) and 100,000 Btuh (30 kW), 36 in (91 cm) for appliances > 100,000 Btuh (30 kW)

) for appliances 10,000 Btuh 4 ft (121 cm) below or to side of

> 100,000 Btuh (30 kW)

"Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's

installation instructions."

Canadian Installations US Installations

family dwellings and serves both dwellings

Permitted only if veranda, porch ,deck, or balcony is fully open on a minimum of two sides beneath the floor.

***

232

Direct Vent Terminal Clearances

Canadian Installations US Installations

A = Clearance above grade, veranda, 12 in (30 cm) 12 in ( 30cm )

porch, deck, or balcony

B = Clearance to window or door that 6 in (15 cm) for appliances 10,000 6 in (15 cm) for appliances 10,000

may be opened Btuh (3 kW),12 in (30 cm) for Btuh (3 kW), 9 in (23 cm) for

C = Clearance to permanently closed * *

window

D = Vertical clearance to ventilated soffit * *

located above the terminal within a horizontal distance of 2 ft(61 cm) from the center line of the terminal

E = Clearance to unventilated soffit * *

F = Clearance to outside corner * * G = Clearance to inside corner * * H = Clearance to each side of center 3 ft (91cm ) within a height 15 ft *

line extended above (457 cm) above the meter / regulator

eter/regulator assembly assembly

I = Clearance to service regulator 3 ft (91 cm)

vent outlet

J = Clearance to nonmechanical air 6 in (15 cm) for appliances 10,000 Btuh 6 in (15 cm) for appliances 10,000 Btuh

supply inlet to building or the (3 kW),12 in (30 cm) for appliances > (3 kW ), 9 in (23 cm) for appliances > combustion air inlet to any other 10,000 Btuh (3 kW) and 100,000 Btuh 10,000 Btuh (3 kW) and 50,000 Btuh appliance (30 kW ), 36 in (91 cm) for appliances (15 kW), 12 in (30 cm) for appliances

K = Clearance to a mechanical air supply 6 ft (183 cm) 3 ft (91 cm) above if within 10 ft

inlet (305 cm) horizontally

L = Clearance above paved sidewalk or 7 ft (213 cm) ** *

paved driveway located on public property

M = Clearance under veranda, porch 12 in (30 cm) *** *

deck or balcony

appliances > 10,000 Btuh (3 kW) and appliances > 10,000 Btuh (3 kW) 100,000 Btu (30 kW), 36 in (91 cm) and 50,000 Btuh (15 kW), 12 in (30 cm) for appliances > 100,000 Btuh (30 kW) for appliances > 50,000 Btuh (15 kW)

> 100,000 Btuh (30 kW) > 50,000 Btuh (15 kW)

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B1 49.1, the following statement shall be included:

"Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's installation instructions."

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two

single family dwellings and serves both dwellings

*** Permitted only if veranda, porch ,deck, or balcony is fully ope

n on a minimum of two sides beneath the floor.

CONDENSATE DRAINS

The furnace will condense as much as a half pound of water per hour (approximately 2 imperial quarts, 2 quarts or 2 draining the condensate away. The furnace is supplied with a drain trap assembly. See

page 26, Figures 11-14 for possible locations of the drain trap.

The drain coupling on the inducer will work better if the drain holes are pointed down about 15 degrees. The drain hose supplied with the furnace is long enough to reach either side panel; however, it must be cut near the blower division panel and fitted with the elbows and clamps provided. This is to prevent kinking in the drain lines.

/4liters). It is necessary to make provisions for

/2U.S.

DRAIN PIPING

ondensate from the outlet of the drain trap assembly

C must be conveyed to a floor drain, sump pit, or, if these are unavailable, to a condensate pump. If using a condensate pump, be sure that it is approved for use for furnace

ondensate.

CAUTION

Do not drain the condensate outdoors. Do not run the condensate line through areas where freezing might occur. Freezing of condensate can result in erratic furnace operation and in property damage.

CAUTION

The two inlets to the drain trap are for vent pipe and condensate collection. The vent pipe inlet is smaller than the condensate collection inlet. Ensure that the drain hoses are properly connected.

DRAIN HOSE INST

1. Select a drain trap location suitable for the orientation of the furnace and remove the corresponding knockouts. See page 26, figures 11-14.

2. Affix the drain trap assembly to the exterior of the side panel when the furnace is upflow or downflow using two screws provided. For horizontal positions the installer will need to use the mounting bracket supplied and secure the bracket to the top panel. Remove two top panel screws and fasten bracket to top panel with removed screws. Secure trap assembly using screws provided to the mounting bracket.

2. Slide a hose clamp over the end of each hose.

3. Slide each hose over the appropriate inlet.

4. Slide each hose clamp to approximately 1/8” from the end of the hose.

5. Fasten each drain hose to its inlet by tightening the hose clamps.

6. Cut each drain hose near the blower division panel, at the point where kinking is able to occur.

7. Slide a hose clamp over the ends of the hose connect ing to the vent drain and condensate drain.

8. Insert an end of the plastic elbow (supplied) into each hose. Cut hose lengths from the remaining lengths of hose

9. to fit between elbows and the drain trap inlets of both the vent drain and the condensate drain.

10. Slide a hose clamp over the ends of the hoses and secure to their appropriate connection. Slide each hose clamp to approximately 1/8” to 1/4” from the end of the hose then tighten.

ALLATION

The condensate drainage configuration requires a vent. It takes less than a one inch rise anywhere along the horizontal route of the drain tube to create a vapor lock, which will prevent condensate from draining away freely, and result in erratic furnace operation.

IMPORTANT

If an air conditioning evaporator coil drain is to share the furnace drain line, it should be connected with a tee fitting down-stream from the trap. Do not connect the evaporator coil condensate drain upstream of the furnace drain trap assembly

FIGURES 11-14 : CONDENSATE TRAP / CONDENSATE

DRAINAGE WITH VENT.

(NEXT PAGE)

CAUTION

Ensure that drain hoses do not create traps prior to the condensate trap assembly. A secondary trap will cause intermittent operation due to the pressure switches opening.

HORIZONTAL FLOW RIGHT

CONDENSATE TRAP

HORIZONTAL FLOW LEFT

UPFLOW

DOWNFLOW

CONDENSATE

CONDENSATE TRAP

TRAP

FIGURE 11 FIGURE 12

FIGURE 13

FIGURE 14

CONDENSATE DRAIN INSTALLATION

1. Identify which side the condensate drain trap will be nstalled on the unit. Condensate trap may be mount-

i ed on either the left or right side of the unit, when looking at the front. Some installation positions will only allow one option to mount the drain.

. Using the appropriate template (left vs. right), mark

the mounting and drain holes.

. Drill holes and de burr, if necessary

4. Secure the condensate drain trap to the side of the fur-

ace using the mounting holes that were just drilled

5. Install one rubber grommet (provided) into each of the

drain holes and then insert the 90 degree (black) drain tubes so that they extend down into the top of the drain trap.

Inside the top front cover, connect the drain tubing

from the flue connector to one of the drain pipes that were just installed.

Do the same for the second drain pipe located located

in the lower right of the inner front panel. 1/2 ID tubing should be used. It may be necessary to secure the tubing with a hose clamp depending on the fit. Be cautious not to over tighten the clamp.

7. Pipe the remainder of the drain to the condensate

pump using PVC pipe. A 3/4” PVC coupling will fit over the drain connection on the trap.

IMPORTANT

The condensate drain trap assembly should be full of water before starting the furnace.

CONDENSATE NEUTRALIZERS

Some local codes may require the use of a condensate neutralizer. If the furnace condensate is to be routed to a septic system, it may be advisable to use a condensate neutralizer.

Condensate neutralizers such as the Ward Industries 90+ Neutralizer are available through heating supply wholesalers.

When condensate neutralizers are used, it is advisable to install it with an overflow bypass tube.

A - Condensate

Trap Assembly

B - Open to

Atmosphere

C - Standpipe (1/2"

PVC)(Minimum 1"

Higher than Trap

Assembly)

D - Tee(1/2" PVC) E - Overflow

Bypass Tube

AS SUPPLY

WARNING

THIS FURNACE IS FACTORY EQUIPPED TO BURN NATURAL GAS ONLY.

CONVERSION TO L.P. GAS REQUIRES SPECIAL KIT No.

194301570001. AILURE TO USE THE PROPER CONVERSION KIT CAN

F CAUSE FIRE, EXPLOSION, CARBON MONOXIDE POISONING, PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

CAUTION

CONVERSION OF THIS FURNACE REQUIRES SPECIALIZED EQUIPMENT. A TRAINED AND QUALIFIED INSTALLER, SERVICE AGENCY OR GAS SUPPLIER MUST COMPLETE CONVERSION.

CAUTION

CONNECT THIS FURNACE ONLY TO GAS SUPPLIED BY A COMMERCIAL UTILITY OR SUPPLIER. PRIVATE GAS WELLS DO NOT GENERALLY PROVIDE GAS WITH CONSISTENT, UNIFORM AND PREDICTABLE HEATING VALUES AND DENSITIES. MANY NON-COMMERCIAL WELLS CONTAIN IMPURITIES SUCH AS SULPHUR, WHICH MAY DAMAGE THE FURNACE. THIS FURNACE CANNOT OPERATE PROPERLY OR SAFELY USING FUELS OUTSIDE NORMAL COMMERCIAL STANDARDS.

Gas Piping

In the United States, the gas piping should be installed in accordance with ANSI Z223.1 / NFPA 54 and any local codes. In Canada, the gas piping should be installed in accordance with CAN/CSA-B149, and in accordance with any local codes.

The gas piping may enter the furnace from either side. Install a BMI ground joint union between the gas valve and

the side panel to allow easy removal of the burner for service purposes.

Install a manual gas shutoff valve and drip leg as close to the furnace as possible. Some local codes call for the manual gas shutoff valve to be located between 4 to 5 feet above floor level to prevent tampering by small children. Ensure that the valve is readily accessible.

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance.

CAUTION

ENSURE THAT THE MANUAL SHUTOFF VALVE AND GAS VALVE ARE NOT SUBJECTED TO HIGH PRESSURES.

DISCONNECT THE MANUAL SHUTOFF VALVE AND GAS VALVE DURING ANY PRESSURE TESTING THAT EXCEEDS 1/2 P.S.I.G. (3.45 KPA

The natural gas inlet supply pressure should be 5 to 10.5 inches water column (w.c.); 7 inches w.c. is recommended.

The L.P. gas inlet supply pressure should be 11 to 13 inches w.c.; 12 inches w.c. is recommended.

These pressures must be maintained while all other gas fired appliances are operating at maximum conditions.

Do not exceed 13 inches w.c. inlet pressure with LP. Do not exceed 10.5 inches w.c. inlet pressure with NG.

The gas valve has an adjustable internal regulator for controlling burner manifold pressure. Burner manifold pressure is listed on the furnace rating plate.

Leak Testing

All new gas piping installations should be pressure tested as specified by CAN/CGA-B149 or NFPA 54 ANSI Z223.1 or ANSI/NFPA 58, Standard for the Storage and Handling of Liquefied Petroleum Gases.

IMPORTANT

YS USE A BACKUP WRENCH TO PREVENT

AL TWISTING OF THE CONTROL ASSEMBLY AND GAS VALVE. ANY STRAINS ON THE GAS VALVE CAN AFFECT POSITIONING OF THE ORIFICES RELATIVE TO THE BURNERS. THIS COULD RESUL OPERATION.

T IN F

AULTY BURNER

Gas piping that has not been pressure tested, from the

GAS VALV E

manual shutoff valve to the furnace gas valve for example, should be leak tested using an electronic combustible gas detector, a commercially prepared leak detector such as Gas Leak Detector® or Search®, or other locally approved method. A leak detector solution can be prepared by mixing

small quantity of dish detergent with water and daubing

t onto the gas piping and connections.

WARNING

NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER.

NEVER USE A MATCH, TAPER, CIGARETTE LIGHTER, FLAME OR ANY OTHER IGNITION SOURCE TO CHECK FOR LEAKS IN A GAS LINE.

FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.

CONVERSIONS

High Altitude

In the United States, the modifications for high altitude are based on a 4 percent reduction of input capacity for every 1000 feet above sea level. Table on page 30 illustrates the impact of altitude for selected elevations. Ratings shown apply to the highest elevation in range.

Consult with local fuel suppliers or authorities to determine local regulations or customs.

In Canada, the furnace may be converted for high altitude (2000 - 4500 feet) by changing the burner orifices. Use Kit No. 30552. The kit contains both natural gas and L.P. gas orifices; see Table on page 30.

Natural to L.P. Gas

This series furnace is manufactured as a natural gas (sea level) appliance. It may be converted to L.P. gas with the use of Kit No.194301570001(contact manufacturer for availability). The kit contains the orifices needed for all models, the regulator spring for the gas valve, and a label to affix adjacent to the appliance rating plate to alert subsequent service technicians of the conversion.

. to Natural Gas

L.P

Although the furnace is manufactured initially as a natural gas appliance, if after an L.P. Gas conversion it becomes necessary to convert back to natural gas, and if the original parts are unavailable, Kit No. 194301580001 may be purchased. It is similar in nature and content to the L.P. Gas

conversion kit.

onversion Steps

To convert from sea level to high altitude, from natural gas to L.P. gas, or from L.P. gas to natural gas, follow these steps:

Turn off gas supply to the furnace if applicable.

1. Shut off electrical power to the furnace if applicable.

2. Remove the upper front door to expose the gas train and urner assembly.

3. Unfasten the ground joint union between the gas valve

and gas supply piping if applicable.

4. Unfasten the burner manifold pipe from the burner

ssembly. It is held in place by 2 screws on either end of

a the manifold pipe.

5. Remove the existing orifices with a 7/16 inch socket, box

or open-end wrench. Install the replacement orifices. The orifice spuds are brass, and do not normally require pipe dope. A light grease may be used to lubricate the threads. The orifice spuds have tapered threads; do not over-tighten them.

If completing a fuel conversion, remove the protective screw cap from the gas valve regulator adjustment. Remove the regulator adjustment screw by turning it counterclockwise. Remove the existing regulator springs.

6. Install the new regulator springs.

NOTE

If converting the gas valve, the regulator spring is tapered. The tapered end (small end) is inserted back into the gas valve regulator adjustment cavity.

7. Reinstall the adjustment screw. Give it 3 full clockwise turns initially. Do not reinstall the protective screw cap yet.

8. Reinstall the burner manifold pipe assembly following steps 4, 5, and 6 in reverse order.

3 Pin Connector

Regulator Adjustment

Regulator Vent

On/Off Switch

Inlet Pressure Post Set Screw

Regulator Adjustment

Outlet Pressure Post Set Screw

For USA HIGH ALTITUDE SPECIFICATIONS

Rating Plate

High Fire

Input BTU/hr Altitude(ft) Input Output Input Output Natural Gas LP Gas

(BTU/hr)

0-2000 54000 51300 35100 33350 1.95mm 1.20mm

2000-3000 47520 45144 30888 29344 1.90mm 1.15mm

54,000 3000-4000 45360 43092 29484 28010 1.90mm 1.10mm 3

4000-5000 43200 41040 28080 26676 1.85mm 1.10mm 5000-6000 41040 38988 26676 25342 1.85mm 1.10mm

0-2000 72000 68400 46800 44460 1.95mm 1.20mm

2000-3000 63360 60192 41184 39125 1.90mm 1.15mm

72,000 3000-4000 60480 57456 39312 37346 1.90mm 1.10mm 4

4000-5000 57600 54720 37440 35568 1.85mm 1.10mm 5000-6000 54720 51984 35568 33790 1.85mm 1.10mm

0-2000 90000 85500 58500 55600 1.95mm 1.20mm

2000-3000 79200 75240 51480 48906 1.90mm 1.15mm

90,000 3000-4000 75600 71820 49140 46683 1.90mm 1.10mm 5

4000-5000 72000 68400 46800 44460 1.85mm 1.10mm 5000-6000 68400 64980 44460 42237 1.85mm 1.10mm

0-2000 108000 102600 70200 66690 1.95mm 1.20mm

2000-3000 95040 90288 61776 58687 1.90mm 1.15mm

108,000 3000-4000 90720 86184 58968 56020 1.90mm 1.10mm 6

4000-5000 86400 82080 56160 53352 1.85mm 1.10mm 5000-6000 82080 77976 53352 50684 1.85mm 1.10mm

(BTU/hr)

*MANIFOLD PRESSURE NATURAL GAS=3.5 INWC **MANIFOLD PRESSURE L.P. GAS=10.5 INWC

Low Fire Orifice

(BTU/hr)

(mm)* (mm)**

Qty

For- CANADA HIGH ALTITUDE SPECIFICATIONS

Rating Plate Input BTU/hr Altitude(ft) Input Output Input Output Natural Gas LP Gas

54,000

72,000

90,000 5

108,000

0-2000 54000 51300 35100 33350 1.95mm 1.20mm

2001-4500 48600 46170 31590 30011 1.90mm 1.15mm

0-2000 72000 68400 46800 44460 1.95mm 1.20mm

2001-4500 64800 61560 42120 40014 1.90mm 1.15mm

0-2000 90000 85500 58500 55560 1.95mm 1.20mm

2001-4500 81000 76950 52650 50018 1.90mm 1.15mm

0-2000 108000 102600 70200 66690 1.95mm 1.20mm

2001-4500 97200 92340 63180 60021 1.90mm 1.15mm

*MANIFOLD PRESSURE NATURAL GAS=3.5 INWC **MANIFOLD PRESSURE L.P. GAS=10.5 INWC

High Fire Low Fire Orifice

(BTU/hr)

(mm)* (mm)**

Qty

SETTING THE MANIFOLD (Outlet) GAS PRESSURE

(F92-1003 36G Valve Pressure Check Kit)

The manifold outlet pressure is specified on the rating plate.

1. Shut off the gas upstream of valve and move valve switch to OFF.

. Using the 3/32 inch hex wrench that is included in the

valve pressure check kit, rotate outlet pressure tap screw one revolution counter-clockwise.

. Attach the 5/16 inch hose that is included in the valve

pre check kit to the outlet pressure boss of the valve. Hose should overlap boss 3/8 inch.

4. Connect 5/16 inch side of connector that is included in the valve pressure check kit to the hose on outlet boss. Connect 1/4 inch side of connector to manometer hose.

5. Turn on gas supply to valve and move valve switch to the ON position.

6. Turn on furnace. For the two stage valve the low rate must be adjusted first and then the high rate. This can be done by wiring the Thermostat so that only low fire runs. Turn off the 1-stage T-stat mode on the control board if set!

Remove regulator cover screw from the high or low outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclock wise decrease pressure. Always adjust regulator as specified on the furnace rating label.

Natural Gas: Low outlet pressure is limited to 1 to 4” W.C. range and high outlet pressure 2 to 5” W C range. The valve cannot be adjusted outside this range and the high outlet pressure setting must always be set at least 1” above the low outlet pressure setting.

LP Gas: Low outlet pressure is limited to 6 to 10” W.C. range and high outlet pressure in the 8 to 12” W.C. range. The valve cannot be adjusted outside this range and the high outlet pressure setting must always be set at least 2” above the low outlet pressure setting.

7. Using a leak detection solution check for leaks at hose connections.

DANGER

SHUT OFF GAS AND FIX LEAKS IMMEDIA PROCEEDING.

8. Read manometer. This reading is the system outlet/supply pressure.

9. Follow manufacturer’s instructions to adjust outlet/supply pressure, if necessary.

Shut-off gas supply upstream of valve and move the

10. valve switch to the OFF position.

11. Remove manometer and hose from outlet boss.

TELY BEFORE

12. Turn outlet pressure tap screw clockwise to seal the pressure point using the supplied hex wrench. Tighten to 13 in-lbs. minimum. Return all pressure regulator caps.

13. Turn on gas supply to valve and move valve switch to the ON position.

14. Turn on furnace following manufacturer instructions.

15. Using leak detection solution check for leaks at outlet

ressure tap. Shut off gas and fix all leaks immediately

p before proceeding.

If problems were encountered with obtaining enough pressure on the manifold, first examine the gas piping

ystem to ensure that it is correctly sized. Pipe sizing is

s specified in ANSI Z223.1/ NFPA 54 in the U.S., or the B148 Natural Gas and Propane Installation Code in Canada.

SETTING THE SUPPLY GAS PRESSURE

(F92-1003 36G Valve Pressure Check Kit)

1. Back inlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn) with a 3/32 inch Allen wrench.

2. Attach a hose and manometer to the inlet pressure boss of the valve. The manometer should be capable of reading 0 -15 inches water column.

3. Turn on the gas supply and electrical power to the furnace.

4. Start the furnace, and any other gas burning appliances on the same gas piping system.

5. Note the gas inlet pressure. It should be: Natural Gas: 5 to 10.5 inches water column L.P. Gas: 11 to 13 inches water column.

6. If working on a natural gas system, contact the gas utility. They may insist on any service regulator adjustments being made by their own staff.

7. Adjustments are made in a similar fashion as the gas valve regulator. Turn the adjustment screw clockwise to increase manifold pressure, or counter clockwise to reduce manifold pressure. When the correct pressure has been established, securely replace the service regulator protective screw cap.

8. Shut off the gas at the manual valve and remove manometer hose from inlet pressure boss.

DANGER

A TRAINED, QUALIFIED TECHNICIAN MUST DO ALL REGULA OR ADJUSTMENTS CAN RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR LOSS OF LIFE.

In some circumstances, high inlet pressure can be remedied with the use of an inline appliance regulator appliance regulator is used, ensure that it has the capacity to adequately handle the gas volume required by the furnace and any other appliances receiving gas from the header serving the furnace.

TOR ADJUSTMENTS. IMPROPER MODIFICATIONS

. If an inline

ELECTRICAL SPECIFICATIONS

Before proceeding with the electrical connections, ensure that the available electrical supply is compatible with the voltage, frequency, and phase listed on the appliance rating

late.

p All furnaces are rated 120 VAC, 60 Hz, 1 phase. The

amperage rating is indicated on the furnace rating plate. Each furnace requires a dedicated overcurrent device either

a circuit breaker or a Type D, time delay fuse. It is permissible to connect furnace accessories such as humidifier transformers, condensate pumps and electronic air cleaners. If adding accessory equipment to the furnace circuit, ensure that the combined amperages listed on the appliance rating plates do not exceed the rating of the over current device.

IMPORTANT

USE COPPER CONDUCTORS ONLY

If the junction box must be moved to the right hand side:

1. Unfasten the junction box from the left hand side. . Remove the right side panel knockout.

3. Remove the junction box cover hook screw and reinstall

t on the opposite side of the box.

4. Fasten the junction box to the right hand panel.

IMPORTANT

L1 (hot) and L2 (Neutral) polarity must be observed when making field connections to the furnace. The ignition control may not sense flame if L1 and L2 are reversed. The ground is also essential.

DANGER

SHUT OFF ELECTRICAL POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.

DANGER

THE FURNACE CABINET MUST HAVE AN UNINTERRUPTED GROUND.

A GROUND WIRE IS PROVIDED IN THE ELECTRICAL JUNCTION BOX.

DO NOT USE GAS PIPING AS A GROUND. FAILING TO GROUND THE FURNACE PROPERLY CAN

RESULT IN ELECTRIC SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

In the United States, all electrical work must be in accordance with the latest edition of the National Electrical Code, ANSI / NFPA 70, in Canada, all electrical work must be in accordance with the latest edition of CSA-C22.1, Canadian Electrical Code Part 1, and any applicable local code.

Although a suitably located circuit breaker may serve as a service switch, a separate service switch is recommended.

A separate service switch is necessary if the circuit breaker is in a location where accessing it would require getting close to the furnace, or if the furnace is located between the main electrical panel and the entry to the furnace room. The furnace switch (service switch) should be clearly labeled and installed in a location where it is not likely to be mistaken as being a light switch or similar control.

Furnace Connection

: The furnace is shipped fully wired except for the

120V connections to the house wiring. The furnace power connections are made in a junction box inside the blower compartment. The junction box is factory installed on the left hand side; however, it may be moved to the right hand side. The junction box contains a BLACK wire to be connected with L1 (hot), a WHITE wire to be connected with L2, the Neutral, and a GREEN wire to be connected to the ground.

IMPORTANT

The furnace shall be installed so the electrical components are protected from water.

WARNING

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECTRICAL SHOCK, PERSONAL INJURY, OR LOSS OF LIFE.

CAUTION

ELECTRICAL WIRING AND COMPONENTS MUST BE PROTECTED FROM MOISTURE, INCLUDING WATER AND CONDENSATE.

Low Voltage Wiring

The low voltage terminals are located on the control board mounted to the blower assembly; see Figure 15 on page 37.

The furnace is prewired for air conditioning. Insert the thermostat and air conditioner contactor low voltage wiring through the bushing provided in the side panel. Route the control wiring through the blower compartment to the 24 volt terminal screws.

Thermostat

The room thermostat must be compatible with the integrated control in the furnace. Electromechanical thermostats should be rated 30 V / 1.5 amps.

Most electronic or microprocessor based thermostats except those with "current robbing" circuits should work satisfactorily manufacturer for technical and installation details.

Most compatibility problems can be overcome by the use of an isolation relay 24-volt coil. The switch ratings should be a minimum of 0.5 amps; see figure on next page.

The thermostat and control wiring should be a minimum of 18 AWG copper. Excessive lengths of wire may result in enough voltage drop to impair the proper functioning of the furnace. For thermostat wires in excess of 25 feet, use

WG; 50 feet, use 14 AWG.

16 A

. Consult the instructions of the thermostat

. The isolation relay should be SPST with a

THERMOSTAT

COOLING CONTAC TOR

FAN RELAY

HEATING RELAY

24V

115V

ISOLATION RELAY

THERMOSTAT LOCATION

The thermostat should be located approximately 5 feet above the floor, on an inside wall where there is good natural air circulation, and where the thermostat will be exposed to average room temperatures. Avoid locations where the thermostat will be exposed to cold drafts, heat from nearby lamps or appliances, exposure to sunlight, heat from inside wall stacks, etc.

THERMOSTAT HEAT ANTICIPATOR SETTING: 0.45 AMP (WhiteRodgers) See page 39 for information on connecting optional accessories such as electronic air cleaners and power humidifiers.

ELECTRICAL WIRING AND COMPONENTS MUST BE PROTECTED FROM MOISTURE, INCLUDING WATER AND CONDENSATE.

DEHUMIDIFICATION OPTION

The controller has a dehumidification option. When high humidity is sensed (requires a 24 volt Humidistat that opens on high humidity) the air flow is reduced to increase condensing. To activate, the jumper labeled “DEHUM” must be moved to the “yes” position.

AIRFLOW

ALL CONTROLLER JUMPER CHANGES MUST BE MADE WITH POWER DISCONNECTED TO THE FURNACE.

The ECM TM blower is preprogrammed from the factory to hold constant flow. (Replacement motors must have the correct part number and can only be ordered from the furnace manufacturer.) Changing the Taps allow adjustment for various size A/C tonnage as well as an adjustment in flow. Changing the Heating Tap changes the Temperature Rise in about 5 F increments. The Taps are in a row of jumper labeled “COOL”, “HEAT” and “ADJUST”.

Table on page 36 shows the recommended taps for heating and cooling speed. Heating Tap A is factory set for heating speed. If the Adjust Tap is used for cooling then the heating speed should be adjusted to counter the ef tap. Rule of thumb: The Heating Tap will be the same as the “ADJUST” Tap.

ARNING

fects of the adjustment

WARNING

Make adjustments to the controller with the electrical power off.

START UP PROCEDURES

This furnace is equipped with a hot surface ignition (HSI) device. Each time that the room thermostat calls for heat, the HSI lights the main burners directly. See the lighting instructions on the furnace.

To Start The Furnace:

1. Remove the burner compartment access door.

2. Shut off the electrical power to the furnace and set the room thermostat to its lowest setting.

3. Ensure that the ignition system control switch on the gas valve is in the “ON” position.

Replace the burner compartment access door

5. Restore electrical power to the furnace.

6. Set the room thermostat to a point above room temperature to light the furnace.

7. After the burners are lit, set the room thermostat to the desired temperature.

To Shut Down The Furnace:

1. Set the room thermostat to its lowest setting.

2. Remove the burner compartment access door. The ignition system control switch on the gas valve may

be switched to the “OFF” position.

4. The furnace appliance shutoff valve may be closed if

desired.

WARNINGi

SHOULD OVER HEATING OCCUR, OR THE GAS BURNERS FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE FURNACE BEFORE SHUTTING OFF THE ELECTRICAL POWER TO THE FURNACE. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

Sequence of Operation

1. Room temperature drops causing the room thermostat heating W1 contacts to close.

2. The inducer blower is energized at high speed and the control waits for the low pressure switch contacts to close.

3. Once the low pressure switch contacts close, a 15second pre-purge is initiated. Then the inducer changes to low speed and the 120VAC ignitor is powered.

4. After the prepurge period, the hot surface ignitor heats up; 10 seconds on a first try, maximum 14 seconds on a subsequent retry.

6. The circulating fan begins 30 seconds after flame is sensed.

7. Furnace continues to run in this state until a call for second stage heat (W1 and W2) after a call for first stage heat will energize the inducer at high speed and the circulator high heat. The second stage pressure switch contacts will close and energize the second stage gas valve (high fire).

8. When the second stage of the thermostat is satisfied, the inducer motor is reduced to low speed and the second stage gas valve is de-energized. When the first stage of the thermostat is satisfied, the first stage gas valve is de-energized and the HEA

T delay-to-fan-of

begins timing. With the thermostat heating contacts open, the burner

flames extinguish immediately, the induced blower stops after a 5 second postpurge period. The pressure switch contacts open.

9. The circulating fan continues to run until timed out, depending on the program settings.

Sequence if the fur

nace does not light up or

detect flame:

1. If flame is not detected during the trial-for-ignition period, the gas valve is de-energized, the ignitor is turned of sequence.

The "retry" sequence provides a 30-second wait with the inducer interpurge following an unsuccessful ignition attempt (flame not detected). After this wait, the ignition attempt is restarted. Two retries will be attempted before the control goes into system lockout.

If the flame is established for more than ten seconds after ignition, the controller will clear the ignition attempt (or retry) counter. If flame is lost after 10 seconds, the control will restart the ignition sequence.

A momentary loss of gas supply, flame blowout, or a shorted or open condition in the flame probe circuit will be sensed within 2 seconds. The gas valve will de-energize and the control will restart the ignition sequence. Recycles will begin and the burner will

perate normally if the gas supply returns, of the fault

ondition is corrected, before the last ignition attempt.

c Otherwise, the control will go into system lockout.

If the control has gone into system lockout, it may be possible to reset the control by a momentary power interruption of 10 seconds or longer.

Room temperature drops causing the room thermostat heating contacts to close.

2. If pressure switch contacts are closed; and have failed to open since the last cycle, all subsequent steps will fail to occur.

3. The induced blower begins a prepurge cycle of 15 seconds.

4. The pressure switch contacts close. The pressure switch contacts must close within 30 seconds. If they fail to do so, the induced blower will shut off for a five minute period, then the sequence will begin again at Step 2.

f, and the control goes into the "retry"

5. After the prepurge period, and after pressure switch contacts have closed, the hot surface igniter heats up; 5 seconds on a first try, 10 seconds on a subsequent retry.

Additional information is available in the Troubleshooting section that starts on page 38 of this manual.

Checking Furnace Input

• The natural gas supply pressure should be a maximum of

10.5 inches w.c. and minimum of 5 inches w.c.

• The burner manifold pressure is normally set to 3.5 inches for high fire input, 1.8 inches for low fire input

• The input rating of the furnace is based on 1075 BTU/ ft gas with a specific gravity of 0.60

Since heating values for the gas vary geographically, the actual furnace input and output will vary accordingly.

For example, natural gas with a 1000 BTU/ ft will reduce the input to 93% of the rated input. Natural gas with a 1100 BTU/ ft

heating value will increase the input to

heating value

approximately 103% of the rated input. This is not usually a problem; however, adjustments to compensate for this can be made by minor adjustments to the burner manifold pressure or by changing the burner orifice size.

In the previous example where the heating value of the gas is 1100 BTU/ ft

, the burner manifold pressure can be

reduced .3” w.c. to 3.4’ w.c. which is within the ±0.30 inches

.c. specification to bring the input into compliance. Refer

w also to

Setting the Gas Pressure section, and contact the fuel

supplier for specific gas heating content values. If using a gas meter to check the furnace input, be sure that

all gas fired appliances other than the furnace are off during the test.

Any adjustments to the burner manifold pressure should be carried out with the use of a manometer or calibrated magnehelic gauge. Do not adjust the gas valve pressure regulator more than ± 0.30 inches water column.

(See next page for formula.)

Heating Value of Gas X 3000

nput =

Heating Value of Gas X 3000

Time in Sec. or 1 cu. ft.

Input =

Bonnet Output

1.085 x T

Airflow (CFM) =

The formula for determining the furnace input via the gas A temperature rise within 35-65 degrees F is acceptable meter test dial is:

when the furnace is operating with both stages of heat on. If a higher temperature rise is desired, refer to the dip switch settings for “Heating”. This can be adjusted to

ime in Sec. for 1 cu. ft.

here:

W Input is expressed in BTU/Hr. Heating value of the gas is expressed in BTU/ ft

Time means time required for the test dial to indicate 1 ft3/sec.

f using a gas meter with SI (metric) units:

1 ft

= 0.0283 m

1 m3= 35.315 ft

0.01 m3= 0.3531 ft

0.5 m3= 1.766 ft

Nominal-Plus to reduce the air temperature rise or

ominal-minus to increase the air temperature rise.

AIRFLOW

or proper furnace operation, airflow over the heat

xchanger is of utmost importance. Insufficient airflow

e accelerates metal fatigue and failure in the heat exchanger and excessive airflow promotes accelerated corrosion of the heat exchanger.

IMPORTANT: Do not bypass this step of the start up procedures.

Calculating Airflow

There are circumstances where it may be desirable to know the airflow delivery through the duct system, such as when estimating the amount of airflow available for air

IMPORTANT: NEVER ADJUST THE INPUT OF THE FURNACE TO EXCEED THE INPUT SHOWN ON THE RATING PLATE.

conditioning. This can be done by direct measurement with electronic or sloped manometers and velometers, or by using the formula below.

Circulating Air Blower And Temperature Rise Check

The FV95A series 2-stage gas furnace is supplied with a variable speed circulation air blower motor that will supply a constant airflow when operated within the external static pressure limits of the unit. One of the benefits of a variable speed circulation air blower is soft starting and stopping. The motor will ramp up to normal operating speed gradually. This will minimize noise and increase comfort by eliminating the initial blasts of cooler air encountered with constant speed motors. At the end of a heating or cooling cycle, the variable speed motor will slowly ramp down after the blower off delay timer expires. If the fan is set to operate as a continuous blower, the motor will slowly ramp down to the airflow set for that mode.

Temperature Rise Check

When the duct system is complete and the air filters are in place, determine the air temperature rise of the furnace.

Insert a duct thermometer in the supply air duct. The thermometer should be placed as close as practical to the furnace, but out of the “line of sight” of the heat exchanger so to prevent a false reading due to radiated heat. Ensure that the thermometer is within the duct air-stream. Avoid locations such as the inside radius of an elbow

Insert a duct thermometer into the return duct as close to the furnace as possible. Ensure that the thermometer location will be unaffected by humidifier bypass ducts, etc. Choose a location that ensures the thermometer will be within the air-stream of the duct. Operate the furnace long enough to obtain a steady state condition.

When the two thermometers have stabilized, compare the two readings. Subtract the return air duct temperature from the supply air duct temperature. This difference is the temperature rise.

, etc.

Where: CFM is airflow in cubic feet per minute

∆T is the temperature rise Bonnet output is the furnace output capacity from the

rating plate. NOTE: The bonnet output will vary directly with the input.

If the actual input is below the stated input, the output will be reduced in the same ratio.

Adjusting Dip Switches

If the blower speeds require adjusting, follow these steps:

WARNING

DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED.

AILURE TO DO SO COULD RESULT IN ELECTRICAL SHOCK

F RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.

Remove the blower compartment door.

2. Refer to the tables next page for adjusting DIP

switches/jumpers and select the appropriate settings

3. DIP switches or jumpers are found on the integrated

furnace control board. NOTE: some integrated furnace controls are equipped

with jumpers for blower adjustments. Please reference “Letter” on adjustment table and control board when making adjustment.

4. Re-install the blower compartment door.

5. Upon completion, recheck the furnace temperature rise

to ensure that the desired condition exists.

Rating Plate Input BTU/hr

Switch

Description

Cool

Jumper

AC Tonnage

Rise

Heating

Jumper

54,000

72,000

90,000

108,000

54,000

72,000

90,000

108,000

DIP Switch Configurations

To obtain the correct airflow for the cooling mode, please refer to the table above. Note the position of the delay tap. It is recommended that the heating airflow be set for the Nominal-Plus setting when the furnace is matched for this cooling capacity. Furnace is set at the factory for maximum cooling capacity and DIP switches must be field configured to match the cooling system.

3.0

2.5

2.0

1.5

2.5

2.0

1.5

1.0

Cool

3.0

2.0

2.5

1.5

Cool

5.0

3.5

2.5

1.5

4.0

3.0

2.0

1.0

Cool

5.0

3.5

2.5

1.5

4.0

3.0

2.0

1.0

Cool

ADJUST

(NORM)

ADJUST

( - )

3.5

1.0 1.0

3.0

All Delay

Off

delayNodelay

30 30

Off

6On

180

Off

ADJUSTING BLOWER SPEEDS

Cooling Mode

The unit is factory set to provide the highest airflow.

djustments can be made to match the furnace with a small-

A er cooling coil by changing the DIP switch or jumper settings, located on the integrated ignition control board. Refer to the Cooling DIP switch or jumper settings table for instructions on how to set the switches. Please note that if the furnace is to be matched to the lowest airflow for cooling, the "Adjust" DIP switches or jumper setting must be set to the decreased

setting. When using this setting, it is recommended that the

Heating DIP switches or jumper setting be set for NominalPlus.

Heating Mode

The unit is set from the factory to operate at the center of the temperature rise range. For this model furnace, the air temperature rise is between 35 and 65 degrees F. Heating airflow can be increased or decreased by changing the heating mode DIP switches or jumpers, located on the integrated ignition control board, to the Nominal-plus/minus settings. Please note that Nominal-plus will decrease the air temperature rise and the Nominal-minus will increase the air temperature rise. At the end of a call for heat, the main blower has a fixed off delay at a reduced airflow to remove residual heat from the heat exchanger.

How To Install The Blower

1. Place blower into blower compartment.

2. Keep blower assembly tight to top of blower compartment. Line up blower assembly to slide into blower rails. Push blower assembly towards back of

urnace ensuring blower assembly is correctly placed in blower rails. Insert blower shroud on the front of the blower housing. Insert blower housing bolts and tighten.

3. Connect thermostat wiring to the integrated furnace control.

4. Connect L1, Neutral and Ground connections between the integrated furnace control and the furnace electrical connection junction box.

5. Connect 12 pin male molex connector to female connection point, and ground connection to the integrated furnace control.

6. Turn on power to the furnace.

WARNING

Ensure that there is a drip bend in the connect wires to the blower motor to prevent condensate from following the wire into the connector.

WARNING

Make adjustments to the controller with the electrical power off.

How To Remove The Blower

1. Disconnect power from furnace.

2. Remove thermostat wiring from the integrated furnace control.

3. Remove L1, Neutral and Ground connections between the integrated furnace control and the Furnace electrical connection junction box.

4. Remove 12 pin male molex connector from female connection point, and ground connection from integrated furnace control.

5. Unscrew 2 blower housing bolts located in the front blower shroud as indicated in figure 15 (right). Remove

front blower shroud from furnace.

6. Slide blower assembly towards front of furnace. Blower is mounted on rail system, and will slide forward about 10 inches before blower is clear of rails.

FIGURE 15

BLOWER BOLTS

Bolts

TABLE 8

30 30

Off

180

Off On

MAINTENANCE

WARNING

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.

ir Filter

The filter should be inspected frequently and cleaned as necessary. We recommend a monthly inspection at first,

erhaps coinciding with the arrival of the monthly fuel bill

p as a reminder. The frequency may be increased or decreased depending on experience and conditions.

CAUTION

DO NOT OPERATE THE FURNACE WITHOUT AN AIR FILTER.

Lubrication

Both the induced draft blower motor and circulating fan motor are ball bearing type motors. Neither requires routine lubrication.

The motor bearings were prelubricated by the motor manufacturer. Do not attempt to lubricate them. Excess lubrication will void the warranty, shorten the service life of the motors, and will attract the buildup of dust and dirt.

The induced blower motor and circulating fan motor must be cleaned on a periodic basis by a qualified service technician. Dust buildup in the ventilation ports of the motor will cause the motor to not dissipate heat properly resulting in reduced service life.

Vent Connector

The exhaust venting between the furnace vent box and chimney should be inspected periodically for sags, pitting, evidence of leakage etc. If any of these conditions exist, contact your installation contractor, service agency or fuel supplier.

IMPORTANT

WARNING

HOLES IN THE EXHAUST PIPING OR FURNACE HEAT EXCHANGER CAN ALLOW TOXIC FUMES TO ENTER THE HOME AND CIRCULATE THROUGH THE DUCT SYSTEM RESULTING IN CARBON MONOXIDE POISONING OR DEATH. IF LEAKS ARE FOUND IN THE FURNACE HEAT EXCHANGER, IT MUST BE REPLACED.

Operating Tips

1. Clean air filters maximize efficiency and reduce heating costs.

During the heating season, keep windows and doors

2. closed to reduce the heating load on the system.

void excessive use of kitchen exhaust hoods and other

exhaust fans to reduce the heating load on the system.

4. Arrange the furniture and drapes so that the supply air registers and return air grilles are unobstructed.

5. If you have a perimeter duct system, ideally, the warm air should bathe the cold exterior walls. Avoid the use of plastic deflectors on the supply air registers that tend to short circuit the warm air straight into the return air grilles. These deflectors are often the cause of cool draughts across the floor

6. Avoid placing heat producing appliances such as televisions, radios, lamps, etc. in a location to influence the thermostat.

7. Keep combustible articles at least 3 feet away from the furnace. Do not block access for servicing the furnace. Do not use the vent connector as a hanger for clothes or anything else.

8. Never attempt to operate the furnace without the blower door in place.

ANNUAL INSPECTION / SERVICE

A qualified installation contractor, service agency or fuel supplier must inspect the furnace annually.

Your annual inspection will normally cover the following:

Heat Exchanger

The heat exchanger should be inspected for corrosion. The flue passages (heat exchanger tubes) should be free of scale or excessive corrosion. Observe the burner flames. If there appears to be flame distortion, check venting for blockage. Also check for signs of inadequate combustion air supply. If flame distortion continues after eliminating the blockage in the venting as the cause, it may be necessary to replace the tubular heat exchanger. The tubular heat exchanger cannot be field cleaned. If the tubular heat exchanger is blocked by soot or excess scale, replace it. Check NOX baffles (installed in heat exchanger tubes) for any distortion. If distorted, replace NOX baffles.

Burners

The burners should be inspected to ensure that they are free of deterioration, dust and debris, and properly aligned with the heat exchanger. In most cases, a simple vacuuming with a brush attachment will adequately clean the burner assembly and burner compartment.

CAUTION

BE CAREFUL WHEN WORKING ON THE BURNER ASSEMBLY. THE HOT SURFACE IGNITER IS FRAGILE AND CAN BREAK EASILY.

The flame sensor should be inspected and cleaned with fine steel wool or Scotch-Brite™ scrubbing pad. The wiring connection should be checked to ensure that it is tight and corrosion free.

IMPORTANT

This is a critical connection. Small amounts of corrosion can significantly increase the internal resistance of the connection. A relatively small increase in resistance can result in a large decrease in flame signal.

Induced Blower

The induced blower motor should be inspected and cleaned if necessary. Clear any dust buildup from the ventilation ports.

Circulating Fan

The condition of the circulating fan should be checked to ensure that it is free of excessive dust buildup, debris, etc. The mechanical fasteners should be inspected and checked for proper tightness and parts alignment. The motor ventilation ports should be cleaned if necessary to prevent restriction to cooling by air over the motor.

Electrical

WARNING

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING THIS MAINTENANCE PROCEDURE. FAILURE TO DO SO CAN CAUSE

LECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR

OSS OF LIFE.

ll electrical connections should be examined to ensure that

A they are tight and corrosion free. Repair any connections that have become loose or corroded.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Always verify proper operation after servicing.

Furnace Operation

The furnace should be cycled during the annual inspection and servicing to:

1. Test all safety related controls.

2. Determine that the temperature rise falls within the range shown on the appliance rating plate.

3. Ensure that the burner ignition is smooth and that the flames are smooth soft blue, and not impinging on the heat exchanger.

FIELD SUPPLIED AND INSTALLED OPTIONAL ACCESSORIES

Electronic Air Cleaner

The integrated furnace control has provisions to supply power and control an electronic air cleaner rated at 120vac,

1.0 amp max.

Line voltage for an electronic air cleaner may be picked up from the "EAC-N". 120 volt power will be available at these terminals whenever the circulating fan is operating in the heating or cooling modes.

Humidifiers/ Electronic Air Cleaners

The integrated furnace control has provisions to supply power and to control a line voltage humidifier or the primary of a 120 / 24 volt humidifier step down transformer rated at 120vac, 1.0 amp max.

Line voltage for a humidifier may be picked up from the "HUM-H" terminal and from the "HUM-N" terminal. 120 volt power will be available at these terminals whenever the circulating fan is operating in the heating mode.

IMPORTANT

All HUM (humidifier) and EAC (electronic air cleaner) terminals are 120v. Do not directly connect 24v equipment to them.

WARNING

ALL WIRING INSIDE THE FURNACE MUST HAVE A MINIMUM TEMPERATURE RATING OF 105C.

Troubleshooting

Page 41, Table 9, Page 42, Table 10 and Figure (trouble shooting) will aid in trouble shooting.

The controller ignites the furnace in low heat and high inducer (only the low pressure switch is required to make) and after a 60 second warm-up period adjusts either the gas or inducer to heat demand. With the single stage thermostat option, there is a selectable low heat period before high heat. If there is a problem with high or low

eat the UTEC 1170-25 controller will attempt to continue

h to supply heat in one of three alternate firing scenarios.

Scenario one:

• if, after the warm-up period and the low heat period with a single stage thermostat, or with a two stage T-stat the demand for heat is high and the high heat pressure switch fails to make, the furnace will run in low gas and high inducer until the high pressure switch makes.

The second scenario;

If the low heat fails after the warm-up period, the controller will wait 3 minutes before ignition retrial and then after the warm-up period go to high heat. Most likely the failure of the low heat is temporary and may be due to a combination of high wind and long vent length and low voltage. If there is a blocked drain the furnace will not turn the igniter or gas on. If there is an air trap in the heat exchanger drain tube the furnace will cycle and flash code for pressure switch failed to close.

The third scenario;

If the low heat fails after the warm-up period, and when the next trial for high fails to make the high pressure switch, the unit will stay in low heat and high inducer (as long as the low pressure switch is made). If, during this period, the high pressure switch makes, the gas valve will switch to high. A loss of high pressure switch will force the gas valve to low. If there is ice in the vent the continuous heat should free it. Note: When the inducer is in high and

the gas low the flame noise sounds deceptively like high heat.

The fourth scenario:

If there is a demand for high heat (low heat firing period is finished) and during the trial for ignition the high pressure switch does not pull in the controller will continue in low heat and make a retrial for high every 5 or 10 minutes.

IMPORTANT

All furnace and furnace accessory wiring shall conform to the temperature limitations of 63

°F (35°C) rise.

TABLE 9

ED FLASH(ES)

Green Off

1 Red

2 Red

3 Red

4 Red

5 Red

6 Red

NDICATES (FEDDERS UTEC 1170-25 CONTROLLER)

Internal controller or Room Air Fan failure. DO NOT operate on heat until Fan failure cleared. Roll-out open. Cycle power to reset.

Flame sensed with gas valve de-energized.

Pressure switch(es) remains open. Combustion Blower cycles until low pressure switch closes. If running, high pressure switch is open.

Pressure switch(es) remains closed. Combustion Blower will not operate until switch(es) opened.

Open high room air limit switch.

Room Air Fan failed or rollout switch(es) open. System lockout reset by recycling power. Caution: Do not run on heat until fan operational.

115 Volt AC power reversed or improper ground.

CHECK and REPAIR

1. Replace Integrated Furnace Control. . Rollouts or Fan failure– see 5 Red

Flashes.

Mis-wiring is probable cause.

. Pressure switch failure.

2. Pressure switch tubing, and wiring.

3. Obstructions in air intake or exhaust

flue system that prevent proper combustion air flow.

1. Pressure switch(es) failure.

2. Pressure switch(es) mis-wired or

jumpered.

Dirty filter or room air vents closed.

1. Wiring in good condition and securely

connected. Drip leg at Motor connector.

2. Check Room Air Fan by running A/C or

Fan (not heat).

3. Blockage in heat exchanger or venting.

Line voltage polarity, and earth ground.

7 Red

8 Red

9 Red

10 Red

Low flame sense signal. 1 hour lockout.

Too many high air temperature limit trips. 1 hour lockout.

Too many low pressure switch trips after ignition. 1 hour lockout

1 hour lockout. Reset by cycling power or thermostat.

1. Flame at burner.

2. Dirty or cracked flame sensor.

See 4 Red Flashes

See 2 Red Flashes.

1. Gas supply off or at too low pressure.

Smell gas? Igniter failure.

3. Earth grounded.

IF AND CHECK or REPAIR

Induced blower does not energize

3 Flash code does not come on

1. Induced blower wiring.

2. Induced blower.

Induced blower does not energize

3 Flash code does come on

1. Pressure switch stuck closed.

2. Pressure switch is mis-wired or jumpered.

Induced blower is energized

2 Flash code does not come o n

Wait for the pre-purge to expire.

2 Flash code comes on

Induced blower turns off

1. Pressure switch stuck in the open position.

2. Pressure switch, tubing and wiring.

3. Obstruction in furnace venting that is preventing proper combustion airflow.

Pre-purge time h as expired

HSI element does not glow r ed within 10 seconds.

1. Broken or damaged HSI element.

2. Broken or damaged HSI element leadwires.

HSI element i s glowing red.

No other visible control system action

Wait for HSI element warm up time to expire.

HSI element warm u p time has expired a nd main valve has been energized.

Main valve does not light within trial for ignition period

1. Induced blower moving main burner gas away from the HSI element.

2. Inlet gas pressure too low for main burner ignition.

3. Input line voltage too low to heat HSI element.

4. HSI element incorrectly positioned.

5. Clogged or incorrect main burner orifice.

Main burner lights within trial for ignition period.

Main valve i s de-energized a t the end of the trial for ignition period.

If main flame i s not sensed during trial for ignition, system will shut o ff HSI element and main gas flow, then g o through another purge period and initiate another ignition trial. A total o f 4 ignition trials will be attempted before the system goes into lockout.

Line voltage to L1 terminal of integrated furnace control must be 120 volts with reference to furncace chassis.

2. Furnace must be reliably connected to earth ground.

3. Induced blower moving main burner flame away from the flame sensor rod.

4. Inlet gas pressure too low for proper flame sensing.

5. Flame sensor rod contaminated or in incorrect position.

Main burner stays o n after the end of t he trial for ignition p eriod.

Circulating fan is not turned on after 30-second time delay.

1. Wiring between system control and integrated furnace control.

Proper operation of integrated furnace control.

Main burner goes o ut before thermostat call for heat ends.

4 Flash code comes on

Open high limit switch.

High limit wiring in good condition and securely connected.

Main burner goes o ut before thermostat call for heat ends.

4 Flash code does not come on

Green LED off

Induced blower moving main burner flame away from flame sensor rod.

Pressure switch has opened.

Open flame rollout switch

Rollout switch wiring in good condition

Broken or damaged blower

Flame sensor rod ceramic or leadwire overheated.

Gas supply / flow reduced or interrupted.

5 Flash code comes on.

TABLE 10 : GENERAL TROUBLESHOOTING INTEGRATED FAN CONTROL

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User’s Information Manual

TABLE OF CONTENTS

FURNACE COMPONENTS . . . . . . . . . . . . . . . . . .1

REGULATOR VENT . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . .1

FURNACE OPERATION INFORMATION

TO START THE FURNACE . . . . . . . . . . . . . .2

FURNACE SHUTDOWN PROCEDURE . . . . .2

MAINTENANCE

REPLACING AIR FILTER . . . . . . . . . . . . . . . .3

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .3

ROUTINE EXAMINATION . . . . . . . . . . . . . .3

FURNACE APPEARANCE . . . . . . . . . . . . . . .4

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . .3

. . . . . . . . . . . . . . . .

SEQUENCE OF OPERA

READ THESE INSTRUCTIONS THOROUGHL ATTEMPTING TO OPERATE THIS FURNACE.

This furnace has been designed to deliver many years of

ficient, dependable service. With regular

ef maintenance, some of which requires the attention of a qualified installer some of which you may do yourself, the furnace will operate satisfactorily over many heating seasons.

Please read this manual to familiarize yourself with safety procedures, operation, and routine maintenance procedures.

TION

Y BEFORE

, service agency or gas supplier,

WARNING

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 PHONE OUTSIDE THE BUILDING. 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

DO NOT USE THIS FURNACE IF ANY PART HAS BEEN UNDER WATER. A FLOOD DAMAGED FURNACE IS EXTREMELY DANGEROUS. ATTEMPTS TO USE THE FURNACE CAN RESULT IN FIRE OR EXPLOSION. A QUALIFIED SERVICE AGENCY SHOULD BE CONTACTED TO INSPECT THE FURNACE AND TO REPLACE ALL GAS CONTROLS, CONTROL SYSTEM PARTS, ELECTRICAL PARTS THAT HAVE BEEN WET OR THE FURNACE IF DEEMED

NECESSAR

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE V THIS OR ANY OTHER APPLIANCE.

FIRE OR EXPLOSION HAZARD

APORS AND LIQUIDS IN THE VICINITY OF

FAILURE TO FOLLOW SAFETY WARNINGS EXACTLY

TH, OR

COULD RESULT IN SERIOUS INJURY

, DEA

PROPERTY DAMAGE.

FURNACE COMPONENTS

FIGURE 2

GAS REGULATOR VENT

FIGURE 1

URNACE COMPONENTS

REGULATOR VENT

Most natural gas systems and all LP gas systems have a service regulator located near the point where the gas piping enters the building. The propane tank will normally have an additional first stage regulator located at the tank outlet valve. All of these regulators (located outdoors) will have a vent; see Fig. 2 (below).

Regulator vent Keep free of ice, snow,

and debris

It is important for these vents to remain clear. Do not allow moisture, which could freeze, to build up in the vent. If you see moisture building up in the regulator vent, contact your gas supplier.

our gas supplier should periodically inspect and clean the

Y air vent screen to prevent any obstruction. Keep the protective regulator cover in place, as exposure to the elements can cause ice buildup and a regulator failure.

AN OBSTRUCED AIR VENT ON AN LP (PROP CYLINDER OR T OR FIRE RESUL PERSONAL INJURY OR DEATH.

Rollout Switch

Burners

Igniter

Flame Sensor

Gas valve

Limit Switch

Induced blower

Pressure Switch

Control Panel

Transformer

Furnace Control

Door Switch

Junction Box

Blower

ARNING

ANE)

ANK REGULA

TOR CAN CAUSE EXPLOSION

TING IN PROPERTY DAMAGE, SEVERE

ENERAL SAFETY RULES

1. Combustible materials should not be stored against or around the furnace. Keep the furnace area clear and free from all combustible materials such as newspapers,

ags, cardboard, clothing, etc. This applies especially to

r gasoline and other flammable vapors and liquids.

2. A furnace needs adequate amounts of combustion and

entilation air to operate properly. Do not block or

v obstruct air openings on the furnace, or air openings supplying combustion or ventilation air to the area where the furnace is installed. There are many areas from which your furnace could be receiving combustion

nd ventilation air including from within the heated

a area (inside air), from outdoors, from an attic or crawl space. If renovations are done, be sure that air supply openings are not inadvertently covered over with insulation, vapor barrier, or similar construction material.

3. All doors and panels must be in place during normal furnace operation. Attempting to operate the furnace with missing doors or panels could lead to the creation of carbon monoxide gas.

4. If the furnace is installed in a confined space or if you intend to build a furnace room where insulation is present, be aware that some insulating materials are combustible. Do not allow building insulating materials to come into contact with the furnace.

5. Any additions, alterations or conversions required in order for the furnace to properly match the application requirements must be done by a qualified installation contractor, service agency or gas supplier, using factory specified or approved parts.

6. Familiarize yourself with the location of the furnace gas manual shutoff valve and any electrical switches, fuse or circuit breaker associated with the furnace.

7. For your protection, the furnace is equipped with manually reset flame rollout switches. If either switch trips frequently, do not ignore this, call your installation contractor, service agency or gas supplier.

8. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.

9. Familiarize yourself with the location of your furnace filter or filters. A blocked air filter will reduce efficiency, increase fuel consumption, raise the furnace operating temperature, and shorten the life of furnace components.

Do not cover return air grilles and supply air registers

10. with drapes, curtains, throw rugs, etc.

11. Avoid shutting off supply air registers in the interests of saving heat. The furnace requires a suf

ficient quantity of air passing over the heat exchanger to operate within design temperatures, (system temperature rise). Reducing the availability of supply air registers may have the unforeseen consequence of raising the furnace operating temperature above design, thereby reducing furnace efficiency, and shortening the life of the furnace components.

URNACE OPERATION INFORMATION

FIGURE 3

GAS VALV E

During the heating season, the operation of the furnace is

ully automatic.

o Start The Furnace:

. First read these instructions and safety notices

thoroughly.

2. Set the thermostat to the lowest setting.

3. Ensure that all supply air registers and return air grilles are open.

4. Turn off the electric power to the furnace.

. Remove the burner access door.

6. Ensure that the appliance manual shutoff valve is in the "ON" position. The valve handle is normally in-line with the gas pipe and valve body when it is in the "ON" position perpendicular to the gas piping and valve body when it is in the "OFF" position.

7. Wait 5 minutes to clear out any gas. If, after this time you smell gas, STOP. Turn the appliance manual shutoff valve to the "OFF" position. If burning propane or other LP gas, smell for gas near the floor since propane and butane are both heavier than air. If after this time you do not smell gas, continue to the next step.

8. Gas valve: Ensure that the Gas Valve Control is in the "ON" position, see Figure 3 at right.

9. Replace the burner access door, ensuring that it is properly in place.

10. Restore the electric power to the furnace.

11. Adjust the thermostat to the desired setting. If the thermostat also controls an air conditioning system, ensure that the thermostat system switch is in the "HEAT" or "AUTO" mode.

If this is the first time that the furnace has undergone a trial ignition since installation, or if there has been work done on the gas lines, the furnace might not light because of air trapped in the gas supply line.

Simply turn the thermostat down to its lowest setting, wait five minutes, then adjust the thermostat to the desired setting. If the problem persists, proceed to the

Down Procedure

gas supplier If you intend to be away from home for lengthy periods of

time during the non-heating season, it is advisable to follow the furnace shut down procedure.

and call your installer, service agency or

Furnace Shut

WARNING

urnace Shutdown Procedure

1. Set the thermostat to its lowest setting.

2. Shut off electric power to the furnace.

3. Turn the appliance manual shutoff valve to the "OFF" osition.

4. Remove the burner access door, move the manual gas

control switch to the "OFF" position, then reinstall the burner access door.

f you intend to be away from home for lengthy periods of

I time during the nonheating season, it is advisable to follow the furnace shutdown procedure.

Inlet Pressure Post Set Screw

3 Pin Connector

Regulator Adjustment

Vent

Regulator Adjustment

On/Off Switch

Outlet Pressure Post Set Screw

WARNING

DEVICES ATTACHED TO EITHER THE VENT OR COMBUSTION AIR INTAKE FOR THE PURPOSES OF EXCEEDING THE LIMITATIONS DESCRIBED IN THE INSTALLATION MANUAL, INCLUDING FIELD INSTALLED INDUCED BLOWER FANS HAVE NOT BEEN TESTED AND ARE NOT INCLUDED IN THE DESIGN CERTIFICATION OF THE FURNACE.

THE MANUF SPECULATE ON THE EFFECTS OF SUCH MODIFICATIONS, AND CANNOT AND WILL NOT BE RESPONSIBLE FOR

Y OR DAMAGE CAUSED BY THE USE OF SUCH

INJUR UNTESTED AND/OR UNCERTIFIED DEVICES, ACCESSORIES OR COMPONENTS.

ACTURER CANNOT AND WILL NOT

NEVER USE TOOLS TO TURN A MANUAL GAS CONTROL HANDLE. IF THE CONTROL HANDLE WILL NOT TURN BY HAND, DO NOT A COULD RESULT IN FIRE OR EXPLOSION RESULTING IN SERIOUS PERSONAL INJURY OR DEATH, OR PROPERTY DAMAGE. CALL A QUALIFIED INSTALLATION CONTRACTOR, SERVICE AGENCY OR GAS SUPPLIER.

TTEMPT TO FORCE IT. DOING SO

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

FOR ASSISTANCE OR ADDITIONAL INFORMA CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY, OR YOUR GAS SUPPLIER.

TION,

AINTENANCE

FIGURE 4

AIR FILTER

Replacing Air Filter

1. Disconnect electrical power to the furnace.

2. Pull the filter out the front.

3. Replace with a fresh filter and reconnect power to the furnace. The filter will have an arrow indicating proper airflow direction.

O NOT OPERATE YOUR FURNACE (OR AIR CONDITIONER)

D WITHOUT AN AIR FILTER.

WARNING

DISCONNECT THE ELECTRICAL POWER TO THE FURNACE BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO MAY CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

Consult your installation contractor or service technician if you have any questions on filters.

The furnace should be well supported on a level floor or

• by the means used to suspend the furnace in a horizontal configuration. Base support should be physically sound without sagging, cracks, gaps, etc. around the base so as to provide a seal between the support and the base.

• Check the furnace for obvious signs of deterioration. The gas burner should be observed from time to time

• during the heating season to ensure that the flames are clean and blue. A bit of orange color in the flame is not likely to be a problem and is probably dust particles

urning. If you observe lazy yellow flames, call your

b heating or service contractor immediately. The yellow flames inevitably lead to soot buildup.

Furnace Appearance

The furnace exterior finish is a durable automotive-like coating. It may be washed with mild soap if necessary. Galvanized metal surfaces require no maintenance.

Cleaning

It is advisable to keep dust buildup on warm surfaces to a minimum, since dust, in some cases, can be combustible.

Dust buildup in the circulating fan can impair blower performance; therefore, reduce efficiency. Because the blower wheel is fastened directly to the blower motor, we recommend that major cleaning be left to your service contractor.

Lubrication

Minimal lubrication is required for your furnace. The induced blower assembly motors have sealed bearings. The bearings contain permanent special purpose lubricants. Attempting to force common oil into the induced blower motor bearings will deteriorate the original lubricant and shorten bearing life.

Routine Examination

It is good practice to give a quick inspection of your furnace each time you inspect or clean the air filter. Things to check:

• All areas around the vent connector and chimney should be clear and free of obstructions.

Check the venting to ensure that it is still fastened to

• the furnace. It should not sag and should have a slope upwards to the chimney without holes or excessive corrosion.

• The return air duct connection must be sound and securely fastened to the furnace casing. In most cases, the filter rack provides the means to connect the return air to the furnace. There should be no return air inlets in the vicinity of the furnace.

• All ductwork should be secured to the furnace, and all ductwork should be solidly supported throughout the heating system.

. It should be physically sound,

CAUTION

DO NOT PERMIT WATER OR CLEANING SOLUTIONS TO ENTER THE ELECTRIC MOTOR.

The burner area should be inspected and cleaned periodically. Be careful when cleaning around the burner area. The hot surface igniter is fragile and will break easily. Do not touch the hot surface igniter or flame rod.

WARNING

NEVER ATTEMPT TO CLEAN THE BURNER AREA WHILE THE BURNERS ARE OPERATING. DOING SO MAY RESULT IN EXPLOSION OR FIRE RESULTING IN SEVERE PERSONAL

Y OR DEATH.

INJUR

ARNING

ALWAYS DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE REMOVING THE BURNER COMPARTMENT ACCESS DOOR.

CAUTION

THE FURNACE SHOULD BE OPERA PLACE. NEVER OPERATE THE FURNACE WITH THE BLOWER DOOR REMOVED EXCEPT FOR SER

TED WITH ALL PANELS IN

VICE PURPOSES.

The furnace achieves its mid-efficiency in two general areas. First, there is no wasteful standing pilot. The furnace consumes no gas in between cycles. Secondly, the furnace is designed to allow very small amounts of excess air in the combustion process. Older furnaces had heat exchangers that were commonly 40% larger than necessary for

omplete combustion. While this prevented the creation of

c carbon monoxide, the heated excess air was expelled up the chimney where it could not benefit the interior of the home. Special safety controls now prevent the formation of carbon monoxide.

IMPORTANT: Your furnace should be cleaned and

inspected annually by a trained and qualified service technician.

Your service technician has the knowledge and test equipment to determine the condition of your furnace.

ARNING

UL AND CUL 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.

equence Of Operation

1. Thermostat, responding to cool room, calls for heat.

2. Combustion air blower begins. . After 15 second prepurge, hot surface igniter warms up.

4. After approximately 5 seconds, the gas valve will open,

and the burners ignite.

5. Thirty seconds after the burners ignite and flame sense

is proven, the main blower starts on the heating speed.

. System remains in this state until the room air

temperature rises causing the thermostat to terminate its call for heat.

7. The gas valve shuts off; the burners extinguish.

8. After brief postpurge period, (5 seconds), the

combustion air fan stops. The main blower continues to run. Elapsed time ranges from 60 seconds to 180 seconds, depending on the manufacturer’s requirement.

9. The furnace remains idle until the next call for heat.

Variations

If your system includes air conditioning, your thermostat (supplied by the installer) will likely have two switches. The first switch is the system switch. The switch settings usually include HEAT, COOL, and OFF. Some thermostats have system switches which include HEAT, COOL, AUTO, and OFF. The system switch must be in the HEAT or AUTO position for the furnace to run.

The second switch is the fan switch. It usually has settings of ON and AUTO. The fan switch may be in either position when using the furnace. If the fan switch is set to ON, the main blower will run continuously, and the blower delays mentioned in the sequence of operation points 5 and 9 will be ignored.

Illustrations cover the general appearance of the units at the time of publication and the manufacturer reserves the right to make changes in design and construction at any time without notice.

For replacement parts contact: Airwell Fedders North America 2 Centre Drive, Monroe Township, NJ 08831

Phone: 1-800-332-6658

Fedders FV95A108, FV95A054, FV95A072, FV95A090 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual