Goodman GMVC8 Installation Manual

NST ALLATION

NSTRUCTIONS

FOR

*(D, M)VC8 G

URNACE

(CA TEGORY I )

Installer: Affix all manuals adjacent to the unit.

These furnaces comply with requirements embodied in the American National S tandard / National Standard of Canada ANSI Z21.47·CSA-

2.3 Gas Fired Central Furnaces.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer , you have an obligation to know the product better than the customer.

This includes all safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.

Pay special attention to all safety warnings. Often during installation or repair , it is possible to place yourself

in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough

to be able to instruct a customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting.

Most dealers have a list of specific, good safety practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices.

However, if there is a direct conflict between existing practices and the content of this manual,

the precautions listed here take precedence.

NOTE: Please contact your distributor or our website listed below

for the applicable Specification Sheet referred to in this manual.

WARNING

OODMAN WILL NOT BE RESPONSIB LE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES

F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIB ILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH

MAY RESU LT

INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPM EN T

. M

ANY JURISDICTIONS REQUIRE A LICENSE TO

IO-429B 5/2014

5151 San Felipe Suite 500 • Houston, TX 77056

www.goodmanmfg.com • www .amana-hac.com

Table of Contents

SAFETY CONSIDERA TIONS ........................................................................................................................................................... 4

ADDITIONAL SAFETY CONSIDERATIONS ................................................................................................................................... 5

SHIPPING INSPECTION........................................................................................................................................................ 5

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................... 6

TO THE INSTALLER............................................................................................................................................................ 6

PRODUCT DESCRIPTION ............................................................................................................................................................. 6

FEATURES ........................................................................................................................................................................ 6

PRODUCT APPLICATION .............................................................................................................................................................. 6

LOCATION REQUIREMENTS AND CONSIDERATIONS ............................................................................................................................. 7

CLEARANCES AND ACCESSIBILITY ......................................................................................................................................... 9

INSTALLATION POSITIONS ..................................................................................................................................................... 9

HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY) ............................................................................................................... 9

FURNACE SUSPENSION ...................................................................................................................................................... 9

EXISTING FURNACE REMOVAL .............................................................................................................................................. 9

THERMOST AT LOCATION ....................................................................................................................................................... 9

COMBUSTION AND VENTILATION AIR REQUIREMENTS ...................................................................................................................... 10

EXTERIOR MASONRY CHIMNEYS .................................................................................................................................................. 11

(CATEGORY I FURNACES ONLY).................................................................................................................................................. 11

CHECKLIST SUMMARY ...................................................................................................................................................... 12

CHECK 1 - PROPER CHIMNEY TERMINATION. ........................................................................................................................ 12

CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL ....................................................... 13

CHECK 3 - CHIMNEY CROWN CONDITION. ........................................................................................................................... 13

CHECK 4 - DEBRIS IN CLEANOUT....................................................................................................................................... 13

CHECK 5 - LINER CONDITION. .......................................................................................................................................... 13

CHECK 6 - DILUTION AIR. ............................................................................................................................................... 14

CHECK 7 - COMPLETE THE INSTALLATION. ............................................................................................................................ 14

FIX 1 - LINER TERMINATION .............................................................................................................................................. 14

FIX 2 -CHANGE VENTING ARRANGEMENTS ........................................................................................................................... 14

FIX 3 - REBUILD THE CROWN ........................................................................................................................................... 15

FIX 4 - RELINING............................................................................................................................................................ 15

ELECTRICAL CONNECTIONS ....................................................................................................................................................... 15

WIRING HARNESS ........................................................................................................................................................... 16

115 VOLT LINE CONNECTIONS .......................................................................................................................................... 16

JUNCTION BOX RELOCATION ............................................................................................................................................. 16

24 VOLT THERMOSTAT WIRING .......................................................................................................................................... 17

SINGLE-STAGE HEATING THERMOSTAT APPLICA TION ................................................................................................................ 17

24 VOLT DEHUMIDIST AT WIRING ........................................................................................................................................ 18

FOSSIL FUEL APPLICATIONS .............................................................................................................................................. 18

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER).................................................... 18

24 VOLT HUMIDIFIER ....................................................................................................................................................... 19

AUXILIARY ALARM SWITCH ............................................................................................................................................... 19

GAS SUPPLY AND PIPING .......................................................................................................................................................... 19

HIGH ALTITUDE DERATE ................................................................................................................................................... 20

PROPANE GAS CONVERSION .............................................................................................................................................. 20

GAS PIPING CONNECTIONS ............................................................................................................................................... 20

UPFLOW INSTALLA TIONS .................................................................................................................................................... 21

COUNTERFLOW INSTALLATIONS ........................................................................................................................................... 21

GAS PIPING CHECKS ....................................................................................................................................................... 22

PROPANE GAS TANKS AND PIPING...................................................................................................................................... 22

CIRCULATING AIR AND FILTERS.................................................................................................................................................. 23

CHECKING DUCT STATIC ................................................................................................................................................... 23

FILTERS - R EAD THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK .................................................................... 24

UPRIGHT INSTALLA TIONS ................................................................................................................................................... 24

CIRCULATION AIR FILTERS................................................................................................................................................ 24

HORIZONTAL INSTALLATIONS ............................................................................................................................................... 24

Table of Contents

START-UP PROCEDURE AND ADJUSTMENT ................................................................................................................................... 24

HEAT ANTICIPATOR SETTING ............................................................................................................................................... 24

FURNACE OPERATION....................................................................................................................................................... 24

GAS SUPPLY PRESSURE MEASUREMENT .............................................................................................................................. 25

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................................. 26

GAS INPUT RATE MEASUREMENT (NA TURAL GAS ONL Y)........................................................................................................... 27

TEMPERATURE RISE ......................................................................................................................................................... 27

CIRCULATOR BLOWER SPEEDS .......................................................................................................................................... 28

BLOWER HEAT OFF DELAY TIMINGS .................................................................................................................................... 30

COMFORTNET™ SYSTEM .......................................................................................................................................................... 30

OVERVIEW ..................................................................................................................................................................... 30

FOSSIL FUEL APPLICATIONS .............................................................................................................................................. 31

CTK0* WIRING ............................................................................................................................................................. 31

COMFORTNET™ COMPATIBLE FURNACE WITH NON-COMFORTNET COMPATIBLE SINGLE-STAGE AIR CONDITIONER .............................. 32

COMFORTNET™ SYSTEM ADVANCED FEATURES ............................................................................................................................. 32

THERMOSTAT MENU ......................................................................................................................................................... 32

DIAGNOSTICS.................................................................................................................................................................. 32

FURNACE ADVANCED FEATURES MENUS (ACCESSED THROUGH COMMUNICATING THERMOSTAT)..................................................... 33

NETWORK TROUBLESHOOTING ........................................................................................................................................... 34

YSTEM TROUBLESHOOTING .............................................................................................................................................. 34

NORMAL SEQUENCE OF OPERATION ............................................................................................................................................ 34

POWER UP .................................................................................................................................................................... 34

HEATING MODE ............................................................................................................................................................... 35

COOLING MODE ............................................................................................................................................................. 36

FAN ONLY MODE ............................................................................................................................................................ 36

OPERATIONAL CHECKS ............................................................................................................................................................. 36

SAFETY CIRCUIT DESCRIPTION ................................................................................................................................................... 37

INTEGRATED CONTROL MODULE ......................................................................................................................................... 37

PRIMARY LIMIT ................................................................................................................................................................ 37

AUXILIARY LIMIT ............................................................................................................................................................. 37

ROLLOUT LIMIT .............................................................................................................................................................. 37

PRESSURE SWITCHES...................................................................................................................................................... 37

FLAME SENSOR .............................................................................................................................................................. 37

TROUBLESHOOTING ................................................................................................................................................................. 37

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................. 37

DIAGNOSTIC CHART ......................................................................................................................................................... 37

FAULT RECALL ................................................................................................................................................................ 37

RESETTING FROM LOCKOUT .............................................................................................................................................. 38

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

ANNUAL INSPECTION ........................................................................................................................................................ 38

FIL TERS ........................................................................................................................................................................ 38

BURNERS ...................................................................................................................................................................... 38

INDUCED DRAFT AND CIRCULATOR BLOWERS ....................................................................................................................... 39

FLAME SENSOR (QUALIFIED SERVICER ONLY)...................................................................................................................... 39

FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................................... 39

BEFORE LEAVING AN INSTALLA TION.............................................................................................................................................. 39

REPAIR AND REPLACEMENT PARTS .............................................................................................................................................. 39

TROUBLESHOOTING CHART ....................................................................................................................................................... 40

ST ATUS CODES ....................................................................................................................................................................... 45

AIR FLOW DATA ...................................................................................................................................................................... 46

DIP SWITCHES ....................................................................................................................................................................... 47

*MVC8, *DVC8 WHITE RODGER GAS VALVE WIRING DIAGRAM .................................................................................................... 48

*MVC8, *DVC8 HONEYWELL GAS VAL VE WIRING DIAGRAM .......................................................................................................... 49

AFETY

ONSIDERA TIONS

WARNING

Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. T o ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P . gas by using the appropriate L.P . conversion kit listed in the PROPANE GAS/HIGH AL- TITUDE INSTALLATIONS section of this manual

Install this furnace only in a location and position as specified in LOCATION REQUIREMENTS & CONSIDERA TIONS sec- tion and INSTALLATION POSITIONS section of this manual.

Provide adequate combustion and ventilation air to the furnace as specified in COMBUSTION & VENTILATION AIR RE-

QUIREMENTS section of this manual.

Combustion products must be discharged to the outdoors. Connect this furnace to an approved vent system only , as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section of this manual.

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 GAS SUPPLY AND PIPING section of this manual.

Always install a furnace to operate within the furnace’s intended temperature-rise range with a duct system which has external static pressure within the allowable range, as specified on the furnace rating plate and OPERATIONAL CHECKS section of these instructions.

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

A gas-fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIREMENTS AND CONSIDERATIONS section of this manual.

This furnace may be used as a construction site heater only if certain conditions are met. These conditions are listed in the PRODUCT APPLICATION section of this manual.

THE INFORMATIO N IN THESE INSTRUCTIONS IS NOT FOLLOWED

EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY

DAMAGE

PERSONAL INJURY OR LOSS OF LIFE

NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

WHAT TO DO IF YOU SMELL GAS:

O NOT TRY TO LIGHT ANY APPLIANCE



O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE

IN YOUR BUILDING



MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

PHONE

. F



F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

DEPARTMENT

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS

WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE

KNOWN DEFECTS OR OTHER REPRODUCTIVE HARM

THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH

WARNING

EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUT INE, INSPECTION, MAINTENANCE AND SUPERVISION BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACAN T CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUT INELY INSPECTED MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACAN T ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED

AND WILL BE VACAN T, ANY HYDRONIC COIL UNITS

. IF

THE

WARNING

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

WARNING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE REFER TO THIS MANUAL INFORMATIO N, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR THE GAS SUPPLIER

. FOR

ADDITIONAL ASSISTANCE OR

CARBON MONOXIDE POISONING HAZARD

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

Carbon monoxi de produci ng device s ( such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

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

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

B10259-216

WARNING

HOULD OVERHEAT ING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE

BEFORE TURNING OFF THE ELECTRICAL SUPPLY

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, EXPLOSION, SMOKE, SOOT, COND E NSATION, ELECTRICAL SHOCK OR CARBON MONOXID E MAY RESU LT FROM IMPROPER INSTALLATION REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT

WARNING

PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS

FURNACE MUST BE CATEGORY

ATEGORY

ROVIS IONS MUST BE MADE FOR VENTI NG COMBUSTION PRODUCTS OUTDOORS THROUGH A PROPER VENTI NG SYSTEM FLUE PIPE COUL D BE A LIMITING FACTOR IN LOCATING THE FURNACE

III

VENTI NG

VENTED

. DO

NOT VENT USING

. THE

LENGTH OF

ADDITIONAL SAFETY CONSIDERATIONS

• This furnace is approved for Category I Venting only .

• Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

SHIPPING INSPECTION

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

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

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

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon

as possible - preferably within five days.

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

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

• Original paid freight bill or indemnity in lieu thereof.

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

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

WARNING

. FOR

ADDITIONAL ASSISTANCE OR

WARNING

HIS UNIT MUST NOT BE USED AS A “CONSTRUCTION HEATER” DURING THE FINISHING PHASES OF CONST RUCTION ON A NEW STRUCTURE TYPE OF USE MAY RESU LT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY CORROSIVE

LOW RETU RN AIR TEMPERATURES AND EXPOSURE TO

VERY DIRTY ATMOSPHERES

. T

HIS

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

portation damage.

Keep this literature in a safe place for future reference.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body’s static electricity before touching unit.

An electrostatic discharge can adversely affect electrical components.

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

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

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

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

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

TO THE INSTALLER

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

WARNING

PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO

FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICL E

RODUCT DESCRIPTION

FEATURES

This furnace is a part of the ComfortNet™ family of products. The CTK0* ComfortNet thermostat kit allows this furnace to be installed as part of a digitally communicating system. The ComfortNet system provides automatic airflow configuration, enhanced setup features, and enhanced diagnostics. It also reduces the number of thermostat wires to a maximum of four. It may be also installed as part of a “legacy” system using a standard 24 V AC thermostat.

This product may also be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conditioning unit. However, this reduces the benefits of the ComfortNet system as the enhancements will only apply to the furnace.

RODUCT APPLICA TION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door).

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

Schools, Office buildings, Churches, Retail stores,

Nursing homes, Hotels/motels, Common or office areas

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

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

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

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

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

• All other warranty exclusions and restrictions apply .

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

• The vent system is permanently installed per these installation instructions.

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

• Return air ducts are provided and sealed to the furnace.

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

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

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

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

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized for adequate combustion and ventilation in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ ANSI Z223.1 orCAN/CSA B149.1 Installation Codes.

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

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

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

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

• A T -handle gas cock must be used.

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

WARNING

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

In the USA, this furnace MUST be installed in accordance with the latest edition of the ANSI Z223.1 booklet entitled “National Fuel Gas Code” (NFP A 54), and the requirements or codes of the local utility or other authority having jurisdiction. In Canada, this furnace must be installed in accordance with the current CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing or waste water codes and other applicable codes. Additional helpful publications available from the NFPA are, NFPA 90A Installation of Air Conditioning and Ventilating System and NFP A 90B - Warm Air Heating and Air Conditioning System.

All venting shall be in accordance with P ART 7, V enting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable local building and/or air conditioning codes. These publications are available from:

National Fire Protection Association, Inc.

1 Batterymarch Park, Quincy, MA 02269

NOTE: Furnaces with NOx screens meet the California NOx emission standards and California seasonal efficiency standards. ANNUAL inspections of the furnace and its vent system is strongly recommended.

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of

the National Fuel Gas Code (NFP A 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFP A 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute

1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy , MA 02269

CSA International

8501 East Pleasant V alley

Cleveland, OH 44131

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

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

OCATION REQUIREMENTS AND CONSIDERATIONS

Y our unit model type determines which installation procedures must be used. For *MVC8 models, you must follow instructions for Horizontal Left, Horizontal Right or Upflow installations only . These furnaces are not approved for Downflow installations. Downflow models *DVC8 ARE NOT APPROVED FOR HORI- ZONT AL OR UPFLOW INST ALLA TIONS. For these models, use only the instructions for downflow installation only .

WARNING

PREVENT POSSIBLE EQUIPM EN T DAMAGE, PROPERTY DAMAGE PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT

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

Combustion and Ventilation Air Requirements.

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

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

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

• Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

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

• The furnace must be level. If the furnace is to be set on a floor that may become wet or damp at times, the furnace should be supported above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace.

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

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

chlorinated waxes or cleaners

chlorine-based swimming pool chemicals

water softening chemicals deicing salts or chemicals

carbon tetrachloride

halogen type refrigerants

cleaning solutions (such as perchloroethylene)

printing inks

paint removers

varnishes

hydrochloric acid

cements and glues

antistatic fabric softeners for clothes dryers

and masonry acid washing materials

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

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

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

• Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.

• For counterflow installations, the air conditioning coil must be downstream from the heat exchanger of the furnace.

• Counterflow installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicon rubber caulking compound or cement grout.

• Counterflow installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory subbase (see Specification Sheet applicable to your model for det ails). A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Follow the instructions with the subbase for proper installations. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.

ent Pi p e Clearance to Combustib les6" using Single Wall Connector or 1" using B-1 vent.

Top - 1"

Back - 0"

Side Clearance - 1"

Front Clearance - 3"

• Adequate combustion/ventilation air must be supplied to the closet.

• Furnace must be completely sealed to floor or base. Combustion/ ventilation air supply pipes must terminate 12" from top of closet and 12" from floor of closet. DO NOT remove solid base plate for side return.

• Return air ducts must be completely sealed to the furnace and terminate outside the enclosure surfaces.

CLEARANCES AND ACCESSIBILITY

Unobstructed front clearance of 24" for servicing is recommended.

VENT

B1-VENT SINGLE

1" 6" 1" 3" 0" 1"

Top clearance for horizontal configuration - 1"

SIDES FRONT BACK

TOP

(PLENUM)

INSTALLATION POSITIONS

An upflow furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For vertically installed upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontally installed upflow furnaces, return air ductwork must be attached to the basepan. For counterflow furnaces, return ductwork must be attached to the top end of the blower compartment.

NOTE: Ductwork must never be attached to the back of the furnace.

HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY)

Line contact to framing is permitted when installed in the horizontal configuration. Line contact is defined as the portion of the cabinet that is formed by the intersection of the top and side. ACCESSIBILITY CLEARANCE, WHERE GREATER, SHOULD T AKE PRECEDENCE OVER MINIMUM FIRE PROTECTION CLEARANCE. A gas-fired furnace for installation in a residential garage must be installed so that the ignition source and burners are located not less than eighteen inches (18") above the floor and is protected or located to prevent physical damage by vehicles. A gas furnace must not be installed directly on carpeting, tile, or other combustible materials other than wood flooring.

FURNACE SUSPENSION

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x3/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting

system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47-Latest Edition, CSA-2.3-Latest Edition Section 1.23.1. The following

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

a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and

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

c. In so far as practical, close all building doors and

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

d. Follow the lighting instructions. Place the appliance

being inspected in operation. Adjust thermostat so appliance shall operate continuously;

e. T est for draft hood equipped appliance spillage at the

draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;

f. After it has been determined that each appliance

connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

g. If improper venting is observed during any of the above

tests, the common venting system must be corrected.

Suspended Furnace

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

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

THERMOSTAT LOCATION

In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. Do not install the thermostat where it may be influenced by any of the following:

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

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

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

HOT COLD

Thermostat Influences

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

OMBUSTION AND VENTILATION AIR REQUIREMENTS

This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed combustion) furnace.

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

CATEGORY I VENTING (VERTICAL VENTING)

WARNING

PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS FURNACE MUST BE CATEGORY VENT USING CATEGORY

III

VENTI NG

Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.” NOTE: Single stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing, in some instances, common venting with natural draft appliances (i.e. water heaters). All installations must be vented in accordance with National Fuel Gas Code NFP A 54/ANSI Z223.1

- latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

NOTE: The vertical height of the Category I venting system must be at least as great as the horizontal length of the venting system.

WARNING

VENTED

. DO

NOT

WARNING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH SUFFICIEN T FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE

GASES MUST BE SUPPLIED

SUPPLIED INTO THE FURNACE AREA

. M

OST HOMES REQUIRE OUTSIDE AIR BE

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

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

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, COMMON VENTI NG WITH OTHER MANUFACTURER’S INDUCED DRAFT APPLIANCES IS NOT ALLOWED

The minimum vent diameter for the Category I venting system is as shown:

MINIM UM VENT

MODEL

UPFLOW COUNTERFL OW

060 4 in ch 4 inch 080 4 in ch 4 inch 100 5 in ch 4 inch

Under some conditions, larger vents than those shown above may be required or allowed. When an existing furnace is re- moved from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated 90 degrees for Category I venting. For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet.

THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCKWISE INDUCED DRAFT BLOWER ROTA TION.

Vent the furnace in accordance with the National Fuel Gas Code NFP A 54/ANSI Z223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

Venting

THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORIZONT ALL Y VENTED.

To rotate the induced draft blower clockwise, you will need to purchase one (0270F01 1 19) chimney transition bottom kit.

1. Disconnect electrical power from the furnace.

2. Disconnect the induced draft blower power leads, flue pipe, and pressure switch tubing.

3. Remove the round cutout from the right side of the wrapper.

4. Remove and save the four screws that fasten the induced draft blower to the flue collector box.

5. Remove and save the three screws that hold the chimney assembly to the induced draft blower .

6. Remove and save the four screws that fasten the chimney top to the chimney bottom.

7. Remove the chimney transition bottom from the transition bottom kit.

8. Install the chimney top with the four screws retained from step 6 onto the new chimney transition bottom from the transition bottom kit.

9. Install chimney assembly with the three screws retained from step 5 onto the induced draft blower.

10.Reinstall the induced draft blower rotating it 90 degrees clockwise from the original upflow configuration using the four screws retained in step 3. Ensure the gasket located between the induced draft blower and the collector box is rotated accordingly .

11. Reconnect the induced draft blower power leads. NOTE: If the wires are not long enough, pull extra wire from the wire bundle in the blower compartment.

12. Reconnect the flue pipe, and the pressure switch tubing. Ensure that all wires and the pressure switch tubing is at least one inch from the flue pipe, or any other hot surface.

13. Restore power to furnace.

WARNING

EVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXID E, TO ENTER THE RETU RN DUCTWORK OR CIRCULATION AIR SUPPLY

XTERIOR MASONRY CHIMNEYS

ATEGORY

I F

URNACES ONLY

)

An exterior masonry chimney is defined as a “Masonry” chimney exposed to the outdoors on one or more sides below the roof line.” The ability to use a clay lined masonry chimney depends on a parameter not associated with interior chimneys. This variable is the geographic location of the installation. Researchers have discovered that the winter design temperatures have a direct impact on the suitability of this type of venting. In most situations, the existing masonry chimneys will require a properly sized metallic liner .

WARNING

OSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DAMAGING COND E NSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN

SINGLE FAN-ASSISTED CATEGORY FURNACE) IS VENTED WITHOUT ADEQUATE DILUTION AIR CONNECT AN FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPE D APPLIANCE METAL VENT SIZED IN ACCORDANCE WITH THE APPROPRIATE VENTI NG TABLES

80%

APPLIANCE, THE POTENTIAL FOR COND E NSATION DAMAGE MAY STILL EXIST WITH EXTREMELY COLD CONDITIONS, LONG VENT CONNECTORS EXTERIOR CHIMNEYS, OR ANY COMBINATIO N OF THESE CONDITION S

HE RISK OF COND E NSATION DAMAGE IS BEST AVOIDED BY USING MASONRY CHIMNEY AS A PATHWAY FOR PROPERLY SIZED METAL LINER OR

80%

FURNACE TO A MASONRY CHIMNEY UNLESS THE

THE CHIMNEY IS LINED WITH A METAL LINER OR TYPE

. ALL

INSTALLATIONS USING MASONRY CHIMNEYS MUST BE

FURNACE IS COMMON VENTED WITH A DRAFT HOOD EQUIPPE D

YPE

METAL VENT

APPLIANCE

(80% AFUE

. DO

NOT

. IF AN

Counterflow units are shipped with the induced draft blower discharging from the top of the furnace. (“T op” as viewed for a counterflow installation.)

Vent the furnace in accordance with the National Fuel Gas Code NFP A54/ANSI Z223.1-latest edition. In Canada, vent the furnace in accordance with the national standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and amendments.

Wash

Roof Line

Clay Tile Size: 8" x 8" x12"

(Each x 24" Length)

Attic Floor

1/2" to 1" Air Space

Second Floor

Throat

Damper

Breech

Fan Assisted

Clean Out

Typical Multiple Flue Clay Tile Chimney

Forced Air Furnace

F.A .F. Vent Connector

First Floor

Water Heater Vent Connector

Natural Draft Water Heater

Basement Floor

CHECKLIST SUMMARY

This checklist serves as a summary of the items to be checked before venting an 80+ furnace into a masonry chimney . In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system.

Proper Chimney

Termination?

(Check 1)

Chimney channel

free of solid and

liquid fuel

appliances?

(Check 2)

Crown in good

condition

(Check 3)

Cleanout free of

debris?

(Check 4)

Change venting

arrangements

(Fix 2)

Rebuild crown

(Fix 3)

and/or Reline

(Fix 4)

Reline (Fix 4)

This checklist is only a summary . For det ailed information on each of the procedures mentioned, see the paragraph referenced with each item.

This inspection is based upon a draft topical report, “Masonry Chimney Inspection and Relining”, issued by the Gas Research Institute. While not yet finalized, we believe this report represents the best information on this subject which is currently available.

Liner in good

condition?

(Check 5)

Dilution air

available?

(Check 6)

Reline (Fix 4)

Complete the

installation.

(Check 7)

CHECK 1 - PROPER CHIMNEY TERMINATION.

A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it passes through the roof. It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet. In addition, the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet. The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar .

If the chimney does not meet these termination requirements, but all other requirements in the checklist can be met, it may be possible for a mason to extend the chimney . If this will not be practical, see Fix 1.

10' or Less

2' Min.

Wall or Parapet

Chimney

3' Min.

Appliances which burn propane (sometimes referred to as LP (liquefied petroleum)) gas are considered gas-fired appliances.

CHECK 3 - CHIMNEY CROWN CONDITION.

Damage from condensate usually shows up first in the crown. If any of the following trouble signs are present, the condition of the crown is not satisfactory:

a) Crown leaning b) Bricks missing c) Mortar missing d ) Tile liner cracked e ) No tile liner f ) Salt staining at mortar joints. (White stains, and mortar

becomes sandy and/or erodes.)

10' or Less

2' Min.

3' Min.

Chimney

Termination 10 Feet Or Less From Ridge, Wall or Parapet

More than 10’

3’ Min.

NOTE:

No Height

above parapet

Wall or Parapet

Ridge

required when distance from walls or parapet is more than 10 feet.

More than 10’

10’

2” Min.

Chimney

Height above any roof surface within 10 feet horizo ntall y.

3’ Min.

For problems a, b, or c, see Fix 3. If problems d, e, or f are present, see Fix 4. IMPORT ANT: It may be necessary to follow both Fix 3 and Fix 4.

CHECK 4 - DEBRIS IN CLEANOUT.

A cleanout (dropleg) must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blocked by debris. If no cleanout is present, the chimney must be relined (Fix 4). Remove the cleanout cover, and examine the cleanout for debris. If significant amounts of any of the following are found:

• Fuel oil residue

• Bricks

• Mortar or sand

• Pieces of the tile liner

• Rusted pieces of the metallic liner - reline the chimney (Fix 4).

CHECK 5 - LINER CONDITION.

If a metal liner is present, it must be checked. It cannot be assumed that all existing metal liners are correctly installed and in good condition.

Remove the lowest existing vent connector , and examine the inside of the elbow or tee at the base of the liner. A small amount of soot may be considered acceptable, provided the installer vacuums it away. If rusted pieces of the liner have collected here, the metal liner must be removed and replaced (Fix 4).

Chimney

Termination More Than 10 Feet From Ridge, Wall or Parapet

CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED

THIS CHIMNEY CHANNEL

INTO

Solid fuel appliances include fireplaces, wood stoves, coal furnaces, and incinerators.

Liquid fuel appliances include oil furnaces, oil-fired boilers and oil-fired water heaters.

Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping does not sound like metal hitting metal, the liner must be removed and replaced (Fix 4).

Remember that all appliances must be vented inside the liner . Venting one appliance inside the liner and another appliance outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner . B vent must be supported so as to not come into direct contact with the chimney walls or tile liner . If it is not, it can probably be rehung so as to be acceptable. A thimble or fire stop may be helpful here.

Flexible liners should be hung straight or nearly straight. If it is spiraled in the chimney and in good condition, it should be rehung. To do this, break the top seal; pull up and cut off the excess liner length, and refit the top seal. Use caution when doing this, as the cut edges of flexible liners may be sharp.

The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4). Finally , confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA tables and rules.

If a metal liner is not present, a clay tile liner must be present, or the chimney must be lined (Fix 4).

Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner. If any of the following problems are present:

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent connectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an approved fire clay tile reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to do this from the cleanout. The liner must be at least as large as the minimum size established by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments. If the liner is too small or too large, then the chimney must be relined (Fix 4).

CHECK 6 - DILUTION AIR.

If gas-fired appliances are to be vented into a clay tile liner, a source of dilution air is required.

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

CHECK 7 - COMPLETE THE INSTALLATION.

If Checks 1 through 6 have been satisfactory, and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments, then the clay tile liner can probably be used as a vent for the gas appliances. However, the inst aller must keep in mind the following factors which may render the tile liner unsuitable for use as a vent:

• Extremely cold weather

• Long vent connectors

• Masonry chimneys with no air gap between the liner and the bricks. (In practice, this can be difficult to detect.)

• Exterior chimneys (The tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments assume interior chimneys.)

If, in the judgment of the local gas utility , installer , and/or local codes; one or more of the above factors is likely to present a problem, the chimney must be relined (Fix 4).

FIX 1 - LINER TERMINATION

Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use. The liner and cap/roof assembly must then terminate above the roof in accordance with the manufacturer’s instructions.

In some cases, a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney .

For further information on relining, see Fix 4.

FIX 2 -CHANGE VENTING ARRANGEMENTS

If the masonry chimney has more than one channel, it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance(s) into another channel(s). Do not vent an 80+ Furnace inside of a metal liner with other appliances vented outside the liner .

Alternatively , the homeowner may agree to discontinue use of the fireplace (solid fuel appliance). If so, the tile liner must be cleaned to remove creosote buildup. The fireplace opening must then be permanently sealed.

Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance’s vent connector does not include a vent damper. If dilution air will not be available, the chimney must be relined (Fix 4).

If oil-fired appliance(s) are being replaced by gas-fired appliance(s), the tile liner must first be cleaned to remove the fuel oil residue.

If none of the above options is practical, the furnace may need to be vented vertically with a B V ent.

Under some conditions, a 90%+ furnace could be installed rather than an 80% furnace. The 90%+ furnace can be vented horizontally or vertically through PVC pipe.

FIX 3 - REBUILD THE CROWN

If the chimney crown is damaged, a qualified mason must repair it in accordance with nationally recognized building codes or standards. One such standard which may be referenced is the Standard for Chimneys, Fireplaces, V ent s, and Solid Fuel Burning Appliances, ANSI/NFPA 211.

FIX 4 - RELINING

Relining options include B vent and flexible liners. If the chimney has diagonal offsets, B vent probably cannot be

used. If B vent is to be used, it must be supported adequately . Sup-

ports (such as fire stops or thimbles) must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls. Direct contact would result in higher heat loss, with an increased possibility of poor venting system performance.

It is not acceptable to vent one appliance inside the B vent and other appliances outside. The excess space between the B vent and the chimney walls must be covered at the top of the chimney by a weatherproof, corrosion resistant flashing.

The B vent should then be topped with a listed vent cap. The listed vent cap will, when installed per the manufacturer’s instructions, prevent problems due to rain, birds, or wind effects.

A B-vent installed as described in this section is considered to be an enclosed vent system, and the sizing tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National St andard of Canada, CAN/CSA B149.1 and CAN/ CSA B149.2 - latest editions and amendments may be used.

For sizing of flexible liners, see Note 22 and the tables in the National Fuel Gas Code NFP A 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

T o inst all the liner, read and follow the liner manufacturer’s instructions and your local codes. Excess liner length should be pulled out of the chimney and cut off. Use caution when doing this, as the cut edges of flexible liners may be sharp. Do not spiral excess liner inside of the chimney . Support the liner as recommended by the liner manufacturer.

Some manufacturers of flexible liners offer an insulation sleeve designed to be added to the liner before it is installed in the chimney. (Poured insulation, either vermiculite or other materials, is no longer recommended.) Insulation will need to be added to the flexible liner if:

• It is required by the liner manufacturer’s instructions.

• The previous liner was properly sized and installed, and suffered from condensation damage.

• It is required by your local building codes.

Even if none of those three conditions exist which require additional liner insulation, the installer may wish to consider it if:

• The local climate is very cold.

• The chimney is very tall.

• The vent connectors used are very long or have a large number of elbows.

• Local experience indicates that flexible liners installed without insulation are likely to have condensation problems.

Insulation must be selected and installed in accordance with the liner manufacturer’s instructions.

If a flexible liner is to be used, it must be made of the proper materials:

• For most residential applications, an aluminum liner should be acceptable.

• If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine, a liner of AL 29-4C stainless steel should be used. Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine bleaches, paint strippers, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. V arious commercial and industrial processes may also be sources of chlorine/fluorine compounds.

• Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel appliances. They are not suitable for use with gas-fired appliances. Flexible liners specifically intended and tested for gas applications are listed in the UL “Gas and Oil Equipment Directory”. (UL Standard 1777).

Finally , cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.

LECTRICAL CONNECTIONS

WARNING

HIGH VOLTAGE !

AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO

THE UNIT MUST BE POLARIZED AND GROUNDED

WARNING

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING

CAUTION

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS OPERATION

. W

IRING ERRO RS CAN CAUSE IMPROPER AND DANGEROUS

. V

ERIFY PROPER OPERATION AFTER SERVICING

WARNING

HIGH VOLTAGE !

AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR

ABSENCE, WITH THE LATEST EDITION OF THE

ATIONAL ELECTRIC CODE

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency , and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or , in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.

Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door .

Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection with the junction box located inside the burner compartment (blower compartment for downflows). To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner (or blower) compartment prior to making electrical connections. T o relocate the junction box, follow the steps shown below .

Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. T o relocate the junction box, perform the following step s.

WARNING

PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT

1. Remove both doors from the furnace.

2. Remove and save the screws holding the junction box to the right side of the furnace.

3. Models that have the junction box located in the burner or blower compartment will need to move the junction box directly over .

4. Attach the junction box to the left side of the furnace, using the screws removed in step 2.

5. Check the location of the wiring. Confirm that it will not be damaged by heat from the burners or by the rotation of the fan. Also confirm that wiring location will not interfere with filter removal or other maintenance.

After the junction box is in the desired location, use washers to connect field-supplied conduit to the junction box in accordance with NEC and local codes. Connect hot, neutral, and ground wires as shown in the furnace wiring diagram. The wires and ground screw are located in the furnace junction box.

NOTE: In downflow applications the power leads should be routed through the supplied wire tabs when locating junction box to the left side.

Low voltage wires may be connected to the terminal strip. IMPORT ANT NOTE: T o avoid possible equipment malfunction,

route the low voltage wires to avoid interference with filter removal or other maintenance.

WARNING

HIGH VOLTAGE !

AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN

ABSENCE, WITH THE LATEST EDITION OF THE

THEIR

ATIONAL ELECTRIC CODE

NOTE: Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance.

JUNCTION BOX RELOCATION

WARNING

DGES OF SHEET METAL HOLES MAY BE SHARP

PRECAUTION WHEN REMOVING HOLE PLUGS

. USE

GLOVES AS A

To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check.

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