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.

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